description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a simple and less expensive female component for a mechanical refastenable fastening device (i.e., “touch and close fastener” or “hook and loop-type fastener”) which is conveniently used in mostly disposable applications such as disposable diapers, disposable operating gowns, disposable underwear and other clothing.
2. Description of Related Art
Hook and loop-type fasteners have been constituted of two components, a female component having loop-shaped female elements placed on the surface of cloth such as knitted or woven fabric and a male component having hook-shaped or mushroom-shaped male elements capable of engaging with the female element, the male elements being placed on the surface of another cloth. When the female component and the male component are pressed together in a face-to-face relationship to close the fastener, the two elements placed on both clothes engage each other to form a plurality of mechanical bonds therebetween. This engagement is utilized not only for clothing but also for various daily necessaries such as bags. Conventional female elements which have been widely known are female components wherein multi-filaments or mono-filaments made of synthetic resins such as nylon and polyester are utilized and loops made up of such filaments are formed on a cloth for their support.
In the case of a female component constituted from the above-mentioned knitted or woven fabric as a support, a strong structure can be adopted and, therefore, a big engaging force between the female component and the male component can be achieved. On the other hand, however, due to the use of knitted or woven fabric, the cost is high in the above female component which is produced via complicated manufacturing steps. Accordingly, it is difficult to utilize the simple and easy engaging function of the touch and close fastener (hook and loop-type fastener) in such a use where products (such as a disposable diaper) are disposed after about five to ten engagements and a relatively small magnitude of the engaging force acting therebetween is enough for actual use.
There have been various proposals for female components utilizing nonwoven fabric which is relatively in low cost due to its high productivity instead of such knitted or woven fabric. As mentioned already, the nonwoven fabric female component is inferior in terms of absolute engaging capability to the female component made up of knitted or woven fabric. In applying to the use where relatively small engaging ability will do, however, the advantage of the use of nonwoven fabric is not only that it has a high productivity but also that a constituent in a sheet form and a female element constituting the loop can be utilized substantially in one constituent component whereby it is possible to offer a very less expensive female component. It is also expected that, unlike the knitted or woven fabric, the nonwoven fabric female component would have a good characteristic that fraying upon cutting hardly takes place.
However, in known female components made of nonwoven fabric, there is a disadvantage that a reduction in an engaging capability is high, as compared with those made of knitted or woven fabric, after repeated engagements to the extent of 5 to 10 times in view of disposable applications.
The present inventors paid their attention to this point, have conducted an intensive study for keeping the above engaging capability of a touch and close fastener (hook and loop-type fastener) made of nonwoven fabric, even having excellent advantages, and have succeeded in producing the present invention.
Accordingly, an object of the present invention is to provide an art capable of preventing a female component from the reduction of its inceptive engaging force (engaging force at an initial use) after repeated engagements and to achieve and provide an improved low-cost female component for a touch and close fastener (hook and loop-type fastener) with highly advantageous characteristics.
SUMMARY OF THE INVENTION
The present invention firstly provides a nonwoven fabric female component for a touch and close fastener (i.e., hook and loop-type fastener) in which projecting loops are formed on one of the superficial sides of the nonwoven fabric, said female component wherein
(i) said nonwoven fabric comprises a hydroentangled web, and
(ii) said loops are projectingly formed by needle punching on or at one of the superficial sides of said hydroentangled web.
The present invention secondly provides a method for the manufacture of a nonwoven fabric female component for a touch and close fastener in which loops are projectingly formed on one of the superficial sides of the nonwoven fabric, said method comprising the steps of:
(i) forming a hydroentangled web, and
(ii) needle punching said hydroentangled web to form the loops.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic side view of an embodiment of the nonwoven fabric female component of the present invention.
FIG. 2 is a simplified schematic side view of an embodiment of the nonwoven fabric female component wherein one of the steps in the manufacturing method according to the present invention is applied.
FIG. 3 is a simplified schematic side view of an embodiment of the nonwoven fabric female component wherein one of the steps in the manufacturing method according to the present invention is conducted after the step of FIG. 2 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Described below is a mode of carrying out the present invention by showing several suitable embodiments and by referring to the drawings. In the technique for manufacturing nonwoven fabrics, needle punching techniques and hydroentangling techniques by means of high pressure jets of water have been well known as the art for entangling a fiber web. The present inventors have applied a hydroentangling technique to a fiber web to form a hydroentangled web and then have also applied a needle punching technique to the resultant hydroentangled web to form loops. As a result, the present inventors have found that a female component for a touch and close fastener can be made up of said treated nonwoven fabric and has advantageous and improved characteristics with less reduction in an engaging capability even after repeated engagements.
First, an embodiment of the female component according to the present invention will be illustrated hereinbelow by referring to FIG. 1 in which a simplified schematic side view thereof is shown. The female component ( 11 ) of the present invention is prepared by techniques which will be mentioned later in detail. The female component ( 11 ) is equipped with loops ( 15 ) projected from a hydroentangled web ( 13 ) which is obtained by applying the above-mentioned hydroentangling. In a preferred embodiment of the present invention, a flat and smooth region ( 17 ) constituted by heat fusing fiber constituents can be formed on the surface of the hydroentangled web ( 13 ), the surface being different from the surface on which loops ( 15 ) are formed. The flat and smooth region is set up there for reducing fluffs which are produced via drawing out the loops from the fiber web upon detachment by a male element (not shown in the drawings) during repeated engagements. Such a reduction of the fluffs is not an effect which has resulted exclusively from setting up the flat and smooth region, but, preferably, it can also be expected when a fiber web is made up of heat-fusible fibers in an amount of not less than 50 mass %. Especially not only for holding the loops firmly but also for inhibiting the reduction in engaging force due to the above fluffing upon engagement with and peeling from the male component, it is also effective that the fiber web is composed of the heat-fusible fibers exclusively. The heat-fusible fiber used herein includes conventionally known composite fibers wherein two or more resins each having a different melting point are oriented in a form such as side-by-side or core-and-sheath.
The fiber web used in the present invention may include not only a product obtained by carding short fibers, but also a spun bond nonwoven fabric made up of long fibers. At that time, a part of the fibers constituting the hydroentangled web ( 13 ) is treated with a needle punching technique to form loops ( 15 ) projectingly, the loops ( 15 ) being constituting elements directly related to an engagement with the male elements. Therefore, in order to achieve an entangling force sufficient for actual use, it is preferred that the hydroentangled web ( 13 ) is made up of fibers where the strength of the single filament is not less than 2 g/denier. In addition, it is preferred that the size of such a fiber is from 0.5 denier to 10 deniers. If a finer fiber than above is used, the loops are crestfallen due to a low rigidity of the fiber, whereby in some cases its engagement with the male component may be deteriorated and it may be difficult to achieve a sufficient engaging force.
It has been known that, when short fibers are carded to form a fiber web, the carded fiber is usually oriented unidirectionally along the production direction of the web (the web having such an orientation is called a “unidirectional web”). Such a unidirectional web is formed in a certain surface density depending upon the ability of a carding machine and, therefore, when one sheet of the unidirectional web lacks, for example, a desired surface density, the following two means can ensure its surface density:
(1) lamination is conducted so that plural unidirectional webs show the same orientation, and
(2) the resulting unidirectional web is laminated and oriented by folding from one end of the width direction of a running endless belt to another end thereof.
There are three forms regarding the fiber web obtained by those two laminating means, i.e.,
(i) a unidirectional web which is formed only by the former means,
(ii) a cross-lay web which is formed only by the latter means, and
(iii) a crisscross web, formed by a combination of both the means, in which the state of fiber orientation within a web surface is in a shape of an asterisk(*).
According to experiments conducted by the present inventors, it is preferred that a suitable female component for a touch and close fastener is selected from the above-mentioned two species, i.e., the cross-lay web and the crisscross web. To be more specific, it is desirable that the weight ratio W (%) of a cross-lay web is from 30% to 100%, or more preferably from 60% to 100%, for the surface density of a fiber web used as a female component for a touch and close fastener. For such a ratio in weight, the value in the fiber web prior to hydroentangling is substantially equal to that in the finally obtained female component for a touch and close fastener. Although a detailed mechanism is not clear for an improvement in engaging force reduction by a product containing a cross-lay web in such a suitable range, it is likely that, when needle punching is applied to the fiber web transferred in a predetermined direction in order to form loops, the fiber orientation, crossing the transferring direction as in the case of the cross-lay web, is highly resistant to punching needles and serves advantageously to form stronger loops. Further, when a female component for a touch and close fastener is constituted by a combination of the above-mentioned short fiber web with a long fiber web represented by a spun-bond nonwoven fabric, the change in the position of the long fiber is relatively small upon application of needle punching and, therefore, such a long fiber web shows the same behavior as the unidirectional web does.
Now described below are modes of carrying out the method of the present invention in detail. FIGS. 2 and 3 are the drawings which show each of the steps for an embodiment of the method according to the present invention by way of a simplified schematic cross-sectional side view, similarly in FIG. 1 . First, as mentioned already, the hydroentangled web ( 13 ) is manufactured, with a surface density corresponding to the design (refer to FIG. 2 ). At that time, the surface density of the hydroentangled web is to be designed in such a manner that the surface density of the final female component product obtained by the step which will be mentioned hereinbelow is to be around 20 to 200 g/m 2 , or more preferably from 40 g/m 2 to 80 g/m 2 . When the surface density of the female component is made less than the above suitable range, the nonwoven fabric constituting the component becomes non-uniform, and, in addition, the number of the fibers which constitute the loops may become small whereby there are some cases where it is difficult to achieve a good engaging force after repeated use. Further, when the surface density is made more than the above-mentioned suitable range, the thickness of the fiber web may become large prior to the hydroentangling and prior to application of needle punching, and, especially, it may become difficult to process the fiber web to the thickness direction thereof such as in the formation of loops whereby there are some cases where good engaging characteristics are hardly achieved.
The first step, characteristic to the method of the present invention, i.e., a hydroentangling technique for applying hydroentangling to the fiber web (not shown) to form a hydroentangled web ( 13 ), is carried out by placing the fiber web on a conveyer net. Thus, for example, a hydroentangled web having a uniform entangled state can be prepared by generating high-pressure water jets of 0.98 to 29.43 MPa (10 to 300 kgf/cm 2 ) using plural nozzles with a nozzle diameter of 0.05 to 0.3 mmφ on a conveyer net having openings of around 15 to 120 mesh, the nozzles being placed on a nozzle plate in a pitch of about 0.08 to 0.2 mm (pitch in the width direction for production). There is no particular limitation for how many times the hydroentangling process should be applied, but the hydroentangling may be applied at least against one of the superficial sides of the fiber web, or may be applied against one of the superficial sides followed by against another superficial side.
Thereafter, the second step of the method according to the present invention is carried out. The second step includes applying needle punching to the resulting hydroentangled web ( 13 ) from one of the superficial sides thereof (an example thereof is shown in FIG. 3 with an arrow “a”) whereupon loops ( 15 ) are formed. In that case, according to experiments by the present inventors, it may include either a method for applying needle punching to the hydroentangled surface side or a method for applying needle punching to a surface side different from the hydroentangled surface side. There is no particular limitation for the needle used for conducting the present invention, but it is preferred to use crown barb needles in which the cross section of the blade thereof is triangular or nearly square, etc., and plural (e.g., from around 3 to 4) barbs are placed at the positions which are in the same distance from the top end of the blade. When such a needle is used, it is possible to form bunchily loops projecting in nearly the same height on the superficial side different from the side of the fiber web into which the needle enters, thereby efficiently forming a female element having a high engaging capability.
Further, in another preferred mode of carrying out the method of the present invention, a third step may be added after the formation of the above-mentioned loops, the third step including the heat fusing of the needle punched superficial side of the fiber web (the superficial side is a side where needles entered and no loop is formed) to form a flat and smooth region ( 17 ) (see FIG. 1) on the web. This step may be conducted, for example, in such a manner that one of a pair of rolls encountering with a certain slit (gap) is heated nearly at the melting point of the constituting fiber (preferably, the low-melting component of the above-mentioned heat-fusible fiber) of the above web when the above web is passed between the rolls, followed by bringing the web surface having no formed loops into contact with the roll. The third step may be conducted in such a manner that the fiber web is previously heated with a high temperature hot air, infrared ray, etc. and the surface having no formed loops is contacted to the roll or drum.
Described below are examples of the present invention which are provided only for illustrative purposes, and not to limit the scope of the present invention. It is to be understood that the present invention is not limited to those examples but may include numerous other embodiments.
Examples disclose the touch and close fasteners to which the techniques according to the present invention are applied and the evaluation results thereof. In the following disclosure, specific conditions are provided for making it easier to understand the present invention, but it should be also noted that the art of the present invention is not limited to such examples only.
Female components concerning Examples 1 to 7 are made up of commercially available heat-fusible fibers (size: 3 deniers; fiber length: 64 mm; and core/sheath-type PP/PE composite fiber) exclusively wherein the fibers are carded and standardized to about 76 g/m 2 with regard to the surface density thereof to form a fiber web in which the weight ratio W of a cross-lay web was 100%. This fiber web was treated with high-pressure water jets under various conditions to form a hydroentangled web, dried under heating to such an extent that no thermal influence was resulted on the constituting fiber, and subjected to needle punching using the above-mentioned crown needles under a standardized condition (needle depth: 10 mm and needle density: 50 needles/cm 2 ). After that, each of the webs was subjected to the above-mentioned third step wherein a pair of encountering rolls was used under the temperature condition of 140° C. to manufacture a female component. The resultant female components are used as embodiments of Working Examples. For Comparative Example 1, no hydroentangling was conducted while the second step for forming loops and the third step for forming flat and smooth regions were conducted under the same conditions as in the Examples, thereby manufacturing a sample where the weight ratio W as above-mentioned was 100%. Further, for Comparative Example 2, a commercially available female component made up of knitted or woven fabric (“Take Care”, trade name, Sumitomo 3M, Japan; manufactured by bonding a film (surface density: about 29 g/m 2 ; thickness: about 0.15 mm) to a base cloth containing loops (surface density: about 76 g/m 2 ; thickness: about 0.64 mm)) was used as a sample for evaluation.
Furthermore, Example 8 and 9 samples for evaluation were manufactured in the same manner as the above-mentioned samples, except that as a result of preparing a crisscross web containing a unidirectional web the weight ratios (W) of the cross-lay web were 60% and 30%, respectively, and that the surface density was different. Table 1 shows the feature each of those eleven kinds of samples for evaluation and also shows the manufacturing conditions and the final surface density and thickness each for the samples where nonwoven fabric was used.
Remarks: In the column of “Side Where Needle Entered” in this table, the term “Head” means that the firstly hydroentangled side of the fiber web was identical with the needle-entered one in each of the Example samples, while the term “Tail” means that the needle-entered side was different from the hydroentangled one. In other words, when loops were formed on the side identical with the firstly hydroentangled one, it was given as “Tail”, while it was given as “Head” when loops were formed on the side different from the firstly hydroentangled one.
TABLE 1
Weight
Ratio of
Side
Final
Crosslay
Water Jet
Where
Surface
Thick-
Web:W
Entangling
Needle
Density
ness
(%)
Conditions
Entered
(g/m 2 )
(mm)
Examples
1
100
3 MPa
Tail
52.1
1.25
one side only
2
100
3 MPa
Head
58.3
1.09
one side only
3
100
5 MPa
Tail
66.6
1.09
one side only
4
100
5 MPa
Head
64.0
1.02
one side only
5
100
8 MPa
Tail
63.6
1.05
one side only
6
100
5 MPa
Tail
57.8
1.15
both sides
7
100
3 MPa
Tail
65.0
1.16
both sides
8
60
3 MPa
Tail
77.3
1.04
both sides
9
30
3 MPa
Tail
73.4
1.44
both sides
Comparative
Examples
1
100
—
—
60.3
1.27
2
—
—
—
105.0
0.80
Described below is a method for evaluating an engaging force. As a means for evaluating the engaging force between a male component and a female component for a touch and close fastener, the measurement in accordance with “Peeling Strength” as stipulated in “Test Method for Touch and Close Fastener” (JIS L3416) was conducted in the present examples. To be more specific, commercially available male component “3M CS200” (trade name; manufactured by Sumitomo 3M, Japan; where mushroom-shaped male elements were located in a density of 900 elements/square inch) and each of the female component samples given in Table 1 were cut in strips of 5 cm length and 2.5 cm width, respectively. Each of those samples was used and one male component was placed on one female component in such a manner that the elements of the female component were encountered with those of the male component face-to-face within a width of 2.5 cm and a length of 3 cm leaving the remaining length of 2 cm in a non-engaging manner by inserting a sheet of paper therebetween. Then an engaging operation was conducted by compressing the set sample for evaluation twice for coming-and-going along the longitudinal direction thereof with an engaging roller having a flat surface allowing us to apply a load of 19.6 N (2 kgf) per cm of the effective width of the touch and close fastener thereto. Thereafter, the touch and close fastener was disengaged at a breaking rate of 30 cm/min. wherein a male or female component end which did not participate in engagement was caught by each of a pair of chucks of a tensile tester. Chronological changes in the tension upon the peeling were recorded on a chart paper and an average of total 12 values (6 maximum points and 6 minimum ones) recorded on this chart paper was calculated. Five measurements were conducted for each of the samples and an average of the five measurements was converted to a value per cm of the width of the sample, which was recorded as the initial engaging force. Engaging force measurements were also conducted by subjecting the sample (its initial engaging force was measured) to the above engaging operation five times and ten times, respectively. The results are given in Table 2. In Table 2, for each engaging force at the fifth operation and the tenth operation, the ratio of the fifth engaging force and the tenth engaging force to the initial engaging force is given in terms of % in parentheses, respectively.
TABLE 2
Results of Measurement of Engaging Force (N/cm)
Initial
tenth
operation
fifth operation
operation
Examples
1
0.245
0.216 (88%)
0.186 (76%)
2
0.353
0.490 (139%)
0.284 (81%)
3
0.235
0.196 (83%)
0.226 (96%)
4
0.265
0.245 (93%)
0.216 (81%)
5
0.265
0.265 (100%)
0.216 (81%)
6
0.167
0.157 (94%)
0.137 (82%)
7
0.343
0.471 (137%)
0.349 (100%)
8
0.330
0.380 (115%)
0.253 (77%)
9
0.359
0.375 (104%)
0.244 (68%)
Comparative
Examples
1
0.265
0.196 (74%)
0.127 (48%)
2
0.657
0.490 (75%)
0.373 (57%)
It will be understood from the result shown in Table 2 and also from the constitution of each of the samples explained in Table 1 that, when Examples 1 to 9 where the present invention was applied were compared with Comparative Example 1, it is possible to improve an engaging force after repeated engagements in view of its reduction as a result of needle punching formation of the loops on or at a hydroentangled web. It will be particularly noted from the result for Examples 4 and 5 as compared with Comparative Example 1 that, although all of their initial engaging forces were substantially identical, the engaging forces achieved in the two Examples were 20 to 30% higher than that of Comparative Example 1 at the fifth operation and about 50% higher than that even at the tenth operation, respectively.
Further, it was noted from the comparison of Example 1 with Example 2 and also from the comparison of them with Example 7 that the relation between the firstly hydroentangled surface and the needle punched surface was not particularly limited when hydroentangling was applied to at least one side of the fiber web (in other words, a satisfactory durability was noted regardless of both cases where the surface to which high-pressure water jets were entered upon hydroentangling is identical with and different from the surface on which the loops were formed). In addition, it is clear that, although the absolute engaging force of the female component composed of only nonwoven fabric is inferior to that of Comparative Example 2 component composed of knitted or woven fabric, an engaging force after repeated engagements in each of Examples 1 to 9 was improved in view of its reduction to an extent of only about 20 to 30% from the initial stage, while Comparative Example 2 component's engaging force thereupon was around 40% of the initial stage in view of its the reduction.
Furthermore, it is understood from the comparison of Examples 1 to 7 with Examples 8 to 9 where the weight ratio of cross-lay web was changed that the effect of improving an engaging force in view of its reduction was lost, depending on where the content of the unidirectional web was increased and the weight ratio (W) of the cross-lay web was reduced to 60% or to 30%.
As mentioned hereinabove, the application of the techniques according to the present invention can solve the problem inherent in a nonwoven fabric female component for a touch and close fastener, with a good productivity, i.e., the problem of reduction in the engaging force upon repeated engagements whereby it is now possible to provide a low-cost female component, with good characteristics, for a touch and close fastener. | A simple and less expensive nonwoven female component for a mechanical refastenable fastening device (“touch and close fastener”) can be conveniently used in mostly disposable applications such as disposable diapers, disposable operating gowns, disposable underwear and other clothing. The nonwoven fabric female component includes projecting loops formed on one of the superficial sides of the nonwoven fabric. The nonwoven fabric comprises a hydroentangled web, and the loops are projectingly formed by needle punching on or at one of the superficial sides of the hydroentangled web. | 3 |
BACKGROUND OF THE INVENTION
(a) The Field of the Invention
The present invention relates to a process and a device for interlacing multifilament yarns.
(b) The Prior Art
A process is known for imparting a certain degree of coherency to yarns constituted by a plurality of substantially parallel filaments--whereby it is meant that the yarn is without twist or has a very low twist--so that they may be employed in weaving and typically for making warps. The known process consists essentially in directing an air jet onto the yarn which travels in a straight line while limiting the freedom of motion of the yarn and containing and deflecting the air stream after contact with the yarn, to an extent and in a manner which are different from case to case.
Typically such processes are carried out by means of devices which comprise a nozzle and a yarn guide and control organ. It is customary in the art improperly to call both those organs together "nozzle", while they should be considered as two distinct elements even when they are formed in a single body. The nozzle proper is of course essentially an air outlet orifice fed with air under pressure through an air feed passage or channel. The yarn guide and control organ, on the other hand, embodies either yarn guide devices or surfaces which limit the yarn motion in the direction of the air jet axis and/or in a direction perpendicular thereto, and often also comprises curved surfaces which are stricken by and deflect the air jet. In some devices, the nozzle and the guide and control organ are clearly distinguished and this latter sometimes merely consists of a surface, e.g. cylindrical, which limits the motion of the yarn in the direction of the air jet axis and lateraly deflects the flow lines of the air jet (see e.g. Italian Pat. No. 700.695). Other devices, e.g. that of U.S. Pat. No. 2,985,995, and others described in a series of patents which are developments and modifications of this latter, comprise a guide and control organ the functional portion of which is a cylindrical channel through which the yarn passes, while the nozzle is nothing but a bore having an axis perpendicular to the axis of the channel, and from which the air jet enters into the channel and therein acquires swirling motions. In nozzles of this type, it is usual that both the yarn passage channel and the air feed channel be formed in a single body, which justifies the fact that the whole device is called "nozzle".
The known processes and devices make it possible to interlace essentially parallel multifilament yarns at high speeds and with good efficiencies. The degree of coherency is measured, e.g., as described in the cited U.S. Pat. No. 2,985,995, by passing a hook carrying a standard weight between the filaments of the yarn and registering the number of times it is stopped while traversing a given length, or in other words by measuring the number of knots or more exactly "pseudo-knots" which the yarn has acquired. It is obvious that in such measurements the morphology of the yarn is at least temporarily modified by the measuring instrument, and the quantitative results they furnish have a comparison value but do not define or express the intimate structure of the interlaced yarn.
However, such known processes and devices involve a rather substantial consumption of compressed air which increases the cost of the final product. They have other drawbacks as well, different from case to case, e.g. a limitation of the range of yarns which may be processed, difficulties of starting the yarn in the device, sensitivity to tension variations, difficulty of regulation, complexity of construction and control, and so forth. Attempts to eliminate these drawbacks have not been wholly successful.
The present invention completely eliminates such disadvantages, and substantially improves the efficiency and the economy of the yarn interlacing operation, thanks to a process and a device which are based on a new principle, while remaining in the class of pneumatic yarn treatments and devices.
SUMMARY OF THE INVENTION
The process which is the object of the invention is characterized in that the yarn is forwarded through an interlacing zone, to which a jet of an interlacing gas, normally air, is also conveyed, in a non-rectilinear trajectory which is essentially planar and symmetric with respect to the jet axis, and under tension, the resultant of the tensional forces having a line of application which ideally coincides with the jet axis and a direction opposite to that of the jet. The jet is so directed as to contact the yarn in a zone about the point of application of the resultant force, and the freedom of motion of the yarn is limited both in the direction of the jet axis and in the direction perpendicular to such axis and to the plane in which the yarn trajectory lies.
The expression "ideally coincides" is to be understood as follows. The non-rectilinear trajectory of the yarn in the interlacing zone is determined by the contact of the yarn with surfaces located in such zone and in the vicinity of the gas jet. If the friction of the yarn on the surfaces is not taken into account, the yarn tension measured at any point of the yarn axis is constant. Under such conditions, i.e. if there were no friction, the line of application of the resultant of the tensional forces would substantially coincide with the jet axis. The friction, however, causes tension downstream of the surfaces, with respect to the direction of the yarn motion, to be greater than tension upstream thereof, and this difference causes a dissymmetry whereby the aforesaid resultant force is deviated by a small angle with respect to the jet axis, the deviation being towards the downstream direction. In any case, the resultant force is equal as to absolute value and opposite as to direction to the deviating force which may be considered as applied to the yarn to deviate it from the rectilinear trajectory which otherwise it would follow. In other words, the yarn is caused to travel between two fixed points, one situated upstream and the other downstream, of the interlacing zone, and in such zone a deviating force is applied to the yarn in the vicinity of the point in which it is contacted by the gas jet, which force displaces the yarn beyond the straight line defined by the two fixed points, the displacement being approximately in the direction of the jet.
Preferably, the invention is additionally characterized in that the jet is deviated by curved surfaces constituting a part of a cylindrical surface having its axis on the plane of the yarn trajectory and perpendicular to the gas jet axis and having a concavity directed towards the jet, swirling motions being imparted to the gas by such curved surfaces, which additionally serve to limit the freedom of motion of the yarn and to guide such motion in the interlacing zone.
The words "cylindrical surface" are to be understood in their broadest geometric meaning, i.e. as defining a surface generated by a straight line moving along a generatrix while remaining parallel to itself and that such cylindrical surface may have a circular or partially circular cross-section, but also, in general, any curvilinear, e.g. elliptical or generally oval, cross-section.
The device according to the invention comprises a nozzle for feeding and projecting a jet of a gas, practically air, into the interlacing zone, which nozzle comprises an orifice located substantially at the vertex of a convex surface, the convexity thereof being directed towards the trajectory of the yarn. Means guide the yarn in an essentially planar trajectory tangent to such convex surface at least in the vicinity of the nozzle orifice. An element limits the freedom of motion of the yarn both in the direction of the air jet axis and in directions perpendicular thereto and to the plane whereon the yarn trajectory lies. Preferably such element may comprise a grooved body having a plane of symmetry which coincides with the yarn trajectory plane and which has a cross-section, in a plane perpendicular to said last mentioned plane, which comprises a concave surface having its concavity directed towards the nozzle and serving both as a surface for containing and guiding the air jet and for limiting the freedom of motion of the yarn and guiding such motion.
Still preferably, the nozzle has two walls at its top and at the two sides of the orifice of the convex surface which embrace the trajectory of the yarn in the interlacing zone and still more preferably have a configuration, in a plane perpendicular to the air jet axis, which is slightly convex and directed towards the nozzle orifice, on the one and on the other side thereof, and is also preferably convergent towards the orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following description of a number of non-limitative embodiments thereof, with reference to the attached drawings wherein:
FIG. 1 is a schematic lateral view of a device according to a first embodiment of the invention;
FIG. 2 is a cross-section of FIG. 1 taken as indicated by the broken line II--II--II--II of FIG. 1, but on an enlarged scale;
FIG. 3 is a cross-section of FIG. 2 taken along line III--III of FIG. 2;
FIG. 4 is a lateral view, similar to FIG. 1, of a second embodiment of the invention;
FIG. 5 is an axial cross-section of the terminal portion of the nozzle taken on the plane of the yarn trajectory;
FIG. 6 is a lateral view of the nozzle portion of FIG. 5, a right angle to the plane of FIG. 4;
FIG. 7 is an end view of the nozzle;
FIG. 8 is an axial cross-section of the guide and control organ in the second embodiment of FIGS. 4 to 7;
FIGS. 9 and 10 are two cross-sections of the organ, both taken along line IX--IX of FIG. 8 but illustrating two constructional variants;
FIG. 11 is a cross-section of the organ taken along line XI--XI of FIG. 8 and illustrating both the variants of FIGS. 9 and 10; and
FIGS. 12 and 13 are respectively a lateral view with a part in cross-section and an axial cross-section of a comparison device or "nozzle" built according to the known art.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 to 3, in a first embodiment of the invention, the nozzle proper, generally indicated at 10, is constituted by a body having a cylindrical portion 11 which has a channel 12, terminating in an orifice 13, for the passage of compressed air, and which preferably tapers in its upper part 11' wherein it has a groove 14 whereby the nozzle body is reduced to two fins 15. Fins 15 are preferably limited towards the nozzle orifice 13 by surfaces 16 which are convex towards the nozzle. Yarn 20 is guided by suitable devices, e.g. yarn guides 21, 21', in such way that its trajectory comprises (FIG. 3) a curvilinear portion or arc 22 tangent to at least the central portion of a convex surface 17, and portions 23, 23' directed along the tangents to the ends of arc 22. In other words, it might be said that the thread guides or other guide organs 21, 21' tend to impart to the yarn a rectilinear trajectory therebetween and that the nozzle 10 is located in such a position as to deviate the yarn from such trajectory displacing the yarn beyond it in the direction of the air jet. It is obvious that, as a consequence of this arrangement, since the yarn travels with a certain tension, as more fully discussed hereinafter, and given the essential symmetry of the yarn trajectory, the resultant of the tension in the segment 23-22-23', is a force T, the line of application of which ideally coincides (and would actually coincide if there were no friction of the yarn on the nozzle) with the axis of channel 12 and therefore with the compressed air jet axis and is directed oppositely to the air jet, as shown in FIG. 3.
The fins 15 limit the freedom of motion of the yarn in directions which are perpendicular on the one hand to the air jet axis and on the other to the yarn trajectory plane, as is clearly seen in FIGS. 2 and 3. Such fins also limit to a certain extent the flow of the air jet which exits from the nozzle orifice 13.
The movement of the yarn in a direction parallel to that of the air jet is limited by suitable stop members, e.g. by thread guides 24, 24'.
A preferred embodiment of the device is illustrated in FIGS. 4 to 11. As is seen, nozzle 40 is similar to nozzle 10, and is provided with a body 41, a channel 42, and an orifice 43, respectively similar to body 11, channel 12, and orifice 13 of FIGS. 1 to 3, and with a convex surface 47, correponding to surface 17 of FIG. 3, on which the yarn slides and at the center of which the orifice 43 is located, but the fins 45 which correspond to fins 15 are much shorter and are adapted to engage the yarn only in the immediate vicinity of the nozzle orifice.
Preferably, body 41 is made of two parts, e.g. it may be of metal in its initial portion and have a top or plug 41' (FIGS. 4 to 6) of a ceramic material, wherein all the surfaces which contact the yarn are embodied. In this case too, surfaces 46 of fins 45 have a convexity towards the nozzle, as seen in FIG. 7.
Channel 42 preferably comprises a first cylindrical portion 50, a frusto-conical portion 51 and a narrower cylindrical orifice portion. Surfaces 46, of which FIG. 6 shows the widest profile 46' and the narrowest profile 46" as they are seen when looking along the yarn trajectory, are slanted inwardly from top to bottom to form a "V" shape and a "U" shape, respectively. The angle α of the two sides of profile 46" has a certain importance. The yarn control and guide organ, which contains and guides the air jet as well, is constituted by an open sleeve 60, located with its axis lying on the plane of the yarn trajectory and parallel to the average direction of the yarn, which may be identified with the tangent to the trajectory at the point at which the yarn rides over the orifice 43. As is seen in FIGS. 9 to 11, in the interlacing zone, i.e. in a plane perpendicular to the axis 68 of sleeve 60 and passing through the axis of nozzle channel 42 (FIGS. 5, 9 and 10), the sleeve has an outer surface 61 which may be of any shape, though for constructive reasons it is preferably circular cylindrical, and defines in its inner cavity an open concave channel, the cross-section of which may be circular (62', FIG. 10) or oval (62, FIG. 9) and e.g. approximately elliptical with the major axis directed in the direction of the air jet. The inner surface 63 or 63' of such channel spans an angle greater than 180° about the channel axis 68 passing through the center of such surface, which center has a precise geometrical meaning if the surface has a circular or elliptical cross-section as in the drawings, and anyway may be determined at least approximately from symmetry considerations if the surface has any other configuration. Preferably, where the surface ends, the cavity of sleeve 60 is limited by two connecting segments 64 (FIG. 9) or 64' (FIG. 10).
In a plane perpendicular to its axis, distant from the interlacing zone, such as the plane of FIG. 11, the cross-section of sleeve 60 is similar, however it extends at the two sides of the nozzle with fins 65 having rectilinear inner surfaces 66.
In FIG. 11, two possible profiles of the inner channel cavity are shown corresponding to those of FIGS. 9 and 10, the one 63 being elliptical and the other 63' being circular (the latter in broken lines).
Control and guide organ 60 is preferably arranged with respect to the nozzle as is shown in FIG. 4, in such a way that the yarn will face the opening of channel 62 (FIG. 9) when it is displaced by the air jet.
The device of FIGS. 4 to 11 is also provided with yarn guides 67, 67' or other yarn guide organs which perform the same function as the guide yarns 21, 21' of FIGS. 1 to 3.
The operation of the device hereinbefore described and the process which it carries out are, as has been said, different as to conception from those of the prior art. Indeed the nozzle, and more precisely the portion thereof which constitutes the air orifice and the zone adjacent thereto, has the additional function of deviating the yarn from its theoretical rectilinear trajectory and of imparting thereto a tension having the resultant in the desired direction. As a result, were no air to be fed to the nozzle, the yarn would slide on the nozzle orifice. The air jet displaces the yarn from the orifice and the resultant of the tension urges the yarn constantly back against the orifice. Therefore, the nozzle proper concurrently performs besides its normal air feed function, additional functions which in the prior art devices were performed by different portions of the interlacing device. The nozzle proper according to the invention, besides causing the displacement of the yarn from its rest trajectory by the impact of the air jet also has, as has been said, the function of initially containing such displacement, a further containment being effected by the control and guide organ which, in its simplest form, may be constituted merely by restraining bodies (21--21') as in the embodiment of FIGS. 1 to 3, and in its preferred form comprises a channel wherein not only is the yarn contained and guided, but also the air jet is deflected. Since the yarn has a constant, significant tendency to return towards the nozzle orifice, under the tension to which it is subjected, it does so by sliding on the surface of the guide and control organ cavity, and in all likelihood it rolls on such surface, so that instantaneous twists occur not only by effect of the air vortices but also and mainly by the effect of a planetary motion on the cavity surface, which intensify the interlacement of the yarn and confer to it a marked coherency although its average twist is obviously zero as in the prior art devices.
The preferred dimensional geometrical data of the device according to the invention, are the following: the radius of curvature in the axial plane (of FIGS. 3 and 5) of the yarn guide surfaces in the nozzle (17 or 47 in the embodiments illustrated) varies from 2 mm to 18 mm (greater radiuses causing contact problems). The diameter of orifice 13 or 43 varies from 0.4 mm to 2 mm. Angle α , above defined, varies from 25° to 120°. The average diameter of the channel of the guide and control organ varies from 1.5 mm to 6 mm. The distance of the axis 68 (FIGS. 9 to 11) of the guide and control organ channel from the nozzle orifice varies from 0.75 mm to 4.5 mm.
In carrying out the process, the yarn is maintained preferably at a tension between 3 and 300 g. and more preferably between 5 and 150 g., depending on the count. Angle β, (FIG. 4) defined between the two branches of the yarn, upstream and downstream of the nozzle orifice, varies from 140° to 175°. The pressure at which the compressed air is fed to the nozzle varies from 1 to 8 ATE (relative atmospheres).
The nozzle itself or at least its terminal portion in which the orifice and the surfaces which have been described are formed, is preferably made of a ceramic material, and so is the control and guide organ.
Some embodiments of the process according to the invention will now be described.
EXAMPLE 1
______________________________________count 210/36processing speed = 391 m/1'(sec.)radius of curvature (47) = 10 mmdiameter of the nozzle orifice (43) = 0.8 mmaverage diameter of theguide channel (62) = 3 mmdistance of axis (68) ofthe channel from nozzle orifice (43) = 2.7 mmangle β = 165°yarn tension = 20-25 g.______________________________________
The average number of pseudo-knots per meter of yarn which are obtained at various pressures are tubulated in the following
TABLE 1______________________________________PRESSURE (ATE) NUMBER OF KNOTS______________________________________2.5 22.43 27.83.5 31.64 31.84.5 32______________________________________
EXAMPLE 2
______________________________________count 940/136processing speed = 391 m/1'radius of curvature (47) = 10 mmdiameter of the orifice (43) = 1.2 mmangle α = 40°average diameter of theguide channel (62) = 4 mmdistance of axis (68) of thechannel from orifice (43) = 3.2 mmangle β = 165°yarn tension = 50-60 g.______________________________________
The average number of pseudo-knots per meter of yarn which are obtained at various pressures are tabulated in the following
TABLE 2______________________________________PRESSURE (ATE) NUMBER OF KNOTS______________________________________2.5 20.43 26.43.5 28.54 29.84.5 29.8______________________________________
The following Examples 3 and 4 are comparison examples carried out with the device according to the prior art illustrated in FIGS. 12 and 13, wherein 70 is the nozzle proper with a channel 71 and orifice 72, 73 is the control and guide organ in the form of a channel, and 74 is the yarn which follows a rectilinear trajectory.
EXAMPLE 3
______________________________________count 210/36processing speed = 391 m/1'diameter of the nozzleorifice (72) = 1.5 mmdiameter of the guide channelof control and guide organ (73) = 3 mmyarn tension = 20-25 g.______________________________________
The average number of pseudo-knots per meter of yarn thus obtained are tabulated in the following
TABLE 3______________________________________PRESSURE (ATE) NUMBER OF KNOTS______________________________________2.5 11.53 153.5 194 234.5 26______________________________________
EXAMPLE 4
______________________________________count 940/136processing speed = 391 m/l'diameter of the nozzle orifice (72) = 1.5 mmdiameter of the guide channel of control and guide organ (73) = 4 mmdistance of the axis (74) of the channel from the nozzle orifice (72) = 2.5 mmyarn tension = 50-60 g.______________________________________
The average number of pseudo-knots per meter of yarn obtained are tabulated in the following
TABLE 4______________________________________PRESSURE (ATE) NUMBER OF KNOTS______________________________________2.5 103 123.5 134 194.5 24______________________________________
A number of non-limitative embodiments of the invention have been described, but the invention may be carried into practice by persons skilled in the art with numerous variations and adaptations. | A process and a device for interlacing multifilament yarns includes forwang the yarn through an interlacing zone, to which an interlacing air jet is also conveyed through a nozzle, in a non-rectilinear trajectory which is essentially planar and symmetrical with respect to the jet axis, and under tension. The resultant of the tension forces have a line of application which ideally coincides with the jet axis and a direction opposite to that of the jet. The jet is so directed as to contact the yarn in a zone about the point of application of the resultant force. The nozzle includes an orifice located at the vertex of a convex surface directed towards the yarn trajectory, and means for guiding the yarn near the nozzle and for limiting the freedom of motion of the yarn. | 3 |
[0001] This application is a divisional of copending application Ser. No. 11/528,490 filed on Sep. 27, 2006 claims the benefit thereof and incorporates the same by reference.
FIELD OF THE INVENTION
[0002] The present invention provides a novel bisphenol compound. The present invention also provides a process for preparation of novel bisphenol compounds. More particularly the present invention provides a novel bisphenol compound of Formula I, where R 1 and R 2 are the same or different and independently, are either hydrogen or methyl at each occurrence.
[0000]
[0003] The present invention also provides a method for the synthesis of a compound of formula I from Cashew Nut Shell Liquid (CNSL), which is a renewable resource material.
BACKGROUND OF THE INVENTION
[0004] Cashew nut shell liquid (hereinafter “CNSL”) has been known for years to contain compounds useful in various aspects of chemical industry, with particular reference to plastics production. It is of immense interest for various applications. Technical grade CNSL is a commercially available product. CNSL comprises, in major proportion (typically about 80% by weight), a material also sold separately under the trade name CARDANOL™ which is a mixture of the hydroxyalkenylphenols 3-(pentadec-8-enyl)phenol, 3-(pentadeca-8,11-dienyl)phenol and 3-(pentadeca-8,11,14-trienyl)phenol. Minor constituents include about 18% of a material also sold separately under the trade name CARDOL™, which is a mixture of the 5-substituted resorcinols, and about 2% 2-methylcardol, which is a mixture of the corresponding 2-methyl-5-substituted resorcinols, and other materials that have not been identified.
[0005] Bisphenols are known in the art to be useful chemicals. They have been used as difunctional monomers in preparation of various polymers, such as epoxy resins, polyesters, polyethersulfones, polyetherketones, polyetherimides, polyarylates and, in particular, polycarbonates.
[0006] It is well known in the art that incorporation of a long alkyl chain in a polymer backbone imparts properties such as increase in the segmental mobility, solubility and hence it improves processability of the material. The use of bisphenols having long chain aliphatic substituent as a comonomer is known to offer polymer material with high flow and improved impact resistance. It is therefore of great interest and importance to synthesise new bisphenols with alkyl radical in their structure having the potential of affording polymer material with high processability and impact strength. It is of particular interest to develop bisphenols, which may be easily and cheaply obtained from readily available and renewable resource material such as CNSL.
[0007] The inventors herein are unaware of any prior art for preparation of the bisphenols of the structure identified above as Formula I.
OBJECTS OF THE INVENTION
[0008] The main object of the present invention is to provide a novel bisphenol compound of formula (I).
[0009] Another object of the invention is to provide a class of novel bisphenol compounds starting from naturally occurring renewable material; CNSL.
[0010] Another object of the invention is to provide a process for the preparation of a novel bisphenol compound of formula (I).
SUMMARY OF THE INVENTION
[0011] Accordingly the present invention provides a bisphenol compound of formula (I)
[0000]
[0000] wherein R 1 and R 2 are the same or different and are independently either hydrogen or methyl at each occurrence.
[0012] In one embodiment, the bisphenol compound is selected from 1,1,1-[bis(4-hydroxyphenyl)-4′-pentadecylphenyl]ethane and 1,1,1-[bis(3-methyl-4-hydroxyphenyl)-4′-pentadecylphenyl]ethane.
[0013] The present invention also provides a process for the preparation of a bisphenol compound of formula (I),
[0000]
[0000] wherein R 1 and R 2 are the same or different and are independently either hydrogen or methyl at each occurrence, the process comprising the steps of:
[0014] (a) dehydroxylating 3-pentadecyl phenol of formula (II)
[0000]
[0000] by reacting the 3-pentadecyl phenol with 1-phenyl-5-chlorotetrazole of formula (III)
[0000]
[0000] in presence of a weak base in acetone, refluxing the reaction mixture, removing solvent and pouring the resulting concentrate in water to obtain a precipitate, followed by recrystallization in alcohol to obtain 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl of formula (IV),
[0000]
[0000] (b) hydrogenolysing 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl of formula (IV), in the presence of about 5% palladium-on-charcoal, in an aromatic hydrocarbon solvent, filtering the reaction mixture and washing insoluble residue with hot alcohol, combining the filtrates, concentrating the combined filtrate by removing the solvent to obtain a sticky residue, extracting residue with toluene and washing it with an aqueous metal hydroxide and then again by water, followed by removal of solvent to obtain pentadecyl benzene of formula (V),
[0000]
[0000] (c) acetylating the pentadecyl benzene of formula (V) with an acetylating agent, in the presence of a Lewis acid catalyst, in an organic solvent, warming the reaction mixture, pouring the reaction mixture in ice, extracting the resultant compound with a halocarbon solvent, washing extracts so obtained with dilute HCl and then again by water, followed by removal of solvent to obtain 4-acetyl pentadecyl benzene of formula (VI),
[0000]
[0000] (d) reacting 4-acetyl pentadecyl benzene of formula (VI) with substituted or unsubstituted phenol, in the presence of an acidic catalyst, dissolving the reaction mixture in ethyl acetate and subsequently washing with an aqueous solution of a weak base and water, respectively, removing the solvent and purifying the resultant product to obtain the desired bisphenol compound of formula (I).
[0015] In one embodiment of the invention the weak base used in step (a) is selected from potassium carbonate and sodium carbonate.
[0016] In another embodiment the alcohol used in step (a) is selected from methanol and ethanol.
[0017] In another embodiment, the refluxing in step (a) is carried out for a period of at least 16 hours.
[0018] In another embodiment the aromatic hydrocarbon solvent used in hydrogenolysis in step (b) is selected from toluene and benzene.
[0019] In another embodiment, hydrogenolysing in step (b) is carried out in a Parr reactor.
[0020] In another embodiment, step (b) is carried out at a pressure of about 40 psi and at a temperature in the range of 3540° C. for at least 8 hours.
[0021] In another embodiment the acetylating agent used in step (c) is selected from the group consisting of acetic acid, acetic anhydride and acetyl chloride.
[0022] In another embodiment the metal hydroxide used is an alkali metal hydroxide selected from sodium hydroxide and potassium hydroxide.
[0023] In another embodiment the Lewis acid catalyst used in step (c) is selected from AlCl 3 and BF 3 .
[0024] In another embodiment the organic solvent used for acetylation in step (c) is selected from a halogenated hydrocarbon or a nitrogen compound.
[0025] In another embodiment the halogenated hydrocarbon solvent is selected from dichloromethane and chloroform.
[0026] In another embodiment the nitrogen compound used as an organic solvent is selected from nitro methane and nitro benzene.
[0027] In another embodiment, in step (c) acetylation is carried out at a temperature below 5° C., for a period of at least about 2 hours, followed by warming the reaction mixture to a temperature of 30-40° C., for at least 5-6 hours.
[0028] In another embodiment the acid catalyst used in phenol condensation in step (d) is selected from the group consisting of acidic clays, sulfated zirconia, 3-mercaptopropionic acid, glacial acetic acid, hydrogen chloride and any mixture thereof.
[0029] In another embodiment, in step (d) reaction of 4-acetyl pentadecyl benzene of formula (VI) with substituted or unsubstituted phenol is effected at a temperature in the range of 30-50° C., for a period of about 4 days.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention relates to novel bisphenol compounds useful as difunctional monomers for the synthesis of various high performance polymers. The compounds of the invention are preferably synthesized from Cashew Nut Shell Liquid (CNSL), which is a renewable resource material. The bisphenol compounds prepared according to the invention are 1,1,1-[bis(4-hydroxyphenyl)-4′-pentadecylphenyl]ethane and 1,1,1-[bis(3-methyl-4-hydroxyphenyl)-4′-pentadecylphenyl]ethane.
[0031] The bisphenol compounds of the present invention are of formula (I),
[0000]
[0000] wherein R 1 and R 2 are identical or different and independently at each occurrence represent hydrogen or methyl.
[0032] Preparation of Bisphenol Compounds of Formula I Comprises of Three Steps, Viz., Step A, B and C as shown in Scheme (I) below.
[0000]
[0033] Step A of the method of the invention comprises dehydroxylation of 3-pentadecyl phenol to obtain pentadecyl benzene.
[0034] The replacement of phenolic hydroxyl group by hydrogen is an important organic transformation. Several methods are available for dehydroxylation such as, use of: cyclohexene/Pd/C/AlCl 3 (Synthesis, 1978, 397), HI/CH 3 COOH (J. Org. Chem., 1979, 44, 26, 4813), NaBH 4 /NiCl 2 (J. Chem. Soc. Perkin Trans. I, 1992, 1897), 1-phenyl-5-chlorotetrazole/[H]/Pd—C (J. Am. Chem. Soc., 1966, 88, 4271). Phenolic hydroxyl group can be replaced by hydrogen in two steps: conversion of phenol to ether followed by cleavage with an alkali metal in liquid ammonia. (J. Org. Chem., 1973, 38, 13, 2314; J. Org. Chem., 1964, 29, 3124; J. Org. Chem., 1966, 31, 1662), (J. Am. Chem. Soc., 1937, 59, 603; J. Am. Chem. Soc., 1937, 59, 1488; J. Am. Chem. Soc., 1938, 60, 94). A traceless perfluoroalkylsulfonyl (PFS) linker was reported for the deoxygenation of phenols (Org. Lett., 2001, 3, 17, 2769).
[0035] In Step A of the process of preparation of pentadecyl benzene, the use is made of 1-phenyl-5-chlorotetrazole for etherification reaction with 3-pentadecyl phenol, followed by catalytic hydrogenolysis being most preferred; among the methods available for dehydroxylation of phenol.
[0036] In the present invention, the process for the preparation of 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl, comprises reaction of 3-pentadecyl phenol with 1-phenyl-5-chlorotetrazole in presence of potassium carbonate as a base and acetone as a solvent, refluxing temperature is necessary in the duration of 16-18 hours for complete etherification reaction. The amount of potassium carbonate is double over stoichiometric amount of substrate.
[0037] In catalytic hydrogenolysis step, while subjecting 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl to hydrogenolysis, the catalyst 5% palladium-on-charcoal is most preferred, with a proportion of 20%-40% by weight, pressure of 40-60 p.s.i., and temperature in the range of 35-40° C. being most preferred.
[0038] Step B of the method of the invention comprises acetylation of pentadecyl benzene of formula II with acetyl chloride selectively at para-position using a Lewis acid catalyst., under classical acetylation reaction conditions.
[0039] U.S. Pat. No. 4,663,484 describes acetylation of aromatics. Suitable conditions for acetylation are described in J. Am. Chem. Soc. 1999, 121, 2657-2661. Usable examples of acetylating agents can include acetic acid, acetic anhydride and acetyl chloride, with acetyl chloride being particularly preferred. The acetylating agent is preferably used in a proportion from 1 to 1.5 moles per mole of pentadecyl benzene, with 1 to 1.2 moles being more preferred.
[0040] The Lewis acid catalysts used in acetylation reaction are generally AlCl 3 or BF 3 . The acetylation reaction in step A may preferably be conducted in a solvent. In general, it is possible to use any one of the solvents, which are typically employed for acetylation of aromatic compounds. Usable examples can include any organic halogen compounds such as dichloromethane, chloroform and nitro compounds such as nitromethane, nitrobenzene. However, use of halocarbon solvents such as dichloromethane, chloroform is preferred. Preferably acetylation reaction is conducted in a nitrogen atmosphere. The reaction can be effected in a temperature range of from 0° C. to 40° C. to attain selectivity and better yield. The yields from this reaction are virtually quantitative and the quality of acetylated 4-pentadecyl benzene is such that it can be directly used for phenol condensation reaction.
[0041] Step C of the present invention comprises reacting 4-acetyl pentadecyl benzene, under reaction producing conditions, with a phenolic compound, substituted or unsubstituted one. Such conditions include presence of an acidic catalyst, as illustrated by ion exchange resins in the acid form, acidic clays, sulfated zirconia and excess hydrogen chloride, the later preferably used in combination with a mercaptan such as 3-mercaptopropionic acid. U.S. Pat. No. 6,255,439 describes methods of phenol condensation reaction with carbonyl compound for bisphenol synthesis, the disclosures of which are incorporated by reference herein. For phenol condensation reaction temperatures in the range of about 10° C.-50° C. are typical.
[0042] The intermediates and products formed in each step A-B-C can be worked up and isolated by conventional means. These include solvent removal (when solvent is employed), washing, drying and recrystallisation.
[0043] The following examples are illustrative of the invention and should not be construed to limit the scope thereof in any manner.
EXAMPLE I
Synthesis of 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl
[0044] A 500-ml., round-bottomed flask fitted with an efficient condenser and a magnetic stirring bar was charged with 3-pentadecyl phenol (25 g, 82 mmol), 1-phenyl-5-chlorotetrazole (14.82 g, 82 mmol), anhydrous potassium carbonate (22.69 g, 164.1 mmol) and 250 ml acetone. The mixture was stirred and heated under reflux for 18 hours. After cooling, the reaction mixture was concentrated; 100 ml water was added and cooled overnight at 5° C. The solid obtained was collected by filtration and dried in air, giving a crude product, which was then dissolved in 100 ml hot methanol. The solution was filtered while hot to remove small amount of insoluble material and cooled in ice, yielding 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl as a white solid. The yield obtained was 26 g. (70% of the theoretical).
EXAMPLE II
Synthesis of pentadecyl benzene
[0045] Into a solution of 3-pentadecyl-1-(1-phenyl-tetrazolyloxy)phenyl (20 g, 44.5 mmol) in 200 ml toluene palladium-on-charcoal (4 g, 20% by weight) was added, and the mixture was shaken with hydrogen in a Parr apparatus at 40 p.s.i. and 40° C. for 8 hours. The mixture was filtered, and the insoluble residue was washed with hot ethanol (3×100 ml). The filtrates were combined and concentrated leaving a sticky residue, which was dissolved in 200 ml toluene, shaken with 100 ml of 10% aqueous sodium hydroxide solution, and the layers were separated. The aqueous layer was again extracted with 100 ml toluene. After combining, organic layer was washed with water and dried over sodium sulfate. Removal of toluene yielded crude pentadecyl benzene, which was then purified by column chromatography. Pure pentadecyl benzene was obtained in a yield of 11 g (85% of the theoretical).
EXAMPLE III
Synthesis of 4-acetyl pentadecyl benzene
[0046] A 500-ml-three-necked round-bottomed flask, with an efficient cooling was charged with aluminium chloride (5.82 g, 43.67 mmol) and dichloromethane (100 ml). Acetyl chloride (3.42 g, 43.67 mmol) was added to the vigorously stirred reaction mixture over a period of 15 minutes. Pentadecyl benzene (10 g, 34.66 mmol) was added over a period of 30 minutes; the clear solution was stirred at 0° C. for 2 hours and allowed to warm to room temperature. The reaction mixture was poured in ice and extracted with dichloromethane (3×100 ml), the combined organic layers was washed with 1 N hydrochloric acid (2×30 ml) and water (3×50 ml), dried over sodium sulfate and the solvent was evaporated to obtain 4-acetyl pentadecyl benzene as a low melting faint yellow solid. The yield was 10 g (87% of theoretical).
EXAMPLE IV
Synthesis of 1,1,1-[bis(4-hydroxyphenyl)-4′-pentadecylphenyl]ethane
[0047] A 250-ml-three-necked round-bottomed flask fitted with a magnetic stirrer and gas dip tube was charged with 4-acetyl pentadecyl benzene (5 g, 15.15 mmol), phenol (8.54 g, 90.90 mmol) and 0.13 ml of 3-mercaptopropionic acid. The resulting mixture was stirred at room temperature for 15 minutes, after which anhydrous hydrogen chloride gas was bubbled into the reaction mixture for 4 days at 50° C., whereupon the mixture solidified. The reaction mixture was dissolved in ethyl acetate (500 ml), washed with aqueous sodium bicarbonate (3×100 ml) solution and water (3×100 ml), layers separated and dried over sodium sulfate. Vacuum stripping of solvent afforded a pink solid, which was purified by column chromatography. The desired 1,1,1-[bis(4-hydroxyphenyl)-4′-pentadecylphenyl]ethane was obtained in a yield of 4 g (52% of theoretical).
EXAMPLE V
Synthesis of 1,1,1-[bis(3-methyl-4-hydroxyphenyl)-4′-pentadecylphenyl]ethane
[0048] A 250-ml-three-necked round-bottomed flask fitted with a magnetic stirrer and gas dip tube was charged with p-acetyl pentadecyl benzene (5 g, 15.15 mmol), o-cresol (9.83 g, 90.90 mmol) and 0.13 ml of 3-mercaptopropionic acid. The resulting mixture was stirred at room temperature for 15 minutes, after which anhydrous hydrogen chloride gas was passed in to mixture for 4 days at 50° C., whereupon the mixture solidified. The reaction mixture was dissolved in ethyl acetate (500 ml), washed with aqueous sodium bicarbonate (3×100 ml) solution and water (3×100 ml), and dried over sodium sulfate. Vacuum stripping of solvent afforded a pink solid, which was purified with column chromatography. The desired 1,1,1-[bis(3-methyl-4-hydroxyphenyl)-4′-pentadecylphenyl]ethane was obtained in a yield of 4 g (50% of theoretical).
ADVANTAGES OF THE INVENTION
[0049] The present invention provides novel bisphenol compounds with alkyl radical in their structure, which has the potential to be utilized as difunctional monomers for the preparation high performance polymers with excellent processability by virtue of the presence of pentadecyl chain.
[0050] The present invention also provides a simple and economical procedure for the synthesis of novel bisphenol compounds since it uses CNSL as the starting material, which is a naturally occurring and renewable resource material.
[0051] It will be apparent to those skilled in the art that various changes and modifications may be made to the disclosure herein without departing from the invention. It is intended that the appended claims cover changes and modifications that fall within the true spirit and scope of the invention. | The present invention provides a novel bisphenol compound of formula (I).
wherein R 1 and R 2 are the same or different and are independently either hydrogen or methyl at each occurrence. The present invention also provides a process for preparation of these bisphenol compounds starting from Cashew Nut Shell Liquid (CNSL);—a renewable resource material. The bisphenols prepared in the present invention can be utilized as difunctional monomers for the preparation of various polymers such as epoxy resins, polyesters, polyethersulfones, polyetherketones, polyetherimides, polyarylates, polycarbonates, etc. | 2 |
RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Patent Application No. 60/932,644 filed Jun. 1, 2007 the contents of which are incorporated by reference herein.
FIELD OF INVENTION
[0002] This invention relates to the field of Atmospheric Pressure Ion (API) sources interfaced to mass spectrometers. Such API sources include but are not limited to Electrospray, Atmospheric Pressure Chemical Ionization (APCI), Combination Ion Sources, Atmospheric Pressure Charge Injection Matrix Assisted Laser Desorption, DART and DESI. The invention comprises the use of new electrolyte species to enhance the analyte ion signal generated from these API sources interfaced to mass spectrometers.
BACKGROUND OF THE INVENTION
[0003] Charged droplet production unassisted or pneumatic nebulization assisted Electrospray (ES) requires oxidation of species (positive ion polarity ES) or reduction of species (negative ion polarity) at conductive surfaces in the sample solution flow path. When a metal Electrospray needle tip is used that is electrically connected to a voltage or ground potential, such oxidation or reduction reactions (redox) reactions occur on the inside surface of the metal Electrospray needle during Electrospray ionization. If a dielectric Electrospray tip is used in Electrospray ionization, redox reactions occur on an electrically conductive metal surface contacting the sample solution along the sample solution flow path. This conductive surface typically may by a stainless steel union connected to a fused silica Electrospray tip. The Electrospray sample solution flow path forms one half cell of an Electrochemical or voltaic cell. The second half of the Electrochemical cell formed in Electrospray operates in the gas phase. Consequently, operating rules that can be used to explain or predict the behavior of liquid to liquid Electrochemical cells may be applied to explain a portion of the processes occurring in Electrospray ionization. The electrolyte aids in promoting redox reactions occurring at electrode surfaces immersed in liquid in electrochemical cells. The electrolyte not only plays a role in the initial redox reactions required to form single polarity charged liquid droplets but also fundamentally affects the production of sample related ions from rapidly evaporating liquid droplets and their subsequent transport through the gas phase into vacuum. Additional charge exchange reactions can occur with sample species in the gas phase. The mechanism by which the electrolyte affects liquid and gas phase ionization of analyte species is not clear
[0004] The type and concentration of electrolyte species effects ES ionization efficiency. The electrolyte type and concentration and sample solution composition will affect the dielectric constant, conductivity and pH of the sample solution. The relative voltage applied between the Electrospray tip and counter electrodes, the effective radius of curvature of the Electrospray tip and shape of the emerging fluid surface determine the effective electric field strength at the Electrospray needle tip. The strength of the applied electric field is generally set just below the onset of gas phase breakdown or corona discharge in Electrospray ionization. With an effective upper bound on the electric field that is applied at the Electrospray tip during Electrospray operation, the Electrospray total ion current is determined by the solution properties as well as the placement of the conductive surface along the sample solution flow path. The effective conductivity of the sample solution between the nearest electrically conductive surface in contact with the sample solution and the Electrospray tip plays a large role in determining the Electrospray total ion current. It has been found with studies using Electrospray Membrane probes that the ESMS analyte signal can vary significantly with Electrospray total ion current. A description of the Electrospray Membrane probe is given in U.S. patent application Ser. Nos. 11/132,953 and 60/840/095 and incorporated herein by reference.
[0005] ES signal is enhanced when specific organic acid species such as acetic and formic acids are added to organic and aqueous solvents. Conversely, ES signal is reduced when inorganic acids such as hydrochloric or trifluoroacetic acid are added to Electrospray sample solutions. Although mechanisms underlying variation in Electrospray ionization efficiency due to different electrolyte counter ion species have been proposed, explanations of these root modulators underlying Electrospray ionization processes remain speculative. Conventional electrolytes added to sample solutions in Electrospray ionization are generally selected to maximize Electrospray MS analyte ion signal Alternatively, electrolyte species and concentrations are selected to serve as a reasonable compromise to optimize upstream sample preparation or separation system performance and downstream Electrospray performance. Trifluoroacetic acid may be added to a sample solution to improve a reverse phase gradient liquid chromatography sample separation but its presence will reduce the Electrospray MS signal significantly compared with Electrospraying with art organic electrolyte such as Formic or Acetic acid added to the sample solution Generally for polar analyte species, the highest Electrospray MS signal will be achieved using a polar organic solvent such as methanol in water with acetic or formic acid added as the electrolyte. Typically, a 30:70 to 50:50 methanol to water ratio is run with acetic or formic acid concentrations ranging from 0.1% to over 1%. Running non polar solvents, such as acetonitrile, with water will reduce the ESMS signal for polar compounds and adding inorganic acid will reduce ESMS signal compared to the signal achieved using a polar organic solvent in water with acetic or formic acid. Several species of acids bases and salts have been used at different concentrations and in different solvent compositions as electrolyte species in Electrospray ionization to maximize ESMS analyte species. For some less polar analyte samples that do not dissolve in aqueous solutions, higher ESMS signal is achieved running the sample in pure acetonitrile with an electrolyte. For compounds such as carbohydrates with low or no proton affinity, adding a salt electrolyte may product higher ESMS signal.
[0006] The invention comprises using a new set of electrolyte species in Electrospray ionization to improve the Electrospray ionization efficiency of analyte species compared with ES ionization efficiency achieved with conventional electrolyte species used and reported for Electrospray ionization. Electrospraying with the new electrolyte species increases ESMS analyte signal amplitude by a factor of two to ten compared to the highest ESMS signal achieved using acetic or formic acids. ESMS signal enhancements have been achieved whether the new electrolytes are added directly to the sample solution or added to the second solution of an Electrospray membrane probe. When convention acid or salt electrolytes added to the sample solution are Electrosprayed in positive polarity mode, the anion from these electrolytes does not readily appear in the positive ion spectrum. As expected, the anion of these electrolytes does appear in the negative ion polarity ESMS spectrum. One distinguishing characteristic of the new electrolytes comprising the invention is that a characteristic protonated or deprotonated parent related ion from the electrolyte species appears in both positive and negative polarity spectrum acquired using Electrospray ionization. The positive polarity electrolyte ion appearing in the positive polarity Electrospray mass spectrum is the (M+H) + species with the (M−H) − species appearing in the negative polarity Electrospray mass spectrum.
SUMMARY OF THE INVENTION
[0007] One embodiment of the invention comprises conducting Electrospray ionization of an analyte species with MS analysis where at least one of a new set of electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic is added directly to the sample solution. The electrolyte may be included in the sample solution from its fluid delivery system or added to the sample solution near the Electrospray tip through a tee fluid flow connection.
[0008] Another embodiment of the invention is running at least one of a set (Anew electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic in the second solution flow of an Electrospray membrane probe during Electrospray of the sample solution. The concentration of the new electrolyte can be varied or scanned by running step functions or gradients through the second solution flow path. The second solution flow is separated from the sample solution flow by a semipermeable membrane that allows reduced concentration transfer of the new electrolyte into the sample solution flow during Electrospray ionization with MS analysis.
[0009] Another embodiment of the invention is running at least one of a set of new electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic in the second solution of an Electrospray membrane probe during Electrospray of the sample solution that contains a second electrolyte species. The addition of the new electrolyte to the second solution flow increases the Electrospray MS signal even if the second electrolyte species, when used alone, reduces the ESMS analyte signal. The concentration of the new electrolyte in the second solution flow can be step or ramped to maximize analyte ESMS signal
[0010] Another embodiment of the invention comprises running at least one of a set of new electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic in the downstream membrane section second solution flow of a multiple membrane section Electrospray membrane probe during Electrospray ionization with MS analysis. One or more membrane sections can be configured upstream in the sample solution flow path from the downstream Electrospray membrane probe. Electrocapture and release of samples species using upstream membrane sections can be run with electrolyte species that optimize the Electrocapture processes independently while a new electrolyte species is run through the downstream membrane section second solution flow to optimize Electrospray ionization efficiency of the analyte species.
[0011] In yet another embodiment of the invention, at least one of the new electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic are added to the sample solution in a single APCI inlet probe or sprayed from a second solution in a dual APCI inlet probe to enhance the ion signal generated in Atmospheric Pressure Corona Discharge Ionization.
[0012] In another embodiment of the invention, at least one of the new electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic are added to the solution Electrosprayed from a reagent ion source comprising an Electrospray ion generating source configured in a combination ion source including Electrospray ionization and/or Atmospheric Pressure Chemical Ionization.
[0013] In yet another embodiment of the invention, at least one of the new electrolytes including but not limited to Benzoic acid, Cyclohexanecarboxylic Acid or Trimethyl Acetic are added to the solution that is nebulized followed by corona discharge ionization forming a reagent ion source configured in a combination ion source including Electrospray ionization and/or Atmospheric Pressure Chemical Ionization.
BRIEF DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a schematic of an Electrospray Ion Source interfaced to a mass spectrometer.
[0015] FIG. 2 is a cross section diagram of an Electrospray Membrane probe.
[0016] FIG. 3 is a zoomed in view of the sample solution flow channel, the second solution flow channel and the semipermeable membrane in an Electrospray Membrane Probe
[0017] FIG. 4 shows a single section Electrospray Membrane probe integrated with pneumatic nebulization sprayer mounted on an Electrospray ion source probe mounting plate.
[0018] FIG. 5 is a schematic of a three section Electrospray Membrane probe
[0019] FIG. 6 is a diagram of a combination atmospheric pressure ion source comprising a sample solution Electrospray inlet probe and an Electrospray reagent ion source.
[0020] FIG. 7 shows the ESMS ion signal curves for a 1 μM Hexatyrosine in a 1:1 methanol:water solution Electrosprayed at a flow rate of 10 μl/min while running electrolyte concentration gradients in the Electrospray Membrane probe second solution flow using conventional electrolyte species and a new electrolyte species.
[0021] FIG. 8 shows the ESMS signal curves for a 1 μM Hexatyrosine in a 1:1 methanol:water solution Electrosprayed at a flow rate of 10 μl/min while running conventional and new electrolyte species concentration gradients in the Electrospray Membrane probe second solution flow and with benzoic acid added directly to the sample solution at different concentrations.
[0022] FIG. 9 shows a set of ESMS signal curves comparing ESMS ion signal of a 1 μM Hexatyrosine in a 1:1 methanol: water solution Electrosprayed at a flow rate of 10 μl/min for different concentrations of acetic acid and cyclohexanecarboxylic acid added directly to the sample solution
[0023] FIG. 10 shows a set of ESMS signal curves comparing positive polarity ESMS ion signal of a 1 μM Hexatyrosine in a 1:1 methanol:water solution Electrosprayed at a flow rate of 10 μl/min while running acetic acid and benzoic acid electrolyte concentration gradients in the Electrospray Membrane probe second solution flow with pure solvent sample solutions and with 0.001% trifluoroacetic acid added to the sample solution.
[0024] FIG. 11 shows a set of ESMS signal curves comparing negative polarity ESMS ion signal of a 1 μM Hexatyrosine in a 1:1 methanol:water solution Electrosprayed at a flow rate of 10 μl/min while running acetic acid and benzoic acid electrolyte concentration gradients in the Electrospray Membrane probe second solution flow with pure solvent sample solutions.
[0025] FIG. 12 shows a set of ESMS signal curves comparing positive polarity ESMS ion signal of a 1 μM reserpine in 1:1 methanol:water solution running at a flow rate of 10 μl/min for acetic acid, benzoic acid and trimethyl acetic acids added individually to the sample solution at different concentrations.
[0026] FIG. 13 shows a set of ESMS signal curves comparing positive polarity ESMS ion signal of a 1 μM leucine enkephalin in a 1:1 methanol:water solution running at a flow rate of 10 μl/min for acetic acid, benzoic acid, cyclohexanecaboxylic acid and trimethyl acetic acids added individually to the sample solution at different concentrations.
[0027] FIG. 14A is a positive polarity Electrospray mass spectrum of benzoic Acid and FIG. 14B is a negative polarity mass spectrum of benzoic acid.
[0028] FIG. 15A is a positive polarity Electrospray mass spectrum of trimethyl acetic acid and FIG. 15B is a negative polarity mass spectrum of trimethyl acetic acid.
[0029] FIG. 16A is a positive polarity Electrospray mass spectrum of cyclohexanecarboxylic acid and FIG. 16B is a negative polarity mass spectrum of cyclohexanecarboxylic acid.
DESCRIPTION OF THE INVENTION
[0030] Electrospray total ion current, for a given applied electric field, is a function of the sample solution conductivity between the Electrospray tip and the first electrically conductive surface in the sample solution flow path. The primary charge carrier in positive ion Electrospray is generally the H+ ion which is produced from redox reactions occurring at electrode surfaces in contact with the sample solution in conventional Electrospray or a second solution in Electrospray Membrane probe. The electrolyte added to the sample or second solution plays a direct or indirect role in adding or removing H+ ions in solution during Electrospray ionization. The indirect role in producing H+ ions is the case where the electrolyte aids in the electrolysis of water at the electrode surface to produce H+ ions. The direct role an electrolyte can play is to supply the H+ ion directly from dissociation of an acid and loss of an electron at the electrode surface. The type and concentration of the electrolyte anion or neutral molecule in positive ion polarity and even negative ion polarity significantly affects the Electrospray ionization efficiency for most analyte species. The mechanism or mechanisms through which the electrolyte operates to affect ion production in Electrospray ionization is not well understood. Even the role an electrolyte plays in the redox reactions that occur during Electrospray charged droplet formation is not well characterized. Consequently, the type and concentration of the electrolyte species used in Electrospray ionization is determined largely through trial and error with decisions based on empirical evidence for a given Electrospray MS analytical application. To this end, a number of electrolyte species were screened using an Electrospray membrane probe to determine if electrolyte species different from those used conventionally or historically provided improved Electrospray performance. A set of such new electrolytes was found which demonstrated improved analyte ESMS signal in both positive and negative positive modes. The set of new electrolytes comprises but may not be limited benzoic acid, trimethylacetic acid and cyclohexanecaboxylic acid.
[0031] As noted above, unlike electrolytes conventionally or historically used in Electrospray ionization, when Electrospraying with a new electrolyte, a characteristic electrolyte ion peak is generated in both positive and negative ion polarity mode. The (M+H) + ion is generated for benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid in positive polarity Electrospray ionization. Conversely, the (M−H) − ion, as expected, is generated when Electrospraying benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid in negative polarity as shown in FIGS. 14 , 15 and 16 . The mechanism or mechanisms by which the new electrolyte enhances the Electrospray signal may occur in the liquid phase, gas phase or both. Benzoic acid has a low gas phase proton affinity so protonated benzoic acid ion may readily donate an H+ to gas phase neutral analyte species or may reduce the neutralization of the Electrospray produced analyte ion by transferring protons to competing higher proton affinity contamination species in the gas phase.
[0032] A cross section schematic of Electrospray ion source 1 is shown in FIG. 1 . Electrospray sample solution inlet probe 2 comprises sample solution flow channel or tube 3 , Electrospray tip 4 and annulus 5 through which pneumatic nebulization gas 7 flows exiting concentrically 6 around Electrospray tip 4 . Different voltages are applied to endplate and nosepiece electrode 11 , capillary entrance electrode 12 and cylindrical lens 13 to generate single polarity charged droplets in Electrospray plume 10 . Typically, in positive polarity Electrospray ionization, Electrospray tip 4 would be operated at ground potential with −3 KV, −5 KV and −6 KV applied to cylindrical lens 13 , nosepiece and endplate electrode 11 and capillary entrance electrode 12 respectively. Gas heater 15 heats countercurrent drying gas flow 17 . Charged droplets comprising charged droplet plume 10 produced by unassisted Electrospray or Electrospray with pneumatic nebulization assist evaporate as they pass through Electrospray source chamber 18 . Heated countercurrent drying gas 14 exiting through the orifice in nosepiece electrode 11 aids in the drying of charged liquid droplets comprising Electrospray plume 10 . A portion of the ions generated from the rapidly evaporating charged liquid droplets are directed by electric fields to pass into and through orifice 20 of dielectric capillary 21 into vacuum. Ions exiting capillary orifice 20 are directed through skimmer orifice 27 by the expanding neutral gas flow and the relative voltages applied to capillary exit lens 23 and skimmer electrode 24 . Ions exiting skimmer orifice 27 pass through ion guide 25 and into mass to charge analyzer 28 where they are mass to charge analyzed and detected as is known in the art
[0033] The analyte ion signal measured in the mass spectrometer is due in large part to efficiency of Electrospray ionization for a given analyte species. The Electrospray ionization efficiency includes the processes that convert neutral molecules to ions in the atmospheric pressure ion source and the efficiency by which the ions generated at atmospheric pressure are transferred into vacuum. The new electrolyte species may play a role in both mechanisms that affect Electrospray ionization efficiency. In one embodiment of the invention, at least one of the new electrolytes including, benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid is added to sample solution 8 delivered through sample solution flow channel 3 to Electrospray tip 4 where the sample solution is Electrosprayed into Electrospray ion source chamber 18 .
[0034] FIG. 2 shows the cross section diagram of an Electrospray Membrane Probe 30 that is used in an alternative embodiment of the invention. Electrospray Membrane probe 30 , more fully described in U.S. patent application Ser. No. 11/132,953 and incorporated herein by reference, comprises sample solution flow channel 31 A through which sample solution flow 31 flows exiting at Electrospray tip 4 . Common elements with FIG. 1 retain the element numbers. A second solution 32 , in contact with electrode 33 , passes through second solution flow path 32 A. Voltage is applied to electrode 33 from power supply 35 . Sample solution 31 and second solution 32 are separated by semipermeable membrane 34 . Semipermeable membrane 34 may comprise a cation or anion exchange membrane. A typical cation exchange membrane is Nafion™ that may be configured with different thicknesses and/or conductivity characteristics in Electrospray Membrane probe assembly 30 . Second solution 32 flow is delivered into second solution flow channel 32 A from an isocratic or gradient fluid delivery system 37 through flow channel 36 and exits through channel 38 . Sample solution 31 flow is delivered to sample solution flow channel 31 A from isocratic or gradient fluid delivery system 40 through flow channel 41 . Dielectric probe body sections 42 and 43 comprise chemically inert materials that do not chemically react with sample solution 31 and second solution 32 . Sample solution 31 passing through flow channel 31 A is Electrosprayed from Electrospray tip 4 with or without pneumatic nebulization assist forming Electrospray plume 10 . Electrospray with pneumatic nebulization assist is achieved by flowing nebulization gas 7 through annulus 5 exiting at 6 concentrically around Electrospray tip 4 . To effect the Electrospray generation of single polarity charged liquid droplets, relative voltages are applied to second solution electrode 33 , nosepiece and endplate electrode 11 and capillary entrance electrode 12 using power supplies 35 , 49 and 50 respectively. Heated counter current drying gas 14 aids in drying charge liquid droplets in spray plume 10 as they move towards capillary orifice 20 driven by the applied electric fields. A portion of the ions produced from the rapidly evaporating droplets in Electrospray plume 10 pass through capillary orifice 20 and into mass to charge analyzer 28 where they are mass to charge analyzed and detected.
[0035] FIG. 3 is a diagram of one Electrospray Membrane probe 30 operating mode for positive polarity Electrospray ionization employing an alternative embodiment of the invention At least one new electrolyte species comprising benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid is added in higher concentration to the solution contained in Syringe 54 of fluid delivery system 37 . Syringe 55 is filled with the same solvent composition as loaded into Syringe 54 but without a new electrolyte species added. A specific isocratic new electrolyte concentration or a new electrolyte concentration gradient for second solution 32 can be delivered to second solution flow channel 32 A by setting the appropriate ratios of pumping speeds on syringes 54 and 55 in fluid delivery system 37 . During positive ion polarity Electrospray ionization, H+ is produced at the surface of second solution electrode 33 and passes through semipermeable membrane 34 , most likely as H 3 O + , into sample solution 31 , driven by the electric field. A portion of the new electrolyte species flowing through second solution flow channel 32 A also passes through semipermeable membrane 34 entering sample solution 31 and forming a net concentration of new electrolyte in sample solution 31 . The new electrolyte concentration in solution 31 during Electrospray operation is well below the new electrolyte concentration in second solution 32 . The Electrospray total ion current and consequently the local sample solution pH at Electrospray tip 4 , the new electrolyte concentration in sample solution 31 and the sample ion Electrospray MS signal response can be controlled by adjusting the new electrolyte concentration in second solution 32 flowing through second solution flow channel 32 A. The solvent composition of second solution 32 can be configured to be different from the solvent composition of the sample solution to optimize solubility and performance of a new electrolyte species.
[0036] FIG. 4 shows one embodiment of Electrospray Membrane probe 57 comprising single membrane section assembly 58 connected to pneumatic nebulization Electrospray inlet probe assembly 59 mounted on Electrospray ion source probe plate 61 . Common elements diagrammed in FIGS. 1 , 2 and 3 retain the same element numbers.
[0037] FIG. 5 is a diagram of three membrane section Electrospray Membrane probe assembly 64 comprising Electrocapture dual membrane section 67 and single Electrospray Membrane section 68 . Each membrane section operates in a manner similar to the single section Electrospray membrane probe described in FIGS. 2 and 3 . Electrocapture Dual membrane section 67 comprises second solution flow channel 70 with electrode 71 and semipermeable membrane section 76 and second solution flow channel 72 with electrode 73 and semipermeable membrane section 77 . Single membrane section 68 comprises second solution flow channel 74 and electrode 75 with semipermeable membrane 78 . The electrolyte type and concentration and solution composition can be controlled in second solutions 80 , 81 and 82 as described previously. Common elements described in FIGS. 1 through 4 retain their element numbers in FIG. 5 . Electrical potential curve 84 is a diagram of one example of relative electrical potentials set along the sample solution flow path for positive polarity Electrospray ionization and positive ion Electrocapture. Dual membrane Electrocapture section 67 can be operated to trap and release positive or negative polarity sample ions in the sample solution as described in pending PCT Patent Application Number PCT/SE2005/001844 incorporated herein by reference. In an alternative embodiment of the invention, at least one new electrolyte including benzoic acid, trimethyl acetic acid or cyclohexanecarboxylic acid species is added to second solution 82 with the concentration controlled to maximize Electrospray sample ion signal as described above. Second solution 82 composition and flow rate can be varied and controlled independently from second solutions 80 and 81 compositions and flow rates to independently optimize Electrocapture and on line Electrospray performance.
[0038] FIG. 6 is a diagram of atmospheric pressure combination ion source 88 comprising Electrospray inlet probe assemblies 90 and 91 with pneumatic nebulization assist. Electrospray inlet probe 90 comprises Electrospray tip 4 and auxiliary gas heater 92 heating gas flow 93 to aid in the drying of charged liquid droplets comprising Electrospray plume 10 . Voltage applied to ring electrodes 94 and 95 allow control of the production of net neutral or single polarity charged liquid droplets from Electrospray inlet probes 90 and 91 respectively while minimizing undesired electric fields in spray mixing region 96 . Electrospray inlet probe 91 provides a source of reagent ions that when drawn through spray plume 10 by electric fields 97 effect atmospheric chemical ionization of a portion of the vaporized neutral sample molecules produced from evaporating charged droplets in spray plume 10 . Combination ion source 88 can be operated in Electrospray only mode, APCI only mode or a combination of Electrospray and APCI modes as described in pending U.S. patent application Ser. No. 11/396,968 incorporated herein by reference. In an alternative embodiment of the invention, at least one new electrolyte, including benzoic acid, trimethyl acetic acid or cyclohexanecarboxylic acid, can be added to the sample flow solution of Electrospray inlet probe 90 and/or to the reagent solution of Electrospray inlet probe 91 which produces reagent ions to promote gas phase atmospheric pressure chemical ionization in mixing region 96 New electrolyte species run in sample solutions can increase the sample ESMS ion single as described above. In addition, new electrolytes in the reagent solution Electrosprayed from Electrospray probe 91 form low proton affinity protonated ions in positive ion polarity Electrospray which serve as reagent ions for charge exchange in atmospheric pressure chemical ionization or combination ES and APCI operation New electrolyte species may also be added to sample solution in corona discharge reagent ion sources or APCI sources to improve APCI source performance.
[0039] FIG. 7 shows a set of ESMS ion signal curves for 1 μM Hexatyrosine sample in a 1:1 methanol:water sample solutions Electrosprayed using an Electrospray Membrane probe configuration 30 as diagrammed in FIGS. 1 , 2 and 3 . All sample solutions were run at a flow rate of 10 μl/min. Concentration gradients of different electrolyte species were run in the second solution flow channel while acquiring Electrospray mass spectrum. The second solution solvent composition was methanol:water for all electrolytes run with the exception of Naphthoxyacetic acid which was run in a methanol second solution. As the concentration of the added electrolyte increased in the second solution flow, the Electrospray total ion current increased. Each curve shown in FIG. 7 is effectively a base ion chromatogram with the Hexatyrosine peak amplitude plotted over Electrospray total ion current. Signal response curves 100 , 101 , 102 , 103 and 104 for Hexatyrosine versus Electrospray total ion current were acquired when running second solution concentration gradients of acetic acid (up to 10%), 2 napthoxyacetic acid (up to 37M), trimellitic acid (up to 244 M), 1,2,4,5 Benzene Carboxylic acid (up to 233 M) and terephthalic acid (saturated) respectively. Conventional electrolyte, acetic acid, provided the highest hexatyrosine ESMS signal amplitude for this set of electrolytes as shown in FIG. 6 . Hexatyrosine signal response curve 108 was acquired while running a concentration gradient in the second solution of new electrolyte cyclohexanecarboxylic acid (up to 195 M). The maximum hexatyrosine signal achieved with new electrolyte run in the second solution of Electrospray Membrane probe 30 was two times the maximum amplitude achieved with acetic acid as an electrolyte. The limited cross section area of the semipermeable membrane in contact with the sample solution limited the Electrospray total ion current range with new electrolyte cyclohexanecarboxylic acid run in the second solution. As will be shown in later figures, higher analyte signal can be achieved by adding new electrolyte species directly to the sample solution. The difference in the shape and amplitude of curve 108 illustrates the clear difference in performance of the Electrospray ionization process when new electrolyte cyclohexanecarboxylic acid is used.
[0040] FIG. 8 shows another set of ESMS ion signal curves for 1 μM hexatyrosine sample in a 1:1 methanol:water sample solutions Electrosprayed using an Electrospray Membrane probe configuration 30 as diagrammed in FIGS. 1 , 2 and 3 . Hexatyrosine Electrospray MS signal response curves 110 through 112 and 115 were acquired while running electrolyte concentration gradients in the second solution flow of Electrospray Membrane probe 30 . Hexatyrosine Electrospray MS signal response curve 118 was acquired by Electrospraying different sample solutions having different new electrolyte benzoic acid concentrations added directly to the sample solution. ESMS signal response curve 114 with end data point 113 for hexatyrosine was acquired by Electrospraying different sample solutions comprising different concentrations of citric acid added directly to the sample solutions. No Electrospray membrane probe was used to generate curves 114 or 118 . Signal response curves 110 , 111 , 112 and 115 for Hexatyrosine versus Electrospray total ion current were acquired when running second solution concentration gradients of conventional electrolytes, acetic acid (up to 10% in the second solution), formic acid (up to 5%) and nitric acid (up to 1%) and new electrolyte benzoic acid (up to 0.41 M in the second solution) respectively. Comparing the hexatyrosine ESMS signal response with new electrolyte benzoic acid added to the second solution of membrane probe 30 or directly to the sample solution during Electrospray ionization, similar ion signals are obtained for the same Electrospray ion current generated. Electrospray performance with the electrolyte added to the Electrospray Membrane probe second solution generally correlates well with the Electrospray performance with the same electrolyte added directly to the sample solution during Electrospray ionization for similar Electrospray total ion currents. As shown by curves 115 and 118 , increased hexatyrosine ESMS signal is achieved when new electrolyte benzoic acid is added to the second solution of Electrospray Membrane probe 30 or directly to the sample solution during Electrospray ionization. The maximum hexatyrosine ESMS signal shown by signal response curve 118 was over five times higher than that achieved with any of the conventional electrolytes acetic, formic or nitric acids or non conventional electrolyte citric acid.
[0041] Electrospray MS signal response curves 120 and 121 for 1 μM hexatyrosine sample in a 1:1 methanol:water solutions are shown in FIG. 9 Curve 121 was generated by Electrospraying different sample solutions containing different concentrations of conventional electrolyte acetic acid. Curve 120 was generated by Electrospraying different sample solutions containing different concentrations of new electrolyte cyclohexanecarboxylic acid. The maximum hexatyrosine ESMS signal achieved with new electrolyte cyclohexanecarboxylic acid was over two time higher than the maximum hexatyrosine signal achieved with conventional electrolyte acetic acid.
[0042] Three ESMS signal response curves using Electrospray membrane probe 30 for 1 μM hexatyrosine sample in 1:1 methanol:water solutions are shown in FIG. 10 . Curve 122 was generated by running a concentration gradient of acetic acid in the Electrospray Membrane probe second solution flow. Over a factor of two increase in hexatyrosine signal was achieved by running a concentration gradient of benzoic acid in the second solution of the Electrospray Membrane probe as shown by signal response curve 123 . The addition of inorganic electrolytes to the sample solution generally reduces the analyte signal response for a given Electrospray total ion current. Hexatyrosine signal response curve 124 was acquired with 0.001% trifluoroacetic acid (TFA) added to the sample solution while running a concentration gradient of benzoic acid in the Electrospray Membrane probe second solution. The Electrospray total ion current of approximately 100 nA was measured at data point 125 on curve 124 . A data point 125 , the Electrospray signal of hexatyrosine was lower with 0.001% TFA added to the sample solution compared with the ESMS signal response with acetic acid added to the ES Membrane probe second solution. Very low concentration benzoic acid was added to the second solution when data point 125 was acquired. Increasing the concentration of benzoic acid in the second solution increased the hexatyrosine signal overcoming the ESMS signal reducing effect of TFA in the sample solution. Even with 0.001% TFA added to the sample solution, the addition of new electrolyte benzoic acid to the second solution of an ES Membrane probe increases the hexatyrosine ESMS signal to a maximum of over two times the maximum hexatyrosine ESMS signal achieved with acetic acid added to the second solution
[0043] FIG. 11 shows negative ion polarity ESMS signal response curves for 1 μM hexatyrosine sample in 1:1 methanol:water solutions run using an Electrospray membrane probe. Curve 127 was acquired while running a concentration gradient of acetic acid in the second solution. Signal response curve 128 was acquired while running a concentration gradient of benzoic acid in the second solution of Electrospray Membrane probe 30 . The maximum negative ion polarity hexatyrosine ESMS signal acquired with new electrolyte benzoic acid was over two times the maximum ESMS signal achieved with conventional electrolyte acetic acid.
[0044] 1 μM reserpine sample in 1:1 methanol:water solutions were Electrosprayed to generate the ESMS signal response curves shown in FIG. 12 New electrolytes benzoic acid and trimethyl acetic acid and conventional electrolyte acetic acid were added at different concentrations to different sample solutions to compare ESMS signal response. As shown by reserpine ESMS signal response curves 127 , 128 and 129 , a two times signal increase can be achieve when new electrolyte species benzoic acid and trimethyl acetic acid are added to the sample solution compared to the ES MS signal achieved by Electrospraying with conventional electrolyte acetic acid added to the sample solution.
[0045] A comparison of ESMS signal response for 1 μM leucine enkephalin sample in 1:1 methanol:water solutions using four electrolytes added to the sample solution is shown in FIG. 13 . New electrolytes, benzoic acid, trimethyl acetic acid and cyclohexane carboxylic acid and conventional electrolyte acetic acid were added at different concentrations to different leucine enkephalin sample solutions to generate ESMS signal response curves 130 , 131 , 132 and 133 respectively. When running the new electrolytes, a maximum leucine enkephalin signal response increase of two times was achieved compared with the maximum signal response achieved with electrolyte acetic acid. Individually, a factor of three increase in leucine enkephalin ESMS maximum signal response was achieved by adding benzoic acid to the sample solution.
[0046] A characteristic of the new electrolytes is the presence of an (M+H) + electrolyte parent ion peak ion in the ESMS spectrum acquired in positive ion polarity Electrospray as shown in FIGS. 14A , 15 A and 16 A for benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid respectively Such a parent positive ion is not generally observed when running conventional electrolytes in Electrospray ionization. As expected, the presence of an (M−H) − electrolyte species peak was observed in the ESMS spectrum acquired in negative ion polarity mode as shown in FIGS. 14B , 15 B and 16 B The presence of gas phase electrolyte parent ions present in positive ion polarity Electrospray may play a role in increasing the ESMS analyte signal.
[0047] The use of new electrolytes benzoic acid, trimethyl acetic acid and cyclohexanecarboxylic acid increases ESMS signal amplitude for samples run in positive or negative ion polarity Electrospray ionization. An increase in Electrospray MS analyte signal can be achieved by adding a new electrolyte directly to the sample solution or by running a new electrolyte in the second solution of an Electrospray Membrane probe during Electrospray ionization. Having described this invention with respect to specific embodiments, it is to be understood that the description is not meant as a limitation since further modifications and variations may be apparent or may suggest themselves. It is intended that the present application cover all such modifications and variations. | Electrospray ionization sources interfaced to mass spectrometers have become widely used tools in analytical applications Processes occurring in Electrospray (ES) ionization generally include the addition or removal of a charged species such as II+ or other cation to effect ionization of a sample species. Electrospray includes ionization processes that occur in the liquid and gas phase and in both phases ionization processes require a source or sink for such charged species. Electrolyte species, that aid in oxidation or reduction reactions occurring in Electrospray ionization, are added to sample solutions in many analytical applications to increase the ES ion signal amplitude detected by a mass spectrometer (MS). Electrolyte species that may be required to enhance an upstream sample preparation or separation process may be less compatible with the downstream ES processes and cause reduction in MS signal. A new set of Electrolytes has been found that increases positive and negative polarity analyte ion signal measured in ESMS analysis when compared with analyte ESMS signal achieved using more conventional electrolytes. The new electrolyte species increase ES MS signal when added directly to a sample solution or when added to a second solution flow in an Electrospray membrane probe. The new electrolytes can also be added to a reagent ion source configured in a combination Atmospheric pressure ion source to improve ionization efficiency. | 7 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to fluid handling, and more particularly to apparatus and methods for fluid manifolds in gas turbine engines.
[0002] A gas turbine engine includes a turbomachinery core having a high pressure compressor, a combustor, and a high pressure turbine in serial flow relationship. The core is operable in a known manner to generate a primary gas flow. Depending on the engine's configuration, the core may be combined with a fan and low pressure turbine system to generate propulsive thrust, or with a work turbine to extract mechanical energy and turn a driveshaft or propeller.
[0003] In conventional gas turbine engines, fuel is introduced to the combustor through an array of fuel nozzles which are coupled to an external manifold surrounding the combustor. In operation, pressurized fuel is fed to the manifold. The manifold then distributes the pressurized fuel to the individual fuel nozzles. Such manifolds are commonly manufactured from various tubes and fittings, and are secured to the combustor with brackets and other mounting hardware. Such manifolds experience significant vibration during engine operation.
[0004] Thermal growth is a critical design criterion for these fuel manifolds. The cases that support the fuel nozzles grow as the engine warms, but the temperature of the fuel in the manifold stays relatively cool. This temperature difference, coupled with the different material growth rates of various components, creates a thermal loading on the manifold. To avoid fatigue failure, the manifold's properties such as stiffness, damping, etc. must be designed so as to avoid excitation of one or more of the manifold's natural frequencies within the engine operating range while providing proper flexibility for thermal growth.
[0005] These manifolds are unique to each specific engine model. This requires a substantial design effort and testing iterations, leading to high engineering costs. Furthermore, the typical geometry and large part count leads to relatively high system weights.
BRIEF SUMMARY OF THE INVENTION
[0006] These and other shortcomings of the prior art are addressed by the present invention, which provides a frequency-tunable fluid manifold apparatus.
[0007] According to one aspect of the invention, a fluid manifold apparatus includes:
[0000] (a) an array of spaced-apart manifold fittings, each manifold fitting aligned in a predetermined angular orientation. Each manifold fitting includes: (i) a tubular neck; (ii) a pair of spaced-apart tubular arms extending away from a first end of the neck; and (iii) a coupling connected to a second end of the neck; and (b) a plurality of curved tubes, each tube being coupled to one arm of each of two adjacent manifold fittings.
[0008] According to another aspect of the invention, a method of assembling a fluid manifold includes: (a) providing an array of spaced-apart manifold fittings, each manifold fitting having: (i) a tubular neck; (ii) a pair of spaced-apart tubular arms extending away from a first end of the neck; and (iii) a coupling connected to a second end of the neck; (b) placing each manifold fitting in a predetermined angular orientation; and (c) providing a plurality of curved tubes, and coupling one end of each tube to one arm of each of two adjacent manifold fittings; (d) such that the assembled manifold has a predetermined first natural frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
[0010] FIG. 1 is a schematic half-sectional view of a gas turbine engine incorporating a fluid manifold constructed in accordance with an aspect of the present invention;
[0011] FIG. 2 is a partial perspective view of a combustor of the engine of FIG. 1 , showing a fluid manifold mounted thereto;
[0012] FIG. 3 is a plan view of the manifold shown in FIG. 2 , with fluid fittings installed in a first position;
[0013] FIG. 4 is a plan view of the manifold shown in FIG. 2 , with fluid fittings installed in a second position;
[0014] FIG. 5 is a cross-sectional view of one of the fluid fittings of the manifold;
[0015] FIG. 6 is a plan view of the fitting of FIG. 5 ;
[0016] FIG. 7 is a side view of the fitting of FIG. 5 ;
[0017] FIG. 8 is a rear view of the fitting of FIG. 5 ;
[0018] FIG. 9 is a left side view of the fitting of FIG. 5 ; and
[0019] FIG. 10 is a right side view of the fitting of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 depicts an exemplary gas turbine engine 10 having a fan 12 , a low pressure compressor or “booster” 14 and a low pressure turbine (“LPT”) 16 collectively referred to as a “low pressure system”, and a high pressure compressor (“HPC”) 18 , a combustor 20 , and a high pressure turbine (“HPT”) 22 , collectively referred to as a “gas generator” or “core”. Together, the high and low pressure systems are operable in a known manner to generate a primary or core flow as well as a fan flow or bypass flow. While the illustrated engine 10 is a high-bypass turbofan engine, the principles described herein are equally applicable to turboprop, turbojet, and turboshaft engines, as well as turbine engines used for other vehicles or in stationary applications. The principles of this invention are also equally applicable to other fields where a vibration-resistant fluid manifold is required.
[0021] The combustor 20 includes a radial array of fuel nozzles 24 which are coupled to a manifold 26 surrounding the combustor 20 . In operation, pressurized fuel is fed to the manifold 26 by a fuel metering system such as a hydromechanical unit, FMU, PMU, or FADEC system of a known type (not shown). The fuel is then distributed by the manifold 26 to the individual fuel nozzles 24 . The illustrated example shows a single-stage manifold and fuel nozzles, but it will be understood that the principles of the present invention are applicable to multi-circuit systems as well.
[0022] The manifold 26 is shown in more detail in FIG. 2 . The casing 28 of the combustor 20 can be seen with the inlet stems 30 of the fuel nozzles 24 protruding therefrom. Each inlet stem 30 incorporates an inlet fitting 32 of a known type. In the illustrated example, the nozzle inlet stems 30 penetrate the case 28 in a generally radial direction, and the inlet fittings 32 extend in a generally axial direction. Coupled to each inlet fitting 32 is a manifold fitting 34 . The manifold fittings 34 are interconnected by tubes 36 . In the illustrated example each tube 36 is generally “C”-shaped when seen in plan view, and has a constant radius of curvature. One or more feed tubes 37 are coupled to the manifold 26 and serve to allow fuel flow into the manifold 26 from a fuel metering and control system of a conventional type (not shown). Most typically the manifold 26 and its constituent components would be made from a metallic alloy, such as an iron- or nickel-based alloy.
[0023] FIGS. 5-10 illustrate one of the manifold fittings 34 in more detail. The manifold fitting 34 is generally “Y”-shaped with a tubular central neck 38 and two spaced-apart, generally parallel tubular arms 40 extending therefrom. As used herein, the term “tubular” denotes a member which has a wall that encloses a volume for fluid flow therethrough and does not necessarily imply a structure that has a purely circular cross-section or a constant wall thickness. The neck 38 is connected to a coupling 42 .
[0024] The coupling 42 includes a tubular inner member 44 having a first end 46 connected to the neck 38 , and a second end which defines a seat 48 . When connected to the inlet stem 30 , the seat 48 receives a ball-nose 50 of the inlet fitting 32 which has a shape complementary to the seat 48 . A groove 53 is formed in the cylindrical surface of the inlet fitting 32 adjacent the ball-nose 50 and receives a resilient sealing element 55 , which seals against the inner member 44 . In the illustrated example the sealing element 55 is an O-ring. The outer surface of the inner member 44 includes an annular shoulder 51 . A collar 52 surrounds the inner member 44 and includes an annular, radially-inwardly-extending flange 54 that engages the shoulder 50 . The interior of the collar 52 includes threads 56 that engage mating threads 57 of the inlet fitting 32 . The exterior of the collar 52 is formed into polygonal flats or other suitable wrenching surfaces 60 . Other types of coupling configurations could be used to couple the manifold fitting 34 to the inlet fitting 32 so long as they provide a leak-free joint.
[0025] As best seen in FIG. 3 , the tubes 36 are continuously curved so as to form a “U” or “C” shape. In this example the tubes 36 have a constant radius of curvature, but this aspect may be varied as desired to suit a particular application. Each tube 36 has opposed ends 58 which are connected to the arms 40 of adjacent manifold fittings 34 . The tubes 36 may be connected to the manifold fittings 34 in any manner that provides a secure, leak-free joint, for example by the use of thermal or mechanical bonding, adhesives, or mechanical joints or fasteners. As illustrated, the tubes 36 form butt joints 62 (see FIG. 5 ) with the manifold fittings 34 that are brazed or welded together in a known manner.
[0026] The manifold configuration is “modular” in the sense that a single type of manifold fitting 34 may be coupled to the inlet stems 30 in a variety of different angular orientations and then interconnected with tubes 36 suitable for the selected orientation. By “twisting” the manifold fitting 34 clockwise or counter-clockwise from a nominal position, a designer may effectively increase or decrease the tubing length between neighboring fuel nozzles 24 , with the result of changing or “tuning” the manifold's natural frequency. Smaller engines generally have a higher frequency of operation, and generally experience less total thermal growth. Larger engines generally have a lower frequency of operation, and generally experience more total thermal growth. The ability to tune the manifold's natural frequency allows it to be designed to each engine's specific needs, without the typical systemic redesign seen in the prior art when comparing one engine model to another.
[0027] For example, FIG. 3 shows a portion of the manifold 26 with the manifold fittings 34 rotated or “clocked” to a first angular orientation. For the sake of illustration, an arrow depicts the plane in which the arms 40 lie. In this position, the lateral spacing between the connected arms 40 of two adjacent fittings 34 , denoted “S 1 ”, is relatively small and the radius of the tube 36 which interconnects the arms 40 , denoted “R 1 ”, is relatively small as well. As a result, the first natural frequency of the manifold 26 is relatively high. Because the tube 36 spans a relatively short point-to-point distance as compared to prior art designs, there is no need for a separate bracket to mount the tubes 36 to the casing 28 .
[0028] FIG. 4 shows a portion of a manifold 26 ′ assembled using manifold fittings 34 of identical construction to those shown in FIG. 3 . The manifold fittings 34 in FIG. 4 are rotated or “clocked” to a second angular orientation. An arrow depicts the plane in which the arms 40 lie, which is about 60 degrees away from the position shown in FIG. 3 . In this position, the lateral spacing between connected fitting arms 40 , denoted “S 2 ”, is larger than the spacing S 1 , and the tube 36 ′ which interconnects the arms 40 is relatively larger than the tubes 36 as well. For example, the radius R 2 of the tube 36 ′ may be about 1.25 times the radius R 1 of the tube 36 . As a result, the first natural frequency of the manifold 26 ′ is computed to be about 25% lower than that of the manifold 26 . In this example, the stress induced by thermal loading on manifold 26 ′ with a tube radius of R 2 is computed to be about 15% lower in magnitude than the stress induced by thermal loading on manifold 26 with a tube radius of R 1 . The position of the manifold fittings 34 is infinitely variable as dictated by design requirements.
[0029] As part of the design process, the manifold's vibration characteristics would be analyzed, for example using a tool such as finite element analysis software, and then a fitting orientation and tube radius would be selected based on the required natural frequency. The design process is vastly simplified compared to the prior art because the manifold fittings 34 are common to many different manifolds 26 . The tubes 36 may be produced in one or more “stock” lengths corresponding to several default orientations of the manifold fittings 34 .
[0030] The fluid manifold 26 described herein has several advantages over a conventional design. Depending on the specific configuration, the manifold 26 may contain as few as one-tenth as many parts as prior art manifold system designs. It may weigh only about half as much as a prior art manifold system and has a reduced part envelope. Design cycle time will also be decreased because of the simplified nature of the design.
[0031] The foregoing has described a frequency-tunable fluid manifold. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation. | A fluid manifold apparatus includes: (a) an array of spaced-apart manifold fittings, each manifold fitting aligned in a predetermined angular orientation. Each manifold fitting includes: (i) a tubular neck; (ii) a pair of spaced-apart tubular arms extending away from a first end of the neck; and (iii) a coupling connected to a second end of the neck; and (b) a plurality of curved tubes, each tube being coupled to one arm of each of two adjacent manifold fittings. | 5 |
PRIORITY CLAIM
[0001] This is a U.S. national stage of International Application No. PCT/EP2011/057511, filed on 10 May 2011, which claims priority to German Application No. 10 2010 020 264.9, filed 28 May 2010, the contents of which are incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an air mass flow meter having a housing made of plastic which has an electrically insulating effect, a flow channel being formed in the housing, and having a sensor element which is arranged in the housing and detects the air mass flowing in the flow channel, and conductor tracks which connect the sensor element to connection pins being arranged in the housing.
[0004] 2. Description of the Related Art
[0005] In the context of this application, the term “air” is used as an example of a gas or gas mixture, the mass flow of which can be determined. In principle, the mass flow of any gas or gas mixture can be determined using the air mass flow meter according to the invention.
[0006] Such air mass flow meters are known and are used in large numbers, for example, in automobiles in order to detect the air mass flowing to an internal combustion engine. Depending on the air mass flow detected by the air mass flow meter, both diagnoses, for example of the operation of the internal combustion engine, and control of the internal combustion engine can be carried out. For these purposes, detection of the actual air mass flow, which is also reliable and as precise as possible under different operating conditions, is important.
[0007] European Published Patent Application EP 0 458 998 A1 discloses an air mass flow meter having a housing in which a flow channel is formed and in which a flow straightener is introduced upstream of a sensor element. The flow straightener comprises a honeycomb body and a ring which projects beyond the honeycombs in the direction of flow and in which a grating is embedded at a distance from the honeycombs, which grating generates microvortices.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to specify an air mass flow meter which can be produced in a cost-effective manner and makes it possible to measure an air mass flow in an accurate manner, the air mass flow meter being intended to operate without errors for as long as possible.
[0009] As a result of the entire housing consisting of plastic, and at least one part of the flow channel having electrostatically dissipative properties, the air mass flow meter can be produced in a particularly cost-effective manner, for example in an injection-molding method. Because at least one part of the flow channel has electrostatically dissipative properties, electrically charged dirt particles are discharged before they can reach the sensor element. An accumulation of electrically charged dirt particles on the sensor element is thus prevented. Since no dirt particles are deposited on the sensor element, it is possible to measure the air mass flowing in the tube in a precise and interference-free manner over the entire service life of the air mass flow meter. Regions whose sheet resistance is less than 10 12 ohms are referred to as electrostatically dissipative. The sheet resistance is thus small enough to discharge electrostatically charged particles in the air mass and to protect the sensor element from the deposition of these particles.
[0010] Since the entire housing, including the flow channel having the part with electrostatically dissipative properties, consists of plastic, it is possible to achieve a particularly long service life of the sensor. No conductive regions which were applied to the flow channel and could possibly become detached again are situated in the flow channel. The flow channel forms, with its electrically dissipative part, a single-piece component made of plastic, the electrically dissipative region of the flow channel obtaining its electrically dissipative property as a result of conductive particles in the plastic.
[0011] In one embodiment, the sensor element is produced with a MEMS design. Particularly for air mass flow meters with sensor elements constructed using microsystem (MEMS) technology, it is particularly important to discharge charged dirt particles in a part of the flow channel with electrostatically dissipative properties. If charged dirt particles (for example charged dust particles) are present in the air flow, they are attracted by the charged surfaces of the sensor element and the charged dirt particles are deposited on these charged surfaces. However, discharge of the dirt particles is prevented by the highly insulating passivation layer on the charged surfaces of the sensor element. In order to prevent this, the charged dirt particles are discharged in the electrostatically dissipative part of the flow channel before reaching the sensor element constructed using microsystem (MEMS) technology, as a result of which they can no longer be deposited on the surface of the sensor element.
[0012] In a next development, the electrically dissipative part of the flow channel consists of plastic with conductive polymers and/or of plastic with conductive fibers and/or of plastic with conductive carbon black. Carbon or metal particles, for example, are suitable as conductive fibers in the plastic. Plastic with conductive components (polymers, fibers and/or conductive carbon black) can be integrated in the flow channel in a cost-effective and simple manner.
[0013] If the electrically dissipative part of the flow channel is electrically connected to a fixed potential, the charge carriers can be easily discharged from the dirt particles and the dirt particles are thus neutralized in a simple manner. These particles are thus no longer deposited on the sensor element.
[0014] In one preferred embodiment, the fixed potential is the sensor ground. The sensor ground is the neutral reference potential for the air mass flow meter and is able to absorb large quantities of charge carriers without being subject to a potential shift.
[0015] If the housing has a housing body and a housing cover, it is particularly easy to produce the air mass flow meter. In this case, the electrically dissipative part of the flow channel may be formed in and/or on the housing body and/or in and/or on the housing cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows an air mass flow meter in a tube.
[0017] FIG. 2 shows a perspective view of the air mass flow meter.
[0018] FIG. 3 schematically shows a sensor element produced using MEMS technology.
[0019] FIG. 4 shows an air mass flow meter having a housing.
[0020] FIG. 5 shows a housing cover.
[0021] FIG. 6 shows a housing body.
[0022] FIG. 7 shows a housing cover again.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1 shows an air mass flow meter 1 . The air mass flow meter 1 is arranged in a tube 2 . The air mass flow meter 1 has a housing 17 with a start 5 and an end 6 with respect to the main direction of flow 4 of the air mass in the tube 2 . In order to be able to measure across all flow velocities of the air mass in the tube 2 in an error-free manner, a flow guiding element 8 is formed upstream of the air mass flow meter 1 at a certain distance from the start 5 of the latter. This flow guiding element 8 consists of a grating 11 in this case. Both the tube 2 and the grating 11 may have regions 9 with electrically dissipative properties.
[0024] FIG. 2 shows a perspective view of the air mass flow meter 1 in a tube 2 . The air mass flow meter 1 has a flow channel 7 which receives part of the air flowing in the tube 2 and guides it via a sensor element 3 . Extended flow guiding elements 8 which are oriented parallel to the main direction of flow 4 are arranged in the tube 2 of the air mass flow meter 1 . These flow guiding elements 8 may also have regions 9 with electrically dissipative properties. FIG. 2 also shows a connection element 16 in which the connection pins are arranged, which pins electrically connect the sensor element 3 and its downstream electronic circuit 10 to an electronic engine controller, for example.
[0025] FIG. 3 schematically shows a sensor element 3 produced using MEMS technology in the air flow 4 . Modern sensor elements 3 constructed using microsystem (MEMS) technology detect the air mass flow very quickly and measure virtually every change in the air mass flow 4 with a high degree of precision. The sensor element 3 and the electronic circuit 10 for processing the signals from the sensor element 3 may be formed on a single semiconductor component 11 using microsystem technology (MEMS). One disadvantage of the sensor elements 3 produced using microsystem technology is that a thin but highly insulating passivation layer 14 , for example made of silicon dioxide, is generally arranged above the electrically conductive surfaces 12 of the sensor element 3 which are charged with charge carriers 13 . If charged dirt particles 15 (for example charged dust particles) are present in the air flow 4 , these are attracted by the charged surfaces 12 of the sensor element 3 and the charged dirt particles 15 are deposited on these charged surfaces 12 . However, discharge of the dirt particles 15 is prevented by the highly insulating passivation layer 14 on the charged surfaces 12 of the sensor element 3 . The charged dirt particles 15 are literally trapped on the electrically conductive surface 12 of the sensor element 3 , and this contamination distorts the measurement of the air mass 4 flowing past.
[0026] FIG. 4 shows an air mass flow meter 1 having a housing 17 . The housing 17 consists of a housing body 18 and a housing cover 19 . The connection element 16 in which electrically conductive pins are accommodated can be seen on the housing body 18 . The pins establish electrical contact between the sensor element 3 and downstream electronics, for example an engine controller. The flow channel 7 can also be seen in the housing body 18 . In this case, the flow channel 7 has an Ω-shaped construction. However, this is only one example of a flow channel. There are various configurations for such flow channels in air mass flow meters 1 . The housing cover 19 may be connected to the housing body 18 . This may be effected, for example, by adhesive bonding or laser welding. A region 9 with electrically dissipative properties can be seen in the housing cover 19 . This region 9 with electrically dissipative properties largely covers the flow channel 7 . Dirt particles 15 present in the air flow 4 with charge carriers 13 can thus be discharged by means of contact with the region 9 with electrically dissipative properties. This ensures that only electrostatically neutral dirt particles 15 flow past the sensor element 3 with the air mass 4 . The regions 9 with electrostatically dissipative properties prevent, in a highly effective manner, electrically charged dirt particles 15 from being deposited on the sensor element 3 . The reference symbol 20 is used to denote the ground connection which is used to connect the region 9 with electrically dissipative properties to the sensor ground 21 or to another fixed potential. The connection to the sensor ground 21 is schematically attached to the region 9 with electrically dissipative properties in FIG. 4 .
[0027] FIG. 5 shows a more detailed illustration of the housing cover 19 . The region 9 with electrically dissipative properties can be easily seen in the housing cover 19 . In this case, the shape of the region 9 with electrically dissipative properties largely corresponds to the shape of the flow channel 7 . The air mass 4 flows along the region 9 with electrically dissipative properties, dirt particles 15 contained in the air mass being able to be discharged at the region 9 with electrically dissipative properties. The connection to the sensor ground 21 is schematically attached to the region 9 with electrically dissipative properties in FIGS. 5 and 6 .
[0028] FIG. 6 shows the housing body 18 . The flow channel 7 can be seen in the housing body 18 ; in this exemplary embodiment, the flow channel 7 is also provided with a region 9 with electrically dissipative properties.
[0029] FIG. 7 shows the housing cover 19 and the region 9 with electrically dissipative properties again. It is possible to see the housing cover 19 before the region 9 with electrically dissipative properties is integrated in the latter. In order to integrate the region 9 with electrically dissipative properties, the region 9 with the electrically dissipative properties is fitted into the housing cover 19 and is adhesively bonded to the housing cover or is connected to the latter by means of laser welding, for example.
[0030] The region 9 with electrically dissipative properties consists of a plastic containing electrically conductive particles. These electrically conductive particles may be, for example, carbon particles or fine iron filings.
[0031] Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | An air mass flow meter, includes a housing made of plastic having an electrically insulating effect. A flow channel is formed in the housing. The air mass flow motion also includes a sensor element which is arranged in the housing and detects the air mass flowing in the flow channel. Conductive paths are arranged in the housing and connect the sensor element to connection pins. In order to provide a mass air flow meter which is cost-effective to produce and allows precise measurement of a mass air flow, the entire housing is made of plastic and at least one part of the flow channel has electrostatically dissipative properties. | 6 |
RELATED APPLICATIONS
The present application is related to my copending application Ser. No. 10/668,805, filed Sep. 24, 2003, which is included herein in its entirety by reference.
FIELD OF THE INVENTION
The invention relates to dental implants, and more particularly, to a screw-type dental implant having helical threads along a shaft. The threads have a broad crest and have at least one helical groove or channel disposed in the crest.
BACKGROUND OF THE INVENTION
The science of dental implantology has been evolving for many years. For an implant to be successful, there must be equilibrium between the implant and the underlying bone when under pressure from chewing. The muscular force from chewing is exerted through the implant design into the underlying bone structure. An inadequate implant design, for example, an implant with poor implant geometry or insufficient implant support values, generates higher stresses against bone, and the implant generally fails because of fibrous tissue build-up and encapsulation over time. To be successful, the implant must directly stimulate the underlying bone to promote equilibrium and osseointegration. Dentists, doctors, and scientists continually strive to develop implants that provide reliable, long-term service to patients into whom such implants are inserted.
Osseointegration is the process by which the bone moves toward the prosthetic implant, developing a close proximity therebetween. Ideally, the bone and implant osseointegrate such that the implant becomes secure in the bone (i.e., the implant has become a “part” of the jawbone).
Osseointegration can be encouraged by stimulating the underlying bone during chewing. This may be accomplished by choosing an appropriate implant geometry, having an adequate Total Surface Area (TSA), and most importantly, sufficient Load Bearing Area (LBA) to reduce stresses and maintain implant stability on a long term basis.
Conversely, bone is naturally stimulated by a tooth root from the downward force resulting from cyclic chewing. This movement stretches the Sharpey's fibers attached to the bone through a pulling action, which causes tension in the bone for osseous stimulation.
A titanium prosthetic dental implant cannot emulate the natural “pulling-type” stimulation described above. Instead, bone stimulation must be achieved through the process of osteocompression on the bone by the implant. Maximizing the LBA of the implant will maximize such compression. The horizontal LBA on any implant is the primary mechanism for bone stimulation and support by the action of osteocompression (metal-to-bone support in a compressive mode). The areas of an implant's surface capable of providing sufficient bone support and physiologic stimulation are the horizontal compressive planes, rather than the vertical implant interface under shear force. If the implant lacks sufficient horizontal load bearing areas, then the implant may act like a knife in the bone (i.e., blade implants), thereby generating greater stresses, and causing the implant to fail.
The laws of physics, particularly Newton's Third Law, dictate that mechanical forces always come in pairs—an applied force and a resisting force, equal in magnitude, opposite in direction, and collinear to establish equilibrium. Therefore, there will always be a force by the implant on the bone, and a resisting force by the existing bone on the implant. The forces resulting from the implant and trabecular bone on one another should be in equilibrium for the implant to be successful. To achieve equilibrium in the bone, successful implant diagnosis and selection should consider the value of the masticatory force magnitude generated through the implant design; the horizontal load bearing values of the selected implant; and the density of bone values or level of mineralization in a specific bone region of the jaw.
The mechanical relationship between implant and bone can be described in units of the modulus of elasticity. The modulus of trabecular bone is 1.5 million psi and cortical bone is up to 3 million psi. On the other hand, titanium is very strong or stiff in comparison, having a modulus of elasticity of 15 million psi. Due to this mismatch, the weaker member is always the bone under compressive or shear forces.
Most conventional prior art implant designs do not provide for large amount of horizontal areas for interfacing with the bone. Prior art implants also have small thread pitches. It would, therefore, be desirable to have a dental implant wherein the load bearing areas are increased through more extensive horizontal planes on the threads of the implant. It would also be advantageous to have a dental implant wherein the threads are spaced apart in accordance with the strength or weakness (i.e., the density) of the bone in which it is to be implanted.
DISCUSSION OF THE RELATED ART
U.S. Pat. No. 4,103,422 for THREADED SELF-TAPPING ENDODONTIC STABILIZER, issued Aug. 1, 1978 to Charles M. Weiss et al., discloses a threaded, self-tapping endodontic stabilizer for insertion in a tooth root canal and into the jawbone of a patient's mouth through a threading aperture in a loose tooth. The WEISS stabilizer includes threads disposed along a longitudinal axis of the stabilizer. The threads have a shallow recess extending along the peripheral edge thereof.
U.S. Pat. No. 5,639,237 For DENTAL PROSTHESIS HAVING INDENTATIONS, issued Jun. 17, 1997 to Mark G. Fontenot, shows a dental implant with a prosthetic attachment having a bulbous proximal end and a threaded distal end having a plurality of convex and concave ridges.
Published United States Patent Application No. 2001/0055744 for DENTAL IMPLANT AND METHOD FOR INSTALLING THE SAME, published Dec. 27, 2001 upon application by Robert S. Ura, shows a dental implant wherein two successive helical threads having two different diameters are disposed along a shaft. The threads have a small pitch and sharp knife-like members.
U.S. Pat. No. 6,743,233 for MEDICAL SCREW AND METHODS OF INSTALLATION, issued Jun. 1, 2004 to Jeffrey P. Baldwin et al., discloses another screw for medical and orthopedic applications, wherein successive sharp, flat threads have different diameters.
United States Published Patent Application No. 2004/0121289 for DENTAL IMPLANT, published Jun. 24, 2004 upon application by Robert G. Miller, teaches a dental implant, wherein the threaded portion carries non-symmetrical threads.
United States Published Patent Application No. 2006/0204930 for HELICAL IMPLANT, published Sep. 14, 2006 upon application by Young-Tack Sul, shows a dental implant having a single course of helical, serrated threads. The threads have a narrow crest and approximately sixty-degree slope.
None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel dental implant of the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a dental implant having a unique thread configuration that maximizes support values of a successful implant for the same osteotomy when compared to other designs. At least one course of helical threads surrounds an elongated, cylindrical body. In an embodiment chosen for purposes of disclosure, the threads have relatively broad crestal surfaces, typically having a rounded profile. One or more helical secondary threaded grooves are disposed in the crestal surface of the threads.
When the implant is installed, the broad crestal thread design compresses bone in one direction while bone is collected by the grooves in the opposite direction. The result is that the implant is immediately stable in a patient's jawbone.
It is, therefore, an object of the invention to provide a dental implant having one or more courses of helical threads.
It is another object of the invention to provide a dental implant, wherein the threads have a broad crest.
It is an additional object of the invention to provide a dental implant, wherein the thread crest carries one or more helical grooves.
It is a further object of the invention to provide a dental implant, wherein the threads are knuckle threads.
It is an additional object of the invention to provide a dental implant having threads of a substantially sinusoidal cross-section and having secondary grooves.
It is a still further object of the invention to provide a dental implant that is adapted to receive a dental restoration directly thereupon.
It is another object of the invention to provide a dental implant that may receive and support various and interchangeable prosthetic abutments for various prosthetic demands.
It is yet another object of the invention to provide a dental implant designed to receive an abutment for a fixed dental bridge.
It is a further object of the invention to provide a dental implant conducive to implantation and installation during a single session or single dental office visit.
It is another object of the invention to provide a method of installing an implant such that a portion of an abutment, whether attached or integral with the implant, sits below the crest of a patient's jawbone.
It is a further object of the invention to provide a method of installing an implant such that an abutment, whether attached or integral with the implant, sits above the crest of a patient's jawbone.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 is a pictorial, perspective view of a dental implant of the prior art with an attached abutment;
FIGS. 2 a and 2 b are pictorial, perspective and side cross-sectional views, respectively, of the dental implant in accordance with the present invention; and
FIG. 2 c is a pictorial, perspective view of the dental implant in accordance with the present invention having a Morse taper for receiving an abutment; and
FIG. 3 is a flowchart illustrating the steps for installing the inventive implant.
FIG. 4 a is a pictorial perspective view of an exemplary abutment attachable to the dental implant of FIG. 2 c.
FIG. 4 b is a pictorial, perspective, and cross-sectional view of the abutment of FIG. 4 a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides an improved dental implant featuring a unique thread configuration. One or more helical grooves are provided at the crest of the implant's threads. Such a groove and crest arrangement is advantageous and results in superior performance of the implant. The novel implant's thread design results in immediate stabilization of the implant in the bone. In addition, the novel groove and crest configuration stimulates bone formation through osteocompression by the process of electro-streaming potential. The concept of electro-streaming potential is believed to be well known to those of skill in the art.
Referring first to FIG. 1 , there is shown a perspective, pictorial view of a two-piece dental implant of the prior art, without its respective abutment, generally at reference number 100 . Implant 100 is of a type well known to those of skill in the art, typically having a single course of threads 104 disposed around an elongated, cylindrical shaft 102 .
Threads 104 have a crestal surface 106 disposed at an outer periphery of the thread. Such threads are similar to “knuckle” threads known to those of skill in the fastener arts. Threads 104 may have various profiles including but not limited to a sharp V, a rounded U, or a flat outer surface (i.e., the well-known square or “Acme” threads), depending upon the specific application for which implant 100 is intended. The common feature of threads disposed on dental implants of the prior art is that the threads are typically V-shaped (i.e., have an extremely narrow crest), and typically have a slope in the range of approximately 30 to 60 degrees.
Dental practitioners should choose implants having greater vertical distances between the implant threads (i.e., pitch) where bone is poorly mineralized to accommodate a larger volume of bone under compression between the thread areas. Studies have demonstrated that an implant is best secured in the bone by increasing the LBA (load bearing area) of the implant. Increased LBA allows the compression caused by chewing to be spread over a larger surface area. Such thread space will offset the differences in modulus of elasticity between metal and bone, thereby increasing the implant-to-bone bulk support values in horizontal planes, or the increase of bulk modulus of the weaker member.
Referring now to FIGS. 2 a and 2 b , there are shown perspective and cross-sectional views, respectively, of a first embodiment of a dental implant in accordance with the present invention, generally at reference number 200 . Implant 200 is a one-piece implant (abutment integral with implant) having internal threads 202 to accept a dental restoration or prosthesis, not shown, as is well known to those of skill in the dental implant arts. Such implants are known as one-piece implants as no intermediary abutment is required between the implant and the prosthesis.
An alternate embodiment of the invention comprises an implant 201 having all of the features of implant 200 , with the modification that instead of having an integral abutment, a Morse taper 203 is provided as shown in FIG. 2 c , for connecting an abutment to implant 201 . FIG. 2 c shows the implant 201 in an environment with an exemplary abutment 400 attached. FIG. 4 a shows a perspective view of an exemplary abutment 400 , and FIG. 4 b shows a cross-section of said exemplary abutment 400 having a cavity 402 shaped to accept a Morse taper on the shaft of implant 201 .
While a specific embodiment of the invention was chosen for purposes of disclosure, it will be recognized by those of skill in the art that other embodiments of the inventive implant may be provided to meet a specific operating circumstance or bone environment. The invention is, therefore, not considered limited to the specific embodiments chosen. Rather, the invention covers any and all variations of the inventive implant.
As is well known to those of skill in the art, numerous types of abutments may interchangeably be attached to implant 201 . Such abutments are believed to be well known and are not further described herein.
Implant 200 has an elongated, substantially cylindrical body 204 having a proximal end 206 . Proximal end 206 may protrude from the jawbone, not shown, when implant 200 is installed in a patient's jawbone.
At least one course of helical threads 208 encircles body 204 . Threads 208 are typically “knuckle” threads, which, in cross-section, have a quasi-sinusoidal form. In other words, both the crest and root of thread 208 are curvilinear. The crest of threads 208 , however, has a pair of helical grooves 212 a , 212 b formed therein. Grooves 212 a , 212 b greatly influence the performance of implant 200 when installed in a patient's jawbone against a viscoelastic bone matrix to be osteocompressed. It will be recognized that other numbers of helical grooves or channels may be desirable for a particular bone density and/or application. Therefore, the invention is not limited to a pair of helical grooves. Rather, the invention may have one, two, or more helical grooves.
At least one apical cutting thread 216 is located at the distal end 214 of implant 200 . It is preferable to have two cutting threads 216 . A cutting thread, preferably the lowermost thread(s), has an edge for cutting through the bone as the implant 200 is installed.
The satisfactory performance of a dental implant depends in large part upon osseointegration (i.e., the growth of bone tissue surrounding the dental implant by the process of osteocompression). Because mechanical implants lack the biological attachment to the bone present in natural dentition, the mechanical design of the implant is of critical importance to reduce stresses and provide functional support and bone stimulation by chewing.
In particular, the implant design must stimulate bone by compression since bone cannot be stimulated by tension as is the case with natural dentition. The areas of an implant's surface capable of providing sufficient bone support and physiologic stimulation are the horizontal compressive planes, not the vertical implant interface under shear force. This fact accounts for failure of many bullet-shaped, push-in implants as evidenced by the Food and Drug Administration's archives of implant failures. Furthermore, if the horizontal planes, or LBAs, of an implant's geometry are not significant enough to sustain the chewing forces generated in a specific bone region, a fibro-osseous condition may ensue. This build-up of connective tissue can cause implant failure under cyclic loading (i.e., chewing). This is particularly prevalent in sharp implants (e.g., blade implants) not having sufficient LBA and typically possessing twice the shear surface area as that of a cylinder or screw implant.
Because the horizontal areas of any implant geometry are the primary mechanism for bone stimulation and implant stability on a long-term basis, any design that increases such horizontal areas can have a significant impact on implant performance. This is especially important in implants that are expected to immediately be functional the day of surgical implantation. The implant 200 , specifically the groove structures 212 a , 212 b , in, the crest 210 provide such enhancement whereby the crestal thread area 210 compresses bone in one direction. Bone responds by immediately compacting bone in the opposite direction into the grooved structures 212 a , 212 b and the longitudinal channel(s) 213 (described herein below) of the implant of the present invention.
As well as stimulating bone tissue, the LBA 9 load bearing area) of an implant typically sustains and supports approximately 95% of all generated forces imposed on the implant's TSA (total surface area) when the mandible is in centric occlusion. The remaining 5% of force is dissipated throughout the vertical axis of the implant's interface in shear. The enhanced design of threads 208 of implant 200 therefore, also improves the stress handling performance of implant 200 .
TABLE 1 shows the LBA and TSA of a variation of the inventive implant, having a shaft, which is 4.0 mm wide.
TABLE 1 No. Implant Approximate Approximate of body LBA of implant TSA of implant threads length (mm) 200 (mm 2 ) 200 (mm 2 ) 4.5 9 93.8 179.0 5.5 11 107.9 207.6 6.5 13 121.9 236.7 7.5 15 136.5 266.3 8.5 17 151.5 295.6
The LBA and TSA measurements shown in TABLE 1 for the inventive implant are approximately at least 66% to 75% higher than all known prior art. While specific combinations of shaft width, implant body length, and/or number of threads have been chosen for purposes of disclosure, it will be recognized by those skilled in the art that other shaft width, implant body length, and/or number of threads may be provided to meet a specific operating circumstance or bone environment. The invention is, therefore, not considered limited to the specific shaft width, implant body length, and/or number of threads chosen. Rather, the invention covers any and all variations of shaft width, implant body length, and/or number of threads.
The thread geometry of the novel implant attains high values of implant-to-bone support in a compressive mode at the LBA. Optimum performance of the novel implant is typically obtained by bone compaction of horizontal osseous levels. Such compaction may be maximized using a specialized rotary osteotome, such as that described in co-pending U.S. application Ser. No. 10/668,805, included herein by reference.
Various histologic studies have demonstrated that compression of bone induces extracellular fluids within the bone to flow over the charged surface of osteoblast cells, causing osteogenic activity. In addition, no bone necrosis occurs at the implant's interface due to unique surgical instrumentation and implant congruity at time of implant placement. Due to the unique geometry of the implants of the present invention, controlled functional osteocompression is achieved for a specific bone region by the present implant design, especially when using the aforementioned rotary osteotome.
Immediate implant fixation and stabilization in the bone is further increased by the novel implant thread design. This is accomplished by understanding the elastic modulus and the viscoelastic properties of bone, and matching the two secondary grooves ( 212 a , 212 b ) for each thread by using at least one rotary osteotome, specifically adapted to the geometry of the implant.
As shown in FIGS. 2 a and 2 c , it is preferable that least one longitudinal groove or channel 213 is provided along the long axis of the implant 200 facing in a counterclockwise direction to the apical cutting threads for insertion. Henceforth, bone chips do not accumulate unnecessarily at surgical sites by the cutting apical threads and are transferred to the two longitudinal channels to fill such concavities for immediate stabilization and immediate implant fixation in the bone to stop counter-rotation. These longitudinal grooves also prevent over-compression and necrosis of the bone and prevents hydraulic buildup at surgical site to offset edema.
As is believed to be known in the dental implant arts, implants of different lengths, diameters, and thread designs may be required, depending upon the bone ridge width and density of the jaw into which they are placed. Another factor, necessitated particularly by bone condition, is the thread pitch of the implant, selected for various bone qualities and forces delegated in a particular region of the maxilla or mandible.
The nominal structure of a particular implant 200 is dependent upon its intended placement area in the jaw. A force-to-bone-density factor has been established to quantify a ratio between the force expected or generated upon a particular tooth area and the bone density typically found in the bone tissue for supporting the implant after tooth extraction. For example, molar regions in both the maxilla and mandible typically receive biting forces in the range of approximately 100-110 psi. Bicuspid regions typically experience biting forces in the range of 40-50 psi, while central teeth only experience biting forces in the range of approximately 10-30 psi.
There is, however, a known difference in bone density or mineralization between similar portions of the maxilla and mandible resulting in different force-to-bone (FB) regions being defined. FB regions are commonly recognized: FB1-FB3. Since forces come in pairs, Region FB1 is for both upper and lower 12anterior teeth; region FB2 for upper and lower eight bicuspids; and, region FB3 for 12 maxillary and mandibular molars.
TABLE 2 provides information relating length of an implant to its intended implant location.
TABLE 2 Force-to- Implant Implant Load Implant Bone Placement Bearing Area Length Region Region (mm 2 ) 9 mm FB1 Upper/Lower 57-68 Anteriors 11 mm FB2 Upper/Lower 69-82 Bicuspids 13 mm FB3 Lower Molars 82-96 15 mm FB3 Upper Molars 94-110
Ironically, the molar regions of greater force magnitude also provide the spongiest bone-to-implant interface. This is region FB3 where bone having the lowest mineral content is located. It should also be noted that significant increase in force magnitude is generated in the molar regions of the jaw having less than desirable bone trabeculation, especially in the maxillary molar region. For instance, the average force on the bicuspid region (FB2) is approximately 100 psi compared to the molar region (FB3) where the average force magnitude is approximately 200 psi in a healthy individual with full dentition. This is because the jaw may be modeled as a class II lever where force magnitude increases in the molar region, and a class III lever from the bicuspids to the anterior incisors where the force magnitude decreases. A class III lever occurs when the resisting force (on the implant design against bone) is between the applied force (by the masseter, temporalis, and medial pterygoid muscles) and the point of rotation or fulcrum (condyle). In the case of the human jaw, this phenomenon doubles the forces in the molar regions relative to that in the bicuspid and anterior regions. Even though the muscles fire with equal force, the implant experiences higher values of force due to class II lever.
The requirement to install implants throughout the maxilla and the mandible has necessitated providing several variations of the implant of the present invention. Some examples of such variations are shown in TABLE 3.
TABLE 3 Major Minor Thread Diameter Diameter Pitch Implant Thread Description (“d” 220) (“md” 222) (“p” 218) 3.3 Wide Thread Implant 3.30 mm 2.50 mm 2.00 mm 3.3 Narrow Thread Implant 3.30 mm 2.50 mm 1.55 mm 4.0 Wide Thread Implant 4.00 mm 2.50 mm 2.00 mm 4.0 Narrow Thread Implant 4.00 mm 2.50 mm 1.55 mm 5.0 Wide Thread Implant 5.00 mm 3.50 mm 2.00 mm 5.0 Narrow Thread Implant 5.00 mm 3.50 mm 1.55 mm
While specific combinations of diameter and/or thread pitch have been chosen for purposes of disclosure, it will be recognized by those skilled in the art that other diameters and/or thread pitches may be provided to meet a specific operating circumstance or bone environment. The invention is, therefore, not considered limited to the specific diameters and/or thread pitches chosen. Rather, the invention covers any and all variations of either diameter or thread pitch.
Conversely, a thread design could be developed to accommodate a tooth extraction site having a tapered cone geometry with the present thread design. All tooth extraction sites (whether from incisors, bicuspids, or molars) are not uniform in nature. However, a common denominator they may have is a tapered cone-shaped geometry from the apex, to an uneven elliptical shape toward the crestal ridge. Since bone quality is spongy toward in the apical root area and denser crestally, it may be advantageous to change the thread design of each implant pitch and its minor diameter.
It has been found advantageous to place the implant in the bone in such a way that a portion of the abutment, whether detachable from or integral with the implant, sits below the bone crest. Referring to FIG. 2 a , the line referenced by reference no. 224 shows the preferable height of crestal bone on the inventive implant. The upper portion of the abutment protrudes from the soft tissue into the oral cavity. However, the lower portion of the abutment sits within the bone structure in a tapered fashion. Such countersinking in a tapered fashion provides larger support for an area of high load concentration under constant chewing. Henceforth, this abutment area is part of the overall implant mechanical structure of LBA.
The novel geometry of the implant of the present invention allows a novel approach to the installation thereof, shown generally at reference number 300 .
First, a dental practitioner evaluates the density of the maxilla or mandible using x-rays, models, and CT scans, block 302 . The practitioner identifies overall structure and jaw trajectory with relevant anatomical landmarks, and notes implant sites on the patient's study cast.
Next, the practitioner identifies proposed implant sites, and measures the distance between vital anatomical structures and opposing teeth, block 304 . The practitioner thereby ensures that the implant site can accommodate an ideal distance of approximately 7 mm to 9 mm between implant-to-implant centers, including natural tooth preparations. The practitioner determines the optimal locations for implant placement, keeping in mind all anatomical, functional, and aesthetic considerations.
Next, the dental practitioner administers an anesthetic, preferably local, but may be general, block 306 .
Following administration of anesthesia, the dental practitioner inserts into the implant site(s), a prefabricated provisional temporary tooth stent, preferably acrylic, having pre-drilled occlusal holes, block 308 .
Next, the dental practitioner marks the bone at the proposed implant site, block 310 . Marking is accomplished by inserting a drill through the stent until the drill bit makes contact with the bone. The drill is used to put a notch or other type of mark on the bone at the proposed implant site, preferably by drilling about one millimeter into the bone.
Next, an incision is made crestally exposing the implant site(s), block 312 . Buccal and lingual mucoperiosteal flaps are elevated. The incision and flap elevation are extended to enable easy access to and control over the implant sites and to permit a good visualization of jaw morphology and vital anatomical sites.
The incision described in block 312 , is then carried distally in order to localize the neurovascular bundles exiting from the mental foramina, block 314 . In the upper jaw, the foramen is localized and the position of the naso-palatine canal is established.
If the alveolar ridge is too knife-edged or irregular in either the maxilla or mandible, the ridge is reduced with a surgical round bur, rongeur, or osteotome described in co-pending U.S. patent application Ser. No. 10/668,805, until a crestal bone ridge approximately 1.5 mm to 2.5 mm wider than the selected implant diameter is achieved, block 316 . Alternatively, bone augmentation procedures may be considered four to six months prior to implant placement.
Next, an implant profile osteotomy is drilled to an appropriate shape and length, block 318 . The profile of the osteotomy should be shaped to accommodate the implant's shape. It should be long enough so that the implant fits into the bone snugly, but comfortably.
Next, the thread areas are compacted, preferably to approximately 3.3 mm, block 320 , preferably using rotary dilator(s). The compacting step may additionally include threading if necessary. The dilator preferably operates at an approximate speed of 50 rpm using a surgical motor.
If the bone surrounding the osteotomy is too dense, the practitioner should tap dense bone osteotomy, block 322 . An example of bone that usually must be tapped is cortical bone because it is very dense, having an elastic modulus of approximately 3 million. Tapping is a procedure whereby a tap is used to extract or cut out bone from the osteotomy. Tapping is not further described herein since it is believed to be a process that is well known to those of skill in the art.
The implant is next installed in the bone, block 324 . Denser bone may require the use of one or two additional osteotomes to cut bone three-dimensionally.
Next, the crestal region of the patient's jawbone is grafted with natural or synthetic bone material, block 326 . Preferably, a synthetic, bioactive, resorbable graft, such as that known as OsteoGen®, is used, which prevents the downward migration of epithelium. Synthetic bone grafting of the crestal region produces a more intimate contact between the bone and the implant, and provides maximum adaptation of metal to bone in a compressive state.
Next, soft tissue adjacent the implant site(s) is repositioned and sutured together with uninterrupted or continuous sutures to obtain primary closure over the implants, block 328 . Primary closure is not further discussed because it is believed to be a term well known to those of skill in the art. It is preferable that to limit the development of any hematoma formation, a gauze pack is placed over the flaps and the patient is asked to maintain it in place with pressure.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims. | A dental implant having a unique thread configuration, which increases the total load bearing area to maximize support values of a successful implant for the same osteotomy when compared to other implant designs. At least one course of helical threads surrounds an elongated, cylindrical body. In an embodiment chosen for the purposes of disclosure, the threads have relatively broad crestal surfaces, typically having a rounded profile. One or more helical secondary threaded grooves are disposed in the crestal surface of the threads. The helical grooves facilitate collection of bone and promote immediate stabilization and osseointegration of the implant. The broad crestal thread design compresses bone in one direction while bone is being collected by the helical grooves in the opposite direction. The result is that the implant is immediately stable in a patient's jaw. The method of installing the dental implant is also novel. | 0 |
FIELD OF THE INVENTION
This invention generally relates to improvements in database accesses and more particularly to reducing the overhead per accessed row using updatable and scrollable cursors.
BACKGROUND OF THE INVENTION
Databases have become the subject of significant recent interest, not only because of the increasing volume of data being stored and retrieved by computerized databases but also by virtue of the data relationships which can be established during the storage and retrieval processes.
Structured Query Language (SQL), and in particular ANSI SQL, has become a preferred language media for communicating queries to relational databases. As a consequence, there presently exist thousands of relational databases and thousands of related queries directed to such databases. Given an investment in such databases and queries, migration is not only a desirable feature, but a substantially necessary capability for new relational database systems and methods.
To a Database Manager (DBM) application program, each fetch of the next row is a separate SQL request. If each row fetch of the next row is implemented as a direct call to the SQL DBM, a large amount of overhead is accrued per request. For local applications resident on a server machine, the per request overhead is two process switches and a DBM Agent process attach and deattach. For a remote application running on a client machine, there is additional overhead associated with the round-trip message per request.
Blocking is an application transparent technique that allows multiple rows at a time to be moved between an application process and a DBM Agent process. Thus, blocking distributes the overhead burden over many rows.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a database blocking technique for updatable and scrollable cursors.
These and other objects of the present invention are accomplished by the operation of a process in the memory of a processor. The processor, under the control of the process, builds a reserved area in the memory of the computer. The reserved area in the memory contains an image of a portion of the information residing on disk in the database. When an application opens a cursor to the database, the type of blocking is specified for the cursor. If writethrough or writeback blocking is requested, then the application issues a fetch request, and if the row is in the reserved area in the memory, then the row is fetched and returned locally without going to the database manager. However, if the row is not in the reserved area in the memory, then a remote procedure call is performed to get the required next block of rows. The database manager modifies the locks on the previous block of information and gets the next block of rows and places them in memory with the appropriate lock structure. The database manager then returns the block containing the rows back to the application. Various lock data structures are employed to manage and control the processing. A row update is handled differently depending on whether writethrough or writeback blocking is selected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a host computer in accordance with the subject invention;
FIG. 2 illustrates three levels of database blocking in accordance with the subject invention;
FIG. 3 illustrates the efficiency benefits acheived through blocking in accordance with the subject invention;
FIG. 4 illustrates how a DX lock is related to other locks in accordance with the subject invention;
FIG. 5 is a flow diagram for an application process and a database manager process in accordance with the subject invention;
FIG. 6 is a flow diagram for an application process and a database manager process in accordance with the subject invention;
FIG. 7 is a flow diagram for an application process and a database manager process in accordance with the subject invention;
FIG. 8 is a flow diagram for an application process and a database manager process in accordance with the subject invention; and
FIG. 9 is an illustration of the data structures in accordance with the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
A representative hardware environment is depicted in FIG. 1, which illustrates a typical hardware configuration of a workstation in accordance with the subject invention having a central processing unit 10, such as a conventional microprocessor, and a number of other units interconnected via a system bus 12. The workstation shown in FIG. 1 includes a Random Access Memory (RAM) 14, Read Only Memory (ROM) 16, an I/O adapter 18 for connecting peripheral devices such as disk units 20 to the bus, a user interface adapter 22 for connecting a keyboard 24, a mouse 26, a speaker 28, a microphone 32, and/or other user interface devices such as a touch screen device (not shown) to the bus, a communication adapter 34 for connecting the workstation to a data processing network and a display adapter 36 for connecting the bus to a display device 38.
A source application program (APPL) can access a Database Manager (DBM) using embedded SQL or other database manager commands. After compilation, the SQL statements access the DBM using a set of library routines that execute in the APPL process. The DBM executes in a separate pool of processes from the APPL. Each request is assigned to one of the DBM processes which are referred to as DBM agents. For a local APPL, ie. the APPL executes in the same machine as the DBM, the overhead per DBM request is two process switches as well as an attach and deattach to a SQL process. For a remote APPL, ie. the APPL executes in a different client machine from the DBM, the overhead per DBM request also includes a round trip message. The APPL locally sees a row-at-a-time interface to the DBM. If row-at-a-time is reflected back to the DBM as a separate request, then there is a high overhead per row.
Blocking is a technique to distribute the overhead over many rows. Blocking is accomplished in a manner transparent to the APPL, but the library routines provide a reserved area in the memory management facility within the APPL process. That is, the APPL sees the row-at-a-time interface and the library routines provide reserved area in the memoryd rows without going back to the DBM until a block full of rows has been exhausted. When the block, ie. one or more pages of rows is exhausted, then the library routines send a single request to the DBM for another block of rows. Although multi-row interfaces may be provided directly to the APPL, they require more sophistication by the APPL programmer. Blocking is transparent to the programmer, so that current applications do not require change.
The current DBM for updateable or scrollable cursors provides blocking for read only cursors with only a one-way information flow. After data is used by the APPL, it is discarded. Updatable cursors refers to making a determination of which rows are to be updated at runtime as opposed to making the determination while compiling the application. FIG. 2 illustrates three levels of blocking. Level 0 200, no blocking, is the only option supported in the current DBM. Level I (writethrough) allows blocking only in the read direction, from APPL process to DBM Agent, and each update requires a separate message back to the DBM Agent to synchronously secure a write lock. Level 1 is always more efficient than Level 0. Level 2, writeback, allows blocking in both directions at the price of temporary overlocking. Level 2 can be employed when there are no interrow integrity constraints to be checked.
The benefit in these new blocking techniques is that they provide balancing between the following features:
distributing overhead between multiple row access operations; and
data contingency based on locking data for all reserved area in the memory operations.
FIG. 3 illustrates the benefits of these operations. A local APPL benefits from minimized DBM Agent attaching, deattaching and minimized process switching. A remote APPL also benefits from minimized messaging.
The tradeoff can be made by offering the following options to application developers: choice of level of blocking; and different block sizes. A smaller block size reduces both the advantages and disadvantages of blocking.
Blocking with updatable and/or scrollable cursors is like multiprocessor caching, but with the additional complexity of maintaining the correct level of isolation between transactions. The locking techniques required to maintain isolation between transactions is an important feature of the invention. The locking techniques also ensure reserved area in the memory consistency between transactions by preventing multiple transactions updates of the same data. Other important features of the invention are the additional reserved area in the memory consistency techniques required within a single transaction.
Locking Techniques
Writethrough and writeback blocking have the following complexities that are not encountered in readonly blocking.
Which row: an update must be efficiently returned to the DBM with enough information to include it in the database. This information includes which row and its updated value.
Locks: locks must be maintained efficiently while maintaining the specified level of isolation. For example, whether the lock is for a repeatable read or cursor stability.
It is critical to solve the "which row" problem by shipping between the DBM Agent process and the APPL process something with each row that uniquely identifies the row, and to solve the locks problem of overlocking data while it is being stored in the reserved area in the memory in the APPL process.
The following three levels of isolation are supported by the DBM:
Repeatable-read: two phase locking to guarantee serializability.
Cursor-stability: to guarantee the value of the row currently pointed to by the cursor will not change. It does not guarantee that the criteria for membership of rows in the cursor set will be kept consistent with the current database or with what has already been seen by the APPL.
Uncommitted read: guarantees only that the rows will not be accessed in the middle of another transaction's update.
The following three types of locks are used to implement the invention. S: shared lock, X: nondemotable exclusive lock, DX: demotable exclusive lock. The DBM already supports S and X locks. The DX lock is introduced here to support writethrough blocking. DX has all of the same characteristics as X, except that DX can be demoted to lower levels of locking and X cannot. The lock compatibility matrix and the lock upper bound matrix are illustrated in FIG. 4. The semantics of UPDATE/DELETE WHERE CURRENT OF, the command for updating or deleting the row currently pointed to by the specified cursor, is that a return code with a status 0K means that the UPDATE/DELETE WHERE CURRENT 0F was completed, which includes getting an X lock on the row. For writethrough blocking, the update or delete processing happens in the reserved area in the memory within the APPL process without going to the DBM Agent until the cursor exits the reserved area in the memory. Then, all updates are sent back together in a single message. To support this processing, DX locks are obtained on all rows that are stored in the reserved area in the memory on the APPL process to reserve the ability to get an X lock in case one is actually required. The distinction between DX and X is needed to note whether a row has actually been updated during a previous visit, for example during another cursor scan or in the same cursor scan with scrolling.
FIG. 5 is an illustration of a flow diagram showing the interaction between an APPL process and a DBM process for a FETCH operation using writeback blocking. The APPL issues a FETCH request via the library routines in the APPL process. The library routines manage the local reserved area in the memory for blocking operations. If the row is in the reserved area in the memory, then it is fetched and returned locally without going to the DBM Agent. Thus, the only overhead incurred is a procedure call to the library routine. If the row is not in the reserved area in the memory, the library routine sends an RPC to the DBM to return any updates in the previous block and to get the required next block of rows. The DBM Agent process assigned to that request receives the RPC. It first applies any updates in the previous block by modifying locks on all rows of the block.
The rules for locking under repeatable-read isolation are:
If the row had a DX lock on it and the lock was not updated, then demote the lock to S.
If the row had a DX lock on it and it was updated, then promote its lock to X. Note that a DX lock ensures that this is possible without waiting.
If the row had an X lock on it, then do not change the lock.
The rules for locking under cursor-stability isolation are:
If the row had a DX lock on it and it was not updated, then demote its lock to no lock.
If the row had a DX lock on it and it was not updated, then promote its lock to X. Note that a DX lock ensures that this is possible without waiting.
If the row had an X lock on it, then do not change the lock.
Next, the DBM Agent gets the next block of rows, which requires getting the appropriate locks. The rules for locking are:
If the row did not have an X lock, then get a DX lock.
If the row had an X lock, then no additional locks are necessary.
The DBM process then returns the block containing the rows with their unique identifiers back to the library routines in the APPL process. The APPL process then returns the next row to the APPL. This process continues until an EOF is reached. When this happens, the library routine sends an RPC request to the DBM to return any updates in this block.
FIG. 6 provides a flow diagram for an UPDATE/DELETE WHERE CURRENT OF request for writeback blocking. The APPL issues an UPDATE/DELETE WHERE CURRENT OF request via the library routines in the APPL process. The updated row will always be in the reserved area in the memory and have a DX lock in the DBM, so that the library routine can simply update it locally.
FIG. 7 provides a flow diagram between the APPL process and DBM process for a FETCH request for writethrough blocking. The APPL issues a FETCH request via the library routines in the APPL process. The library routines manage the local reserved area in the memory for blocking. If the row is in the reserved area in the memory, then it is simply fetched and returned locally without going to the DBM Agent, so the only overhead is a procedure call to the library routine. If the row is not in the reserved area in the memory, the library routine sends an RPC request to the DBM to get the required next block of rows. The DBM Agent process assigned to that request receives the RPC. It first modifies the locks on the previous block.
The rules for locking under repeatable-read isolation are:
Do nothing to the locks
The rules for locking under cursor-stability isolation are:
Release the S locks.
The DBM Agent gets the next block of rows, which requires getting at least an S lock on each row in the block. Note that U locks are substituted for S locks under normal conditions. The DBM process then returns the block containing the rows with their unique identifiers back to the library routines in the APPL process. The APPL process then returns the next row to the APPL. This process continues until an EOF is reached.
FIG. 8 is a flow diagram for an UPDATE/DELETE WHERE CURRENT OF request for writethrough blocking. The APPL issues an UPDATE/DELETE WHERE CURRENT OF request via the library routines in the APPL process. The updated row will always be in the reserved area in the memory, but the update must be synchronously sent to the DBM to be processes before returning to the APPL. The library routine sends an RPC to the DBM requesting the update. The DBM Agent process assigned to the request receives the RPC. It applies the update, which requires a promotion of the lock to X. Then, the DBM process returns the ack back to the library routines in the APPL process and onto the APPL.
Reserved Area in the Memory Consistency
If locking is not considered, then blocking can be considered as simply another occurrence of a reserved area in the memory management. However, locking assures consistency of data in the reserved area between transactions by preventing multiple transactions from updating the same data. This reduces to only intertransaction reserved area in the memory consistency problems.
In the current version of the Database Manager, only one application process can participate in a transaction, so no reserved area in the memory consistency problems can arise. In later releases, if multiple reserved areas in the memory are maintained for different application processes participating in a single transaction for the same table, then there is a possibility of reserved area in the memory inconsistencies.
When the reserved area in the memory manager detects an update to table TB from transaction TR, then it must invalidate all reserved area in the memory of cursors on TB within TR except the reserved area in the memory that was used with an UPDATE/DELETE WHERE CURRENT OF. That is, if a non-cursor update is requested to TB within TR, then the reserved areas in the memory must be invalidated for all cursors on TB within TR. If an UPDATE/DELETE WHERE CURRENT OF Ci is issues on TB within TR, then the reserved areas in the memory must be invalidated for all cursors on TB within TR except Ci. Reserved area in the memory invalidation requires the following extension to the flows:
which reserved areas in the memory to invalidate must be determined
the appropriate reserved areas in the memory are invalidated, which requires setting an invalidation flag for each reserved area in the memory in the APPL process.
the test of whether the next row is in the reserved area in the memory must first check the invalidation flag.
if the invalidation flag is set, then the request for the next block asks for the current block instead of the next block.
the invalidation flag is cleared when the block arrives.
FIG. 9 is an illustration of the data structures in accordance with the subject invention. For each open cursor, certain information must be maintained in the memory of the computer. First, the DBM assigns a contiguous row index number (RIN) 900 to the rows that qualify under the cursor predicated. An array 910 is also created to map the RIN to a Row identifier (RID). RINs are passed instead of RIDs between the application process and the DBM process, so that the application process cannot specify a row outside of those that qualify under a cursor predicate.
Then, the application process must maintain the RIN of the row corresponding to the cursor s current-row indicator and an index that maps RINs into the rows it has in the reserved area in the memory. The implementation of the index can be interchanged between a hash-table, B-Tree or a simple list based on user requirements.
While the invention has been described in terms of a preferred embodiment in a specific system environment, those skilled in the art recognize that the invention can be practiced, with modification, in other and different hardware and software environments within the spirit and scope of the appended claims. | A method, system and process for providing an improved database blocking technique for updatable and scrollable cursors is disclosed. The invention is facilitated by the operation of a process in the memory of a processor. The processor, under the control of the process, builds a reserved area in the memory of the computer. The reserved area in the memory contains an image of a portion of the information residing on disk in the database. When an application opens a cursor to a database, the type of blocking is specified for that cursor. The application issues a fetch request, and if the row is not in the block in the reserved area in the memory, then a remote procedure call is performed to get the required next block of rows and return the block containing the rows back to the application. Various lock data structures are employed to manage and control the processing. | 6 |
This application is a continuation-in-part of U.S. patent application Ser. No. 10/405,169 filed Apr. 2, 2003 (pending), which is a continuation-in-part of U.S. patent application Ser. No. 10/106,741 filed Mar. 26, 2002 (pending) which is a continuation-in-part of U.S. patent application Ser. No. 09/682,440 filed Sep. 4, 2001 (now U.S. Pat. No. 6,592,369 B2) which is a continuation-in-part of U.S. patent application Ser. No. 09/670,364 filed Sep. 26, 2000, (abandoned). This application is a continuation-in-part of U.S. patent application Ser. No. 10/306,096 filed Nov. 27, 2002 now U.S. Pat. No. 6,799,969 which is a continuation of U.S. patent application Ser. No. 09/670,364 filed Sep. 26, 2000, (abandoned). The benefit is claimed of US provisional patent application Ser. No. 60/237,523 filed Oct. 4, 2000, U.S. Provisional Patent Application Ser. No. 60/201,705 filed May 3, 2000, and U.S. Provisional Patent Application Ser. No. 60/164,893 filed Nov. 10, 1999.
A dental device and method of making it, by shaping a first and a second wax-like polymerizable dental material to form a polymerizable dental device.
DETAILED DESCRIPTION OF THE INVENTION
Compositions useful in accordance with the invention may further include fillers, pigments, stabilizers, plasticizers and fibers. Preferably, these polymerizable dental compositions include from about 2 to about 95 percent by weight filler particles. More preferably, these compositions include from about 10 to about 85 percent by weight filler. Nanocomposites and creamers may be formed from these composites. The fillers preferably include both organic and inorganic particulate fillers to further reduce polymerization shrinkage, improve wear resistance and modify the mechanical and physical properties.
Light curable polymerizable dental materials preferably include a light sensitizer, for example camphorquinone, Lucirin TPO, or methyl benzoin which causes polymerization to be initiated upon exposure to activating wavelengths of light; and/or a reducing compound, for example tertiary amine. A room temperature or heat activating catalyst system is preferably included in the polymerizable dental material. For example a peroxide capable of producing free radicals when activated by a reducing agent at room temperature or by heating. Preferred peroxides include benzyl peroxide and lauroyl peroxide.
A preferred embodiment of the invention uses a high strength dental polymeric material formed by light curing polymerizable dental material shaped into at least a portion of a denture base or tooth. Preferably the polymerizable dental material has a flexural modulus of at least 250,000 psi and a flexural strength of at least 7,000 psi. Preferably a denture of the invention comprises a denture base and a tooth integrally connected and comprising an interpenetrating polymer network polymeric matrix and at least 0.1 percent by weight of self-lubricating particles having a particle size less than 500 microns effectively bonded to and distributed in the polymeric matrix. Preferably the integral connection of the denture base and a tooth is effectively greater than a bond strength of 4,480 psi.
“Wax-like material” as used herein refers to material which is flowable (fluid) above 40° C. and becomes dimensionally stable (solidifies: i.e. is nonfluid) at least at and below 23° C., within 5 minutes. Thus, wax-like material is flowable when it is at and above 40° C., and becomes dimensionally stable when it is at and below 23° C. Flowable wax-like material having a temperature from 100° C. to 40° C., becomes dimensionally stable within 5 minutes by cooling by exposure to an ambient temperature between 23° C. and 0° C. Flowable wax-like material having a temperature from 100° C. to 40.° C., becomes dimensionally stable within (in order of increasing preference) 2, 1, 0.5 or 0.3 minutes by cooling by exposure to an ambient temperature between 23° C. and 0° C.
“High strength dental polymeric material” as used herein refers to material having a polymeric matrix having a flexural modulus of at least 250,000 psi and a flexural strength of at least 5,000 psi. Optionally, high strength dental polymeric material includes reinforcing filler. However, the polymeric matrix alone (without any reinforcing filler) has a flexural modulus of at least 250,000 psi and a flexural strength of at least 5,000 psi. Preferably high strength dental polymeric material has a polymeric matrix having a flexural modulus of at least 300,000 psi and a flexural strength of at least 7,000 psi. More preferably high strength dental polymeric material in order of increasing preference has a polymeric matrix having a flexural modulus of at least 350,000 psi and a flexural strength of at least 12,000 psi. Artificial teeth and denture base both made of high strength dental polymeric material are integrally connected in dental products including full dentures, partial dentures and bridges during polymerization of polymerizable dental material.
“Flexural strength, and flexural modulus” as used herein refers to results of testing according to ASTM D790 (1997). “Notched impact strength” as used herein is also referred to as “notched Izod impact resistance” and refers to results of testing according to ASTM D256 (1997). “Un-notched impact strength” as used herein refers to results of testing according to ASTM D4812 (1993).
In the following examples, unless otherwise indicated, all parts and percentages are by weight; Lucirin TPO refers to 2,4,6-trimethylbenzoyldiphenylphosphine oxide made by BASF, and the visible light curing unit used was an Eclipse visible light curing unit, sold by Dentsply International, providing about 30 milliwatts/cm 2 of from 350 to 450 nm light.
Preparation 1
Preparation of Oligomer
A reactor was charged with 1176 grams of trimethyl-1,6-diisocyanatohexane (5.59 mol) and 1064 grams of bisphenol A propoxylate (3.09 mol) under dry nitrogen flow and heated to about 65° C. under a positive nitrogen pressure. To this reaction mixture, 10 drops of catalyst dibutyltin dilaurate were added. The temperature of the reaction mixture was maintained between 65° C. and 140° C. for about 70 minutes and followed by additional 10 drops of catalyst dibutyltin dilaurate. A viscous paste-like isocyanate end-capped intermediate product was formed and stirred for 100 minutes.
To this intermediate product, 662 grams (5.09 mol) of 2-hydroxyethyl methacrylate and 7.0 grams of BHT as an inhibitor were added over a period of 70 minutes while the reaction temperature was maintained between 68° C. and 90° C. After about five hours stirring under 70° C., the heat was turned off, and oligomer was collected from the reactor as semi-translucent flexible solid and stored in a dry atmosphere.
Preparation 2
Preparation of Monomer
A reaction flask was charged with 700 grams of 1,6-diisocyanatohexane and heated to about 70° C. under a positive nitrogen pressure. To this reactor were added 1027 grams of 2-hydroxyethyl methacrylate, 0.75 gram of catalyst dibutyltin dilaurate and 4.5 grams of butylated hydroxy toluene (BHT). The addition was slow and under dry nitrogen flow over a period of two hours. The temperature of the reaction mixture was maintained between 70° C. and 90° C. for another two hours and followed by the addition of 8.5 grams of purified water. One hour later, the reaction product was discharged as clear liquid into plastic containers and cooled to form a white solid and stored in a dry atmosphere.
Preparation 3
Preparation of Polymerizable Denture Base Plate Material
A light curable polymerizable material was prepared by stirring at 85° C. a liquid of 98.0 grams of TBDMA oligomer of Preparation 1, 0.35 gram of 2,4,6-trimethylbenzoyldiphenylphosphine oxide, (Lucirin TPO made by BASF), 1.5 gram of solution containing 8.3% camphorquinone (CQ), 25% ethyl 4-dimethylaminobenzoate (EDAB) and 66.7% 1,6-hexanediol dimethacrylate (HDDMA), 0.1 gram of red acetate fibers and 0.05 gram of pigment.
Preparation 4
Preparation of Polymerizable Wax-Like Denture Contour Material
A light curable wax-like polymerizable dental material was prepared by stirring at 85° C. a liquid mixture of 50.5 grams of oligomer of Preparation 1, 45.0 grams of monomer of Preparation 2 and 4.0 grams of stearyl acrylate from Sartomer. To this mixture were added 0.35 gram of 2,4,6-trimethylbenzoyldiphenylphosphine oxide (Lucirin TPO), 0.1 gram of red acetate fibers and 0.05 gram of pigment concentrates. The polymerizable wax-like material formed becomes flowable at 65 to 68° C.
Preparation 5
Preparation of Polymerizable Denture Set-up Material
A light curable polymerizable material was prepared by stirring at 85° C. a liquid mixture of 84.5 grams of oligomer of Preparation 1 and 15.0 grams of monomer of Preparation 2. To this mixture, 0.35 gram of 2,4,6-trimethylbenzoyldiphenylphosphine oxide (Lucirin TPO), 0.1 gram of red acetate fibers and 0.05 gram of pigment were added.
Preparation 6
Preparation of Polymerizable Wax-like Artificial Tooth Resin
A light curable wax-like polymerizable dental material was prepared by stirring at 85° C. a liquid mixture of 50 grams of oligomer of Preparation 1, 30.0 grams of monomer of Preparation 2 and 20 grams of monomer of Preparation 2. To this mixture were added 0.35 gram of 2,4,6-trimethylbenzoyldiphenylphosphine oxide (Lucirin TPO), and 0.05 gram of pigment concentrates. The polymerizable wax-like material formed becomes flowable at 65 to 70° C.
Preparation 7
Preparation of Monomer
A reaction flask was charged with 168 grams of 1,6-diisocyanatohexane and heated to about 70° C. under a positive nitrogen pressure. To this reactor were added 228 grams of 2-hydroxyethyl acrylate, 0.12 gram of catalyst dibutyltin dilaurate and 0.86 grams of butylated hydroxy toluene (BHT). The addition was slow and under dry nitrogen flow over a period of two hours. The temperature of the reaction mixture was maintained between 70° C. and 85° C. for another three hours and followed by the addition of 0.9 grams of purified water. One hour later, the reaction product was discharged as clear liquid into plastic containers and cooled to form a white solid and stored in a dry atmosphere.
Preparation 8
Preparation of Monomer
A reaction flask was charged with 47.7 grams of p-tolyl isocyanate and heated to about 46° C. under a positive nitrogen pressure. To this reactor were added 48.13 grams of 2-hydroxyethy methacrylate, 0.06 gram of catalyst dibutyltin dilaurate and 0.30 grams of butylated hydroxy toluene (BHT). The addition was under dry nitrogen flow over a period of 40 minutes while the temperature of the reaction mixture was raised to 78° C. and maintained between 72° C. and 78° C. for another 1.3 hours. The reaction product was discharged as clear liquid into a plastic container and cooled to form a semi-opaque off white solid and stored in a dry atmosphere.
EXAMPLES 1A and 1B
Table 1 shows the components and Table 2 shows the properties of the compositions of Examples 1A through 1B. The compositions of Examples 1A through 1B were prepared by mixing the components shown in Table 1 at 95° C.
TABLE I
Example 1A
Example 1B
(grams)
(grams)
Titanium dioxide
0.385
0
Iron oxide
0.0499
0.002
Red-Brown Pigment Blend
0.0132
0.0012
Ultramarine Blue Pigment
0
0.0028
Black Dry Color Blend
0.0134
0
a blend of 82.99% ZnO, 16.18% Magnesium
0.194
0.05
carbonate, 0.62% Lithium sulfate and 0.21%
Sulfur, (sublimed powder). [115 Phosphor]
dihydroxy terepthalate acid ester
0.08
0.024
[FLU-L-BLU]
Monomer of Preparation 2
40.4
17.2
Monomer of Preparation 7
28.0
24.6
Monomer of Preparation 8
24.6
Oligomer of Preparation 1
68.16
41.6
Lucirin TPO
0.6
0.32
Camphorquinone
0.32
0.212
N, N-dimethyl-aminoneopentyl acrylate
1.11
0.74
Methacrylic Acid
0.55
0.368
Butylated Hydroxytoluene
0.03
0.02
γ-methacryloxypropyl-silane
0.39
0.26
silanated fumed silica*** (SiO 2 )
28.54
6
silanated barium aluminoflurosilicate
228.39
168
glass (BAFG)**
silanated barium aluminoflurosilicate
114.19
116
glass (BAFG)*
*Barium glass particles having an average particle size of from about 1 to about 10 micrometers.
**Barium glass particles having an average particle size of from about 0.1 to about 1 micrometers.
***Fumed silica having an average particles size of from about 0.01 to about 0.04 micrometers.
The physical properties of the material of Examples 1A and 1B were tested and results listed in Table 2:
TABLE 2
Property
Example 1A
Example 1B
Localized Wear - mm 3
0.021
Flexural Strength - psi
19,600
17,330
Flexural Modulus - kpsi
1,625
1,580
Compressive Strength - MPa
358**
Water Sorption - μg/mm 3
14.9
**Compressive Strength was measured using 50 kN load cell set to run at 2,000 pounds with crosshead speed at 2 inches (50.8 mm)/per minute. Compressive strength testing specimens were prepared by following the procedure of U.S. Pat. No. 6,387,981. Each composite was packed into a 4 mm inside diameter glass tube, capped with silicone rubber plugs and axially compressed at about 0.28 MPa for 15 minutes, then light cured for 10 minutes inEclipse light curing unit (voltage at 37.5 V, blowers at 80 percent). Cured samples were cut on a diamond saw to form cylindrical plugs 8 mm long and stored in distilled water at 37° C. for 24 hours and then measured for compressive strength.
A three body cyclic abrasion wear machine (Leinfelder/University of Alabama in vitro) was used to determine volume loss (cubic mm at 400,000 cycles), as a measure of the wear resistance of the polymerized composite compositions of Examples 1A and 1B.
Water sorption of the polymerized composite compositions of Examples 1A and 1B was measured according to ISO 4049. The samples were cured for 10 minutes in the Eclipse light curing unit (voltage at 37.5 V, blowers at 80% from 5:30-10:00 minutes).
Flexural Strength and Flexural Modulus of the polymerized composite compositions of Examples 1A and 1B were measured by using three-point bend test on Instron bending unit according to ASTM D790 (1997). Samples were cured in metal molds in an Eclipse light curing unit for 10 minutes (voltage at 37.5 V, blowers at 80% from 5.5-10 minutes).
The composition of Example 1A is dimensionally stable below 60° C., begins to soften at 60° C. and becomes flowable as it is heated less than 1 degree above 70° C. The composition of Example 1B is dimensionally stable below 57° C., begins to soften at 57° C. and becomes flowable as it is heated less than 1 degree above 67° C.
EXAMPLE 2
Continuous Tooth Making
Two steel disks each has a cylindrical outer face with a sequence of tooth mold halves therein. The two steel disks are rotated so that they are in contact along their outer cylindrical faces. The corresponding tooth mold halves on each disk are aligned while their portions of the cylindrical outer faces are in the contact. A sheet of polymerizable wax-like material at 60° C., formed by following the procedure of Preparation 6, is continuously fed between the aligning outer faces of the two rotating steel disks, each at 37° C. The corresponding tooth mold halves on each disk shape 0.5 g to 2 g portions of the polymerizable wax-like material into artificial teeth as they rotate into alignment with each other.
EXAMPLE 3
Multiple Layered Tooth Making
Each of two steel mold halves has fourteen half tooth molds therein. The two steel mold halves (each at 37° C.) are positioned in contact, with the corresponding half tooth molds aligned, and a sheet of polymerizable wax-like composite material (at 60° C.) positioned between the aligned faces of the two mold halves. The polymerizable wax-like composite material is formed by following the procedure of Example 1B. The corresponding tooth mold halves shape 0.3 g portions of the polymerizable wax-like composite material into each of the enamels of artificial teeth as they are aligned with each other. One steel mold half (without enamels of artificial teeth) is removed and an additional steel mold half (at 37° C.) applied in its place, so that the mold halves are in contact along their mold outer faces. The additional steel mold also has fourteen half tooth molds therein. A sheet of polymerizable wax-like composite material at 60° C., formed by following the procedure of Example 1A, is positioned between the two mold halves. The polymerizable wax-like composite material is forced into the tooth mold cavities. The corresponding tooth mold halves shape 1 g portions of the polymerizable wax-like composite material (at 60° C.) into each of the artificial tooth bodies. Each artificial tooth body combines with the enamel in its mold cavity to form a two layer artificial tooth.
The fourteen teeth formed are positioned into a molded denture base of material prepared by following the procedure of Preparation 3, and light cured by impinging light thereon for 60 seconds from a Spectrum 800 light curing unit (sold by Dentsply International Inc), followed by curing for 10 minutes in a Triad 2000 light curing unit (sold by Dentsply International Inc). The adjacent surfaces of the teeth and the denture base combine during polymerization to form an integral denture.
EXAMPLE 4
Continuous Multiple Layered Tooth Making
Each of two steel disks has a sequence of fourteen half teeth molds in its cylindrical outer face. The two steel disks (each at 37° C.) are rotated so that they are in contact along their outer cylindrical faces, with the corresponding half tooth molds aligned, as a sheet of polymerizable wax-like composite material (at 60° C.) continuously fed between the aligned faces of the two disks. The polymerizable wax-like composite material is formed by following the procedure of Example 1B. The corresponding tooth mold halves shape 0.3 g portions of the polymerizable wax-like composite material into each of the enamels of artificial teeth as they are rotated into alignment with each other. One steel disk without enamels of artificial teeth is removed and an additional steel disk (at 37° C.) put in its place, so that the mold halves are in contact along their mold outer faces as they are rotated. The additional steel disk also has fourteen half tooth molds therein. A sheet of polymerizable wax-like composite material at 60° C., formed by following the procedure of Example 1A, is continuously fed between the two disks. The polymerizable wax-like composite material is forced into the tooth mold cavities. The corresponding tooth mold halves shape 1 g portions of the polymerizable wax-like composite material (at 60° C.) into artificial tooth bodies. Each artificial tooth body combines with the enamel in its mold cavity to form a two layer artificial tooth.
The fourteen teeth formed are positioned into a molded denture base of material prepared by following the procedure of Preparation 4, and light cured by impinging light thereon for 10 minutes in an Eclipse light curing unit, sold by Dentsply International Inc. The adjacent surfaces of the teeth and the denture base combine during polymerization to form an integral denture.
EXAMPLE 5
Multiple Layered Crown
Each of two steel mold halves has fourteen half crown molds therein. The two steel mold halves (each at 37° C.) are positioned in contact, with the corresponding half crown molds aligned, and a sheet of polymerizable wax-like composite material (at 60° C.) positioned between the aligned faces of the two mold halves. The polymerizable wax-like composite material is formed by following the procedure of Example 1B. The corresponding tooth mold halves shape 0.3 g portions of the polymerizable wax-like composite material into each of the enamels of crowns as they are aligned with each other. One steel mold half (without enamels of crowns) is removed and an additional steel mold half (at 37° C.) applied in its place, so that the mold halves are in contact along their mold outer faces. The additional steel mold also has fourteen half tooth molds therein. A sheet of polymerizable wax-like composite material at 60° C., formed by following the procedure of Example 1A, is positioned between the two mold halves. The polymerizable wax-like composite material is forced into the crown mold cavities. The corresponding crown mold halves shape 1 g portions of the polymerizable wax-like composite material (at 60° C.) into each of the crown bodies. Each crown body combines with the enamel in its mold cavity to form a two layer crown.
In use the bottom of the body of a crown is warmed to soften it. The crown is pressed and positioned onto a tooth prepared by cutting and applying adhesive. The softened portion of the crown conforms to the upper face of the prepared tooth. The enamel portion of the crown retains its shape. The positioned crown is then light cured.
It should be understood that while the present invention has been described in considerable detail with respect to certain specific embodiments thereof, it should not be considered limited to such embodiments but may be used in other ways without departure from the spirit of the invention and the scope of the appended claims. | A dental device and method of making it, by shaping a first and a second wax-like polymerizable dental material to form a polymerizable dental device. | 0 |
Light emitting diodes (LED's) are semiconductor devices that emit light when they are forward biased and current is flowing. There is an ongoing demand for increasing light intensity, resulting in higher currents, and more heat. Heat is detrimental to the performance of a LED because light output generally drops with increasing temperature. In addition, the life of a LED device may be shortened by high temperatures. Therefore, heat removal is extremely important in systems using LED's.
Semiconductor LED devices are typically mounted on a substrate that is part of a package, and the package is attached to a circuit board (for example, by soldering). Sometimes, a LED package includes a heat slug (a mass of metal, typically copper) between the semiconductor die and the printed circuit board, and heat generated by the LED is dissipated by the heat slug, or transferred through the heat slug to heat dissipating structures on the printed circuit board.
There is an ongoing need for LED devices with improved heat dissipation, reduced manufacturing complexity, and lower cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cross-section side view illustrating an example embodiment of a LED package.
FIG. 1B is a cross-section side view orthogonal to the cross-section of FIG. 1A .
FIG. 1C is a cross-section top view of the LED package of FIGS. 1A and 1B .
FIG. 2 is a cross-section side view of an example embodiment of a variation of the example of FIGS. 1A-1C .
FIG. 3 is cross-section side view of an example embodiment of a LED package with optional heat dissipating structures formed on the top heat slugs.
FIG. 4 is a cross-section side view of an example embodiment of a LED package with an optional secondary reflector cup.
FIG. 5 is a flow-chart of an example method of manufacturing for a LED package.
DETAILED DESCRIPTION
FIG. 1A illustrates an example embodiment of a LED package 100 . A LED semiconductor die 102 is mounted onto a heat spreader 104 . The semiconductor die 102 is wire bonded to two electrical contacts 106 . The heat spreader 104 and the electrical contacts 106 are stamped from a metal sheet, for example, copper, aluminum, or iron. A non-conductive plastic 108 electrically insulates the electrical contacts 106 from the heat spreader 104 . A reflector 110 may also be molded from the non-conductive plastic 108 . The package may be encapsulated, for example, in epoxy or silicone ( 112 ). The electrical contacts 106 are exposed at the bottom exterior of the package for attaching to a substrate, for example by soldering to a PC board. The heat spreader 104 may also be exposed at the bottom exterior of the package to facilitate heat transfer through the bottom of the package to an attached substrate.
FIG. 1B illustrates a cross-section side view orthogonal to the cross-section of FIG. 1A . In FIG. 1B , at least one heat slug 114 , made of high thermal conductive plastic, is mounted on top of the heat spreader 104 . In the example of FIG. 1B , heat flows from the semiconductor die 102 through the heat spreader 104 into the top mounted heat slug(s) 114 , where it is dissipated through the top of and sides of the package 100 . The package may also be mounted onto a substrate (not illustrated), for example a printed circuit board, and heat may also be conducted through the heat spreader 104 to heat dissipating structures (not illustrated) on the substrate.
FIG. 1C illustrates a cross-section top view of the package 100 of FIGS. 1A and 1B . Again, the semiconductor die 102 is mounted onto the top surface of the heat spreader 104 . The semiconductor die is wire bonded to electrical contacts 106 . A non-conductive plastic 108 electrically insulates the electrical contacts 106 from the heat spreader 104 . The non-conductive plastic 108 may also form a reflector 110 . At least one heat slug 114 is mounted on top of the heat spreader 104 .
The non-conductive plastic 108 may be, for example, polyphthalamide (PPA). The high thermal conductive plastic slug(s) 114 may be, for example, a high heat-resistant resin, such as Liquid Crystal Polymer (LCP), Polyphenylene Sulfide (PPS), PolyEtherEtherKetone (PEEK), or polysulfone, which has been loaded with a thermally conductive additive, for example, graphite fibers, aluminum nitride, or boron nitride. Suitable high thermal conductive plastics are commercially available from, for example, Cool Polymers, Inc., 333 Strawberry Field Rd, Warwick, R.I. 02886 USA.
FIG. 2 illustrates a variation of the example of FIGS. 1A-1C . For the LED package in FIG. 2 , the tops, and at least one side, of the heat slugs 202 are exposed and are not covered by the non-conductive plastic or any encapsulating material. This improves heat dissipation.
FIG. 3 illustrates another optional enhancement. In FIG. 3 , a package 300 has heat slugs 302 extending through the top of the package, and the heat slugs have additional surface structure, for example fins, to increase the surface area for improved heat dissipation. The heat slugs 302 may be high thermal conductive plastic and the surface structure may be molded as an integral part of the heat slugs
FIG. 4 illustrates an optional enhancement to the LED package 100 of FIGS. 1A-1C . In FIG. 4 , a supplemental reflector 400 is attached to the top of heat slugs 114 (or heat slugs 202 in FIG. 2 ). The supplemental reflector may be made of a high thermal conductive material to provide additional heat dissipation from the top of the overall assembly.
FIG. 5 illustrates an example method for manufacturing an LED package. At step 500 , a heat spreader and electrical contacts are formed (for example, stamped from a sheet of metal). At step 502 , the heat spreader is insulated from the electrical contacts. At step 504 , a reflector is formed (for example, steps 502 and 504 may be combined into one injection-molding step with a non-conductive plastic). At step 506 , at least one heat slug is formed (for example, injection molding) onto the top side of the heat spreader. At step 508 , a semiconductor LED die is attached to the heat spreader. At step 510 , the semiconductor die is electrically connected to the electrical contacts (for example, by wire bonding). At step 512 , the package is encapsulated (for example, by filling with epoxy or silicone). | An electronic assembly includes a Light Emitting Diode (LED) mounted on a top surface of a heat spreader, at least two electrical contacts co-planar with the heat spreader, and at least one heat slug mounted on the top surface of the heat spreader, where the heat slug is made of high thermal conductive plastic. | 7 |
BACKGROUND OF THE INVENTION
A home air conditioning unit is well known and many embodiments are available. A typical air conditioning unit contains a heat exchanger or condenser and evaporator. Both of these units include a coil. The coil in the evaporator contains a coolant, such as a freon gas, which has been compressed to lower its temperature. Air from inside the home is passed over the coil and is cooled by the coolant positioned within the coil. The coolant is recycled through the condenser wherein it is recooled through compression. The heat picked up by the coolant when passing through the heat exchanger is then transferred to the ambient air passing over the condensing coils. The present invention is not concerned with the air that is used to cool a house, but rather, the present invention is concerned with the air which is used to cool the operating machinery such as the condenser. A condenser unit exchanges the heat from the coolant to the ambient air passing over the condenser coils. Accordingly, more heat can be transferred by the condenser when the temperature of the ambient air is low. Typically, the temperature of the ambient air varies from climate to climate. The compressor works harder when the ambient air temperature is above that selected as the design temperature at which the condenser is rated. The rating is normally given in tons or BTU'S of a cooling power. Most air conditioners are reated at an ambient of 95° F.
The condenser works more efficiently below the design temperature than above. Typically, in those climates having ambient air temperatures above 95° F, the efficiency of the condenser is reduced in its job of lowering the temperature of the coolant. In this environment, the compressor works longer to provide the required cooling to the coolant. The longer the compressor operates to cool the coolant, the more energy is required to operate the compressor and the more wear and tear the compressor experiences. The additional energy means an added expense to pay for the power. The more wear and tear the compressor experiences, the oftener it must be serviced and/or replaced at more additional expense.
Another term used in identifying the operating condition of a compressor is that of "coolant differential temperature." The "coolant differential temperature" is the difference between the temperature of the desired inside air identified by the thermostat and the temperature of the coolant. Under optimum operating conditions, the "coolant differential temperature" should be within the range of 19° to 21° F. However, through a loss of efficiency, the prior art systems are not able to provide this "coolant differential temperature" and the volume of air to be cooled, i.e., a house, is cooled by a coolant having less than the best "coolant differential temperature," i.e., 14° or 15° F. Under these circumstances a greater "on time" is required to reach the temperature identified by the thermostat.
A special form of the problem of not reaching the required "coolant diferential temperature" occurs when a structure is built with an air conditioning unit which just barely provides the required amount of cooling power at the rated temperature. When the ambient temperature exceeds the rated temperature, the air conditioning unit is not able to deliver coolant with the proper "coolant differential temperature" sufficient to reach that cooling level identified by the thermostat. In this situation the air conditioner runs continuously with a waste of power.
One term used in identifying the operating condition of a compressor is head pressure. The term head pressure indicates how hard the compressor is working in order to compress the coolant material used in the air conditioning system. Just as the air conditioner has an ambient design temperature, i.e., 95° F, at which the air conditioner is rated, the condenser unit has a head pressure rating to indicate its maximum allowable head pressure and its optimum head pressure. Frequently, the optimum head pressure is at a figure which is 25 percent below the maximum rating. For a typical two ton air conditioner, the maximum head pressure is typically identified as 400 pounds, while the optimum rating is typically identified as 300 pounds. When the compressor is operating at 400 pounds, its cooling capacity can be reduced by as much as 50% over its rated cooling capacity at 300 pounds. More specifically, this means that the efficiency of a two ton air conditioner rated at 95° F with an optimum head pressure of 300 pounds when operated at a temperature above its rated temperature, i.e., 110° F, with a head pressure of 400 to 425 pounds, is frequently reduced by 50% and hence operates as a one ton unit. Obviously, a one ton unit will have to work at least twice as long to provide the required cooling of a two ton unit. This added time causes an increase in the cycle time of the air conditioning unit.
The cycle time of an air conditioning unit is divided between its "on time" and its "off time." A two ton unit operating at its rated temperature has an "on time" during which it is used to cool the air inside a house to a desired level selected by the home owner and an "off time" during which the air conditioner is off and not operating. The "on time" of an air conditioning unit is principally a function of the air temperature identified by the thermostat, the insulation of the house itself which determines how fast the cool air leaks out of the house to be replaced by the ambient air temperature, and the efficiency of the compressor. The efficiency of the compressor is best maximized by its operation at an ambient air temperature at or below its rated temperature. The establishment of the improved ambient temperature has the following main advantages: first the "on time" is reduced because the coolant is cooled to its "coolant differential temperature" quicker and with less power; second, the "off time" is extended because of the reduction of "on time" thus reducing the wear and tear on the machinery.
Aluminum is a common material used throughout the condenser unit. The coils are often times made of aluminum as well as other parts of the air conditioning system. In prior art, air treatment systems using water, a problem which occurs in these systems is the injection of water droplets into the air stream. The water droplets are carried to the condenser unit where a particular problem occurs. when the water droplets deposit upon the cooling coils, the water acts as an insulator between the consenser surface covered by the water and the air passing over the condenser coil. The area covered by the water does not participate in the cooling operation and the cooling efficiency of the condenser is further reduced.
Certain of the prior art air conditioning systems, which used a precooler for the condenser unit, often times employed an evaporative member which actually was an obstruction to the flow of air through the evaporative member prior to its passing over the condenser coils. Such an obstruction required additional energy to pull the required amount of air over the condenser coils. Typically, a fan is used to cause air to flow through a prior art evaporative member and then over the condenser coils. Hence, additional fan power is required because of the obstructionistic effect of the prior art evaporative member.
In an aggravated situation, i.e., wherein the obstructionistic effect was pronounced, the air passed over the condenser coils in a shadow-like effect of the fan. The shadow was approximately equal to the area of revolution of the fan blades. Typically, the area of the condenser coil is larger than the area of revolution of the fan. In such a situation, the air would only pass over the condenser coils in a shadow image of the fan. This resulted in a portion of the condenser coils being outside of the shadow effect. This area outside of the shadow effect did not contribute to the cooling efforts of the condenser. This also reduced the efficiency of the condenser.
SUMMARY OF THE INVENTION
The present invention relates to the treatment of air, and more particularly, it relates to the treatment of air using water for reducing the temperature of the air without adding individual water droplets to the treated air.
An object of the present invention is to provide an apparatus for the treatment of air which employs a water dispensing means for delivering a uniform amount of effluent at the point of mutual contact of the water dispensing means with an evaporator means.
A further object of the present invention is to provide a collapsible and expandable member as part of the water dispensing means, which member exudes the effluent from a porous type of tubular material which is expandable under water pressure.
A still further object of the present invention is to provide a water treatment apparatus which provides a minimal resistance to the flow of air through the apparatus as the air is being cooled.
Another object of the present invention is to provide a water cooling apparatus which provides a minimum resistance to the flow of air through the apparatus, and the apparatus receives a quantity of water for thoroughly wetting the evaporator means without creating water droplets which droplets can be picked up by the flow of air and carried beyond the apparatus itself.
A still further object of the present invention is to provide an apparatus for the treatment of air by water which delivers a quantity of cool air to the air using machinery as required.
Another object of the present invention is to provide an evaporator means having a first means for delivering water over a plurality of surfaces extending from the top to the bottom of the evaporator means, a first channel means oriented in the direction of air flow having a first substantially higher resistance to the air flow and a second channel means positioned in the direction of air flow having a second relatively lower resistance to the flow of air.
A still further object of the present invention is to provide evaporator means which is constructed to prevent the passage of water from the front region to the back region, yet which is constructed first to provide a broad frontal area which is continually wet by water, and second, to provide a back surface which is substantially dry.
Another object of the present invention is to provide a mechanism for the treatment of air which provides a large area over which water continuously flows for providing an evaporative cooling action upon the air as it passes over the evaporative surface, and which provides a front region which is continuously wet by water for providing an evaporative action and a rear surface which is substantially dry for removing water droplets from the air stream.
A still further object of the present invention is to provide evaporator means having a water source mounted on its upper surface from which a volume of water exudes over the evaporative surfaces of the evaporator means.
A further object of the present invention is to provide an evaporator mechanism having an evaporative surface over which the water flows and which is shaped so as to provide a maximum resistance to water flow from the front to the back of the evaporator, yet a minimum resistance to the water flow from the top to the bottom of the evaporator.
A still further object of the present invention is to provide evaporator means having a maximized thickness for providing maximum temperature drop between the front and back of the evaporator means due to the evaporative effect of the water.
Another object of the present invention is to provide evaporator means with water dispensing means positioned on the top of th evaporator means to provide a uniform flow of water from the top to the bottom of the evaporator means, yet prevents water droplets and/or spray from entering the air stream as the air passes from the front to the back of the evaporator means.
These and other objects, features, characteristics, and advantages will be apparent by consideration of the following description of a preferred embodiment of the invention, as illustrated by the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the prior art use of an evaporator pad which restricted the flow of air over the condenser coils.
FIG. 2 shows an isometric view of the overall system of the present invention.
FIG. 3 shows the soaker sack used in the system shown in FIG. 2.
FIG. 4 shows an isometric view of the soaker sack, shown in FIG. 3, positioned atop the evaporator means used in the system shown in FIG. 2.
FIG. 5 shows a second isometric view of the soaker sack, positioned atop the evaporator means in combination with a water deflecting flap.
FIG. 6 is a cross-sectional view taken along the line 6--6 shown in FIG. 5.
ADVANTAGES OF THE INVENTION
The present invention is specifically intended to treat air which is being delivered for further use by machinery. More specifically, the particular machinery in the preferred embodiment is a compressor unit for an air conditioning system. In operation, this compressor unit has an operating characteristic which is identified as head pressure. The use of the present invention with such a compressor, at a temperature of 115° F, typically lowers the head pressure of the compressor by 25%. Typically, this results in the head pressure being lowered from 400 pounds to 300 pounds.
While precoolers have been used in the prior art in combination with air conditioning units, these precoolers, have provided a resistance to the flow of air so that energy is required to pass the necessary quantity of air through the precooling element. This is not the case of the present invention as the evaporator material used in the present invention is well known as providing negligible resistance to the flow of air. More specifically, the present invention reduces the air resistance from more than 50% to less than 10%. It is possible to reduce the effective resistance to air flow to zero by enlarging by 10% the surface area through which the air is passing. This increase in area provides a comparable increase in volume of air and the greater volume counter-balances the resistance to the flow of air.
A further advantage in the use of the present invention flows from providing an air stream having a substantially constant temperature to the machinery in question. It has been found that the apparatus of the present invention has consistently cooled air from a temperature in excess of 115° F to the design limit of 85° F ± 2°. Additionally, the apparatus of the present invention is only activated when the ambient temperature is above a predetermined ambient temperature of 85° F.
BRIEF DESCRIPTION OF THE INVENTION
The evaporator means employed in the present invention has a plurality of inner surfaces which perform a dual function. These surfaces carry water and define channels for passing air. The evaporator means has first channels flowing upwardly from the front to the back of the evaporator body. The evaporator means has second channels flowing downwardly from the front to the rear surface of the evaporator. Both the first and the second channels have an intercommunicating surface over which water flows from the top to the bottom of the evaporator. A water dispensing means exudes a flow of water directly on to the surfaces of both the first and second channels by direct contact between the water dispensing means and the channel surfaces. In this manner no spray enters the air flow and, hence, the air flow does not convey water droplets from the front to the back of the evaporator. This design of the evaporator provides maximum area upon which water may evaporate and reduce the temperature of the air passing thereover. The direction of the channels prevents water from passing from the front of the unit to the exit surface of the unit prior to the complete evaporation of the water. The water dispensing means provides just enough water to assure its complete evaporation by the air passing through the evaporator means prior to the air leaving the evaporator. To achieve this function, the evaporator means is preferably 3 inches thick. The flow of water through the evaporator is such that only 25% of the water entering the evaporator at the top exits from the bottom. No water exits from the rear of the evaporator based on the water flow selected. Since the water flow from the front to the back of the evaporator is impeded due to the shape of the first and second channels, the water will evaporate prior to its leaving the rear surface of the evaporator. However, water flows over the entire front surface of the evaporator and a percentage exits the evaporator at the bottom. This water exiting the bottom of the evaporator carries with it the dirt and debris collected from the air as the air passes over the interior evaporator surfaces. This keeps dirt and debris from the machinery which is to be cooled by the air flowing through the evaporator. More importantly, this excess water flow cleanses the interior surfaces of the evaporator means.
The preferred form of the water dispensing means is a canvas bag which is in direct contact with the upper surface of the evaporator means. This contact between the water dispensing means and the evaporating surface assures water flow from the water dispensing means over the entire surface area of the evaporator without ejecting water spray or droplets into the air flow. A cloth flap is positioned over the soaker sack and functions as a water deflecting means for preventing any upwardly directed spray from entering the air stream and falling on to the machinery positioned on the other side of the evaporator. The soaker sack or water dispensing means is positioned at a predetermined location on the upper surface of the evaporator member for insuring that the water dispensed from this water dispensing means flows continually over the front surface of the evaporator yet does not wet the rear surface. This position is one-half inch from the back surface of the evaporator and 1-1/2 inches from the front surface of the evaporator. Experiments show that the soaker sack should be one inch wide and the thickness of the evaporator should be three inches thick.
Water from the water dispensing means is adjusted according to the size of the evaporated evaporative surface. This adjustment is such as to provide a water exhaust at the bottom of the evaporator sufficient to carry debris and/or dirt from the air out of the evaporator and yet not so high at a water flow rate as to wet the rear surface of the evaporator.
VARIATIONS OF THE INVENTION
A temperature sensing means is provided to activate the water dispensing means when the outside temperature rises above a predetermined level. In the preferred embodiment, this temperature sensing means is set to operate at 85° .
The water dispensing means continues to provide a water flow on to the evaporator after the condenser has turned off. This pre-wets the evaporator so as to avoid any loss of cooling time between the turning on of the evaporator and the time that the water dispensing means provides water flowing over the entire front surface of the evaporator. In this mode of operation, the evaporator is precharged so as to provide maximum cooling in a minimum amount of time once it is again operated. The water dispensing means provides a 100% wetting action over the evaporator surface by being positioned at a predetermined location. The water dispensing means is made of a canvas fabric so as to avoid the use of a member having holes which can be plugged by the deposits of impurities from the water.
The water provides maximum efficiency when the area of the evaporator matches the area of the condenser for modern units. However, in working with older air conditioning mechanisms, it is desirable to provide a smaller area of the evaporator as compared with the area of the condenser. This provides a venturi effect of the air flowing through the evaporator on to the coils of the condenser and provides a more efficient evaporative effect for the units.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a prior art system generally employing a water moistened precooler which is made from a material which effectively obstructs the flow of air through the precooler member itself. The system 10 comprises a precooler pad 12, a fan 14 and a condenser coil 16. Portions 16a of the condenser coil 16 are positioned within a column of air indicated by the line 18. Other portions 16b of the condenser coil are positioned outside the column of air 18.
The fan 14 is normally placed in such a way as to draw air through the precooler pad 12 and across the condenser coil 16 of the condenser. As is shown, it is normal that the size of the condenser coils 16 form a frontal area which is substantially larger than the frontal area of the fan 14. Normally, when an obstruction is not present in the flow of air, a cone of air larger than the diameter of the fan 14 is easily moved across the total area of the condenser coils 16. However, when an obstruction, which restricts the flow of air is placed intermediate the condenser coils 16, a shadow effect occurs. This shadow effect means that air moving through the precooler pad 12 is substantially the size of the area of rotation of the fan 14. Since the area of rotation of the fan is smaller than the area of the condenser coils 16, all portions of the condenser coils 16 are not in contact with the flow of air. This reduces the efficiency of the condenser unit by that percentage of the condenser coils not within the air stream. As shown in the figure portions 16a are cooled by the flow of air but other portions 16b are not cooled.
Referring to FIG. 2 there can be seen a system's view 19 of the present invention. An air conditioning unit is shown at 20 having a precooler unit 22 made according to the teaching of the instant invention and a protective covering 24 employed to hold the precooler 22 in position with relationship with the air conditioner unit 20. A water intake line is shown at 26 and a water exhaust line is shown at 28. A pressure regulator is shown at 30 for establishing a predetermined water pressure within the intake line. In the preferred embodiment the water pressure is set at 25 pounds per square inch as regulated by a suitable regulator identified as a Watts Water Regulator type 1610 made by the Watts Regulation Company of Lawrence, Massachusetts.
A temperature sensing device is shown at 32 to activate a water valve 34 which turns on the system only above a set temperature. In the preferred embodiment, the preferred temperature is 85° F as selected by a thermostat made by the Franklin Dales Co. of Akron, Ohio.
A suitable valve 34 is identified as a 24 volt solenoid valve model U.S. Pat. No. 826,075 with a one-eighth inch fitting made by the Automatic Switch Co. of Florham Park, New Jersey.
Referring to FIGS. 3 through 6, there can be seen a schematic view of a water dispensing means 38 employed in the present invention. The water dispensing means comprises a tubular member 40 and a water deflecting means 41. The tubular member 40 is made of porous material which is expandable under water pressure. The preferred material is a canvas cotton material and it is sewed with cottom thread 42 along the bottom and one edge as shown at 44. The water dispensing means also includes a water deflecting member 41, best seen in FIGS. 5 and 6, which is disposed over the upper surface of the tubular member 40. In the preferred embodiment, the deflection means is also made of a strip of cotton material. The function of the water dispensing means is to provide a continuous effluent from an exuding surface. This effluent exudes from the porous material, i.e., through the pores and runs from the tubular member 40. At a point in mutual contact with the evaporator means, indicated at 48 in FIG. 6, the effluent runs continuously and in a uniform manner over the vertical surface means of the evaporator 22 for conveying water from the top to the bottom of the evaporator 22. A tray 23 catches any excess which is drained through the exhaust line 28.
One of the requirements of the water dispensing means of the present invention is to provide its water as an effluent. This means that individual spray droplets cannot be injected into the air stream.
In early models of the present invention, minute holes were found in the porous material and under the value of water pressure used herein, these holds passed a stream of water in random directions. The stream of water could enter the air flow and be carried to the coils of the condenser and deposited upon the condenser coils. This water positioned on the condenser coils acted as an insulating member between the coil and the air stream. This insulation effect reduced the efficiency of the condenser coils. Accordingly, effort was necessary to devise a system which eliminated such tiny streams of water. The most common point at which streams of water exited the tubular member 40 was at the stitches 42 holding the canvas material together. When a plastic thread was used which did not expand in contact with water, a stream of water was practically guaranteed to come from each of the stitch holes. Accordingly, a cotton thread was used which expanded in contact with water and effectively filled the hole as a plug when the unit was wet. Accordingly, the water dispensing means of the preferred embodiment employed a porous canvas tubular member using cotton stitching along the bottom and one edge to form a tubular member. To insure that water does not escape from the upper side of the tubular member, a deflection flap 41 is positioned on top of member 40 to deflect downward any streams of water which possibly might escape from the tubular member 40. An equivalent member to the tubular member shown is one made as one piece similar to a sock and having no stitches. Obviously, one end of the sock, such as the open end, is attached to the water supply means while the remaining part of the sock is positioned along the top of the evaporator means.
The water dispensing means 38 shown is expandable and collapsible upon the application and removal of the water pressure. The collapsible feature of the water dispending means 38 is helpful in continuing the water dispensing function over the evaporator means 22 after the water pressure has been removed. More specifically, upon removal of the water pressure, the rate at which the effluent leaves the tubular member decreases. Yet it continues until the entire supply of water within the tubular member 40 is exuded at a rate determined by the porosity of the material and the decreasing pressure from the water itself. This effects a continuing water flow over the evaporator even after the water pressure has been removed.
Obviously, the water pressure need never be turned off, however, this would waste that water flowing down the evaporator means 22 when the unit was not working. Since the water stored within the tubular member 40 continues to wet the evaporator during the "off time" of the unit until the water is expended, the surfaces of the evaporator means 22 are that much wetter as determined by the volume of water contained within the tubular member after the pressure has been removed.
Referring to FIG. 5, the water dispensing means includes a pressure regulator which determines the water pressure applied to the tubular member 40. It has been found through experiments that a water pressure of 25 pounds per square inch is preferred for a tubular member 40 which is 27 inches long and approximately one inch in diameter when expanded. Such a member exudes approximately 4 gallons per hour onto the evaporator means 22. The water exuded in this fashion is evaporated at the rate of 3 gallons per hour leaving a waste of 1 gallon per hour. This rate of evaporation occurs by the mechanism of the air moving through the evaporator means 22 under pressure of the fan (not shown) positioned in the air conditioner 20. The evaporator means 22 can operate efficiently with a total water flow on to the evaporator means 22 which lies within the range of 2 gallons per hour to 6 gallons per hour. It has been found through experiments that the lower flow of water begins to reduce the efficiency of the unit, while the higher flow of water only provides additional run off which is wasted. While the flow of water can be adjusted to a point where actually no water is discharged, it has been found that this is not the best embodiment. The water contains a certain amount of debris including salts which build up on the evaporative surface if a certain amount of run off is not provided to cleanse these debris from the evaporative surface. Accordingly, the preferred embodiment uses a total flow at the rate of 4 gallons per hour which gives a run off at the rate of 1 gallon per hour.
Referring to FIGS. 4 and 5, there can be seen the evaporator means 22 which utilizes a piece of Celdek material which is a registered trademark of the Munters Corporation. The preferred embodiment employs a piece of Celdek material which is approximately 30 inches wide and 23 inches high and 3 inches thick. It has been found that the 3 inch thick piece provides the best embodiment in combination with a water dispensing means 38 operating at 25 pounds pressure with a delivery of water at the rate of 4 gallons per hour to the top of the evaporator means 22. The evaporator means 22 has a first vertically disposed member 50 shown in FIG. 4 extending from the top 52 to bottom 54 of the evaporator means 22. The first vertical member 50 delivers water to a first channel means 60 which extends from the front 56 to the back 58 of the evaporator means 22. A first channel means is shown in FIG. 6 at 60 and is inclined at a relatively greater angle than the angle of a second channel means 62 running downwardly from the front 56 to the back 58. The first and second channel means 60 and 62 have relatively no difference to the resistance to the flow of air from front to back but have a much greater resistance to the flow of water along the surface forming these channels. Accordingly, a greater amount of water is delivered to the first channel means 60 and the first channel means has a greater resistance to water flowing from the front to the back. A smaller degree of water is delivered to the second channel means 62. Through experimentation, it has been found that the combination of the 3 inch thick piece of Celdek material measured front to back, in combination with the water dispensing means exuding an effluent of 4 gallons per hour to the top of the evaporator means will prevent any water droplets from entering the air stream beyond the back surface of the evaporator means.
While the Celdek material has been found to operate satisfactorily within the environment of the present invention, other materials having the same characteristics as described can be substituted therefor.
Referring to FIG. 2, it can be seen that the evaporator means 22 of the present invention is made slightly larger than the intake part of the condenser with which it is designed to operate. Since the evaporator means 22 does not provide a significant obstruction to the flow of air to the air stream, the fan moves a cone of air significantly larger than its area of rotation and, hence, sufficient air can be delivered to all areas of the condenser coils. The resistance to the air flow can be effectively eliminated by making the evaporator member overly large in comparison to the initial entry port of the condenser unit. In this manner an equal amount of air can be delivered to the condenser unit through the evaporator means of the present invention because of its low resistance to the flow of air. | An apparatus is described for treating air for use as a coolant for machinery. The treatment includes cooling the air with water without injecting water droplets into the air stream which droplets can visibly be seen to come to rest on the machinery. The principal elements of this water treatment apparatus comprises: low water resistance evaporation means for cooling air passing therethrough; and water dispensing means for uniformly adding water to the water evaporaton means by having water exude from the water dispensing means over an area of mutual contact with the water evaporation means. Improved embodiments employ a temperature sensing mechanism for activating the air treating mechanism dependent upon the temperature of the ambient air. A further embodiment includes a water pressure regulator means for maintaining the required effluence from the water dispensing means to obtain the optimum wetting of the evaporation means. | 5 |
This application is a continuation of application Ser. No. 09/802,174, filed Mar. 8, 2001, (pending), which is hereby incorporated by reference herein.
This application claims priority to Provisional Application No. 60/189,443, filed Mar. 15, 2000, and to Provisional Application No. 60/196,273, filed Apr. 5, 2000.
This application also claims priority to U.S. patent application Ser. No. 09/802,174, filed Mar. 8, 2001, now U.S. Pat. No. 6,573,483 the entirety of which is incorporated herein.
BACKGROUND OF THE INVENTION
Time and convenience are in short supply for homemakers wishing to supply a home-cooked meal to family members. Some appliances, such as slow-cooker appliances, attempt to meet this need by providing all-day cooking while a homemaker is absent. Such appliances, however, tend to be of the type where only one temperature and all day cooking is possible, regardless of the food item, and thus potentially subjecting the food item to over- or under-cooking. Another option may be to use a cooking unit with, a controller, where a user may set a time or temperature desired. These units, however, tend to be quite a bit larger and more expensive than slow-cooker appliances. If these units are of more reasonable size, they also suffer because the controller inevitably must be placed near the heating element.
What is needed is a cooking appliance in which the user retains control over the time and temperature of cooking, but which is small enough to be convenient. What is needed is a slow-cooker unit in which the controller does not become overheated and damaged by the heating element.
SUMMARY OF THE INVENTION
One embodiment of invention is a programmable slow-cooker appliance, including a heating unit, which includes upstanding sidewalls and a bottom wall. The sidewalls and bottom encompass a heating area. The appliance includes a heating element mounted on the inner surface of the interior wall of the heating unit. In one embodiment, the cooking area may also encompass a cooking unit inside the heating unit, suitable for holding food to be cooked. The appliance includes a programmable controller mounted thereto via a controller housing, which acts to insulate the controller from the heat of the appliance, preferably via a unique system of ventilation. The housing utilizes ventilation holes on its bottom and top to encourage a chimney effect, in which air from the surroundings is drawn through the housing. This air cools the controller, and the air is then exits from ventilation holes near the top of the housing, convecting heat away from the controller.
Another aspect of the invention is a method of using the programmable controller to ensure that food is cooked according to the desires of a user. The user provides a food item and places the food item into the slow-cooker appliance, as described above. The user sets a cooking time and temperature for the programmable slow-cooker unit, using the controls to set both the time and the temperature. The cooking time according to one embodiment may not be set less than four hours, and the temperature may not be set for less than 150 degrees Fahrenheit (66 degrees Celsius). This prevents a user from accidentally setting the cooker to a “warm” temperature, in which food would only be warmed but not cooked thoroughly before consumption. In one embodiment, if the user sets no time or temperature, but merely turns the cooker on, the cooker defaults to a particular time and temperature, set by the user or the factory, such as a default setting of four hours and 175 degrees Fahrenheit or eight hours and 150 degrees Fahrenheit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a prior art slow-cooker appliance having an oval shape that may be utilized in the present invention;
FIG. 2 is a perspective view of a prior art embodiment of a cooking unit 14 which may be utilized with the appliance of FIG. 1;
FIG. 3 is a perspective view of a prior art cooking unit 39 similar to that shown in FIG. 2, but having a circular shape;
FIG. 4 is a perspective view of a slow cooker appliance incorporating the present invention;
FIG. 5 is a detailed plan view of a portion of the control 200 of the embodiment of FIG. 4;
FIG. 6 is a bottom plan view of the embodiment of FIG. 4;
FIG. 7 is a side cutaway view of the embodiment of FIG. 4;
FIG. 8 is a plan view of a heat sink 256 as utilized in the embodiment of FIG. 4;
FIG. 9 is a side view taken along a line 9 — 9 of FIG. 8;
FIGS. 10 and 13 are schematic circuit diagrams showing the circuitry and components implemented in preferred embodiments;
FIG. 11 is a wiring diagram showing some of the electric componentry of the preferred embodiment; and
FIG. 12 is an embodiment of the front panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, one prior art embodiment of a food-heating slow-cooker appliance 10 is shown. The appliance 10 preferably comprises a heating, unit 12 and a cooking unit 14 . An exemplary slow cooker appliance 10 may be a Crock-Pot® Slow Cooker made by The Rival Division of The Holmes Group® of Milford, Mass. The heating unit 12 preferably has a bottom 16 and a continuous outer sidewall 18 . The bottom 16 and an interior sidewall 17 define a well-like heating chamber 20 having an oval cross-section, and the interior sidewall 17 defines an annular lip 22 at an upper edge of the outer sidewall 18 and the interior sidewall 17 . The heating chamber 20 has a heating element 24 disposed therein and mounted to the heating unit 12 , either under the bottom 16 or additionally between the outer sidewall 18 and the interior sidewall 17 . A control switch 26 is conventionally used to provide electricity to the heating element 24 . The heating element 24 functions to heat the cooking unit 14 via the heating chamber 20 .
As shown in FIG. 2, the cooking unit 14 has a bottom 28 with preferably a continuous sidewall 30 upstanding therefrom. The continuous sidewall 30 preferably has an annular lip 38 projecting in flange-like fashion from the upper end thereof and a substantially oval cross-section. The cooking unit 14 is adapted to be at least partially received within the heating unit 12 with the annular lip 38 of the cooking unit 14 preferably engaging the annular lip 22 of the heating unit 12 , supporting the cooking unit 14 within the heating unit 12 . Preferably, the annular lip 38 further defines a pair of handle portions 38 ( a ) and 38 ( b ) to facilitate lifting the cooking unit 14 . The cooking unit 14 is preferably made of ceramic with a coating of conventional glazing compound.
The thermal and heat retaining properties of the ceramic cooking unit 14 allow it to conduct heat from the heating chamber 20 through the sidewall 30 . This provides even heating throughout the unit 14 .
As shown in FIG. 3, an alternative embodiment of the appliance 10 includes a cooking unit 39 having a sidewall 40 and a substantially circular cross-section. This embodiment is preferably adapted to fit within a heating unit having a complementary circular heating chamber. This cooking unit 39 is used in an embodiment of the present invention shown in FIG. 4 .
In use, the heating unit 12 is provided with a first cooking unit 39 . The heating element 24 (not shown) may be powered on and off as necessary to supply heat at a maintained temperature to the cooking unit 39 and the heating chamber via a programmable control 200 . The control 200 preferably includes a circuit board housing 210 , a control panel 220 , and an insulation shield 222 assembled together for attachment to the outer sidewall 18 of the heating unit 12 . The interior of the housing 210 contains a printed circuit board 254 (shown in FIG. 7) containing electronic components of the control.
As shown in FIGS. 5 and 6, the housing 210 preferably includes a control panel user interface 224 located on an inclined front surface of the housing 210 . Preferably, the housing 210 and insulation shield 222 are made from a thermoplastic material such as polypropylene. A pair of side walls 226 , a top wall 228 , and bottom wall 230 are preferably located adjacent the control panel 224 and support the control panel 224 in an inclined position away from the front of the cooking appliance 10 . This gives the user access to the control panel 224 , and also locates the controls and componentry within the housing 210 away from a significant amount of the heat generated by the appliance 10 . The printed circuit board 254 may be mounted via threaded screws 255 to rearwardly projecting screw receiving portions 258 on the rear side of the housing 210 .
The control panel 224 includes a plurality of indicator lights, such as LEDs 262 , spaced on the front panel 224 . As is well-known in the art, a variety of other indicator devices may be provided, including digital readouts, audible alarms, liquid crystal displays, incandescent lamps or fluorescent readouts. Preferably, the control panel 224 also includes a plurality of cantilevered portions 264 and 266 as shown in FIG. 5 . The cantilevered portions 264 , 266 preferably include rearwardly projecting fingers 268 (shown in FIG. 7) which translate the depression of the portions 264 , 266 toward the rear portion of the housing 210 . The fingers 268 are preferably used to depress pushbutton switch portions located on the circuit board 254 . A water-impermeable label membrane may be applied over the front of the control panel 224 to label the indicators 262 and cantilevered portions 264 and 266 for the user. The membrane may also protect the front control panel 224 from damage from spilled foods or liquids and facilitate cleaning.
To further protect the electronic componentry within the housing 210 from the heat generated by the appliance 10 , the annular shield member 222 is preferably sized for interposition between the heating unit 12 and the housing 210 . In particular, as shown in FIGS. 5 and 6, the shield 222 includes a top wall 232 , a pair of side walls 234 , and a bottom wall 236 . The shield 222 acts as a ventilated spacer to hold the electronic components and the housing 210 at a distance away from sidewall of the cooking unit 12 .
In order to dissipate heat that may otherwise be retained between the cooking unit 12 and the rear of the housing 210 , an air circulation space is provided within the shield. In particular, as shown in the side cutaway view of FIG. 7, the air space 240 behind the shield 222 may vent warmer air out through an upper elongated slot 242 defined within the top wall 232 of the shield 222 . Likewise, an elongated slot 244 is defined into the air space 240 in the bottom wall 236 of the shield 222 . Heated air may thus escape through the top elongated slot 242 and cooler air may enter the air space 240 through the bottom elongated slot 244 . As shown in FIG. 7, the shield 222 also preferably defines a rearwardly projecting cylindrical flange 246 that extends into the outer wall 18 to allow passage of control and power wiring between the interior of the heating unit 12 and the interior of the housing 210 .
In a similar fashion, air circulation is promoted through the housing 210 through a set of openings, preferably defined between the upper portion and, the bottom of the housing 210 . In particular, a plurality of openings 250 are defined within the bottom wall 230 of the housing 210 . An elongated upper slot 252 is provided on the front face 224 of the housing 210 . This allows air to freely circulate behind the control panel 224 and assist in the dissipation of heat from the circuit board 254 and its electronic componentry within the housing 210 . Preferably, a heat sink 256 is provided as shown in FIG. 7 and positioned between the circuit board 254 and the front panel 224 inside the housing 210 . The sink 256 preferably includes a plurality of openings defined therein to allow air to circulate between the openings 250 and 252 and through and around the heat sink 256 to dissipate additional heat therefrom. Also shown is the relative position of cooking unit 14 .
FIGS. 8 and 9 show a detailed view of the heat sink 256 . Preferably, the heat sink is machined from 0.063 inch thick 3003-0 anodized aluminum. The heat sink 256 is preferably bent at a 160 degree angle between a bottom flange portion 256 a and an upper portion 256 b . A centrally located retaining tab portion 256 c is bent parallel with the lower portion 256 a , and the portions 256 a and 256 c are used for attachment of the heat sink 256 to the rear side of the housing 210 interior via the rearwardly projecting screw receiving portions 258 . To maximize the dissipation of heat, a plurality of winged sections 257 and 259 are provided on the heat sink 256 and extend outwardly from a center portion 256 a of the heat sink 256 . A plurality of openings are defined through the heat sink 256 to allow the fingers 258 of the control panel cantilevered portions 264 , 266 to project through the heat sink and contact the circuit board 254 at the rear of the housing 210 . The openings 251 also facilitate cooling air flow through and past the heat sink 256 to further dissipate heat therefrom.
The circuit board 254 mounts circuitry and logic allowing the user of the appliance 10 to electronically control and program cooking cycles and temperature. A schematic diagram of the electronic circuitry and components is shown in FIG. 10 . The diagram shows a preferred exemplary circuit incorporating preferred components as utilized in the preferred embodiment of the present invention. One skilled in the art will recognize that the componentry illustrated herein is exemplary only and that many other components may be substituted to achieve the functions described herein. FIG. 10 includes labels for each of the components of the circuit, and only major components will be described herein.
First, as shown in the diagram, the preferred circuit 300 is preferably built around an EPROM/ROM-based CMOS microprocessor controller 302 , such as the PIC16CR54C RISC CPU manufactured by Microchip Technology, Inc. The chip output preferably includes circuited drivers for 6 LED indicators 262 (labeled D 3 -D 8 ) as shown. These LED indicators may be assigned labels as follows:
LED
Indicates
D3
On
D4
WARM
D5
4 HOUR
D6
6 HOUR
D7
8 HOUR
D8
10 HOUR
Two momentary pushbutton contact switches S 1 and S 2 are used to trigger the “Off” and “Cook” features, respectively, as will be described in the cooking procedure below. Of course, other indicators and switches may be substituted. Note that while examples are given, the circuitry may be implemented in numerous ways, as is well-known in the art, to accomplish the varying programming modes described below.
The temperature of the cooking appliance is measured using a thermistor 310 , which is connected externally of the circuit board to the underside of the bottom of the heating chamber. A retention clip 320 , shown in FIG. 7, is utilized to hold the thermistor in thermal contact with the bottom 16 . In a preferred embodiment, the appliance uses a model USX1732 thermistor manufactured by U.S. Sensor, Inc.
Triac 304 , which is preferably a logic Triac Model L4008L6-ND manufactured by Digi-Key, Inc., is utilized to switch the power supplied to the heating elements of the appliance. Preferably, the Triac is of an isolated tab type and includes a heat sink tab that is fastenable to the heat sink 256 shown in FIGS. 8 and 9. Preferably, the Triac is mounted separately to one of the mounting holes on the center portion 256 a of the heat sink 256 so that the tab is in thermal contact with the heat sink 256 to dissipate heat generated from its current controlling function. Most of the other components of the circuit 300 are mounted on a conventional printed circuit board 254 .
FIG. 11 shows the wiring of the external Triac 304 in relation to the circuit board 254 and heating elements 24 . As shown in the Figure, the heating elements 24 are in thermal contact with and wrapping around the interior sidewall 17 of the heating unit.
The operation of the appliance 10 is as follows. The programmable circuitry 300 allows the user to set both the temperature and desired time for cooking. The functions of the switches Si and S 2 , which are activatable via the cantilevered portions 264 and 266 of the control panel 224 , are as follows:
S 1 . OFF pushbutton—turns the appliance 10 off.
S 2 . COOK pushbutton—subsequent pushes of the button cycle through 4 hour, 6 hour, 8 hour and 10 hour cook times.
When the unit is plugged in, the power “on” indicator flashes. The user then pushes the COOK button (switch S 2 ) to set the temperature and cooking time. As the user pushes the COOK switch S 2 , the LED's D 5 -D 8 illuminate to indicate the corresponding time setting as follows.
LEDs
D 3 . POWER—on when appliance 10 is in cook or warm modes.
D 5 . 4 HOUR—on when appliance is in 4-hour cook mode
D 6 . 6 HOUR—on when appliance is in 6-hour cook mode
D 7 . 8 HOUR—on when appliance is in 8-hour cook mode
D 8 . 10 HOUR—on when appliance is in 10-hour cook mode
D 4 . WARM—on when appliance is in half-power mode
Thus, subsequent pushes of the COOK switch S 2 activate different cooking modes, as shown by the 6 HOUR, 8 HOUR and 10 HOUR LEDs 262 on the control panel 224 . If the COOK switch S 2 is pressed in the 10 HOUR mode, the control 200 recycles to the 4 HOUR cooking mode, and its indicator.
In general, full power will be applied to the heating element 24 until the time corresponding to the illuminated LED elapses, after which the power to the heating element 24 is reduced by half, the WARM indicator illuminates and all cook time indicators extinguish. The choices of operation are: 4 or 6 hours on a HI temperature, and 8 to 10 hours on a lower temperature setting. Once the user selects the desired setting, the appliance 10 starts the cooking operation. Once the time setting has expired, the appliance 10 automatically reduces power to the heating element 24 to put the unit in a WARM setting. The unit will stay in the WARM setting until the user pushes the OFF button or unplugs the unit. Of course, other programming schemes are possible.
Preferably, the user cannot set the unit initially in the WARM setting. The system will only go to WARM after one of the time functions has expired. This avoids possible food safety problems that may be associated with cooking food only on the WARM setting. Pressing the OFF switch Si any time the unit is on preferably removes power from the heating element 24 and extinguishes all indicator LEDs 262 .
In another embodiment, the slow-cooker appliance utilizes four push-button switches, rather than two, to set times and temperatures for cooking. An exemplary control panel is depicted in FIG. 12, with control circuitry in FIG. 13 . Four momentary pushbutton contact switches 227 , 229 , 231 , 233 are used to trigger various power and setting functions as will be described in the cooking procedure below. Of course, other numbers or types of indicators and switches may be substituted as well. FIG. 13 shows circuitry applicable to such an embodiment, incorporating controller 302 , external temperature element 310 , digital readout 57 , and Power LED 263 and Timer LED 265 . The Power LED indicates power is present at the microprocessor controller and the Timer LED indicates that the Timer function is on and working.
The operation of the appliance is as follows. The programmable circuitry allows the user to set both the temperature and the desired cooking time. The functions of the switches 227 , 229 , 231 , 233 on an alternative embodiment of a control panel user interface 225 , are as follows:
227 . ON/OFF power pushbutton—turns the appliance on and off.
229 . TIMER pushbutton—activates stepped timer.
231 . UP pushbutton—increases displayed numerical value.
233 . DOWN pushbutton—decreases displayed numerical value.
When the unit is plugged in, the unit defaults to 150-degrees F. as shown on the digital display 57 . The user may adjust the desired cooking temperature in 25-degree increments using the UP 231 button or the DOWN button 233 , with 150 degrees Fahrenheit as a minimum temperature. Once the user has selected the specific temperature, the appliance will start the cooking process.
The user may also select the TIMER mode by pressing the TIMER button 229 . In TIMER mode, the controller defaults to 4 hours. The user can use the UP or DOWN controls to increase or decrease the time in 15-minute increments. Once the time is set, the controller 302 will count down the time remaining for cooking in 1 minute increments until the unit “times out”. At that time, the power is shut off from the heating element.
In all modes, the temperature is read periodically by the thermistor or other temperature element and relayed to the controller. The reading is checked at 4-second intervals. If the temperature is above or equal to the set point, power is removed. If it is below the set point, power is applied to the heating element 32 . Of course, the circuitry can be modified as desired to achieve various program methods and modes.
Another embodiment of the slow cooker appliance adds a piezobuzzer to the circuitry. A piezobuzzer is simply an electrically-activated buzzer that can be programmed to emit a sound at desired moments. In one embodiment, a piezobuzzer may be installed as an output 315 , controlled by the microprocessor controller 302 , as shown in FIG. 13, and programmed to emit a sound when desired. In one embodiment, the buzzer may beep to provide feedback to a user when a pushbutton is pushed. The slow cooker may also be programmed to emit a sound to indicate the end of the cooking time. The buzzer may also be used to emit sounds at other desired times.
It is intended that the foregoing description illustrates rather than limits this invention, and that it is the following claims, including all equivalents, which define this invention. Of course, it should be understood that a wide range of changes and modifications may be made to the embodiments described above. Accordingly, it is the intention of the applicants to protect all variations and modifications within the valid scope of the present invention. It is intended that the invention be defined by the following claims, including all equivalents. | A programmable slow-cooker appliance, in which a user sets a time and temperature for cooking a food item. A programmable controller prevents the unit from being used solely as a “keep warm” appliance, and a unique design allows cooling of the controller during cooking. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a portable, combustion-engined tool and, in particular, a setting tool having a combustion chamber for receiving a fuel gas, and an ignition device for igniting the fuel gas for building up pressure in the combustion chamber for driving a setting piston adjoining the combustion chamber.
[0003] 2. Description of the Prior Art
[0004] The drive energy in the tool described above is obtained by combustion of a fuel gas mixture, e.g., an air-fuel gas mixture, in the tool combustion chamber, and is transmitted to a fastening element, which need be driven in an object, via the piston.
[0005] The combustion-engined tool can have only one combustion chamber. However, a combustion-engined tool can have a combustion chamber that is divided in several chamber sections. In each case, the fuel gas mixture can be present in the chamber sections in different mixture ratios. For the sake of clarity, a combustion chamber would be considered which is divided only into chamber sections, a forechamber section and a main chamber section.
[0006] The combustion starts in the forechamber section by an electrical spark generated by the ignition device. Upon ignition of the mixture, a flame front starts to propagate radially with a relatively small velocity. The flame front pushes the unconsumed air-fuel gas mixture ahead of itself, and the unconsumed air-fuel gas mixture penetrates through the through-openings in the separation plate into the main combustion chamber section, creating there turbulence and pre-compression.
[0007] As the flame front reaches the through-openings, flame penetrates therethrough, due to the small cross-section of the openings, in a form of flame jets into the main chamber section, creating there a further turbulence. The thoroughly intermixed air-fuel gas mixture in the main chamber section ignites over the entire surface of the flame jets. The mixture burns with a high speed which substantially increases the effect of combustion as the losses which are caused by cooling, remain small.
[0008] A combustion chamber, which is divided in several chamber sections, can be formed as a collapsible combustion chamber having limiting opposite walls movable relative to each other.
[0009] An object of the present invention is a combustion-engined tool of a type discussed above having an increased capability of adjusting the energy transmitted to the piston.
SUMMARY OF THE INVENTION
[0010] This and other objects of the present invention, which will become apparent hereinafter, are achieved by providing a gas drain arrangement that permits to control pressure build-up in the combustion chamber by draining a controlled amount of the fuel gas mixture. The fuel gas mixture can be drained through one or more drain channel(s) formed in the bottom region of the combustion chamber or in the main chamber section. By controlling the amount of the fuel gas mixture in the combustion chamber, an energy transmitted to the piston can be directly controlled.
[0011] In accordance with one embodiment of the present invention, the gas drain arrangement has a drain channel with an adjustable cross-section. For controlling the channel cross-section, an adjustable throttle or an adjusting screw with a radial through-channel can be used. In both cases, the channel cross-section can be changed to drain a controlled amount of the gas upon pressure build-up in the combustion (main) chamber.
[0012] According to an advantageous embodiment of the present invention, the gas drain arrangement includes a check valve for closing the combustion chamber when an underpressure prevails therein. The return of the piston into its initial position, after the attachment element has be drived in, is effected as a result of thermal feedback, i.e., during a phase when underpressure prevails in the combustion chamber or the main chamber section. The piston is displaced into its initial position until it engages a stop. To maintain the underpressure in the combustion chamber, it should remain closed during the return movement of the piston. This function is performed by the check valve.
[0013] The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however, both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiments, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 shows an axial cross-sectional view of a combustion-engined tool according to the present invention in the region of the tool combustion chamber; and
[0015] [0015]FIG. 2 a cross sectional view along line A-A in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] A combustion chamber 1 of an inventive combustion-engined tool, in particular, of a setting tool, which is shown in FIG. 1, has a cylindrical shape and includes a cylindrical wall 2 and a ring-shaped bottom 3 adjoining the cylindrical wall 3 . In the center of the bottom 3 , there is provided an opening 4 . A guide cylinder 5 , which as a cylindrical wall 6 and a bottom 7 , adjoins the opening 4 in the bottom 3 of the combustion chamber 1 . A piston 8 is slidably displaceably arranged in the guide cylinder 5 for displacement in the longitudinal direction X of the guide cylinder 5 . The piston 8 consists of a piston plate 9 facing the combustion chamber 1 and a piston rod 10 extending from the center of the piston plate 9 . The piston rod 10 projects through an opening 11 formed in the bottom 7 of the guide cylinder 5 .
[0017] [0017]FIG. 1 shows a non-operational position of the setting tool in which the piston 8 is in its rearward off-position. The side of the piston plate 9 adjacent to the bottom 3 of the combustion chamber 1 is located closely adjacent to the bottom 3 , with the piston rod 10 projecting only slightly beyond the bottom 7 of the guide cylinder 5 .
[0018] Sealing rings 12 are provided on opposite sides of the piston plate 9 to seal the chambers on the opposite sides of the piston plate 9 from each other. For fixing the piston 8 in its rearward off-position, there is provided a stop 13 .
[0019] Inside of the combustion chamber 1 , there is provided a cylindrical plate 14 further to be called a movable combustion chamber wall or movable wall. The plane of the plate 14 extends transverse to the longitudinal direction of the tool. The movable wall 14 is displaceable in the longitudinal direction X of the combustion chamber 1 . For separating the chambers on opposite sides of the movable wall 14 , an annular sealing 15 is provided on the circumference of the movable wall. The movable wall 14 has a central opening 16 , with an annular sealing 17 provided in the wall of the opening 16 . Sidewise of the central opening 16 at a distance therefrom, there is provided a through-opening 19 . An ignition device 20 is sealingly mounted in the opening 19 . The ignition device 20 has two electrodes 21 , 22 forming an electrical path for generating an ignition spark. The electrodes 21 - 22 face in a direction toward the bottom 3 of the combustion chamber 1 .
[0020] A separation plate 18 is provided between the bottom 3 of the combustion chamber 1 and the movable wall 14 . The separation plate 18 likewise has a circular shape and has an outer diameter corresponding to the inner diameter of the combustion chamber 1 . The separation plate 18 has a plurality of axial through-openings 38 spaced from the center of the separation plate 18 . The separation plate 18 is fixedly connected with a central projection 18 a that extends into the through-opening 16 of the movable wall 14 . At the free end of the central projection 18 a , there is provided a ring-shaped circumferential flange 18 b which is engaged by the movable wall 14 when it is displaced in the axial direction. A spring 18 c , which is provided between the flange 18 b and the opposite rear side of the movable wall 14 and is supported on the projection 18 a , always biases the separation plate 18 toward the movable wall 14 by applying a biasing force to the flange 18 b.
[0021] For displacing the movable wall 14 , there are provided several, e.g., three drive rods 23 uniformly distributed along the circumference of the movable wall 14 and fixedly connected therewith. Only one of the drive rods 23 is shown in FIG. 1. The drive rods 23 extend parallel to the axis of the combustion chamber 1 and outside of the cylindrical wall 6 of the guide cylinder 5 . The drive rods 23 extend through openings 24 , respectively, formed in the separation plate 18 and through corresponding openings 25 formed in the bottom 3 of the combustion chamber 1 . Each of the openings 25 is provided win a circumferential seal located in the surface defining the opening 25 for sealing the combustion chamber 1 from outside. The movable wall 14 is connected with drive rods 23 by, e.g., screws 27 which extend through the movable wall 14 and are screwed into the drive rods 23 . The free ends of the drive rods 23 are connected with each other by a drive ring 28 which is arranged concentrically with the combustion chamber axis and which circumscribes the guide cylinder 5 . The drive ring 28 is connected with the drive rods 23 by screws which extend through the drive ring and are screwed into the drive rods 23 through end surfaces of the free ends of respective drive rods 23 . Each of the drive rods 23 supports a compression spring 30 extending between the bottom 3 of the combustion chamber 1 and the drive ring 28 . The compression springs 30 are designed for pulling the movable wall 14 toward the bottom 3 . The displacement of the movable wall 14 in a direction away from the bottom 3 is limited by a stop shackle 32 which is formed as a plate-shaped member. The shackle 32 is mounted in a circumferential groove 33 formed in the upper portion of the combustion chamber 1 . The shackle 32 is secured in the groove 33 with a locking ring 34 . The shackle 32 has an upwardly bulging section which serves as a stop for the central projection 18 a of the separation plate 18 .
[0022] An aeration/deaeration valve is provided in the bottom 3 of the combustion chamber 1 . The aeration/deaeration valve serves for admitting fresh air into the combustion chamber 1 and for removal of waste gases from the combustion chamber 1 , as it will be described in more detail further below. In the condition of the combustion chamber 1 shown in FIG. 1, the aeration/deaeration valve is open. The condition of the combustion chamber 1 shown in FIG. 1 corresponds to the off-condition of the tool.
[0023] At the lower end of the guide cylinder 5 , there are provided openings 39 for letting air out of the guide cylinder 5 upon movement of the piston 8 toward the guide cylinder bottom 7 . At the lower end of the guide cylinder 5 , there is also provided damping means 40 for damping the movement of the piston 8 . As soon as the piston 8 passes the openings 39 , the waste gases are expelled from the guide cylinder 5 through the openings 39 .
[0024] Two radial through-openings 41 , 41 are provided in the cylindrical wall 2 of the combustion chamber 1 . Two conduits (not shown), which extend from outside into the through-openings 21 , 22 , communicate the combustion chamber 1 with a metering valve (likewise not shown) and provide for injection of, e.g., liquefied fuel gas into respective combustion chamber sections which are formed when the movable wall 14 and the separation wall 18 are displace to the operational end positions determined by the stop shackle 32 , as also will be described in more detail further below.
[0025] In the bottom 3 of the combustion chamber 1 , there is also provided a drain valve arrangement 43 . The drain valve arrangement 43 includes a drain channel 44 , an adjusting screw 45 with a radial channel 46 , and a check valve 47 . The check valve 47 is shown schematically and includes a flap valve 48 which is biased by a compression spring 49 against an outlet side of the drain channel 44 , with the compression spring 49 being supported against a shoulder 50 provided on the cylindrical wall 6 of the guide cylinder 5 . The check valve 47 insures flow of waste gases from the combustion chamber 1 through the drain channel 44 outside, on one hand, and prevents any flow of air from the surrounding environment into the combustion chamber 1 through the drain channel 44 , on the other hand, when an underpressure is created in the combustion chamber 1 .
[0026] [0026]FIG. 2, as discussed above, shows a cross-sectional view along line A-A in FIG. 1. The cross-sectional view is taken through the drain valve arrangement 43 . As shown in FIG. 2, for the actuation of the adjusting screw 45 , there is provided a hand wheel 51 . The adjusting screw 45 is screwed tangentionally in bottom 3 of the combustion chamber 1 . The radial channel 46 of the adjusting screw 45 lies in the region of the drain channel 44 so that it becomes open or closed to a greater or lesser extent upon rotation of the adjusting screw 45 .
[0027] Below, the operation of the setting tool, shown in FIGS. 1 - 2 , will be described in detail.
[0028] [0028]FIG. 1 shows the condition of the combustion chamber 1 in the off position of the setting tool. The combustion chamber 1 is completely collapsed, with the separation plate 18 lying on the bottom 3 of the combustion chamber 1 and the movable wall 14 lying on the separation plate 18 . In order to distinguish the movable wall 14 from the separation plate 18 , for the clarity sake, they are shown slightly separated. The piston 8 is in its rearward off-position, which is determined by the stop 13 , so that practically no space remains between the piston 8 and the separation plate 18 if one would disregard a small clearance therebetween. The position, in which the movable wall 14 lies on the separation plate 18 , results from the compressing spring 30 biasing the drive ring 28 away from the bottom 3 , with the ring 28 pulling the movable wall 14 via the drive rods 23 . In this position, the drive ring 28 is still spaced from the aeration/deareation valve, which remains open.
[0029] When in this condition, the setting tool is pressed with its front point against an object, the fastening element should be driven in, a mechanism shown only schematically by an element 57 , applies pressure to the drive ring 28 displacing it in the direction of the bottom 3 of the combustion chamber 1 . This takes place simultaneously with the setting tool being pressed against the object. At that, the movable wall 14 is lifted off the separation plate 18 and entrains therewith, via the compression spring 18 c and the flange 18 , the separation plate 18 . Upon displacement of the separation wall 18 , a so-called main chamber section, which is formed between the separation plate 18 and the bottom 3 , expands. During the expansion of the main chamber section, air is aspirated thereinto via still open aeration/deaeration valve.
[0030] Upon further pressing of the tool against the object, the drive ring 28 is displaced further in a direction toward the bottom 3 , and, in a while, the projection 18 a engages the shackle 32 . If the drive ring 28 is displaced further toward the bottom 3 , the movable wall 14 separates from the separation plate 18 , whereby a so-called forechamber section is formed between the movable wall 14 and the separation plate 18 . Air into the forechamber section is aspirated through the aeration/deaeration valve and the through-openings 38 formed in the separation plate 18 .
[0031] As soon as the movable wall 14 and the separation plate 18 pass the respective openings 41 , 42 , in principle, an injection of a metered amount of the liquified fuel gas into the forechamber and main chamber sections can start. At the end of the displacement of the movable wall 14 , the aeration/deaeration valve is closed by the drive ring 28 .
[0032] In the completely expanded position of the forechamber and main chamber sections, the movable wall 14 and the separation plate 18 become locked. This is effected by actuation of an appropriate lever or a trigger of the tool. The locking can take place shortly after the actuation of the trigger or shortly after ignition of the fuel gas mixture in the combustion chamber 1 of the setting tool. Upon actuation of the ignition device 20 , an electrical spark ignites a preliminary formed mixture of the air and the fuel gas in the forechamber section of the combustion chamber 1 . Upon ignition of the mixture, a flame front starts to propagate radially with a relatively small velocity. The flame front pushes the unconsumed air-fuel gas mixture ahead of itself, and the unconsumed air fuel gas mixture penetrates through the through-openings 38 in the separation plate 18 into the main combustion chamber section, creating there turbulence and pre-compression.
[0033] As the flame front reaches the through-openings 38 , flame penetrates therethrough, due to the small cross-section of the openings 38 , in a form of flame jets into the main chamber section, creating there a further turbulence. The thoroughly intermixed air-fuel gas mixture in the main chamber section ignites over the entire surface of the flame jets. The mixture bums with a high speed which substantially increases the effect of combustion.
[0034] The combustible mixture in the main chamber section impacts the piston 8 , which moves with a high speed toward the bottom 7 of the guide cylinder 5 , forcing the air from the guide cylinder 5 out through the openings 39 . Upon the piston plate 9 passing the openings 39 , the exhaust gas in discharged therethrough. The piston rod 10 effects setting of a fastening element.
[0035] The amount of energy transmitted to the piston 8 depends, among others, on the pressure build-up in the main chamber section. This pressure depends on the extent of opening of the drain channel 44 determined by a selected adjustment position of the adjusting screw 45 .
[0036] After setting or following the combustion of the air-fuel gas mixture, the piston 8 is brought to its initial position, which is shown in FIG. 1, as a result of thermal feedback produced by cooling of the flue gases which remain in the combustion chamber 1 and the guide cylinder 5 . As a result of cooling of the flue gases, an underpressure is created behind the piston 8 which provides for return of the piston 8 to its initial position. The combustion chamber 1 should remain sealed until the piston 8 reaches its initial position. This means that the aeration/deaeration valve also should remain closed, as well as the drain valve arrangement 43 . The closing of the drain channel 44 is effected with the valve flap 48 , which is biased by the spring 49 into a position in which it closes the channel 44 until the underpressure exists in the main chamber section of the combustion chamber 1 .
[0037] After it is insured that the piston 8 reached its initial position, which is shown in FIG. 1, again, the movable wall 14 and/or the drive ring 28 , and/or the aeration/deaeration valve is (are) unlocked. The compression springs 30 bias the drive ring 28 in a direction away from the bottom 3 of the combustion chamber 1 , whereby the aeration/deaeration valve completely opens. Upon movement of the drive ring 28 away from the bottom 3 , the drive rods 23 pull the movable wall 14 in a direction toward the bottom 3 . Upon the movement of the movable wall 14 in the direction toward the bottom 3 , the compression spring 18 c biases, via the flange 18 b of the projection 18 a of the separation plate 18 , the separation plate 18 toward the movable wall 14 . Thus, first, the forechamber section is deaerated, with the flue gases exiting through the aeration/deaeration valve. After the movable wall 14 abuts the separation plate 18 , both move in the direction toward the bottom 3 , with now the main chamber section being deaerated through the aeration/deaeration valve. In a while, the separation plate 18 abuts the bottom 3 , with the movable wall 14 lying on the separation plate 18 . The combustion chamber 1 becomes completely collapsed and free of flue gases. Now, an aeration process can begin anew upon the next setting of a fastening element.
[0038] The structure and operation of the tool was discussed above with reference to an embodiment with a collapsible combustion chamber. However, it should be clear that the present invention can be used with a setting tool or another tool in which the combustion chamber wall and/or separation plate are not displaced in the axial direction of the combustion chamber. In effect the present invention can be used with any tool the combustion chamber of which consists of a single chamber section and is not divided into forechamber and main chamber sections.
[0039] Although the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and are not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is therefore not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | A portable, combustion-engined tool including a combustion chamber ( 1 ) in which a fuel gas in combusted upon ignition for building up pressure in the combustion chamber for driving the tool piston ( 8 ), an ignition device ( 20 ) for igniting the fuel gas in the combustion chamber ( 1 ), and gas drain means ( 43 ) provided in the combustion chamber ( 1 ) for controlling a pressure build-up therein. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electric lid closures which close and open a lid by force of an electric power, and more particularly to electric closures of a type which is applied to a trunk lid of a motor vehicle to draw down the lid to its fully close position by force of the electric power once the lid comes to a predetermined almost close position.
2. Description of the Prior Art
Hitherto, various lid closures of the above-mentioned type have been proposed and put into practical use particularly in the field of motor vehicles. Some are of a type which comprises a lock unit mounted on a lid and an electric closing unit mounted on a trunk mouth of the vehicle. The lock unit includes a latch plate for latching a striker possessed by the electric closing unit. That is, when the lid is pivoted to an almost close position where the latch plate engages with the striker, the electric closing unit starts to operate and causes a drawing section thereof to draw down the lid, via the latched striker, to a fully close position by force of an electric power. In this fully close position of the lid, the drawing section assumes its lower work position.
When, under this fully close position of the lid, a trunk open lever installed in the vehicle cabin is manipulated, the latch plate disengages the striker to release the lid. Upon this, the electric closing unit operates to move the drawing section upward to its upper stand-by position. Once the drawing section reaches the upper stand-by position, operation of the electric closing unit is stopped.
However, due to the inherent construction, some of the above-mentioned electric lid closures have failed to provide users with satisfied performance. That is, when, for instance, in winter, manipulation of the trunk open lever fails to have the lid sufficiently open due to freezing of some parts of the mechanism irrespective of disengagement of the latch plate from the striker, the following drawback tends to occur. That is, when, under this half-finished condition, the lid is accidentally or carelessly pushed down to a position to bring about an engagement between the latch plate and the striker, the drawing section is forced to move down to the lower work position from the upper stand-by position, which inevitably induces unexpected full closing of the lid. This unexpected action is very inconvenient because an operator has to manipulate the trunk open lever again for opening the lid.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an electric lid closure which is free of the above-mentioned drawback.
That is, according to the present invention, there is provided an electric lid closure wherein even when the drawing section is ready to start its drawing action, the drawing action is not permitted if a lid condition detecting means does not sense passing of the trunk lid by a predetermined critical position.
According to the present invention, there is provided an electric lid closure for use with an automotive trunk lid which is able to close a trunk room of the vehicle. The electric lid closure comprises a lock unit mounted to the trunk lid, the lock unit including a latch plate and a locking plate, the locking plate being able to lock the latch plate at a latch position; an electric closing unit mounted to a mouth portion of the trunk room, the electric closing unit including a movable striker engageable with the latch plate, and an electric power mechanism for moving the movable striker between an uppermost position and a lowermost position with an electric power; a first position sensor which senses whether the movable striker assumes the uppermost position or the lowermost position; a second position sensor which senses whether the trunk lid passes by a critical position or not, the critical position corresponding to a position of the movable striker which is above the uppermost position; a third position sensor which senses whether the locking plate locks the latch plate or not; and a control unit which energizes the electric closing unit to pull down the trunk lid to a full close position only when the first position sensor senses the movable striker assuming the uppermost position, the second position sensor senses the trunk lid passing by the critical position and the third position sensor senses the latch plate being locked by the locking plate.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a front view of an electric lid closure which embodies the present invention;
FIG. 2 is a rear view of a motor vehicle, showing the electric lid closure of the invention applied to a trunk lid of the vehicle;
FIG. 3 is a side view of the electric lid closure of the invention;
FIGS. 4A, 4 B and 4 C are illustrations of a striker, showing operation of the electric lid closure;
FIG. 5 is a control circuit for controlling the electric lid closure;
FIGS. 6A, 6 B and 6 C are views taken from the direction of the arrow “VI” of FIG. 3, respectively showing different conditions of the electric lid closure;
FIG. 7 is a view taken from the direction of the arrow “VII” of FIG. 6A;
FIG. 8 is a drawing of the electric lid closure, showing one condition of the same; and
FIG. 9 is a drawing similar to FIG. 8, but showing another condition of the lid closure.
DETAILED DESCRIPTION OF THE INVENTION
In the following, description will be made with respect to an electric lid closure “ELC” of the present invention, which is operatively applied to a trunk lid of a motor vehicle.
Referring to FIG. 2, there is shown a rear part of the motor vehicle, which has a trunk room “TR” equipped with a trunk lid “TL”. In the illustrated vehicle, the trunk lid “TL” is pivotally connected to the vehicle body to open and close the trunk room “TR”.
As is seen from this drawing, the electric lid closure “ELC” generally comprises a lock unit 15 mounted on a free center end of the lid “TL” and an electric closing unit 20 mounted on a periphery 12 of a mouth portion 11 of the trunk room “TR”. A weather strip “WS” is bonded to the periphery 12 of the mouth portion 11 . With this weather strip “WS”, a water-tight abutment of the lid “TL” to the periphery 12 of the mouth portion 11 is achieved when the lid “TL” assumes its full close position relative to the trunk room “TR”.
As is seen from FIGS. 2 and 6A, the lock unit 15 comprises a lock base 16 which is formed with a striker inserting guide slot 16 a, a latch plate (not shown) which is pivotally connected to the lock base 16 to pivot between a latch position to latch a striker 45 held by the electric closing unit 20 and an unlatch position to unlatch the striker 45 , and a locking plate (not shown) which is pivotally connected to the lock base 16 to pivot between a lock position to lock the latch plate at the latch position and a release position to release the latch plate to permit the same to take the unlatch position. The detail of this lock unit 15 is described in for example U.S. Pat. No. 5,443,292 granted on Aug. 22, 1995.
As is seen from FIGS. 1 and 2, the electric closing unit 20 comprises a support base 20 a which is secured to the periphery 12 of the mouth portion 11 of the trunk room “TR” and a striker base 40 which is integrally formed with the above-mentioned striker 45 .
As is seen from FIGS. 1 and 3, the support base 20 a comprises a first vertical wall 22 , a second vertical wall 24 and a stepped wall 23 through which the first and second vertical walls 22 and 24 are integrally connected. The stepped wall 23 is formed with a through opening 25 .
As is seen from FIG. 1, the support base 20 a has at its right side a pivot pin 21 fixed thereto. A right end of the striker base 40 is pivotally connected to the pivot pin 21 so that the striker base 40 can pivot between an uppermost position as shown in FIG. 8 and a lowermost position as shown in FIG. 9 . As will become apparent as the description proceeds, the uppermost position of the striker base 40 is referred to a draw action starting position and the lowermost position of the same is referred to a draw action finishing position.
As is seen from FIGS. 1, 3 and 8 , the striker 45 is provided at a middle portion of the striker base 40 . The striker 45 comprises a bent portion 46 provided by bending a part of the striker base 40 and a striker bar 48 provided by forming an opening 47 in an upper part of the bent portion 46 .
As will be seen from FIG. 3, the pivotal striker base 40 is slidably placed on the front surface of the first vertical wall 22 of the support base 20 a.
As is seen from FIGS. 2 and 3, when the trunk lid “TL” is about to take the full close position during its closing movement, the striker bar 48 of the striker 45 inserts into the striker inserting guide slot 16 a of the lock base 16 of the lock unit 15 fixed to the trunk lid “TL”.
As will become apparent hereinafter, during the time when the striker base 40 pivots between the draw action starting position and the draw action finishing portion, the striker bar 48 of the striker 45 moves upward or downward in the striker inserting guide slot 16 a of the lock base 16 .
As is seen from FIGS. 4A to 4 C, the striker bar 48 has a generally trapezoidal cross section with its leading edge made thinner than a trailing edge.
As is seen from FIG. 1, the support base 20 a has on a left side thereof a drawing unit 50 mounted thereon. As will be described in detail hereinafter, the drawing unit 50 functions to draw the latch plate of the lock unit 15 downward through the striker 45 . The striker base 40 passes through the through opening 25 of the support base 20 a having a left portion thereof exposed to the rear side of the support base 20 a. The left portion of the striker base 40 is formed with a cam slot 41 .
The drawing unit 50 generally comprises the cam slot 41 of the striker base 40 , a power arm 55 rotatably supported on the left portion of the support base 20 a, a cam follower 56 pivotally connected to a peripheral portion of the power arm 55 and slidably engaged with the cam slot 41 and a power mechanism 70 for driving the power arm 55 . The power mechanism 70 is mounted on the front surface of support base 20 a.
As is seen from FIGS. 1 and 8, the power arm 55 has an input shaft 57 fixed to an eccentric part thereof. The input shaft 57 passes through an opening formed in the support base 20 a and is operatively connected at its leading end to an output shaft of a speed reduction gear of the power mechanism 70 . As is seen from FIG. 1, the power mechanism 70 comprises a housing 71 in which an electric motor and the speed reduction gear are installed. Thus, upon energization of the electric motor, the power of the motor is transmitted through the speed reduction gear to the power arm 55 . Thus, the power arm 55 is rotated about an axis of the input shaft 57 to cause the cam follower 56 to move in the cam slot 41 while pivoting the striker base 40 upward or downward about the pivot pin 21 between the above-mentioned draw action stating and finishing positions.
As is seen from FIG. 1, to the left side of the support base 20 a, there is mounted a draw condition detecting switch 80 which has a detecting follower 81 slidably engaged with a periphery of the power arm 55 .
The power arm 55 comprises a semicircular part 55 a which constitutes a half of the arm 55 and first and second depressed parts 55 b and 55 c which are located at circumferential ends of the semicircular part 55 a. The outer periphery of the semicircular part 55 a is concentric with the rotation center (viz., input shaft 57 ) of the power arm 55 .
It is to be noted that the first depressed part 55 b is used for detecting the above-mentioned draw action starting position, and the second depressed part 55 c is used for detecting the draw action finishing position. That is, when the detecting follower 81 of the draw condition detecting switch 80 is in contact with either one of the first and second depressed parts 55 b and 55 c, the detecting switch 80 assumes ON state.
As is seen from FIG. 1, a lid position sensing lever 85 is pivotally connected to an upper part of the support base 20 a through a pivot shaft 28 . The sensing lever 85 has a generally L-shaped cross section to increase a mechanical strength thereof. The sensing lever 85 is formed with a detecting arm 86 and biased to pivot counterclockwise in FIG. 1 by means of a return spring 87 disposed about the pivot shaft 28 . The detecting arm 86 is contactable with the lock base 16 of the lock unit 15 mounted to the trunk lid “TL”.
A lid critical position sensing switch 88 is fixed to the support base 20 a of the closing unit 20 , which produces an electric signal representing a critical position of the trunk lid “TL” based on the movement of the position sensing lever 85 .
FIGS. 6A, 6 B and 6 C show a positional relationship between the lid position sensing lever 85 and the lock base 16 with respect to the locked condition between the striker 45 and the latch plate of the lock unit 15 . For showing the detail of the turn spring 87 disposed about the pivot shaft 28 , these drawings are those viewed from a back side of FIG. 1 .
FIG. 6A shows, by a phantom line, a position assumed by the sensing lever 85 when the striker bar 48 fully engages with the latch plate of the lock unit 15 with the striker base 40 taking the lowermost position of FIG. 9 . As shown, in this case, the detecting arm 86 is turned largely by the lock base 16 against the force of the spring 87 . It is to be noted that the position of the sensing lever 85 shown by a solid line is a rest position assumed by the lever 85 when the trunk lid “TL” is fully open. That is, when having no load, the sensing lever 85 assumes a relatively horizontal position.
FIG. 6B shows, by a phantom line, a position assumed by the sensing lever 85 when the striker bar 48 fully engages with the latch plate of the lock unit 15 with the striker base 40 taking the uppermost position of FIG. 8 . As shown, in this case, the detecting arm 86 is turned small by the lock base 16 against the force of the spring 87 .
FIG. 6C shows, by a phantom line, a position assumed by the sensing lever 85 when the striker bar 48 is fully engaged with the latch plate of the lock unit 15 with the striker base 40 taking a position corresponding to the critical position of the trunk lid “TL”, which is slightly higher than the uppermost position of FIG. 8 . As shown, in this case, the detecting arm 86 is turned slightly by the lock base 16 against the force of the spring 87 .
As will be described in detail hereinafter, when the trunk lid “TL” is pushed down to such critical position after establishing the latched engagement between the striker bar 48 and the latch plate, the drawing unit 50 becomes energized to start to draw down the trunk lid “TL”.
FIG. 5 shows a control circuit for controlling the power mechanism 70 of the drawing unit 50 . As shown, one terminal of the lid critical position sensing switch 88 is connected to a negative terminal of a battery “BT”. The other terminal of the switch 88 is led to a control unit 100 . A lock switch 90 has one terminal connected to the negative terminal of the battery “BT” and the other terminal led to the control unit 100 . A lock lamp 92 has one terminal connected to a positive terminal of the battery “BT” and the other terminal connected to the other terminal of the lock switch 90 . It is to be noted that the lock switch 90 assumes its ON state to energize the lock lamp 92 when the latch plate of the lock unit 15 is properly engaged with the striker 45 and locked by the locking plate. The draw condition detecting switch 80 has terminals connected to the control unit 100 , one of which is connected to the negative terminal of the battery “BT”. The electric motor “M” of the power mechanism 70 has one terminal connected to the negative terminal of the battery “BT” and the other terminal led to a switching section of a relay “R” which has one terminal connected to the negative terminal of the battery “BT” and the other terminal led to the control unit 100 . An energizing section of the relay “R” has one terminal connected to the control unit 100 and the other terminal connected to the negative terminal of the battery “BT”. A diode “D” is possessed by the energizing section.
The control unit 100 is programmed to carry out the following operation. That is, energization of the motor of the power mechanism 70 is effected only when all of the lock switch 90 , the draw condition detecting switch 80 and the lid critical position sensing switch 88 assume their ON state. In other words, even when the latch plate of the lock unit 15 fully engages with the striker 45 and the draw condition detecting switch 80 detects the draw action starting position, energization of the motor is not carried out if the trunk lid “TL” fails to pass by the critical position. That is, only when, under this condition, the lid critical position sensing switch 88 senses passing of the trunk lid “TL” by the critical position that is somewhat higher than the position assumed by the trunk lid “TL” when the striker base 40 assumes the uppermost position of FIG. 8, the electric motor “M” is energized.
In the following, operation will be described.
For ease of understanding, description will be commenced with respect to a full open condition of the trunk lid “TL”.
Under this condition, the lock unit 15 assumes a release condition inducing OFF state of the lock switch 90 , and the striker base 40 of the electric closing unit 20 assumes the draw action starting position (viz., uppermost position) of FIG. 8 . Thus, the detecting follower 81 of the draw condition detecting switch 80 is in contact with the first depressed part 55 b of the power arm 55 inducing ON state of the switch 80 . Furthermore, under this open condition of the trunk lid “TL”, the detecting arm 86 of the sensing lever 85 assumes the rest position shown by the solid line in for example FIG. 6B, inducing OFF state of the lid critical position sensing switch 88 .
When, due to application of a certain force to the trunk lid “TL”, the lid “TL” starts to be pivoted downward, that is, in a closing direction, the lock unit 15 approaches obliquely the striker 45 provided by the draw unit 50 . During this approaching, the striker bar 48 of the striker 45 enters the striker inserting guide slot 16 a of the lock base 16 (see FIG. 6C) and finally engages with the latch plate of the lock unit 15 . It is now to be noted that any shock then applied to the striker bar 48 from the latch plate of the lock unit 15 is assuredly received by the first vertical wall 22 of the support base 20 a which slidably supports a base part of the bent portion 46 and its neighboring part. Since the striker bar 48 of the striker 45 and the first vertical wall 22 of the support base 20 a are positioned close to each other, any moment produced around the base part of the bent potion 46 upon receiving the shock is small, which induces a satisfactory durability of the striker 45 , the striker base 40 and the first vertical wall 22 .
When the striker bar 48 of the striker 45 is brought into engagement with the latch plate of the lock unit 15 as is described hereinabove, the locking plate of the lock unit 15 is pivoted to the lock position to lock the latch plate at the latch position. Upon this, the lock switch 90 is turned ON.
When, due to further downward pivoting of the trunk lid “TL”, the lock base 16 of the lock unit 15 becomes into abutment with and pushes down the detecting arm 86 of the lid position sensing lever 85 beyond the above-mentioned critical position of FIG. 6C, the lid critical position sensing switch 88 is turned ON.
Upon this, the control unit 100 starts the drawing unit 50 and thus rotates the electric motor “M” of the power mechanism 70 in a lid drawing direction. With this, the power arm 55 (see FIG. 8) is rotated in a counterclockwise direction in FIG. 8 about the axis of the input shaft 57 to start operation of the drawing unit 50 .
That is, when the power arm 55 is rotated in the counterclockwise direction in FIG. 8, the cam follower 56 of the power arm 55 turns in the same direction while moving in the cam slot 41 of the striker base 40 pushing down the striker base 40 about the pivot pin 21 . Thus, during this, the trunk lid “TL” is gradually pulled down.
During this downward movement of the trunk lid “TL”, the striker 45 is slidably guided at one edge by the first vertical wall 22 of the support base 20 a. That is, even when the striker bar 48 receives a force from the latch plate of the lock unit 15 from the oblique direction (see FIG. 3 ), a subsequent downward movement of the striker base 40 is carried out vertically, which can minimize the degree by which the electric closing unit 20 projects into the trunk room “TR”. That is, provision of the unit 20 does not affect the capacity of the trunk room “TR”.
As will be seen from FIG. 8, during the counterclockwise rotation of the power arm 55 inducing the downward pivoting of the striker base 40 about the pivot 21 , the detecting follower 81 slides on the outer edge of the semicircular part 55 a of the power arm 55 .
When, thus, the striker base 40 is brought to the lowermost position (viz., the draw action finishing position) of FIG. 9, the detecting follower 81 comes to the second depressed part 55 c of the power arm 55 . With this, the draw condition detecting switch 80 is turned OFF stopping energization of the electric motor “M”. Upon stopping energization of the motor “M”, the control unit 100 returns the lid critical position sensing switch 88 to OFF state.
The trunk lid “TL” is thus fully lowered and assumes a full close condition. At a final period of the lid closing movement, a periphery of the trunk lid “TL” contacts and presses the weather strip “WS” on the periphery 12 (see FIG. 2) of the trunk room mouth portion 11 . Thus, in the fully close condition of the trunk lid “TL”, a water-tight sealing is achieved between the lid “TL” and the trunk room “TR”.
During the downward pivoting of the trunk lid “TL”, as is seen from FIG. 4B, the striker bar 48 of the striker 45 moves down along a curved path.
Under the full close condition of the trunk lid “TL”, the detecting arm 86 of the lid position sensing lever 85 assumes the largely pivoted position (as illustrated by a phantom line) of FIG. 6 A.
FIGS. 4A to 4 C are provided for explaining an advantage given by the unique structure of the striker bar 48 of the striker 45 . It is to be noted that FIGS. 4A and 4C show respectively positions of the striker bar 48 at the draw action starting and finishing positions of the striker base 40 , which would be assumed when the striker base 40 is inaccurately assembled with its left side displaced down and up with respect to a normal position shown by FIG. 4 B.
As is shown in these drawings and has been mentioned hereinafore, the striker bar 48 has a generally trapezoidal cross section with its leading edge made thinner than its trailing edge. Due to this trapezoidal cross section possessed by the striker bar 48 , the striker inserting guide slot 16 a of the lock base 16 can be made small in size or width as will be understood from the drawings. That is, if the striker bar 48 has a rectangular cross section as is illustrated by a phantom line, the striker inserting guide slot 16 a is compelled to have a wider path for accommodating such striker bar 48 . Furthermore, even if the striker bar 40 is assembled inaccurately as shown in FIGS. 4A and 4C, the striker bar 48 never interfere with the peripheral edge of the guide slot 16 a.
When now, for opening the trunk lid “TL”, a trunk open lever (not shown) installed in the vehicle cabin is manipulated, the locking plate (not shown) of the lock unit 15 unlocks the latch plate to cause the latter to release the striker bar 48 inducing OFF state of the lock switch 90 . In this condition, the trunk lid “TL” is readily opened when a certain force is applied to the lid “TL” in an opening direction. Upon release of the striker bar 48 from the latch plate, by the restoring force of the weather strip “WS”, the trunk lid “TL” is slightly lifted permitting the detecting arm 86 to pivot upward passing by the critical position of FIG. 6 C. Thus, the lid critical position sensing switch 88 is turned ON. Upon receiving the ON signal from the switch 88 , the control unit 100 energizes the electric motor “M” of the power mechanism 70 to run in a reversed direction, and thus the power arm 55 (see FIG. 9) is rotated in a clockwise direction in this drawing pivoting up the striker base 40 about the pivot pin 21 . When the turning of the power arm 55 comes to the position where the detecting follower 81 contacts the first depressed part 55 c of the power arm 55 causing ON state of the draw condition detecting switch 80 , the control unit 100 stops the energization of the electric motor “M”. Thus, upon this, the striker base 40 assumes the uppermost position (viz., the draw action starting position) of FIG. 8 .
When, under this condition, the trunk lid “TL” is applied with a certain force in a lid opening direction, the lid “TL” is lifted up. Thus, the lock base 16 of the lock unit 15 is moved up separating from the striker bar 48 . During this, the detecting arm 86 of the lid position sensing lever 85 is pivoted upward to the horizontal position due to the force of return spring 87 .
Thus, in the full open condition of the trunk lid “TL”, as has been mentioned hereinabove, the lock unit 15 assumes the release condition inducing OFF state of the lock switch 90 , the striker base 40 of the electric closing unit 20 assumes the draw action starting position (viz., uppermost position) of FIG. 8 inducing ON state of the draw condition detecting switch 80 and the detecting arm 86 of the lid position sensing lever 85 assumes the horizontal position inducing OFF state of the lid critical position sensing switch 88 .
In the following, description will be made on an advantageous operation of the electric lid closure of the present invention, which would be expected when the trunk open lever is manipulated under a condition wherein for example in winter the trunk lid “TL” has been frozen to the periphery 12 of the trunk room mouth portion 11 .
As is described hereinabove, in the full close condition of the trunk lid “TL”, the draw condition detecting switch 80 is OFF, the lid critical position sensing switch 88 is OFF and the lock switch 90 is ON.
When the trunk open lever is manipulated for the purpose of opening the trunk lid “TL”, the locking plate of the lock unit 15 unlocks the latch plate causing the latter to release the striker bar 48 inducing OFF state of the lock switch 90 . If now, due to the freezing between periphery of the trunk lid “TL” and the weather strip “WS” on the mouth of the trunk room “TR”, such release of the striker bar 48 from the latch plate fails to have the trunk lid “TL” sufficiently open, the lock base 16 of the lock unit 15 fails to be sufficiently lifted. In this case, the detecting arm 86 of the lid position sensing lever 85 fails to reach or pass by the critical position of FIG. 6C causing the lid critical position sensing switch 88 to keep OFF. Thus, even when the trunk lid “TL” is accidentally or carelessly pushed down to a position to bring about the engagement between the latch plate and the striker bar 48 inducing ON state of the lock switch 90 , the drawing unit 50 does not operate. That is, the trunk lid “TL” is prevented from taking an unexpected full close locked position.
As is described hereinabove, in accordance with the present invention, during a downward movement of the trunk lid “TL”, the striker 45 is slidably guided at one edge by the first vertical wall 22 of the support base 20 a. That is, even when the striker bar 48 receives a force from the latch plate of the lock unit 15 from an oblique direction (see FIG. 3 ), a subsequent downward movement of the striker base 40 powered by the electric motor “M” is carried out in a vertical direction, which can minimize the degree by which the electric closing unit 20 of the electric lid closure “ELC” of the invention projects into the trunk room “TR”. Thus, the trunk room “TR” can be effectively used.
In the foregoing description, the description is made with respect to an arrangement wherein the lock unit 15 is mounted to the trunk lid “TL” and the electric closing unit 20 is mounted on the mouth portion of the trunk room “TR”. However, if desired, the lock unit 15 and the electric closing unit 20 may be mounted to the trunk room “TR” and the trunk lid “TL” respectively.
The entire contents of Japanese Patent Application P10-208303 (filed Jul. 23, 1998) are incorporated herein by reference.
Although the invention has been described above by reference to a certain embodiment of the invention, the invention is not limited to the embodiment described above. Modifications and variations of the embodiment described above will occur to those skilled in the art, in light of the above teachings. | An electric lid closure generally comprises a lock unit mounted to a trunk lid and an electric closing unit mounted to a mouth portion of a trunk room. The lock unit includes a latch plate and a locking plate by which the latch plate is locked at its latch position. The electric closing unit includes a movable striker engageable with the latch plate, and an electric power mechanism for moving the movable striker between an uppermost position and a lowermost position with an electric power. A first position sensor senses whether the movable striker assumes the uppermost position or the lowermost position. A second position sensor senses whether the trunk lid passes by a critical position or not. The critical position corresponds to a position of the movable striker which is above the uppermost position. A third position sensor senses whether the locking plate locks the latch plate or not. A control unit energizes the electric closing unit to pull down the trunk lid to a full close position only when the first position sensor senses the movable striker assuming the uppermost position, the second position sensor senses the trunk lid passing by the critical position and the third position sensor senses the latch plate being locked by the locking plate. | 8 |
BACKGROUND OF THE INVENTION
This invention pertains to tools useful in servicing earth wells and pertains particularly to a running and pulling tool attachable in a string of well servicing tools and connectible to a well tool.
DESCRIPTION OF RELATED ART
Improved running and pulling tools have been developed which may be repeatedly forced or jarred downwardly and upwardly as required after connecting to a well tool fishing neck to run, pull or operate the well tool and later be released from the well tool at any desired time.
Both U.S. Pat. Nos. 4,767,145 and 4,838,594 to Bullard disclose structures of such running and pulling tools and are herein incorporated for reference. On manufacture and use, each of these tools was found to perform the functions for which they were designed very well, but proved to not be as long lasting as desired and each is comprised of a multiplicity of parts.
SUMMARY OF THE INVENTION
This running and pulling tool invention provides a rugged less costly tool which may also be repeatedly forced or jarred downwardly and upwardly as required after connecting to an internal fishing neck on a well tool to be lowered into a well conduit and operated to anchor in the conduit or operate an anchored well tool to release from the well conduit and be pulled from a well. The running pulling tool may be released from the fishing neck of a well tool after operation of the well tool by downward and upward force or jarring at any desired time by forcing or jarring downwardly. The upper section of the invention tool includes new simplified structure with better impact resistant which extends after application of a predetermined upward force on the tool after connection to a well tool fishing neck. The upper section automatically latches extended and in a position to permit operation of the running and pulling tool by subsequent predetermined downward force to release from the well tool fishing neck. After the invention running and pulling tool has connected to a well tool fishing neck and the well tool has been operated to anchor or release and is pulled back to surface, the invention tool may be easily released from the well tool and prepared for further use.
The principal object of this invention is to provide a less costly running and pulling tool having simplified structure.
An object of this invention is to provide a running and pulling tool having greater impact resistance.
Another object of this invention is to provide a running pulling tool which may be used to run and operate a well tool to anchor in a well conduit by downward jarring or forcing and upward forcing as required and later be released from the well tool with downward force.
Another object of this invention is to provide a running pulling tool which after connection to an anchored well tool to be pulled from a well may be forced downwardly and upwardly as required and later be released from the well tool by downward force.
Another object of this invention is to provide a running and pulling tool which may be easily released from a well tool which has been pulled from a well and be easily prepared for further use.
DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are a sectioned drawing in elevation of the running and pulling tool of this invention, shown connected to a well tool fishing neck.
FIG. 2 is a drawing of the cross section along line 2--2 in FIG. 1.
FIG. 3 is a sectioned drawing of a portion of FIG. 1 showing structure of an alternate latch.
FIG. 4 is a drawing of the cross section along line 4--4 in FIG. 3.
FIGS. 5A and 5B are a sectioned drawing in elevation of the invention tool shown latched in extended position.
FIGS. 6A and 6B are a sectioned drawing in elevation showing the invention tool in released from fishing neck position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The running and pulling tool 10 shown in FIGS. 1A and 1B depicts the best mode contemplated for carrying out this invention. This running and pulling tool has an upper body 11 which is slidably mounted around an upper tool mandrel 12. There is a thread 11a on the upper end of the upper body which is useful to connect the tool 10 to a string of well servicing tools. Below thread 11a on body 11 is a fishing neck 11b. Lower in the upper body is an internal groove 11c. There are two openings 11d through body 11 into groove 11c.
Upper mandrel 12 is connected to mandrel 13 at 14 and the connection is secured with screw 15. The upper mandrel has a lateral opening 12a, slots 12b, and a lateral hole with counterbores 12c. Installed in hole 12c is a spring 16 and lugs 17 are slidably mounted in each counterbore (see also FIG. 2).
Mounted through lateral openings 11e in the upper body and 12a in the upper mandrel is a pin 19 which slidably connects upper body 11 to upper mandrel 12. Pin 19 is positioned in the upper body by small cross pin 20 through pin 19 and extending into body slots 12b. The upper body is releasably positioned on the upper mandrel by shearable pin 21 through the upper body and upper mandrel.
When tool 10 is connected to an anchored well tool and upward force shears pin 21 and moves body 11 upwardly around the upper mandrel until groove 11c is adjacent lugs 17, spring 16 moves lugs 17 into groove 11c latching the upper body extended as shown in FIG. 5A. FIG. 3 shows alternate structure for latching the upper body extended which utilizes a spring in the shape of a "C" ring 18 mounted in a recess 12d around the upper tool mandrel 12 -- See also FIG. 4. Upper body 11 has an upper internal groove 11f and an internal lower groove 11g and groove 11f has a camming surface 11h. Body 11 also has pairs of opposed threaded holes 11i in which screws may be installed to retract "C" ring 18 from internal grooves 11f or 11g.
Slidably mounted around lower mandrel 13 is a housing 22 (See FIG. 1). This housing is releasably positioned on the lower mandrel with a shearable pin 23 through the housing and lower mandrel. Connected to the housing by thread 24 is a skirt 25, which has an internal shoulder 25a.
Mandrel 13 has an upper shoulder 13a and a lower shoulder 13b. Slidably mounted around the mandrel is a ring 26 having a shoulder 26a. Housed in a bore in the lower end of housing 22 is a spring 27 which biases the housing upwardly and the ring downwardly into contact with upper mandrel shoulder 13a. A lower compressed spring 28 is mounted around ring 26 between ring shoulder 26a and a retainer ring 29. The retainer ring has a number of openings 29a and pivotally mounted in each opening is a dog 30. Each dog has an external shoulder 30a and a camming surface 30b. Spring 28 biases the retainer ring and each dog downwardly into fishing neck connecting position in contact with mandrel shoulder 13b.
To use the invention running pulling tool as a running tool requires insertion of the invention tool into the fishing neck of the tool to be run for automatic connection as shown in FIGS. 1A and 1B. Tool 10 is then connected in a string of well servicing tools by thread 11a and the well servicing tools carrying a well tool are lowered into a well conduit to be forced or jarred downwardly and upwardly to cause the well tool to anchor itself in the well conduit. Tool 10 connected to a well tool fishing neck as shown in FIG. 1 may be jarred or forced downwardly repeatedly and upwardly repeatedly on the anchored tool as required.
To release tool 10 from the anchored well tool fish neck, the well service tools and upper body 11 must be forced upwardly to shear pin 21, (if not already sheared) and slide body 11 upwardly around upper mandrel 12 and pins 19, 20 in slots 12b and openings 12a until groove 11c is adjacent lugs 17. Spring 16 then moves lugs 17 into groove 11c, latching body 11 in upper extended position on the mandrel as shown in FIGS. 5A and 5B.
If the alternate latching structure of FIG. 3 is used, upward movement of upper body 11 while shearing pin 21 moves camming surface 11h upwardly to cam expanded "C" ring 18 inwardly. Upward movement of body 11 and pins 19, 20 continue until groove 11g is adjacent "C" ring 18. Ring 18 expands, snapping into groove 11g and latches body 11 in upper extended position on upper mandrel 12. Now, if upward force or jarring is required on the anchored tool, this may be done repeatedly as required.
Now, applying downward force on extended tool 10 and the anchored well tool will move tool 10 downwardly into the anchored well tool fishing neck until the lower end of skirt 25 contacts the upper end of the well tool fishing neck. Downward force sufficient to shear pin 23 will permit spring 27 to move housing 22 and connected skirt 25 upwardly on mandrel 13. Skirt 25 lifts dogs 30, via skirt shoulder 25a and dog shoulder 30a, and retaining ring 29 and compresses spring 28 until dog camming surfaces 30b move over the lower outside corners of ring 26 and the dogs are cammed inwardly releasing the well tool fishing neck as shown in FIG. 6.
Tool 10 may now be raised back to surface and prepared for further use as a running or pulling tool by inserting a rod in each of upper body openings 11d and moving lugs inwardly from groove 11c, unlatching body 11 from mandrel 12. If the tool 10 has the alternate latch structure of FIG. 3, screws installed in threaded holes 11i are used to retract "C" ring 18 from groove 11g. Body 11 is moved downwardly from extended position until body and mandrel holes for pin 21 are aligned and sheared pieces of the pin are driven out. An unsheared pin 21 is inserted to again releasably position the upper body on the upper mandrel. Housing 22 and skirt 25 are now moved downwardly while compressing spring 27, until holes for shearable pin 23 in body 22 and mandrel 13 are aligned and the lower end of dogs 30 are in contact with mandrel lower shoulder 13b. Sheared pin 23 pieces are driven out and an unsheared pin is installed.
Running pulling tool 10 of FIGS. 1A and 1B may be used as a pulling tool by attaching to the lower end of a string of well servicing tools and lowering the servicing tools into a well until dogs 30 contact the upper end of an anchored well tool fishing neck. A small downward force may be required on tool 10 to compress spring 28 and move mandrel 13 downwardly and shoulder 13b out of contact with the lower end of dogs 30. Further downward movement of the mandrel permits the dogs to be cammed inwardly around the smaller diameter section of mandrel 13 by the well tool fishing neck until spring 28 can extend and push the dogs back into contact with shoulder 13b, connecting tool 10 to the anchored well tool fishing neck (See FIG. 1B). Tool 10 may now be forced or jarred repeatedly downward or repeatedly upward as required to operate the well tool to release from the well conduit. Any upward force sufficient to shear pin 21 will move upper body 11 upwardly around the upper mandrel and into extended position where the upper body is automatically latched by lugs 17 or "C" ring 18 of FIG. 3, as shown in FIG. 5A. If repeated downward forces followed by repeated upward forces or repeated upward forces followed by repeated downward forces do not operate the well tool to release from the conduit, then the tool 10 may be released from the well tool fishing neck by forcing tool 10 again downwardly against the anchored well tool to shear pin 23 and release tool 10 from the well tool fishing neck as previously described. The well servicing tools and tool 10 may be raised back to surface where parts of tool 10 may be repositioned an sheared pins replaced to prepare the running and pulling tool for further use as a running or pulling tool. | A running and pulling tool is disclosed which is releasably connectible to a fishing neck on a well tool. The running pulling tool has an elongate mandrel on which a connector having dogs is slidably mounted for connecting to and releasing the dogs from a fishing neck. The connector is positioned in a first connecting position by a retainer which is moveable to a position permitting movement of the connector to a second position releasing from the fishing neck. A latch releasably positions the retainer in position for retaining the connector in the first position. The running pulling tool may be used to run and anchor a well tool in a well conduit and to retrieve an anchored well tool. | 4 |
FIELD OF THE INVENTION
The present invention relates in general to wireless communications, and in particular to canceling spurious signal content from signals to be transmitted.
BACKGROUND OF THE INVENTION
Wireless communication systems often incorporate predistortion techniques configured to pre-process signals for transmission to compensate for non-linearities or like anomalies inherent to transmission. Unfortunately, the compactness of wireless architectures makes these systems prone to having spurious noise injected into the signals to be transmitted. The source of the spurious noise may take many forms, including the various local oscillators facilitating reception and transmission of wireless communication signals, harmonics and mixing products from mixing circuitry, and the like. Unfortunately, compensating for the unwanted injection of spurious noise content is difficult to address, and can be even more difficult to address in a cost-effective manner in systems incorporating predistortion techniques.
Accordingly, there is a need for a technique to cancel spurious noise in wireless communication systems, and a further need for a technique to cancel spurious noise in wireless communication systems incorporating predistortion techniques to compensate for non-linearities or other anomalies in the transmission path.
SUMMARY OF THE INVENTION
The present invention provides a technique for canceling spurious noise content in transmitted signals. During transmission, the transmitted signals are fed back to predistortion and cancellation circuitry adapted to provide a predistortion component for signals to be transmitted, as well as to compensate for spurious noise injected into the system. In a first path, the predistortion and cancellation circuitry will predistort the baseband signals to compensate for non-linearity and like anomalies injected by the transmission circuitry to provide a predistorted output. Along a second path, a fast Fourier transform is performed on the feedback signal. The resultant frequency domain signal is then processed to detect spurious noise content above a defined threshold, throughout the range or within defined bands. The spurious noise content is identified and used to recreate a replica of the noise content. The replica will preferably have the same phase and frequency, and a magnitude sufficient to reduce or eliminate the content to a desired degree. The replicated signal is then negatively added to the predistorted signals to create a final signal for transmission.
Those skilled in the art will appreciate the scope of the present invention and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the invention, and together with the description serve to explain the principles of the invention.
FIG. 1 is a block representation of a base station architecture according to one embodiment of the present invention.
FIG. 2 is a block representation of the feedback circuitry used for predistortion and cancellation according to one embodiment of the present invention.
FIG. 3 is a block representation of the predistortion and cancellation circuitry according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the invention and illustrate the best mode of practicing the invention. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the invention and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
As illustrated in FIG. 1, the present invention may be incorporated in a base station transceiver 20 , which includes a receiver front end 22 , a radio frequency transmitter section 24 , an antenna 26 , a duplexer or switch 28 , a baseband processor 30 , a control system 32 , and a frequency synthesizer 34 . The receiver front end 22 receives information bearing radio frequency signals from one or more remote transmitters provided by mobile terminals, such as mobile telephones, wireless personal digital assistants, or like wireless communication devices. A low noise amplifier 38 amplifies the signal. A filter circuit 40 minimizes broadband interference in the received signal, while downconversion and digitization circuitry 42 downconverts the filtered, received signal to an intermediate frequency (IF) signal, which is then digitized into one or more digital streams. The receiver front end 22 typically uses one or more mixing frequencies generated by the frequency synthesizer 34 .
The baseband processor 30 processes the digitized received signal to extract the information or data bits conveyed in the received signal. This processing typically comprises demodulation, decoding, error correction, and interference cancellation operations. As such, the baseband processor 30 is generally implemented in one or more digital signal processors (DSPs), application specific integrated circuits (ASICs), or field programmable gate arrays (FPGAs). Further detail regarding the operation of the baseband processor 30 is described in greater detail below. On the transmit side, the baseband processor 30 receives digitized data, which may represent voice, data, or control information, from the control system 32 , which it encodes for transmission.
The data for transmission is preferably provided in a quadrature format wherein the data is represented by in-phase (I) and quadrature phase (Q) signals. The encoded data is output to predistortion and cancellation circuitry 44 , which will be discussed below in greater detail. In general, the predistortion and cancellation circuitry 44 predistorts each of the in-phase and quadrature phase signals I, Q to compensate for non-linearities introduced by the transmission circuitry 24 , as well as minimizing the impact of spurious signals on the signals to be transmitted. The resultant in-phase (I T ) and quadrature phase (Q T ) signals are sent to the transmitter circuitry 24 , where they are processed by a modulator 46 to modulate a carrier signal that is at a desired transmit frequency. Power amplifier circuitry 48 amplifies the modulated carrier signal to a level appropriate for transmission, and delivers the modulated carrier signal to the antenna 26 through a matching network 50 , coupler 51 , and duplexer 28 .
For the present invention, the transmitted signal is fed back from the coupler 51 in the form of a feedback signal for processing by feedback signal processing circuitry 52 , which will generate a feedback IF signal to send to the predistortion and cancellation circuitry 44 . The predistortion and cancellation circuitry 44 facilitates predistortion and cancellation of the spurious signals from the signals to be transmitted based on the feedback IF signal.
Turning now to FIG. 2, the in-phase and quadrature phase signals I T and Q T , which have been predistorted and processed to cancel spurious signals, are respectively presented in a digitized format to digital-to-analog converters (DAC) 54 I and 54 Q. The DACs 54 I, 54 Q will convert the respective digitized in-phase and quadrature phase signals I T and Q T to an analog format, wherein the respective signals are filtered by filters 56 I and 56 Q, amplified by amplifiers 58 I and 58 Q, and presented to mixers 60 I and 60 Q. The mixers 60 I and 60 Q are driven in a quadrature arrangement by a radio frequency local oscillator 62 such that the signal provided to mixer 60 I is offset by 90 degrees by a 90 degree shift function 64 in traditional fashion. Accordingly, the mixers 60 I and 60 Q modulate the in-phase and quadrature phase signals I T and Q T to generate radio frequency modulated versions of each. The modulated signals are summed at summing circuitry 66 , the output of which is filtered by filter 68 , preamplified by preamplifier 70 , and amplified to a level for transmission by power amplifier 74 . The output of the power amplifier 74 is sent to the coupler 51 and then to the duplexer 28 and transmitted via the antenna 26 . Preferably, the coupling function is located within the transmit circuitry 24 such that the transmitted signal is fed back in the form of the feedback signal to the feedback signal processing circuitry 52 . Alternatively the coupling function could be located within the duplexer 28 .
In one embodiment, the feedback signal is sent directly to an attenuator 76 to reduce the level of the feedback signal prior to being presented to mixer 78 , which is driven by radio frequency oscillator 80 . Thus, the attenuated feedback signal is downconverted to an intermediate frequency (IF) signal by the mixer 78 prior to being amplified by preamplifier 82 , filtered by filter 84 , and presented to an analog-to-digital converter (ADC) 86 to provide a digitized feedback IF signal, which is presented to the predistortion circuitry 44 to control predistortion and cancellation of spurious signals.
Referring now to FIG. 3, the digitized feedback IF signal is split and provided along two separate paths in the predistortion and cancellation circuitry 44 . Along the first path, the feedback IF signal is provided to a quadrature-based mixer 88 controlled by a numerically controlled oscillator 90 . The quadrature-based mixing circuitry 88 provides in-phase and quadrature phase baseband signals I F and Q F derived from the feedback IF signal. The in-phase and quadrature phase baseband signals I F and Q F are presented to adaptive predistortion and modulation compensation circuitry 92 . This circuitry receives the actual in-phase and quadrature phase data I and Q from the baseband processor 30 and provides the following processing. First, the adaptive predistortion aspect of the circuitry 92 processes the baseband I and Q signals to compensate for non-linearities injected by the transmission circuitry 24 . In one embodiment, this is done by multiplying the complex numbers represented by the in-phase and quadrature phase signals I and Q with values from a look-up table that are determined by the in-phase and quadrature phase feedback signals. The modulation compensation aspect of the circuitry 92 adjusts for phase and amplitude imbalance as well as DC offset between the in-phase and quadrature signals incurred in the modulation aspect of transmission circuitry 24 . Those skilled in the art will appreciate the various ways to implement predistortion and compensate for I and Q phase and amplitude imbalance as well as DC offset based on the provided feedback. The outputs of the circuitry 92 are the in-phase and quadrature phase signals I P and Q P , which have been processed to compensate for non-linearities, phase and amplitude imbalances, and DC offsets imposed by the modulation aspect of the transmit circuitry 24 .
The second path in the predistortion and cancellation circuitry 44 processes the feedback IF signal to provide in-phase and quadrature phase components configured to cancel spurious signals that are injected into signals being transmitted. These spurious signals might be injected into the system by the transmitter or receiver's local oscillator fundamental or harmonic signals, mixing products of these signals, and the like. Spurious signals injected into the system may also originate from oscillation in amplifiers or from digital circuit clocks, or from harmonics or mixing products of these signals. Since the feedback IF signal is in the time domain, it is first presented to fast Fourier transform (FFT) circuitry 94 to perform a fast Fourier transform or like Fourier transform. The resultant signal is sent to a spurious signal level detector 96 . The spurious signal level detector 96 calculates the composite power from the FFT signal or receives it from other circuitry in the base station and also calculates the power in one or more narrow band frequency ranges. The entire spectrum may be divided into multiple narrow bands, or select bands may be defined at or around frequency ranges known to have spurious content. If a spurious signal level within the transmission spectrum exceeds a threshold relative to the composite power, the spurious signal level detector 96 will trigger the controller 98 to attempt to cancel the spurious noise component or otherwise reduce it to an acceptable level. Preferably, the spurious signal level detector 96 will identify the frequency or frequency band, as well as a relative signal level, of spurious content. Accordingly, the controller 98 will signal phase and frequency adjust circuitry 100 to control the numerically controlled oscillator 102 to create in-phase and quadrature phase signals I′ and Q′ at the appropriate frequency and phase of the spurious content. The in-phase and quadrature phase signals I′ and Q′ replicating the spurious noise content are respectively sent to in-phase and quadrature phase attenuators 104 I and 104 Q. For spurious signals detected outside of the transmission bandwidth but within the predistortion and spurious cancellation band, the potential spurious signal will be compared to an absolute level rather than a level relative to the composite power.
In addition to controlling the phase and frequency of the replicated in-phase and quadrature phase signals I′ and Q′, the controller 98 provides a control signal to the attenuators 104 I and 104 Q to effectively adjust the magnitude of the replicated in-phase and quadrature phase signals I′ and Q′ to have the same magnitude as the spurious content. Thus, the output of the attenuators 104 I and 104 Q are in-phase and quadrature phase signals I″ and Q″, which have the same frequency, phase, and magnitude as the spurious content. These in-phase and quadrature phase signals I″ and Q″ are combined or summed with the predistorted in-phase and quadrature phase signals I P and Q P at summation circuitry 106 I and 106 Q to create the in-phase and quadrature phase signals for transmission I T and Q T , which are provided to the digital-to-analog converters 54 I and 54 Q (of FIG. 2 ). Notably, the summation circuitry 106 I and 106 Q will actually add the negative of the in-phase and quadrature phase signals I″ and Q″ representing the spurious noise content to effect cancellation of the components in the in-phase and quadrature phase signals for transmission I T and Q T . Alternatively, the controller 98 will operate to control the numerically controlled oscillator 102 and attenuators 104 I and 104 Q to create signal replicas, which are 180 degrees out of phase from the spurious content or being the negative thereof. Those skilled in the art will recognize the variations in effectively subtracting the replicas of the spurious content from the predistorted in-phase and quadrature phase signals I T and Q T . The present invention is particularly beneficial in code division multiple access (CDMA) and wideband CDMA (WCDMA) architectures. Further, the techniques are equally applicable to mobile terminals and wireless LANs in addition to base stations.
Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present invention. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow. | The present invention provides a technique for canceling spurious noise content in transmitted signals. During transmission, the transmitted signals are fed back to circuitry adapted to provide a predistortion component for signals to be transmitted, as well as to compensate for spurious noise injected into the system. In a first path, the circuitry will predistort the baseband signals to provide a predistorted output. Along a second path, a fast Fourier transform is performed on the feedback signal. The resultant frequency domain signal is then processed to detect spurious noise content above an identified defined threshold. The spurious noise content is used to recreate a replica of the noise content. The replica will have the same phase and frequency and a magnitude sufficient to reduce or eliminate the content to a desired degree. The replicated signal is then negatively added to the predistorted signals to create a final signal for transmission. | 7 |
This is a divisional of application Ser. No. 296,209, filed Jan. 12, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a coal combustion apparatus provided with a denitration means. More particularly it relates to a coal combustion apparatus devised so that a denitration catalyst can be hardly poisoned by volatile metal compounds contained in exhaust gases in a denitration means for catalytic reduction with ammonia, and a method for eliminating said volatile metal compounds from said exhaust gases.
2. Description of the Related Art
Heretofore, for removing nitrogen oxides contained in exhaust gases from a coal combustion apparatus such as boiler facilities, etc., a catalytic reduction process using ammonia as a reducing agent has been mainly employed. A model of boiler facilities provided with a denitration apparatus is shown in FIG. 2 of the accompanying drawings. The boiler facilities comprise a boiler furnace 2 provided with a coal-feeding flow path 1 and a slag-discharging flow path 9, and a denitration apparatus 3, an air preheater 5, an electrostatic precipitator 6 and a chimney 7, each successively provided in the exhaust gas flow path of the boiler furnace 2 and further a line 8 for recycling ashes collected in the electrostatic precipitator.
In the boiler facilities shown in FIG. 2, simple substances or oxides of highly volatile elements such as arsenic, selenium, lead, zinc, etc. volatize inside the boiler furnace 2, and are mostly adsorbed to fly ashes (powder of coal combustion ashes), before they are collected by the electrostatic precipitator 6.
The fly ashes having adsorbed the compounds of the volatile elements are blown into the boiler furnace via a fly ash-recycling path 8 and recovered through a slag-discharging path 9 to the outside, but the compounds of the volatile elements are left behind inside the boiler system in the form of vapor and present in the form of a highly concentrated vapor in the exhaust gas. When the denitration apparatus 3 is provided inside the flow path of the exhaust gas containing such a vapor of the volatile metal compounds, a denitration catalyst 4 in the denitration apparatus 3 adsorbs the highly concentrated volatile metal compounds to notably reduce its activity.
The present inventors have previously invented a denitration catalyst having small deterioration enough to be usable even in such boiler facilities and have applied for patent (Japanese patent application No. Sho 62-141176/1988), but nevertheless it is necessary to take some countermeasure for preventing the deterioration, in addition to the catalyst improvement.
SUMMARY OF THE INVENTION
The object of the present invention is to provided a coal combustion apparatus having prevented deterioration of the denitration catalyst due to volatile metal compounds contained in exhaust gases, and a method for eliminating said volatile metal compounds from the exhaust gas.
The present invention resides in;
a coal combustion apparatus comprising a combustion furnace, a denitration means for removing nitrogen oxides contained in an exhaust gas from the combustion furnace by reducing the oxides with ammonia as a reducing agent, a means for collecting ashes contained in the exhaust gas having left the denitration means and a means for recycling the collected ashes into the combustion furnace, which apparatus is provided with an oxygen concentration meter in the flow path of the exhaust gas between the combustion furnace and the denitration means and also provided with an oxygen concentration-controlling means relative to air fed inside the flow path of the exhaust gas from the combustion furnace to the denitration means so as to control the oxygen concentration detected by the oxygen concentration meter to a definite value or higher.
The present invention also resides in;
a method for eliminating volatile metal compounds in an exhaust gas from a coal combustion apparatus provided with a denitration means for catalytic reduction with ammonia, which comprises blowing an air into the exhaust gas at a temperature of 500° C. or heigher until said exhaust gas contains 2% by volume or more of oxygen to oxidize said volatile metal compounds and making said oxidized metal compounds adsorb to fly ashes in the exhaust gas during the process of its moving downstream to the denitration means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a view illustrating an embodiment of the present invention.
FIG. 2 shows a view illustrating the prior art.
FIG. 3 and 4 each show a chart illustrating the effectiveness of Examples of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiment of the present invention will be described in more detail referring to the accompanying drawings.
FIG. 1 shows a flowsheet illustrating a coal combustion boiler furnace provided with a denitration means according to the present invention. The furnace is composed of a furnace 2, a denitration apparatus 3; an air preheater 5; an electrostatic precipitator 6; a chimney 7; a line 8 for recycling ashes collected in the electrostatic precipitator 6 to the furnace 6; a hot-air duct 11 for feeding air heated in the air preheater 5 to the furnace 2; adding air-feeding pipes 13 and 14 successively provided in the flow path of combustion gas of the furnace 2; an oxygen concentration meter 15 provided on an exhaust gas inlet line to the denitration means; valves 13A and 13B for controlling the amount of air added, by receiving a signal from the oxygen concentration meter 15 and controlling the opening degree of the valves so that the oxygen concentration can reach a preset concentration (2% by volume or more); and a line 16 for transmitting the oxygen concentration signal at the oxygen concentration meter 15 to the controlling valves 13A and 14A.
In the above-mentioned system, air sent from a blower 10 to the air preheater 5 is heated up to a definite temperature, followed by passing through a hot-air duct 11 and being fed through a pipe for feeding air for combustion 12 into the boiler furnace 2. The oxygen concentration in the combustion exhaust gas at the exit of the boiler is measured by the oxygen concentration meter 15, and when the measured value is reduced down to a value lower than 2% by volume, air is fed through the added air-feeding pipes 13 or 14 so that the concentration can reach 2% by volume or higher. The oxygen concentration in the exhaust gas, measured by the oxygen concentration meter 15 is proper to be 2% by volume or higher, and there is a tendency that the higher the concentration, the greater the effectiveness. However, since increase in the oxygen concentration is disadvantageous in the aspect of heat loss, the concentration is preferably about 3 to 4% by volume.
The reason that in the present invention, operation is carried out raising the oxygen concentration in the exhaust gas entering the denitration means up to a definite value (2% by volume) or higher is as follows:
Volatile metal compounds contained in coal, for example, arsenic compounds are oxidized in the boiler furnace 2 to form arsenous anhydride (As 2 O 3 ) vapor having a high vapor pressure, which is then adsorbed to fly ashes during the course where it is moved toward the subsequent step, and the resulting fly ashes are collected by the electrostatic precipitator 6, then recycled to the furnace 9 and come to be present in the exhaust gas in the form of vapor having a gradually raised concentration. When the exhaust gas reaches the denitration apparatus 3 in such a manner, if As 2 O 3 vapor is remaining without being adsorbed to fly ashes, then the As 2 O 3 vapor is adsorbed to the denitration catalyst 4 in the denitration apparatus 3 to cause catalyst deterioration. Whereas, when operation is carried out raising the oxygen concentration in the exhaust gas up to a definite value or higher, as in the present invention, then the As 2 O 3 is oxidized into arsenic pentoxide having a lower oxygen pressure during the course before the boiler furnace 2 and the denitration means 3, as shown by the following equation:
As.sub.2 O.sub.3 +O.sub.2 →As.sub.2 O.sub.5.
As the proportion of this As 2 O 5 having a higher vapor pressure increases, the proportion of arsenic compounds adsorbed to fly ashes before they reach the denitration apparatus 3 increases, and it has been observed that As 2 O 3 in the form of vapor is nearly absent. Thus it has been found that adsorption of arsenic compounds to the denitration catalyst 4 is reduced to make it possible to notably reduce its deterioration.
In order to oxidize As 2 O 3 in the exhaust gas into As 2 O 5 , it is preferred that the temperature of the exhaust gas be 500° C. or higher. Thus the site where the added air is fed is preferred to be a site where the combustion exhaust gas temperature is 500° C. or higher. As to the added air, it may be cold air, but it is preferred to be air heated by air preheater, etc. As described above, if combustion inside the furnace is carried out in a high oxygen concentration (oxygen concentration in the exhaust gas: 2% by volume or higher), then coal combustion is completed in a short time and the vapor of volatile metal oxides such as As 2 O 3 , etc. is retained in the oxidation atmosphere for a long time to thereby increase the proportion of As 2 O 3 oxidized into As 2 O 5 .
As described above, when As 2 O 3 in exhaust gas is oxidized into As 2 O 5 before the As 2 O 3 enters the denitration means, adsorption of catalyst poisons such as arsenic compounds to the fly ashes in the exhaust gas advances to thereby reduce the concentration of catalyst poisons in the form of vapor in the exhaust gas, whereby the amount of catalyst poisons adsorbed to the catalyst 4 in the denitration apparatus 3 is reduced to make it possible to retain the catalyst at a high activity for a long time.
The boiler furnace 2 in FIG. 1 is the so-called melting combustion furnace (which is of a type of melting ashes and withdrawing them from the furnace bottom) provided with a combustion furnace of cyclone type or slag-tapping type. In the case of the slag-tapping type combustion furnace, since lower oxygen combustion is carried out as compared with conventional combustion, the oxygen concentration in the combustion exhaust gas is insufficient so that the denitration catalyst is liable to deteriorate; hence the present invention is particularly suitable in such a case.
The denitration apparatus 3 contains a denitration catalyst such as titanium oxide, vanadium oxide, molybdenum oxide, etc. filled in the body of the means. The denitration apparatus is provided usually on the exit side of the boiler furnace, particularly in the flow path at the exit of the economizer, but the combustion gas may be by-passed from the inlet part of the economizer where the denitration apparatus is provided.
The present invention will be described in more detail by way of Examples.
EXAMPLES 1-3
To a metatitanic acid slurry (TiO 2 content: 30% by weight) were added ammonium metavanadate (NH 4 VO 3 ) and ammonium molybdate (3(NH 4 ) 2 O.7MoO 3 .4H 2 O) so as to give an atomic ratio of Ti/V/Mo of 86/4/10, followed by kneading these on heating by means of a kneader to obtain a paste having a water content of 34%. This paste was extruded into the form of a rod of 3 mm φ, followed by cutting it into granules, drying at 150° C., calcining for 2 hours at 350° C., grinding the resulting granules by means of a hammer mill to obtain powder (the proportion of powder of 100 meshes or smaller: 97%), adding water to the powder to obtain a paste, adding alumina-silica fibers in 15% by weight based on the weight of the catalyst powder, kneading the mixture, applying the resulting paste onto both the surfaces of a lath substrate of SUS 304 of 0.2 mm thick having metal aluminum flame-sprayed thereon so as to embed the meshes thereof, drying the resulting material, calcining at 55° C. for 2 hours, impregnating the resulting plate-form catalyst with an aqueous solution of aluminum sulfate (Al 2 (SO 4 ) 3 ) (concentration: 200 g/l), further calcining the resulting material at 470° C. for 2 hours to obtain a catalyst, cutting the catalyst into test pieces of 100 mm×100 mm and placing the pieces at a position inside the flue, corresponding to a definite position of the denitration apparatus 3 in the boiler facilities as shown in FIG. 1, so as to be contacted with the exhaust gas. The test conditions in this case are shown in Tables 1 and 2.
TABLE 1______________________________________ Example Example Example Comp.Item 1 2 3 ex.______________________________________Temperature (°C.) 360 370 360 380Gas compositionin averageO.sub.2 (%) 4 3 7.5 1.5SOx (ppm) 3000 1000 1000 600NOx (ppm) 1800 2400 1600 1200Dust Concentration 15 7 10 30(g/Nm.sup.3)______________________________________
TABLE 2______________________________________Item Condition______________________________________Measured temperature (°C.) 350Area measurement AV (m/h) 51Gas compositionO.sub.2 (%) 3CO.sub.2 (%) 12H.sub.2 O (%) 12SO.sub.2 (ppm) 500NO (ppm) 200NH.sub.3 (ppm) 240______________________________________
The catalyst 4 was sampled each definite time and change in the catalyst activity with lapse of time was measured. The results are shown in FIG. 3.
Further, the concentration of arsenic adsorbed onto the catalyst surface after about 1,000 hours was measured. FIG. 4 shows a chart obtained by plotting the As concentration relative to O 2 concentration in the exhaust gas.
As seen from FIG. 3, when O 2 concentration is low, notable reduction in the activity in a short time is observed, but when O 2 concentration exceeds 2%, activity reduction becomes successively less.
Further, as seen from FIG. 4, as O 2 concentration is raised, the quantity of arsenic accumulated on the catalyst surface is notably reduced.
According to the present invention, it is possible to notably reduce deterioration of the denitration catalyst in boiler apparatus and also it is possible to notably reduce the amount of the catalyst used. | A coal combustion apparatus having prevented deterioration of a denitration catalyst due to volatile metal compounds contained in exhaust gases is provided, which apparatus comprises a combustion furnace, a denitration means for removing nitrogen oxides in an exhaust gas from the furnace by reducing nitrogen oxide with ammonia, a means for collecting ashes in the gas having left the denitration means and a means for recycling the collected ashes into the furnace, and is characterized in providing an oxygen concentration meter in the flow path of the gas between the furnace and the denitration means and also providing an oxygen concentration-controlling means relative to air fed inside the flow path of the gas from the furnace to the denitration means so as to control the oxygen concentration detected by the oxygen concentration meter to a definite value or higher. | 1 |
The present application is a divisional application of U.S. patent application Ser. No. 11/067,491 filed Feb. 28, 2005 now U.S. Pat. No. 7,282,701, the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a lithographic apparatus and a method for manufacturing a device.
BACKGROUND
A lithographic apparatus is a machine that applies a desired pattern onto a substrate, usually onto a target portion of the substrate. A lithographic apparatus can be used, for example, in the manufacture of integrated circuits (ICs). In that instance, a patterning device, which is alternatively referred to as a mask or a reticle, may be used to generate a circuit pattern to be formed on an individual layer of the IC. This pattern can be transferred onto a target portion (e.g. including part of, one, or several dies) on a substrate (e.g. a silicon wafer). Transfer of the pattern is typically via imaging onto a layer of radiation-sensitive material (resist) provided on the substrate. In general, a single substrate will contain a network of adjacent target portions that are successively patterned. Known lithographic apparatus include so-called steppers, in which each target portion is irradiated by exposing an entire pattern onto the target portion at one time, and so-called scanners, in which each target portion is irradiated by scanning the pattern through a radiation beam in a given direction (the “scanning”—direction), while synchronously scanning the substrate parallel or anti-parallel to this direction. It is also possible to transfer the pattern from the patterning device to the substrate by imprinting the pattern onto the substrate.
It has been proposed to immerse the substrate in the lithographic projection apparatus in a liquid having a relatively high refractive index, e.g. water, so as to fill a space between the final element of the projection system and the substrate. The point of this is to enable imaging of smaller features since the exposure radiation will have a shorter wavelength in the liquid. (The effect of the liquid may also be regarded as enabling the use of a larger effective NA of the system and also increasing the depth of focus.) Other immersion liquids have been proposed, including water with solid particles (e.g. quartz) suspended therein.
However, submersing the substrate or substrate and substrate table in a bath of liquid (see for example U.S. Pat. No. 4,509,852, hereby incorporated in its entirety by reference) means that there is a large body of liquid that must be accelerated during a scanning exposure. This requires additional or more powerful motors and turbulence in the liquid may lead to undesirable and unpredictable effects.
One of the solutions proposed is for a liquid supply system to provide liquid on only a localized area of the substrate and in between the final element of the projection system and the substrate using a liquid confinement system (the substrate generally has a larger surface area than the final element of the projection system). One way which has been proposed to arrange for this is disclosed in WO 99/49504, hereby incorporated in its entirety by reference. As illustrated in FIGS. 2 and 3 , liquid is supplied by at least one inlet IN onto the substrate, preferably along the direction of movement of the substrate relative to the final element, and is removed by at least one outlet OUT after having passed under the projection system. That is, as the substrate is scanned beneath the element in a −X direction, liquid is supplied at the +X side of the element and taken up at the −X side. FIG. 2 shows the arrangement schematically in which liquid is supplied via inlet IN and is taken up on the other side of the element by outlet OUT which is connected to a low pressure source. In the illustration of FIG. 2 the liquid is supplied along the direction of movement of the substrate relative to the final element, though this does not need to be the case. Various orientations and numbers of in- and out-lets positioned around the final element are possible, one example is illustrated in FIG. 3 in which four sets of an inlet with an outlet on either side are provided in a regular pattern around the final element.
Another solution which has been proposed is to provide the liquid supply system with a seal member which extends along at least a part of a boundary of the space between the final element of the projection system and the substrate table. Such a solution is illustrated in FIG. 4 . The seal member is substantially stationary relative to the projection system in the XY plane though there may be some relative movement in the Z direction (in the direction of the optical axis). A seal is formed between the seal member and the surface of the substrate. Preferably the seal is a contactless seal such as a gas seal. Such as system with a gas seal is disclosed in European Patent Application No. 03252955.4 hereby incorporated in its entirety by reference.
In European Patent Application No. 03257072.3 the idea of a twin or dual stage immersion lithography apparatus is disclosed. Such an apparatus is provided with two stages for supporting the substrate. Leveling measurements are carried out with a stage at a first position, without immersion liquid, and exposure is carried out with a stage at a second position, where immersion liquid is present. Alternatively, the apparatus has only one stage.
A number of sensors are used at substrate level for evaluating and optimizing imaging performance. These may include transmission image sensors (TIS), spot sensors for measuring exposure radiation dose and integrated lens interferometers at scanner (ILIAS). TIS and ILIAS are described below.
A TIS is a sensor that is used to measure the position at substrate level of a projected aerial image of a mark pattern at the mask (reticle) level. The projected image at substrate level may be a line pattern with a line width comparable to the wavelength of the exposure radiation. The TIS measures these mask patterns using a transmission pattern with a photocell underneath it. The sensor data may be used to measure the position of the mask with respect to the substrate table in six degrees of freedom (three in translation and three in rotation). In addition, the magnification and scaling of the projected mask may be measured. Since the sensor is preferably capable of measuring the pattern positions and influences of all illumination settings (sigma, lens NA, all masks (binary, PSM, etc.)) a small line width is preferable. The TIS may also be used to measure the optical performance of the tool. Different illumination settings are used in combination with different projected images for measuring properties such as pupil shape, coma, spherical aberration, astigmatism and field curvature.
An ILIAS is an interferometric wavefront measurement system that may perform static measurements on lens aberrations up to high order. It may be implemented as an integrated measurement system used for system initialization and calibration. Alternatively, it may be used for monitoring and recalibration “on-demand”.
In systems with high NA and in particular in immersion systems, it has been found that conventional sensors at substrate level suffer poor or no sensitivity to radiation arriving at angles corresponding to an NA of greater than 1. NA is defined as n·sin(θ) where n is the refractive index of the material between the last element of the projection system and the substrate and θ is the angle to the normal of the radiation furthest from the normal.
SUMMARY
It is desirable to provide a sensor at substrate level with high sensitivity and which is suitable for use in a high NA system.
According to an aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector; and
a luminescent layer provided on the back surface of the transmissive plate, the luminescent layer absorbing the radiation and emitting luminescent radiation of a different wavelength, wherein the back surface is rough.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector; and
a Fresnel lens provided on the back surface of the transmissive plate and arranged to couple radiation to the radiation detector.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector; and
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation that is projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector;
wherein a region of the transmissive plate through which the radiation passes has a gradient in its refractive index such that the radiation is refracted towards a normal to the back surface of the transmissive plate.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation that is projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector; and
an inverted Winston cone provided on the back surface of the transmissive plate and arranged to couple radiation to the radiation detector.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector; and
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector;
wherein the radiation detector is mounted directly onto the back surface of the transmissive plate.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector; and
a holographic optical element that is provided on the back surface of the transmissive plate and arranged to couple radiation to the radiation detector.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector;
a convex spherical lens being provided on the back surface of the transmissive plate; and
a cylindrical reflector surrounding the convex spherical lens and arranged to couple radiation exiting the convex spherical lens to the radiation detector.
According to a further aspect of the invention, there is provided a sensor for use at a substrate level in a lithographic projection apparatus having a projection system with a numeric aperture that is greater than 1 that is configured to project a patterned radiation beam onto a target portion of a substrate, the sensor comprising:
a radiation-detector;
a transmissive plate having a front surface and a back surface, the transmissive plate being positioned such that radiation projected by the projection system passes into the front surface of the transmissive plate and out of the back surface thereof to the radiation detector;
a cylindrical body being provided on the back surface of the transmissive plate and being arranged to couple radiation to the radiation detector, the cylindrical body having a reflective coating on its curved side surface and a concave recess in its end surface facing the sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:
FIG. 1 depicts a lithographic apparatus according to an embodiment of the invention;
FIGS. 2 and 3 depict a liquid supply system used in a prior art lithographic projection apparatus;
FIG. 4 depicts a liquid supply system according to another prior art lithographic projection apparatus;
FIG. 5 depicts a liquid supply system according to another prior art lithographic projection apparatus;
FIG. 6 depicts an ILIAS sensor module according to the prior art;
FIG. 7 depicts a sensor module according to an embodiment of the present invention;
FIG. 8 depicts radiation coupling into a luminescence layer without surface roughening;
FIG. 9 depicts radiation coupling into a luminescence layer with surface roughening;
FIG. 10 depicts another sensor module according to an embodiment of the present invention;
FIG. 11 depicts another sensor module according to an embodiment of the present invention;
FIG. 12 depicts another sensor module according to an embodiment of the present invention;
FIG. 13 depicts another sensor module according to an embodiment of the present invention;
FIG. 14 depicts another sensor module according to an embodiment of the present invention;
FIG. 15 depicts another sensor module according to an embodiment of the present invention; and
FIG. 16 depicts another sensor module according to an embodiment of the present invention.
In the Figures, corresponding reference symbols indicate corresponding parts.
DETAILED DESCRIPTION
FIG. 1 schematically depicts a lithographic apparatus according to one embodiment of the invention. The apparatus includes:
an illumination system (illuminator) IL configured to condition a radiation beam B (e.g. UV radiation or DUV radiation).
a support structure (e.g. a mask table) MT constructed to support a patterning device (e.g. a mask) MA and connected to a first positioner PM configured to accurately position the patterning device in accordance with certain parameters;
a substrate table (e.g. a wafer table) WT constructed to hold a substrate (e.g. a resist-coated wafer) W and connected to a second positioner PW configured to accurately position the substrate in accordance with certain parameters; and
a projection system (e.g. a refractive projection lens system) PL configured to project a pattern imparted to the radiation beam B by patterning device MA onto a target portion C (e.g. comprising one or more dies) of the substrate W.
The illumination system may include various types of optical components, such as refractive, reflective, magnetic, electromagnetic, electrostatic or other types of optical components, or any combination thereof, for directing, shaping, or controlling radiation.
The support structure supports, i.e. bears the weight of, the patterning device. It holds the patterning device in a manner that depends on the orientation of the patterning device, the design of the lithographic apparatus, and other conditions, such as for example whether or not the patterning device is held in a vacuum environment. The support structure can use mechanical, vacuum, electrostatic or other clamping techniques to hold the patterning device. The support structure may be a frame or a table, for example, which may be fixed or movable as required. The support structure may ensure that the patterning device is at a desired position, for example with respect to the projection system. Any use of the terms “reticle” or “mask” herein may be considered synonymous with the more general term “patterning device.”
The term “patterning device” used herein should be broadly interpreted as referring to any device that can be used to impart a radiation beam with a pattern in its cross-section such as to create a pattern in a target portion of the substrate. It should be noted that the pattern imparted to the radiation beam may not exactly correspond to the desired pattern in the target portion of the substrate, for example if the pattern includes phase-shifting features or so called assist features. Generally, the pattern imparted to the radiation beam will correspond to a particular functional layer in a device being created in the target portion, such as an integrated circuit.
The patterning device may be transmissive or reflective. Examples of patterning devices include masks, programmable mirror arrays, and programmable LCD panels. Masks are well known in lithography, and include mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. An example of a programmable mirror array employs a matrix arrangement of small mirrors, each of which can be individually tilted so as to reflect an incoming radiation beam in different directions. The tilted mirrors impart a pattern in a radiation beam which is reflected by the mirror matrix.
The term “projection system” used herein should be broadly interpreted as encompassing any type of projection system, including refractive, reflective, catadioptric, magnetic, electromagnetic and electrostatic optical systems, or any combination thereof, as appropriate for the exposure radiation being used, or for other factors such as the use of an immersion liquid or the use of a vacuum. Any use of the term “projection lens” herein may be considered as synonymous with the more general term “projection system”.
As here depicted, the apparatus is of a transmissive type (e.g. employing a transmissive mask). Alternatively, the apparatus may be of a reflective type (e.g. employing a programmable mirror array of a type as referred to above, or employing a reflective mask).
The lithographic apparatus may be of a type having two (dual stage) or more substrate tables (and/or two or more mask tables). In such “multiple stage” machines the additional tables may be used in parallel, or preparatory steps may be carried out on one or more tables while one or more other tables are being used for exposure.
Referring to FIG. 1 , the illuminator IL receives a radiation beam from a radiation source SO. The source and the lithographic apparatus may be separate entities, for example when the source is an excimer laser. In such cases, the source is not considered to form part of the lithographic apparatus and the radiation beam is passed from the source SO to the illuminator IL with the aid of a beam delivery system BD comprising, for example, suitable directing mirrors and/or a beam expander. In other cases the source may be an integral part of the lithographic apparatus, for example when the source is a mercury lamp. The source SO and the illuminator IL, together with the beam delivery system BD if required, may be referred to as a radiation system.
The illuminator IL may comprise an adjuster AD for adjusting the angular intensity distribution of the radiation beam. Generally, at least the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in a pupil plane of the illuminator can be adjusted. In addition, the illuminator IL may comprise various other components, such as an integrator IN and a condenser CO. The illuminator may be used to condition the radiation beam, to have a desired uniformity and intensity distribution in its cross-section.
The radiation beam B is incident on the patterning device (e.g., mask MA), which is held on the support structure (e.g., mask table MT), and is patterned by the patterning device. Having traversed the mask MA, the radiation beam B passes through the projection system PL, which focuses the beam onto a target portion C of the substrate W. With the aid of the second positioner PW and position sensor IF (e.g. an interferometric device, linear encoder or capacitive sensor), the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the radiation beam B. Similarly, the first positioner PM and another position sensor (which is not explicitly depicted in FIG. 1 ) can be used to accurately position the mask MA with respect to the path of the radiation beam B, e.g. after mechanical retrieval from a mask library, or during a scan. In general, movement of the mask table MT may be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which form part of the first positioner PM. Similarly, movement of the substrate table WT may be realized using a long-stroke module and a short-stroke module, which form part of the second positioner PW. In the case of a stepper (as opposed to a scanner) the mask table MT may be connected to a short-stroke actuator only, or may be fixed. Mask MA and substrate W may be aligned using mask alignment marks M 1 , M 2 and substrate alignment marks P 1 , P 2 . Although the substrate alignment marks as illustrated occupy dedicated target portions, they may be located in spaces between target portions (these are known as scribe-lane alignment marks). Similarly, in situations in which more than one die is provided on the mask MA, the mask alignment marks may be located between the dies.
The depicted apparatus could be used in at least one of the following modes:
1. In step mode, the mask table MT and the substrate table WT are kept essentially stationary, while an entire pattern imparted to the radiation beam is projected onto a target portion C at one time (i.e. a single static exposure). The substrate table WT is then shifted in the X and/or Y direction so that a different target portion C can be exposed. In step mode, the maximum size of the exposure field limits the size of the target portion C imaged in a single static exposure. 2. In scan mode, the mask table MT and the substrate table WT are scanned synchronously while a pattern imparted to the radiation beam is projected onto a target portion C (i.e. a single dynamic exposure). The velocity and direction of the substrate table WT relative to the mask table MT may be determined by the (de-)magnification and image reversal characteristics of the projection system PL. In scan mode, the maximum size of the exposure field limits the width (in the non-scanning direction) of the target portion in a single dynamic exposure, whereas the length of the scanning motion determines the height (in the scanning direction) of the target portion. 3. In another mode, the mask table MT is kept essentially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the radiation beam is projected onto a target portion C. In this mode, generally a pulsed radiation source is employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes programmable patterning device, such as a programmable mirror array of a type as referred to above.
Combinations and/or variations on the above described modes of use or entirely different modes of use may also be employed.
As shown in FIG. 5 , a liquid supply system is used to supply liquid to the space between the final element of the projection system and the substrate. The reservoir 10 forms a contactless seal to the substrate around the image field of the projection system so that liquid is confined to fill a space between the substrate surface and the final element of the projection system. The reservoir is formed by a seal member 12 positioned below and surrounding the final element of the projection system PL. Liquid is brought into the space below the projection system and within the seal member 12 . The seal member 12 extends a little above the final element of the projection system and the liquid level rises above the final element so that a buffer of liquid is provided. The seal member 12 has an inner periphery that at the upper end preferably closely conforms to the shape of the projection system or the final element thereof and may, e.g., be round. At the bottom, the inner periphery closely conforms to the shape of the image field, e.g., rectangular though this need not be the case.
The liquid is confined in the reservoir by a gas seal 16 between the bottom of the seal member 12 and the surface of the substrate W. The gas seal is formed by gas, e.g. air or synthetic air but preferably N 2 or another inert gas, provided under pressure via inlet 15 to the gap between seal member 12 and substrate and extracted via first outlet 14 . The overpressure on the gas inlet 15 , vacuum level on the first outlet 14 and geometry of the gap are arranged so that there is a high-velocity air flow inwards that confines the liquid.
FIG. 6 shows an ILIAS sensor module 20 according to the prior art. This module has a shearing grating structure 21 as a radiation-receiving element, supported by a transmissive plate 22 , which may be made of glass or quartz. A quantum conversion layer 23 is positioned immediately above a camera chip 25 (a radiation-detecting element), which is in turn mounted on a substrate 28 . The substrate 28 is connected to the transmissive plate 22 via spacers 26 and bonding wires 27 that connect the radiation-detecting element to external instrumentation. An air gap is located between the quantum conversion layer 23 and the transmissive plate 22 . In a setup such as this designed to be sensitive to 157 nm radiation, for example, the air gap within the sensor cannot easily be purged so that it will contain significant proportions of oxygen and water, which absorb radiation. As a result, signals may be lost. Due to the large difference in diffractive index between the quartz or glass sealing plate 22 and the air in the gap, the critical angle is small and radiation at larger angles to the normal, corresponding to NA>1, may be lost. In addition to signal loss, the sensitivity of the sensor may not uniform with angle of incidence.
FIGS. 7 to 15 depict improved substrate-level sensors according to embodiments of the invention. In the following embodiments, parts that are equivalent to parts of the sensor of FIG. 6 are identified by like reference numerals and a detailed description is omitted for conciseness.
In the embodiment of FIG. 7 , the quantum conversion (luminescent) layer 23 is positioned on the back surface of the transparent plate 22 , rather than on the front of the camera chip (radiation detecting element) 25 . As the quantum conversion layer has a higher refractive index than air, the critical angle is larger and less radiation is internally reflected in the transparent plate 22 . However, as shown in FIG. 8 , the material of the quantum conversion layer, which may be a phosphor, is porous, so there may be incomplete coverage of the back surface of the transparent plate 22 . Thus, more radiation is internally reflected in the transparent plate 22 than would be expected. The sensitivity of the sensor may be improved by making the back surface 22 a of the transparent plate 22 rough.
The roughness of surface 22 a has the effect that radiation propagating through the transparent plate encounters areas of the surface 22 a at a variety of angles. There is therefore a loss of transmission at angles close to the (global) normal but an increase in transmission at angles further from the global normal, as shown in FIG. 9 . The net effect is an increase in the uniformity of the sensor responsivity with incident angle. The diffuseness of the surface may cause some blurring of the image on the camera 25 , but this is acceptable especially if it is less than the pixel size, e.g. 25 μm, and can therefore be neglected. The camera 25 may therefore need to be close to or directly against the conversion layer 23 . Alternatively, a lens or fiber-optic bundle may be used to couple the radiation emitted by the conversion layer 23 to the camera without loss of spatial information.
The roughness of the surface 22 a can be created by any known method, including omitting final polishing steps in the manufacture of the plate.
The surface roughness should be such that the variation in slope across the surface is at least as large as the amount by which the NA is greater than 1, i.e. Δθ>sin −1 (NA−1). This ensures that a ray at the maximum NA will always have an angle of incidence less than the critical angle at some point on the surface.
The roughness RDq determined by a surface roughness tester should be larger than tan (sin −1 (NA−1)), e.g. in the range of from 0.1 to 0.5.
A further embodiment of the sensor 30 , shown in FIG. 10 , has a Fresnel lens 31 formed in the back surface 22 a of the transparent plate 22 . The Fresnel lens is designed such that all radiation passing through the aperture (e.g. pin hole or grating) in chrome layer 21 is incident at the quartz or glass/air interface at less than the critical angle. The Fresnel lens can be formed by many known techniques, e.g. lithographic patterning and etching.
A sensor 40 according to a further embodiment is shown in FIG. 11 and has a region 41 in the transparent plate behind the aperture (e.g. pin hole or grating) in chrome layer 21 that has a gradient in its refractive index. This can be created by locally selective doping of the quartz or glass material forming transparent plate 22 and makes it possible to arrange that all rays passing through the aperture are incident on the quartz/air interface at near normal angles.
FIG. 12 shows a further embodiment of a sensor 50 which uses an inverted Winston cone 51 to reflect all the rays so that they are incident on the bottom surface 52 at less than the critical angle, so there is no internal reflection and maximum transmission into the sensor 25 . A Winston cone is an off-axis parabola of revolution designed to maximize collection of incoming rays within some field of view and is described further in Winston, R. “Light Collection within the Framework of Geometric Optics.” J. Opt. Soc. Amer. 60, 245-247, 1970, which document is hereby incorporated by reference in its entirety. The Winston cone 51 in this embodiment is a solid piece of quartz or glass, preferably formed integrally with the transparent plate 22 , and has a reflective coating on its side surfaces 53 .
In sensor 60 , shown in FIG. 13 , the sensor 25 is mounted directly onto the back surface 22 a of the transparent plate 22 . For this purpose a glue that is stable under the radiation to be detected and has a refractive index close to that of the quartz or glass of the transparent plate 22 can be used.
A further sensor 70 , show in FIG. 14 , uses a holographic element 71 located on the back surface of transparent plate 22 , to direct radiation onto the sensor 25 . The holographic pattern required can readily be made by known techniques. A diffractive optical element may be used instead.
As shown in FIG. 15 , a sensor 80 according to a further embodiment has a convex spherical lens 81 formed in the back surface of transparent plate 22 and a reflective cylinder 82 to direct radiation to the sensor 25 . The spherical lens 81 has its center close to the aperture in the chrome layer 21 so that the angles of incidence at the quartz/air interface are near normal for all rays.
The spherical lens 81 is preferably formed integrally with the transparent plate but may also be formed as a separate body and attached using a suitable glue, i.e. one that is stable under the exposure radiation and has a refractive index close to that of the lens.
However, the cylindrical reflector 82 is preferably made as a separate body and attached to the transparent substrate or sensor thereafter. This is because the requirements on the manner and accuracy of its attachment are considerably less strict than those on its shape.
In the embodiment of FIG. 16 , the sensor 90 has a cylindrical projection 91 provided on the rear side of the transparent plate 22 . The distal end of the projection has a concave cut-away shape, forming a lens. The outer surface 93 of the projection 91 is polished and coated to increase its reflectivity. The concave surface may also be coated to increase its transmissivity. As shown in the figure, radiation can reach the sensor 25 by one of three routes. At small angles to the normal, the radiation will pass directly through the concave surface 92 to reach the sensor 25 . At larger angles to the normal, the radiation will be internally reflected at the concave surface 92 and be reflected by the side surface 93 back on to the concave surface 92 , which it will pass through to reach the sensor. At still larger angles to the normal, the radiation will be reflected by the side surface 93 to pass through the concave surface 92 and thence to the sensor.
Although a luminescence, or quantum conversion, layer has not been shown in the embodiments of FIGS. 11 to 16 , one may be provided as convenient on the sensor or elsewhere. It will also be appreciated that features from the different embodiments of the invention may be combined.
The radiation-receiving element may comprise a grating and or an element having a pinhole, depending on the function of the sensor.
The sensors may be located at the level of the substrate and in particular such that the radiation-receiving element 21 is at substantially the same distance from the final element of the projection system as the substrate W.
Although specific reference may be made in this text to the use of lithographic apparatus in the manufacture of ICs, it should be understood that the lithographic apparatus described herein may have other applications, such as the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, flat-panel displays, liquid-crystal displays (LCDs), thin-film magnetic heads, etc. The skilled artisan will appreciate that, in the context of such alternative applications, any use of the terms “wafer” or “die” herein may be considered as synonymous with the more general terms “substrate” or “target portion”, respectively. The substrate referred to herein may be processed, before or after exposure, in for example a track (a tool that typically applies a layer of resist to a substrate and develops the exposed resist), a metrology tool and/or an inspection tool. Where applicable, the disclosure herein may be applied to such and other substrate processing tools. Further, the substrate may be processed more than once, for example in order to create a multi-layer IC, so that the term substrate used herein may also refer to a substrate that already contains multiple processed layers.
The terms “radiation” and “beam” used herein encompass all types of electromagnetic radiation, including ultraviolet (UV) radiation (e.g. having a wavelength of or about 365, 248, 193, 157 or 126 nm).
The term “lens”, where the context allows, may refer to any one or combination of various types of optical components, including refractive and reflective optical components.
While specific embodiments of the invention have been described above, it will be appreciated that the invention may be practiced otherwise than as described. For example, the invention may take the form of a computer program containing one or more sequences of machine-readable instructions describing a method as disclosed above, or a data storage medium (e.g. semiconductor memory, magnetic or optical disk) having such a computer program stored therein.
The present invention can be applied to any immersion lithography apparatus, in particular, but not exclusively, those types mentioned above.
The descriptions above are intended to be illustrative, not limiting. Thus, it will be apparent to one skilled in the art that modifications may be made to the invention as described without departing from the scope of the claims set out below. | A sensor for use at substrate level in a high numerical aperature lithographic apparatus, the sensor having a transparent plate that covers a sensing element and includes elements that improve coupling of radiation into the sensing element. The elements include Fresnel lenses, holographic optical elements, inverted Winston Cones, spherical lenses and surface roughening. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to accidental needle stick protective devices, more specifically to needle sticks protecting devices applicable to the Manual Catheter Placement Device of patent application Ser. No. 08/249,161, filed on May 24, 1194 and now U.S. Pat. No. 5,527,291.
2. Background--Description of Prior Art
Needle sticks among health care workers are not uncommon. Numerous diseases have been proved to be transmitted via needle sticks: hepatitis, malaria, syphilis, AIDS. Risks of transmission are inherent to the medical profession and prevention cannot be achieved only with heightened awareness, education or application of strict guidelines to avoid accidental needle stick punctures. Nothing could be more successful in reducing if not eliminating the risk of transmission of the above mentioned diseases than safe medical devices which prevent contacts of health care workers with contaminated sharps.
A search in the patent office revealed numerous protective devices for the exposed needle tips of hypodermic needles. Two are the basic types of needle sticks protecting devices.
In one type of devices the needle is retracted within a protective shield, manually or by resilient means. In the other group a sleeve or guard is described which is advanced over the needle manually or by resilient means. Locking of the sleeve or guard in respect to the needle and shielding of the needle tip is achieved in either group via various different mechanisms.
However no known protective mechanism has been described for the Manual Catheter Placement Device described in U.S. Pat. No. 5,527,291.
BRIEF SUMMARY OF THE INVENTION
The unique characteristics of the Manual Catheter placement Device described in the above mentioned patent application demand unique solutions for the shielding of the needle tip of the Manual catheter Placement Device.
The Manual Catheter Placement Device is a vascular access device composed of a needle, a catheter concentric with the needle, a housing, means for manually creating vacuum within said housing to accelerate backflow of blood upon occurred blood vessel penetration by the needle tip, means for manually advancing the catheter, said means for manually advancing the catheter being actuated by the means for accelerating backflow of blood.
The Manual Catheter Placement Device permits insertion of the catheter of a catheter-needle assembly into a blood vessel as a smooth continuum process in which penetration of the needle tip into the blood vessel is immediately followed, practically without any pause, by advancement of the catheter into the blood vessel as the means for manually advancing the catheter are actuated by the means for accelerating backflow of blood.
The advantage of the device over the prior art are self-evident: overpenetration and or loss of engagement of the needle tip with the vessel are practically eliminated.
In the embodiments described in the above named patent application, an interface member is interposed between the manual means of accelerating backflow of blood i.e. a displaceable piston, and the catheter. Upon blood vessel penetration by the needle tip, the vacuum creating piston is displaced posteriorly by the operator acting on a handle connected to it. Such posterior displacement of the piston initiates, causes and sustains simultaneous forward displacement of said interface member which in turn carries forward the catheter into the blood vessel.
In the present invention, "Needle Stick Protector for Manual Catheter Placement Devices" the interface member has the dual function of propelling forward the catheter and of shielding the needle tip. Indeed the interface member front portion, interfacing with the catheter hub, is slideable over the needle up to its tip with the purpose of enclosing and shielding it once fully advanced. Shielding of the needle tip is therefore accomplished by advancement of the interface member front portion, such an advancement being initiated and sustained by the posterior displacement of the vacuum creating means occurring upon blood vessel penetration by the needle tip.
Shielding of the needle tip can be accomplished in one step or in two consecutive steps. Indeed the front portion of the interface member accomplishing the dual function of propelling forward the catheter and of shielding the needle tip can be advanced in one single stroke up to the needle tip by a corresponding full posterior displacement of the vacuum creating means, i.e. a piston, or can be accomplished in two steps via manually displacing forward up to the needle tip the front portion of the interface member after its initial advancement caused by the posterior displacement of the piston has stopped.
The needle protection is completed by the locking of the interface member on the Manual Catheter Placement Device upon full advancement of the interface member to a position which permits enclosing, therefore shielding, of the needle tip by the needle guard carried by the front plate of interface member.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide the Manual Catheter Placement Device with a safe and effective method for needle protection.
It is also an object of the present invention to provide the Manual Catheter Placement with a needle protective mechanism which is initiated upon blood vessel penetration by the needle of the manual catheter placement device.
It is also an object of the present invention to provide the Manual Catheter Placement Device with a needle protective mechanism that is simple to operate being actuable with only one hand.
It is an object of the present invention to provide the Manual Catheter Placement Device with a needle protection which does not allow exposure of the needle tip to the environment at any time after tissue penetration.
It is also an object of the present invention to provide the Manual Catheter Placement Device with a needle coverage mechanism that, by not exposing the needle tip after tissue penetration, makes the manual catheter placement device a closed system device, as the blood is not being exposed once the blood vessel has been penetrated.
DRAWING FIGURES
FIG. 1 a side view of the Manual Catheter Placement device at rest prior to use, provided with the needle stick protector.
FIG. 1A is across sectional view of the device at rest prior to use.
FIG. 2 is a side view of part of the device of FIG. 1, precisely of the needle protector connected to the interface member.
FIG. 3 is a magnified view of the front portion of the device.
FIG. 1B is a cross sectional view of the device of FIG. 1 shown in use, armed, after skin penetration by the needle, prior to blood vessel penetration.
FIG. 1C is cross sectional view of the device of FIG. 1 shown in use, at the an early stage of operation, after blood vessel penetration.
FIG. 1D is cross sectional view of the device of FIG. 1 shown in use in a later stage of operation, showing the initial advancement of the interface member with its needle protector propelling the catheter forward.
FIG. 1E is cross sectional view of the device of FIG. 1 shown in use, in a subsequent stage of operation, showing the catheter hub disengaging from the interface member.
FIG. 1F is cross sectional view of the device of FIG. 1 shown in use, in a subsequent stage of operation, showing the needle protector, fully advanced manually by the operator, enclosing the needle tip and locked to the device. The catheter is also shown fully advanced.
FIG. 1G is cross sectional view of the device of FIG. 1 shown in use, in a subsequent stage of operation, showing the manual catheter placement device being withdrawn from the catheter, with the needle protector needle protector enclosing the needle tip and locked to the device.
DESCRIPTION OF THE INVENTION
In the form of the present invention chosen for the purpose of illustration, a needle stick protective apparatus for the Manual Catheter Placement Device of patent application Ser. No. 08/249,1610 now issued U.S. Pat. No. 5,527,291 is shown in FIGS. 1, 1A through 1G, 2 and 3.
FIG. 1 is a side view of a Manual Catheter Placement Device with its Needle Stick Protector The device generally indicated at 1, is shown prior to use. The Manual Catheter Placement Device, here illustrated, to which the needle stick protector is applied to it, is basically the same as the device shown in FIG. 1 through 9 of Patent Application Ser. No. 08/249,1610 now issued U.S. Pat. No. 5,527,291. The manual catheter placement device with its needle protector is composed of four main components: a housing 2, a needle 4, a catheter 5 and a needle stick protector 60, partially visible in FIG. 1, but fully visible in FIG. 2, 3 and in cross section in FIG. 1A through 1G.
FIG. 1A is a cross-sectional view of the device of FIG. 1 shown at rest. Housing 2 is composed of two parallel chambers of generally cylindrical shape: piston chamber 8 and interface member chamber 10, separated longitudinally by divider wall 9. Piston chamber 8 delimited laterally by sidewall 7, is composed of an anterior or vacuum chamber 12 in communication with hollow needle 4 via opening 11 and posterior chamber 14 of larger diameter than vacuum chamber 12. Piston chamber 8 is closed posteriorly by wall 20. Posterior chamber 14 is in continuity with vacuum chamber 12 via opening 18. Posterior wall 20 is formed with semicircular groove 15 for flexible slideable band or engagements means 16. Flexible slideable band or engagements means 16 is interposed between posterior segment 24 of piston 17, slideably mounted within piston chamber 8, and interface member 44, as it will be apparent from the description below.
Piston, or manually driven vacuum creating means, or blood backflow accelerating means, 17 is composed of two segments: an anterior segment 22, which, prior to use, is in a fully advanced position within chamber 12, and just described posterior piston segment 24 of larger diameter, contained within posterior piston chamber 14. Anterior piston segment 22 has an annular groove 25 formed in proximity of front piston segment 23, where O-ring 26 is mounted in airtight and slideable fashion within side walls 28 of piston chamber 12. Posterior piston segment 24, in continuity with anterior piston segment 22 is slideably mounted in posterior chamber 14. As better seen in FIG. 1, side wall 7 of piston chamber 8 has a lateral slit 19 for arm 30 of side piston handle 32 connected via said arm 30 to posterior piston segment 24 of piston 17. Slit 19 permits the sliding of piston, or vacuum creating means, or blood backflow accelerating means, 17 by the operator acting upon said side piston handle 32.
Piston 17 may also be designed as a piston plunger such as a syringe plunger wherein the operator withdraws the piston by pulling back the plunger. However, the described piston version 17 with side handle 32 is preferable, being designed to render manual withdrawal of piston 17 via displacement of side handle 32 an easy and convenient operation for the operator's hand holding the device, averting the use of two hands, which is likely to occur in the mentioned version with the plunger.
Interface member chamber 10, of generally cylindrical shape, delimited laterally by side wall 40, is open anteriorly via opening 42 while posteriorly receives groove 15 via opening 47. Within groove 15 is slideably mounted, as already described, flexible band or engagement means 16. Flexible band or engagement means 16 is formed with lower end 37 for engagement with posterior aspect 50 of posterior segment 24 of piston 17, and upper end 38 engaging oblique surface 57 of slanted portion of latch 52 as below described. Within chamber 10 is slideably mounted interface member 44. Side wall 40 of interface member chamber 10 is formed posteriorly with window 54 for latch 52, and anteriorly with flexible arrest tab or locking means 53 for the prevention of rearward sliding of the interface member and front arrest, or locking means 43 for the prevention of forward sliding of the interface member.
Latch 52 is pivoted to wall 40 of interface member chamber 10 via flexible pivot 56, and has oblique surface 57 which engages flange 58 of upper end 38 of flexible band 16 and recess 59 which engages arrest tooth 49 of interface member 44. Flexible arrest tab 53 in the anterior portion of intermediate member chamber 10 is pivoted to intermediate member chamber 10 via flexible pivot 46.
As better shown in FIG. 2, interface member 44 of general cylindrical shape to slideably fit chamber 10, is composed of body segment 48 and front portion or needle protector or catheter propelling member 60. As described above, body 48 of interface member 44 has, at its proximal end, arrest tooth 49, slideable, as shown in FIG. 1B, 1C, 1D, within groove 41 of side wall 40 of intermediate member chamber 10, up to arrest 43. As better shown in FIG. 3, front portion or needle protector 60 of interface member 44 is composed of plate 61 to which is connected, in its antero-inferior segment, needle guard or propelling sleeve 74 via arm or bridge 86. Plate 61 is formed with opening 76 to accommodate needle hub 33, with flat seating 78 adapted to base 80 of catheter hub 34, with semicircularly shaped hook 82 to releasably engage flange 84 of catheter hub 34 and, superiorly, with tab or handle 62. As shown in FIG. 1A and better in FIG. 2, propelling sleeve or guard 74 is of generally truncated conic shape in order to fit within catheter hub 34 in front of needle hub nozzle 35 of needle hub 33.
Needle hub 33 protrudes from anterior end 36 of housing 2. Needle hub 33 has base 51 which precisely fits within catheter hub 34 of catheter 5 and has nozzle 35 in continuity with needle hub base 51 to allow adequate radial leeway for release of catheter hub 34 of catheter 5 from hook 82 of plate 60 of intermediate member 44, when catheter 5 is advanced, as it will be evident in the description of the operation. Housing 2 has a slant 55 in its antero-inferior segment to facilitate the direction of insertion of needle 4 into a vessel lumen.
Hollow needle 4 has tip 3 and protrudes from needle hub 33 as previously described. Catheter 5 and catheter hub 34 are slideably mounted respectively over needle 4 and needle hub 33. Catheter hub 34 has flange 84 releasably engaged with hook 82 of plate 60 with the device at rest prior to use.
DESCRIPTION OF THE OPERATION
The device is operated as follows: as shown in FIG. 1A the operator with the device in his or her hands penetrates the skin 66 of a patient with needle tip 3. The device with its needle is advanced within the subcutaneous tissue 67 toward a presumed location of a blood vessel 68 in an area of expected blood vessel location.
Searching for a vessel may require multiple attempts with frequent repositioning of the needle within the subcutaneous tissue. The searching for the vessel indeed may require partial or full withdrawing of the device with its needle attached to it from the skin and reinserting it into the skin. In case the device needs to be withdrawn during said blood vessel search, catheter 5 will be withdrawn concurrently with the device together with needle 4, remaining firmly connected to the device. Indeed interface member 44 will not be allowed to dislodge from it starting fully retracted position by latch 52 engaging arrest tooth 49 of interface member 44 and it will also retain catheter 5 connected to interface member 44 via hook 82 of plate 61 of interface member 44, said hook 82 engaging flange 84 of catheter 5.
As soon as needle tip 3 is well under skin 66, the operator acts upon handle 32 of piston 17 by sliding it posteriorly through slit 19 of side wall 7 of piston chamber 8. The operator can use any finger of the operating hand. Posterior displacement of piston 17 will create a vacuum in front of anterior piston segment 22 in vacuum chamber 12. However posterior displacement of piston 17 will be of a small amount, being limited by the sealing of needle tip 3 caused the patient tissues, as the operator senses the resistance caused by said vacuum.
As shown in FIG. 1C, as soon as needle tip 3 penetrates blood vessel 68, blood backflows into vacuum chamber 12 in front of anterior piston segment 22 in an accelerated fashion. Piston 17 will be no longer retained in an advanced position due to the vanishing of the vacuum in front of anterior piston segment 22. The operator sensing the fall of resistance to the continuous withdrawing force applied upon piston 17 via said piston handle 32, said fall of resistance occurring upon blood vessel penetration, will displace piston 17 further posteriorly. Piston 17, displaced posteriorly by the operator, will contact band 16 via posterior face 50 of posterior segment 24 of piston 17 engaging lower end 37 of band 16, band 16 being spaced a predetermined amount from posterior face 50 of posterior segment 24 of piston 17.
As shown in FIG. 1D, further posterior displacement of piston 17 on its turn will displace flexible band or engagement means 16 slideable within groove 15. Displacement of band 16, slideable within groove 15 will result in lifting of latch 52 as a result of sliding of flange 58 of upper end 38 of band 16 on oblique surface 57 of slanted portion of latch 52. Lifting of latch 52 will result with dislodging of recess 59 of latch 52 from tooth 49 of interface member 44 and consequent unlocking interface member 44. Further advancement of band 16 will propel forward interface member 44 which in turn will insert catheter 5 forward into vessel 68. During said advancement, hook 82, as shown in FIG. 1D, maintains its engagement with flange b4 of catheter hub 34 and retains catheter 5 firmly attached to the device, not allowing separation of the catheter hub 34 from front portion 60 of the interface member 44 even in case of withdrawal of the device.
Catheter 5 is propelled forward by flat seating 78 of plate 60 adapted to base 80 of catheter hub 34 and by propelling sleeve or needle guard 74. Hook 82 continues to engage with flange 84 of catheter hub 34 for a limited predetermined amount of advancement of interface member 44 while catheter hub 34 slides over base 51 of needle hub 33 due to the fact that base 51 fits exactly within catheter hub 34 in a way to prevent radial leeway and consequent disengagement of flange 84 of catheter hub 5 from hook 82 of plate 61.
As shown in FIG. 1E, when catheter hub 34 is furtherly advanced over nozzle 35 of needle hub 33, adequate radial leeway is allowed for catheter hub 34 to disengage from hook 82 of plate 61, permitting disengagement of catheter 5 from propelling sleeve or needle guard 74. Interface member advancement by band 16 will cease as soon as piston 17 is fully displaced posteriorly by the operator. Further advancement of interface member 44 will complete the forward sliding motion of interface member 44 initiated by vacuum creating means 17, and is accomplished with the purpose of enclosing needle tip 3 with needle guard 74. In this embodiment further advancement of interface member 44 is carried out by manually advancing interface member 44 by acting upon tab 62.
FIG. 1F shows the needle protector, fully advanced manually by the operator, enclosing the needle tip and locked to the device. The catheter is also shown fully advanced.
FIG. 1G shows the manual catheter placement device being withdrawn from the catheter, with the needle protector needle protector enclosing the needle tip and locked to the device.
Arrest and locking of propelling sleeve or needle guard 74 in advanced position beyond needle tip 3 for the purpose of needle tip shielding is achieved by the fact that interface member 44 will not be allowed to move in either direction, neither forward nor backward, respectively by arrest 43 and locking means 53 engaging tooth 49.
Indeed engagement of arrest tooth 49 of interface member 1044 with front arrest 43 will not permit further forward advancement of intermediate member 44 or eventual exit of interface member 44 from interface member chamber 10 while flexible tab or locking means 53 will not permit posterior displacement of interface 44 in respect to housing 2.
The enclosing of needle tip by the propelling sleeve or needle guard 74 of the interface member 44 for the purpose of protection from needle sticks is therefore, in the embodiment described, manually accomplished by manual forward sliding of interface member by the operator pushing forward tab or handle 62 of plate 60 of interface member 44, after the initial advancement of catheter 5 by interface member 44 to a predetermined length, in response to vanishing of the vacuum as described above.
In another embodiment, not illustrated, interface member 44 can be fully advanced in a single step by the presence a longer flexible band associated with an elongated backward riding of the piston. Band 16 can indeed be construed of such a length so as to permit full advancement of interface member 44 in one single stroke up to the needle tip 3. Needle tip 3 will be thus enclosed by needle guard or propelling sleeve 74 upon advancement of interface member 44, said advancement being not only initiated but also sustained from beginning to end by rearward displacement of piston or vacuum means 17. In such embodiments no second manual step is thus required to complete the advancement of needle protector 60. Locking of interface member in a fully advanced position is achieved exactly in the same manner as in the embodiments previously described.
After the initial manual predetermined advancement, which is enabled by the vacuum creating means in response to the vanishing of the vacuum, is completed, further advancement of needle protector 60 connected to interface member 44, can also be accomplished by resilient means such as a spring, which can propel needle protector 60 further forward, up to needle tip 3 of needle 4 with the purpose of enclosing it.
Obviously, numerous other variations and modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention described above and shown in the figures of the accompanying drawings are illustrative only and are not intended to limit the scope of the present invention. | A needle stick protective apparatus for medical devices having a hollow needle with a sharp tip, a vacuum chamber in flow communication with the hollow needle and a vacuum creating piston-plunger. The apparatus includes an interface member having a rear arm for engaging the piston-plunger and a front portion plate with a needle guard slideable over the needle up to the needle tip to enclose it and to irreversibly lock upon enclosure of the needle tip, shielding the needle tip to provide protection against needle sticks. The sliding of the needle guard over the needle is initiated and sustained, and in certain embodiments is completed, by posterior displacement of the vacuum creating piston-plunger engaged with the arm of the interface member upon blood vessel penetration by the needle. An engagement member converts the rearward displacement of the piston-plunger into a forward displacement of the interface member with the needle guard up to the needle tip. The piston-plunger is manually displaceable to enable a manually driven advancement of the needle guard over the needle upon blood vessel penetration by the needle tip, by acting on the handle of the piston-plunger away and at a safe distance from the needle tip. | 0 |
FIELD OF THE INVENTION
The present invention relates to a process for preparing a carboxylic acid.
BACKGROUND OF THE INVENTION
The oxidative cleavage of olefins may generally take place in a single step or in two steps, either directly from olefins, or after a prior hydroxylation step of these compounds.
In general, these processes are known to be often hazardous, toxic and difficult to perform due to the presence of toxic solvents, oxidizing agents and/or catalysts, which are difficult to recycle and/or flammable and hazardous.
In neighboring technologies, the oxidative cleavage of various vicinal diols, especially of dihydroxylated stearic acid, uses a catalyst (gold) supported on alumina, in an oxidizing medium, as is described by Kockritz et al. (Eur. J. Lipid Sci. Technol. 2012, 114, 1327-1332).
Mention may also be made of processes for producing carboxylic acids from vicinal diols using Na 2 WO 4 as catalyst (Santacesaria et al. Catalysis Today, 2003, 79-80, pages 59-65).
However, these carboxylic acid preparation processes are known to be hazardous, difficult to perform and to require the use of catalysts that are often toxic, expensive and difficult to recycle, or that require the use of one or more solvents.
There is thus a need to develop novel technologies allowing the oxidative cleavage of diols for the purpose of obtaining carboxylic acids, which are less difficult to perform, have good (high) degrees of conversion, are economically accessible and are more environmentally friendly.
SUMMARY OF THE INVENTION
The aim of the present invention is thus to develop a novel method that is easier to perform, using compounds that are more environmentally friendly and/or less expensive.
To this end, the subject of the invention is a process for preparing carboxylic acid comprising a step of placing at least one vicinal diol or at least one vicinal polyol in contact with an atmosphere comprising oxygen, a catalyst and in the absence of additional solvent, the catalyst having the formula I below:
[Al n Si m O p M q ][A] r (I)
in which:
n, m and q are natural integers ( ), which may be identical or different, chosen, independently of each other, such that n, m and q may simultaneously be equal to 0; p is a nonzero natural integer ( *); r is zero or equal to 1; M corresponds to at least one chemical element chosen from zirconium, tungsten, titanium and rare-earth metals, and A corresponds to at least one chemical element chosen from alkaline-earth metals, alkali metals, rare-earth metals and titanium.
Advantageously, the invention relates to the abovementioned process, in which said catalyst is not Na 2 WO 4 .
In one of the aspects, a subject of the invention is an abovementioned process for preparing carboxylic acid, in which M is not tungsten. In other words, in this aspect, M corresponds to at least one chemical element chosen from zirconium, titanium and rare-earth metals.
Another aspect of the invention relates to an abovementioned process in which the catalyst is free of transition metals.
The process according to the invention has the advantage of not using additional solvents, which makes it possible to reduce the reaction costs, to limit the risks of pollution of the environment and/or to reduce the hazardousness of the reaction.
In addition, the process according to the invention has the advantage of not using, as cocatalyst, any metals other than those envisaged mentioned as compounds A. Generally, these other metals are expensive and difficult to recycle. Thus, the use of a catalyst of formula (I) which is sufficient in itself makes it possible to reduce the costs associated with the reaction and/or to reduce the impact on the environment.
Advantageously, the atmosphere comprising oxygen is an atmosphere enriched in oxygen or constituted of oxygen. In this atmosphere, oxygen is advantageously in the form of dioxygen.
Even more advantageously, the atmosphere containing oxygen is ambient air or is an atmosphere comprising an amount of oxygen at least equal to that present in ambient air (i.e. about 20% of the gas volume).
Typically, in this reaction, oxygen is the oxidizing agent for the reaction.
The use of oxygen in the air as oxidizing agent has the advantage of reducing the hazardousness of the reaction and of not resorting to an addition of additional oxidizing products that might be toxic to the environment.
An advantageous aspect of the invention is thus a process not using any oxidizing agent other than oxygen contained in air or a gaseous mixture of equivalent hazardousness.
The element A contained in the catalyst corresponds to a chemical element or to a group of chemical elements selected from alkaline-earth metals and alkali metals (groups 1 and 2 of the Periodic Table of the Elements).
The alkali metals are lithium, sodium, potassium, rubidium, cesium and francium.
The alkaline-earth metals are beryllium, magnesium, calcium, strontium, barium and radium.
In a nonexhaustive manner, the rare-earth metals are cerium, scandium, yttrium, lanthanum, praseodymium, neodymium, europium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium and lutetium.
Advantageously, M is an element or a group of elements chosen from zirconium, tungsten, titanium, hydrogen, an element among the rare-earth metals listed above or a mixture thereof. Advantageously, A is an element or a group of elements chosen from sodium, calcium, magnesium, beryllium, potassium or a mixture thereof.
Advantageously, the catalyst of formula (I) always comprises at least one oxygen atom and may be in hydrated form, i.e. also comprising in the general formula (I) at least one water molecule.
The term “solvents” means organic compounds comprising at least one carbon atom and inorganic compounds free of carbon which have the capacity of dissolving or diluting at least one of the products used or obtained via the process of the invention.
The expression “absence of solvent” should be understood in its most common sense as not excluding the presence of a minimum amount of solvent, or “trace”. Such an amount may be quantified, for example, as being less than or equal to 1% by mass of the reaction medium, preferably less than 0.1%. The reaction is preferably performed in the absence of additional solvent, i.e. without adding organic solvent or inorganic solvent, including water.
According to another advantageous aspect of the invention, the process may lead to the formation of solvent during the reaction: in such a case, the solvent obtained is not additional solvent.
According to an advantageous embodiment of the invention, the catalyst is an alumina or aluminum oxide, a silica, a zirconia, an aluminosilicate, a zeolite, an acidic clay or a mixture thereof or a mixed oxide formed from a solid solution or a mixture of solid solutions.
Aluminum oxide or alumina has the chemical formula Al 2 O 3 . It exists in the natural state and is commercially available for sale, especially from the company Sigma-Aldrich, under the reference A6139 ALDRICH.
Silica, of chemical formula SiO 2 , is a material that is very abundant in nature in the form of quartz, and is commercially available for sale, especially from the company Sigma-Aldrich, under the reference 381276 ALDRICH.
Zirconia is a ceramic of formula ZrO 2 which may be obtained via standard sintering or plasma projection processes. It is also commercially available for sale from the company Sigma-Aldrich, under the reference 230693 ALDRICH.
Aluminosilicates include several materials of varied formulae, corresponding to the class of minerals containing aluminum oxide and silica oxide. For example, mention may be made of andalusite, sillimanite, kayanite, topaz or beryl. Andalusite, sillimanite and kayanite have the same composition and have the formula Al 2 O(SiO 4 ), whereas topaz has a similar chemical composition corresponding to Al 2 O(SiO 4 )(OH,F) 2 . Beryl, of formula Be 3 Al 2 (Si 6 O 18 , containing (SiO 3 ) 6 rings), is also known under the name aquamarine. Hydrated aluminum silicates of the kaolinite group having the formula Al 2 Si 2 O 5 (OH) 4 and generally having a three-dimensional structure in tetrahedral and/or octahedral leaflets such as dickite Al 2 Si 2 O 5 (OH) 4 , endelite Al 2 Si 2 O 5 (OH) 4 .2(H 2 O), halloysite Al 2 Si 2 O 5 (OH) 4 , kaolinite Al 2 Si 2 O 5 (OH) 4 , nacrite Al 2 Si 2 O 5 (OH) 4 , and odinite (Fe,Mg, Al,Fe,Ti,Mn) 2.5 (Si,Al) 2 O 5 (OH) 4 , may also be found under this name.
Zeolites are microporous minerals belonging to the group of silicates, subgroup of tectosilicates in which they form a family comprising hydrated aluminosilicates of metals, from groups 1 and 2 of the Periodic Table of the Elements (such as calcium, magnesium or potassium). Zeolites are constituted of SiO 4 and AlO 4 tetrahedra, linked together via oxygen atoms. These bonds must satisfy Loëwenstein's rule, namely that the same oxygen cannot be bonded to two aluminum atoms.
They include several materials of varied chemical formulae comprising the following common backbone, in which x1 to x9 are positive or zero integers: Na x1 Ca x2 Mg x3 Ba x4 K x5 [Al x6 Si x7 O x8 ], x9H 2 O.
These materials are thus hydrates of formula (I) according to the invention in which A corresponds to a group of elements [Na x1 Ca x2 Mg x3 Ba x4 K x5 ], x1, x2, x3, x4 and x5 being nonzero integers, and in which n=x6, m=x7, p=x8 and q=0.
Zeolites may be of natural or synthetic origin.
As nonlimiting examples of natural zeolites, mention may be made of: zeolites of the analcime family (analcime, pollucite), zeolites of the chabazite family (faujasite, chabazite, epistilbite), zeolites of the gismondine family (gonnardite), zeolites of the harmotome family (harmotone, phillipsite), zeolites of the heulandite family (heulandite, laumontite), zeolites of the natrolite family (natrolite, mesolite), zeolites of the stilbite family (barrerite, stilbite) or undetermined zeolites (tetranatolite).
As nonlimiting examples of synthetic zeolites, mention may be made of: zeolite “A” or LTA, zeolites “Y”, faujasite “X”, zeolite ZSM-5, mordenite or ferrierite. The processes for preparing a good number of synthetic zeolites are well known and many zeolites are commercially available for sale, for example zeolites Y (referenced CBV500, CBV712, CBV720, CBV760, CBV790) and mordenite (reference CP811G-300) are sold by the company Zeolyst International.
The mixed oxides are advantageously constituted of a simple oxide Al 2 O 3 , TiO 2 , SiO 2 , ZrO 2 and of a metal oxide MO x , with M and x as described previously.
A mixture of solid solution is advantageously constituted of at least one solid solution, a solid solution being a mixture of elements at the atomic scale, similar to a mixture of liquids that are mutually soluble, for example a solidification of a liquid mixture of two pure metals A and B (or of one metal and of a nonmetallic element) whose analysis may be performed by means of a phase diagram, to obtain a binary alloy AB generally constituted in the solid state of an aggregate of one or more species of crystals. The crystals are themselves formed from mixtures of two atomic species A and B, known as solid solutions.
In yet another advantageous embodiment, the invention relates to the process described above, in which the catalyst is aluminum oxide, alone.
Thus, in an advantageous embodiment, the invention relates to a process for preparing carboxylic acid comprising a step of placing at least one vicinal diol or at least one vicinal polyol in contact with an atmosphere comprising oxygen, a catalyst and in the absence of additional solvent, the catalyst being alumina or silica, especially calcined silica.
According to another advantageous embodiment of the invention, the catalyst used is silica or zirconia.
Thus, the process according to the invention allows the preparation of carboxylic acids in a single step using aluminum oxide as catalyst, without resorting to the use of a metal also having catalytic activity, not included in element A, such as gold or ruthenium. In other words, the process according to the invention does not comprise any catalyst based on gold or ruthenium. Besides its great availability, alumina oxide is an inexpensive, nontoxic compound which can be recycled via techniques that are easy to perform, known to those skilled in the art.
The term “vicinal diol” means any compound having a carbon-based structure of varied, linear, branched or cyclic nature, bearing at least two successive hydroxyl groups, a vicinal diol being a diol in which the hydroxyl groups are borne by adjacent carbons.
The catalyst used in the process of the invention advantageously has a specific surface area of from 50 to 200 m 2 /g, preferably from 100 m 2 /g to 175 m 2 /g, more preferentially 150 m 2 /g.
According to a particular aspect of the invention, the catalyst may be in basic, neutral or acidic form, preferably in basic or acidic form respectively of formula (I) [Al n Si m O p M q ] [A] r − for the basic form and [Al n Si m O p M q ] r + for the acidic form.
The catalyst then undergoes a standard treatment for obtaining such a basic or acidic form.
According to a particular aspect of the invention, the catalyst may be in basic, neutral or acidic form, preferably in basic or acidic form respectively of formula (I) [Al n Si m O p Zr q ] [A] r − for the basic form and [Al n Si m O p Zr q ] [A] r + for the acidic form. According to another aspect of the invention, the catalyst may be calcined or non-calcined. The calcined catalyst results from gradual or non-gradual intense heating of the material exposed to temperatures ranging from 150 to 600° C.
The process of the invention may optionally comprise an additional prior step of hydroxylation of an unsaturated olefin making it possible to obtain the vicinal diol or the vicinal polyol required for the process according to the invention.
For example, it is possible to perform this step of hydroxylation of an unsaturated olefin in the presence of KMnO 4 in basic solution and water.
Advantageously, the polyol or the olefin is derived from a plant oil.
The olefin used in the context of the invention is a fatty acid or a fatty acid ester bearing a carbon-based chain of 10 to 30 carbon atoms, preferably from 12 to 20 carbon atoms, typically 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms.
Preferably, the fatty acid ester bears an alkyl group of 1 to 5 carbon atoms: advantageously, the group is a methyl.
The olefin may also be substituted with one or more alkyl and/or hydroxyl groups, the alkyl group ranging from 1 to 5 carbon atoms and is advantageously a methyl.
The fatty acid or the fatty acid ester described in the invention is advantageously chosen from the group constituted by myristoleic acid, palmitoleic acid, oleic acid, ricinoleic acid, gadoleic acid, erucic acid, nervonic acid, linoleic acid, α-linolenic acid, γ-linolenic acid, di-homo-γ-linolenic acid, arachidonic acid, timnodonic acid and cervonic acid, and derivatives thereof.
According to a particularly advantageous embodiment of the invention, the vicinal diol is methyl 9,10-dihydroxystearate.
According to an advantageous embodiment of the invention, the mole ratio between oxygen or dioxygen and said at least one vicinal diol or at least one vicinal polyol is from 0.6 to 3.5 equivalents, preferably from 1 to 2 equivalents and even more preferentially 1.5 equivalents.
Advantageously, the reaction taking place during the step of placing in contact of the various compounds according to the process of the invention is an oxidative cleavage reaction. It makes it possible to obtain at least one, and preferentially two, identical or different compounds such as carboxylic acids.
The term “carboxylic acid” means any compound having a structure of varied linear, branched or cyclic nature, bearing at least one carboxylic acid function.
Advantageously, the carboxylic acid obtained is a mono- or dicarboxylic acid, or a mixture thereof, i.e. a carboxylic acid comprising, respectively, one or two carboxylic acid functions.
The carboxylic acids may be substituted with one or more alkyl groups and/or hydroxyl groups. They may also advantageously bear at least one ester function, the alkyl group of which bears from 1 to 5 carbon atoms, advantageously is a methyl.
Advantageously, such carboxylic acids have a carbon-based chain ranging from 2 to 28 carbon atoms, preferably from 4 to 24 carbon atoms, typically 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 or 22 carbon atoms. The advantageous carboxylic acids are hexanoic (caproic) heptanoic, octanoic (caprylic), nonanoic (pelargonic), decanoic (capric), undecanoic, 1,6-hexanedioic (adipic), 1,7-heptanedioic, 1,8-octanedioic, 1,9-nonanedioic (azelaic), 1,10-decanedioic (sebacic), 1,11-undecanedioic, 1,12-dodecanedioic, 1,13-tridecanedioic (brassylic), 1,14-tetradecanedioic and 1,15-pentadecanedioic acids.
Even more advantageously, in the case where the vicinal diol used is methyl 9,10-dihydroxystearate, the products obtained are pelargonic acid and azelaic acid, alone or as a mixture.
The catalyst is advantageously used in an amount corresponding to from 0.1% to 10% by weight of the mixture (mass percentage), preferably from 1% to 10% and more preferably from 5% to 10% by weight of the mixture.
The reaction is advantageously performed at a temperature from 60 to 200° C., more particularly 90 to 150° C.
The reaction is advantageously performed at a pressure from 1 to 40 bar. Even more advantageously, the pressure is from 30 to 40 bar. Preferably, the reaction pressure is 31, 32, 33, 34, 35, 36, 37, 38 or 39 bar.
Advantageously, the reaction is performed with stirring. The process according to the invention may take place in a reactor with magnetic stirring or with mechanical stirring. Typically, the reactor used is one with mechanical stirring.
The process according to the invention may be performed using a starting material with a degree of purity ranging from 65% to percentages above 99% by weight of the composition. Preferably, the starting material has a purity of greater than 95%, and even more advantageously the purity is greater than 99% by weight of the composition.
The invention also relates to the use of a catalyst in solid form having the formula I below:
[Al n Si m O p M q ][A] r (I)
in which:
n, m and q are natural integers , which may be identical or different, chosen, independently of each other, such that n=m=q is other than zero; p is a nonzero natural integer *; r is zero or equal to 1; M corresponds to at least one chemical element chosen from zirconium, tungsten, titanium and rare-earth metals, and A corresponds to at least one chemical element chosen from alkaline-earth metals, alkali metals, rare-earth metals and titanium, for performing a process for producing carboxylic acids from vicinal diol or polyol, said process not involving any addition of solvent.
The invention also relates to the use of alumina or silica as catalyst for performing a process for producing carboxylic acids from vicinal diol or polyol as defined previously.
Advantageously, the invention relates to the use of alumina as catalyst for performing a process for producing carboxylic acids from vicinal diol or from vicinal polyol, especially from methyl 9,10-dihydroxystearate for the synthesis of pelargonic acid and azelaic acid.
The invention also relates to a composition comprising, essentially comprising or consisting of a mixture of pelargonic acid, or a derivative thereof, and of azelaic acid, or a derivative thereof, said mixture comprising a pelargonic acid/azelaic acid ratio ranging from 40:60 to 70:30.
The abovementioned composition may be obtained via the process as defined previously, and also in the examples that follow.
The abovementioned composition may also comprise up to 50% of 9,10-dihydroxystearic acid. In other words, the composition comprises, essentially comprises or consists of a mixture
of pelargonic acid, and/or a derivative thereof, of azelaic acid, and/or a derivative thereof, and of 9,10-dihydroxystearic acid, and/or a derivative thereof, the composition being such that it comprises up to 50% by weight of the composition of 9,10-dihydroxystearic acid relative to the total weight of the composition, and said mixture comprises a pelargonic acid/azelaic acid ratio ranging from 40:60 to 70:30.
This means that if the composition comprises 50% 9,10-dihydroxystearic acid, it comprises 50% of a mixture of pelargonic acid and of azelaic acid, this mixture comprising from 20% to 35% by weight of pelargonic acid relative to the total weight of the composition, and from 15% to 35% by weight of azelaic acid relative to the total weight of the composition.
The term “acid or a derivative thereof” means in the invention the salts of said acid, or its ionic forms, or alternatively an ester, especially a methyl ester, of the acid function.
Thus, in the invention:
a pelargonic acid derivative may be a sodium, potassium, etc. pelargonate or a methyl pelargonate, an azelaic acid derivative may be a sodium, potassium, etc. azelate or a methyl or dimethyl azelate, and a 9,10-dihydroxystearic acid derivative may be a sodium, potassium, etc. 9,10-dihydroxystearate or a methyl 9,10-dihydroxystearate.
The invention also relates to the use of the abovementioned composition for the preparation of biolubricants and/or low-temperature plasticizers and/or adhesives and/or products for the food or cosmetics industry, and/or in the context of protecting crops. The composition may be used in unmodified form, or after purification of its main components, i.e. azelaic acid and pelargonic acid.
For the term “use in the context of protecting crops”, examples that may be mentioned include use of the composition as a herbicide in order to combat herbaceous or ligneous weeds or any other plant that competes with cultivated plants. This herbicidal action may be total or partial depending on the desired effect.
Azelaic acid may be used in a wide range of applications: biolubricants, low-temperature plasticizers, adhesives, food, cosmetic and pharmaceutical industries.
The uses of pelargonic acid are also varied: as an ingredient in lubricants, alkyd resins and plasticizers, but also more commonly in protecting crops, as far as into niche markets such as the treatment of surfaces or substrates or alternatively in controlled release systems.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be understood more clearly on reading the examples, which do not have any limiting nature.
EXAMPLES
Example 1: Preparation of an Alumina or Silica Catalyst According to the Invention: Example of Calcined Catalyst
Alumina or silica (20 g), in powder form, is calcined for 3 hours up to 550° C., with a temperature increase of the order of 2° C. per minute. The calcined alumina or silica is then stored in a desiccator so as to protect it from moisture.
Example 2: Process for Esterifying and Purifying Methyl 9,10-Dihydroxystearate
The starting methyl 9,10-dihydroxystearate has a purity ranging from 60%-70%.
An amount of 30 g of methyl 9,10-dihydroxystearate, i.e. 90 mM, is placed in contact with 400 mL of pentane. The mixture is stirred for 2 hours at room temperature.
The solvent is then removed by filtration and the precipitate is dried under vacuum. 25 g of a precipitate are recovered, i.e. 83% by weight of the mixture.
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the precipitate is placed in contact with methanol (200 mL) and Amberlyst 15 (10% by weight) and refluxed overnight at 80° C.
The resin thus obtained is removed by filtration and the filtrate is evaporated under vacuum.
The precipitate is finally recrystallized from hot in the methanol.
17 g of 9,10DHSM are obtained (57% yield) in a purity of greater than 98% (analysis by NMR and GC).
Example 3: Reactivity of Methyl 9,10-Dihydroxystearate in Oxidizing Medium in the Absence of Catalyst: Control
An amount of 9.5 g (equivalent to 28.8 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with mechanical stirring.
The reaction is performed at 140° C. for 15 hours under 8 bar of air according to the following reaction scheme:
After cooling to room temperature, an orange oil is obtained corresponding to 95% by weight of the initial mixture.
The reaction medium is analyzed by gas chromatography after dissolution in methanol.
A mixture of methyl 9 and/or 10-oxostearate is obtained after identification by mass spectrometry and proton and carbon nuclear magnetic resonance.
In the absence of catalyst, no oxidative cleavage is observed, but transformation (rearrangement) of the diol into ketone is observed: this is an isophysical reaction without any change in the degree of oxidation.
Example 4: Oxidative Cleavage of Methyl 9,10-Dihydroxystearate According to the Process of the Invention
The oxidative cleavage reaction of the process according to the invention was performed, according to the following reaction scheme, under various conditions of amount of substrate, of calcined or non-calcined catalyst and of reaction times:
a) In the presence of calcined basic alumina: 2 g of DHSM
a1) Oxidative cleavage
An amount of 2 g (equivalent to 6.06 mmol) of methyl 9,10-dihydroxystearate (DHSM) is placed in a 300 mL autoclave with magnetic stirring, in the presence of calcined alumina oxide (i.e. 5% by weight of the mixture). The mixture is maintained at 140° C. for 16 hours under 8 bar of air (mole O 2 =20 mmol), the reaction takes place according to step 1) of the above reaction scheme.
The mixture is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
a2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered, step 2) of the above reaction scheme. Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 64/36.
The DHSM conversion is 100%.
b) In the presence of calcined basic alumina: 12 g of DHSM
b1) Oxidative cleavage
An amount of 12 g (equivalent to 36.4 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with mechanical stirring, in the presence of calcined alumina oxide (5% by weight).
The mixture is maintained at 140° C. for 16 hours under 8 bar of air (mole O 2 =20 mmol), the reaction takes place according to step 1) of the above reaction scheme.
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
b2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered, step 2) of the preceding reaction scheme. Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 65/35.
The DHSM conversion is 64%.
c2) In the presence of non-calcined basic alumina—24 h
c1) Oxidative cleavage
An amount of 2 g (equivalent to 6.06 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with magnetic stirring, in the presence of non-calcined alumina oxide (5% by weight). The mixture is maintained at 140° C. for 24 hours under 8 bar of air (mole O 2 =20 mmol), the reaction takes place according to step 1) of the above reaction scheme.
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (93% by weight).
c2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered (step 2) of the preceding reaction process). Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 63/37.
The DHSM conversion is 100%.
d) In the presence of calcined basic alumina—5 h
d1) Oxidative cleavage
An amount of 2 g (equivalent to 6.06 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with magnetic stirring, in the presence of calcined alumina oxide (5% by weight).
The mixture is maintained at 140° C. for 5 hours under 8 bar of air (mole O 2 =20 mmol), and the reaction takes place according to step 1) of the above reaction scheme.
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (92% by weight).
d2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered (step 2) of the preceding reaction scheme). Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 50/50.
The DHSM conversion is 100%.
e) In the presence of non-calcined neutral alumina—5 h
e1) Oxidative cleavage
An amount of 2 g (equivalent to 6.06 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with mechanical stirring, in the presence of non-calcined neutral alumina oxide (5% by weight).
The mixture is maintained at 140° C. for 5 hours under 8 bar of air (mole O 2 =20 mmol), and the reaction takes place according to step 1) of the above reaction scheme.
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
e2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered, step 2) of the preceding reaction scheme. Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 65/35.
The DHSM conversion is 64%.
f) In the presence of calcined basic alumina—5 h
f1) Oxidative cleavage
An amount of 15 g (equivalent to 45.5 mmol) of methyl 9,10-dihydroxystearate is placed in a 300 mL autoclave with magnetic stirring, in the presence of calcined alumina oxide (5% by weight).
The mixture is maintained at 140° C. for 5 hours under 30 bar of air (mole O 2 =20 mmol), and the reaction takes place according to step 1) of the above reaction scheme.
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (corresponding to 88% by weight of the mixture).
f2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are esterified for the purposes of the analysis techniques.
To this end, the reaction medium is diluted in 50 mL of methanol and is then filtered, step 2) of the preceding reaction scheme. Next, 10% by weight of Amberlyst® is added to the filtrate, which is refluxed for 5 hours.
The resin is removed by filtration and the filtrate is then evaporated under reduced pressure.
The crude product is analyzed by gas chromatography and by NMR.
A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 65/35.
The DHSM conversion is 60%.
The isolated yield after distillation is 23% and 21% for methyl pelargonate and dimethyl azelate, respectively.
g) In the presence of calcined silica
g1) Oxidative cleavage
An amount of 15 g (equivalent to 45.5 mmol) of methyl 9,10-dihydroxystearate (DHSM) with a purity of about 97% is placed in a 300 mL autoclave with mechanical stirring, in the presence of calcined silica (5% by weight).
The mixture is maintained at 140° C. for 5 hours under 30 bar of air (68 mmol of O2), and the reaction takes place according to step 1 (described previously).
The mixture thus obtained is cooled to room temperature, and an orange oil is obtained (corresponding to 89% by weight of the mixture).
g2) Esterification
The products obtained on conclusion of the reaction (oxidation products) are then 100% esterified for the purposes of the analysis techniques. To this end, the reaction medium is diluted in 300 mL of methanol and is then filtered, step 2) of the preceding reaction scheme. Next, 10% by weight of Amberlyst® are added to the filtrate, which is refluxed for 16 hours. The resin is removed by filtration and the filtrate is then evaporated under reduced pressure. An orange oil is obtained (corresponding to 88% by weight of the mixture).
The crude reaction product is analyzed by gas chromatography and by proton NMR. The inventors obtained a mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) with a PM/ADM ratio of 46/54.
The DHSM conversion is greater than 95%.
The summary of the results obtained is given in the table below:
TABLE 1
Conv.
Ex
Time
Ratio
(%)
Ratio (%)
Sel. (%)
No.
Cat.
(H)
O 2 /DHSM
DHSM
PM/ADM
C9/C8
a
Calcined basic
16
3.3
100
64/36
84/16
Al 2 O 3
b
Calcined basic
16
0.6
64
65/35
80/20
Al 2 O 3
c
Non-calcined
24
3.3
100
63/37
83/17
basic Al 2 O 3
d
Calcined basic
5
3.3
100
50/50
95/5
Al 2 O 3
e
Non-calcined
5
3.3
100
65/35
97/3
neutral Al 2 O 3
f
Calcined basic
5
1.5
60
45/55
95/5
Al 2 O 3
g
Calcined silica
5
1.5
>95
46/54
97/3
Example 5: Preparation of a Silica Catalyst According to the Invention: Example of a Calcined Catalyst
Silica (5 g), in powder form, is calcined for 3 hours up to 550° C., with a temperature increment of about 2° C. per minute. The calcined silica is then stored in a desiccator in order to protect it from moisture.
Example 6: Oxidative Cleavage of 9,10-Dihydroxystearic Acid According to the Process of the Invention—Catalysis with Alumina or Silica
The 9,10-dihydroxystearic acid (DHSA) has a purity of 80.8%.
The oxidative cleavage reaction of the process according to the invention was performed, according to the following reaction scheme, in the presence of various natures of calcined substrate:
a) In the presence of calcined basic alumina:
An amount of 60 g (equivalent to 153 mmol) of 9,10-dihydroxystearic acid (DHSA) is placed in a 600 mL autoclave with magnetic stirring, in the presence of calcined basic alumina oxide (i.e. 5% by weight of the mixture; prepared under the conditions of example 1). The mixture is maintained at 140° C. for 5 hours under 30 bar of air (mole O 2 =107 mmol), and the reaction takes place according to the above reaction scheme.
The mixture is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
The crude product is analyzed after esterification by gas chromatography. A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 15/85. The DHSA conversion is 94%.
b) In the presence of calcined neutral alumina:
An amount of 60 g (equivalent to 153 mmol) of 9,10-dihydroxystearic acid (DHSA) is placed in a 600 mL autoclave with magnetic stirring, in the presence of calcined neutral alumina oxide (i.e. 5% by weight of the mixture; prepared under the conditions of example 1). The mixture is maintained at 140° C. for 5 hours under 30 bar of air (mole O 2 =524 mmol), and the reaction takes place according to the above reaction scheme.
The mixture is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
The crude product is analyzed after esterification by gas chromatography. A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 55/45. The DHSA conversion is 90%.
c) In the presence of calcined silica:
An amount of 60 g (equivalent to 153 mmol) of 9,10-dihydroxystearic acid (DHSA) is placed in a 600 mL autoclave with magnetic stirring, in the presence of calcined silica (i.e. 5% by weight of the mixture; prepared under the conditions of example 1). The mixture is maintained at 140° C. for 5 hours under 30 bar of air (mole O 2 =524 mmol), and the reaction proceeds according to the above reaction scheme.
The mixture is cooled to room temperature, and an orange oil is obtained (corresponding to 90% by weight of the mixture).
The crude product is analyzed after esterification by gas chromatography. A mixture of methyl pelargonate (PM) and of dimethyl azelate (ADM) is obtained with a PM/ADM ratio of 35/65. The DHSA conversion is 86%. | A process for preparing a carboxylic acid, including a step of bringing at least one vicinal diol or at least one vicinal polyol into contact with an atmosphere including oxygen, and a catalyst, and in the absence of additional solvent. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is the National Stage of International Application No. PCT/EP2009/055984, filed May 18, 2009, that claims the benefit of European Application No. 08171007.1, filed Dec. 8, 2008 and U.S. Application No. 61/053,788, filed May 16, 2008, the entire teachings and disclosure of which are incorporated herein by reference thereto.
FIELD OF THE INVENTION
The present invention relates to a surgical instrument, in particular to a percutaneous and laparoscopic surgical instrument, and relates also to an electrode guiding device for such surgical instruments.
PRIOR ART AND RELATED TECHNICAL BACKGROUND
Radiofrequency (RF) therapy, is a well known non-invasive and outpatient procedure that uses radio waves. Generally, it is used to treat cancer, more particularly for the ablation of tumors from different organs, e.g. breast, colon, lungs, pancreas, prostate, kidney.
In such procedure, electrodes are placed into contact with the tissue to treat and a current, from a RF generator, is applied to the tissue via the electrodes. As the current passes, the tissue between the electrodes heats, a lesion is created, and the corresponding tissue is destroyed.
RF surgical devices are well known. Generally they are monopolar devices.
The device described in U.S. Pat. No. 5,507,743 may be a monopolar or a bipolar device. In the bipolar form of the device, it comprises one straight and one helical (coiled) electrode, the straight electrode being inside the helix formed by the helical one. In U.S. Pat. No. 5,507,743, to increase the size of the lesion created, both electrodes are hollow with a plurality of fluid distribution ports to deliver, into or onto the tissue to be ablated, a conductive fluid, such as chemotherapeutic agent or as an isotonic or hypertonic saline solution.
One of the main disadvantages of such RF surgical devices is that no confinement of the lesion is achieved. Furthermore it is very difficult to predict how wide the lesion created will be.
In WO2004/100812, the bipolar RF device is a three elements device wherein at least two of the elements are “dry” electrodes, i.e. not hollow and not able to deliver a conductive fluid. In the bipolar RF device described, the electrodes may be either both helical (coiled) and parallel one to another, or one helical and one straight. The bipolar RF device works by a cage effect allowing some confinement of the lesion created.
One of the main disadvantages of such bipolar RF surgical devices working with a cage effect, is the imprecise confinement of the lesion created as the positioning of the RF electrodes, to effectively ablate the tissue, may be imprecise.
To ensure optimal performance, the axis of each electrode should be parallel; However, due to the piercing resistance of the skin, the tissue, or the organ to treat, and even if Radiofrequency electrodes are sharp and not deformable, the electrodes are prone to touch, or come close, one to another, leading to a misalignment of the electrodes and a reduced performance of RF devices.
In addition, a controlled widening of the confinement is not possible with such bipolar RF surgical devices.
AIMS OF THE INVENTION
The present invention aims to provide a percutaneous and laparoscopic surgical device which does not have the drawbacks of the prior art.
Particularly, the invention aims to provide a RF surgical device with enhanced performance.
More particularly, the invention aims to provide a RF surgical device which allow a defined confinement of the lesion created.
The present invention aims also to provide a RF surgical device with stabilised electrodes.
The present invention aims also to provide a device which ensure a dimensional stability of the electrodes of a RF surgical device.
SUMMARY OF THE INVENTION
The present invention relates to a bipolar Radiofrequency surgical instrument comprising at least two dry electrodes, and a electrode guiding device comprising a main body, having a proximal end and a distal end, and at least two insertion holes guiding said electrodes, said insertion holes extending through the body.
The term “dry electrode” should be understood as “solid electrode”, solid electrode meaning that the electrode is not hollow and not able to deliver a conductive fluid.
According to particular embodiments, the bipolar Radiofrequency surgical instrument may comprise one or a combination of any of the following characteristics:
the at least two dry electrodes are helical;
at least one dry electrode is helical, and at least one dry electrode is straight;
the at least two dry electrodes are arranged in a concentric manner;
the shape and the size of the holes correspond to the shape and the size of the corresponding dry electrodes;
the diameter of the holes do not exceed 10% of the diameter of the electrodes;
the bipolar Radiofrequency surgical instrument comprises a RF current generator, positioning means, controlling means, location means and imaging means.
The present invention relates also to a device for guiding at least two Radiofrequency electrodes of a bipolar Radiofrequency surgical instrument, said guiding device comprising a main body, having a proximal end and a distal end, and at least two insertion holes guiding said electrodes, said insertion holes extending through the body.
According to particular embodiments, the guiding device may comprise one or a combination of any of the following characteristics:
the insertion holes are helical and arranged in a concentric manner at the proximal end of said body;
the body comprises at least one helical insertion hole and one straight insertion holes, said holes being arranged in a concentric manner at the proximal end of said body;
the diameter of the insertion holes do not exceed 10% of the diameter of the electrodes;
the body further comprises at least a supplementary hole at the distal end of the body, said supplementary hole being straight;
the body is circular, and a first series of supplementary holes are arranged, in a tangential manner, at the periphery of said body;
the body further comprises a second series of supplementary holes arranged in a tangential manner in respect to the first series of supplementary holes;
the at least one helical insertion hole is formed by engaging a threaded rod into a circular opening of the body;
the guiding device comprises a fixing part to fasten the guiding device to the head of a laparoscopic surgical instrument or to positioning means of a percutaneous surgical instrument.
The present invention relates also to a kit of parts comprising the guiding device according to the invention, and at least two dry Radiofrequency electrodes.
The present invention relates also to a method to remove a tumor comprising the use of a Radiofrequency surgical instrument according to the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the RF surgical device according to a first preferred embodiment.
FIG. 2 is a schematic representation of the RF surgical device according to a second preferred embodiment.
FIG. 3 is a schematic representation of the RF surgical device according to a third preferred embodiment.
FIG. 4 is a schematic representation of the cage effect whereby the RF surgical device treats the tissue.
FIG. 5 is a schematic representation of the guiding device according to a first embodiment of the invention.
FIG. 6 is a schematic representation of the guiding device according to a second embodiment of the invention.
FIG. 7 is a schematic representation of the guiding device according to a third embodiment of the invention.
FIG. 8 is a schematic representation of a two pieces embodiment of the guiding device according to the invention.
FIG. 9 is a schematic representation of a “X, Y” head of a preferred embodiment of the RF surgical device.
DETAILED DESCRIPTION OF THE INVENTION
The bipolar Radiofrequency surgical instrument according to the present invention comprises at least one helical electrode ( FIG. 1 ), preferably two helical electrodes 3 and 4 ( FIG. 2 ), or an helical electrode 3 and a straight electrode 5 ( FIG. 3 ) and a electrode guiding device 6 .
Preferably, the bipolar RF surgical instrument is of the type described in WO2004/100812 which is incorporated herein by reference. The RF surgical device comprise a main body 1 , stabilisation means 2 and at least a set of electrodes which can be helical, more preferably two helical electrodes, and even more preferably three helical electrodes. Optionally, it may further comprise a central member 5 , which may or may not be a straight electrode, and which is surrounded by the helical electrodes 3 or 4 . When the central member 5 is an electrode, it can be used with either a single helical electrode, or with two or more helical electrodes.
The RF electrodes 3 , 4 and/or the central member 5 are sharp, not deformable, and rigid electrodes. They are “dry electrodes”, i.e. not hollow and not able to deliver a conductive fluid. Preferably, they are made of metal, a biocompatible metal, preferably made of biocompatible stainless steel. It may be for example surgical stainless steel type 304 or type 316.
Preferably, the electrodes and/or the central member 5 are coated with an isolating polymeric compound, for example coated with TFE or polyester. More preferably, they are coated along their length but except on their tip, for example over around one turn for helical electrodes and around 1.5 cm for the central member.
The helical electrodes 3 and 4 may have the same diameter or a diameter different. Preferably, their diameter is between 1 and 2 mm, more preferably around 1.2 mm, or around 2 mm. Preferably, their length is of at least 15 turns, or a length of around 150 cm. The pitch is preferably a right-handed pitch, preferably of between 5 and 20 turns by cm. The helix formed by the helical electrodes 3 or 4 have preferably a diameter comprised between 8 to 24 mm. However, it is possible to adapt the diameter of the helix formed by the helical electrodes 3 or 4 according to the volume of the target tissue to treat.
The helical electrodes 3 , 4 are wounded parallel one to the other and have the same pitch. The helix formed by one of the electrode is arranged in a concentric manner in respect to the helix formed by the other, or others, electrodes.
Preferably, the central member 5 have diameter and length corresponding to those of the helical electrode 3 or 4 . More preferably, the diameter of the central member 5 is around 1.5 mm.
The central member 5 can be placed at the centre of the helix formed by the helical electrode 3 or 4 .
In a preferred embodiment, the helical electrodes 3 and 4 , and the central member 5 are fixed in the stabilisation means 2 by any suitable means.
In another preferred embodiment, the helical electrodes 3 and 4 are fixed in the stabilisation means 2 by any suitable means, while the central member 5 is removable.
Preferably, the helical electrodes 3 and 4 are glued in the stabilisation means 2 and are in contact with a connector which can be in electrical contact with a Radiofrequency generator.
As the central member 5 may be removable ( FIG. 3 ), it may comprise at one end a connector which can be in electrical contact with a Radiofrequency generator.
The stabilisation means 2 of the RF surgical instrument have a hollow cylindrical shape, made of a biocompatible polymeric material, for example poly-ether-ether-ketone (PEEK), polycarbonate or polyamide. It further may comprise a channel through which the central member 5 can pass.
Preferably, the stabilisation means 2 , comprising the helical electrodes 3 or 4 , is disposable. Preferably, the central member 5 is also disposable.
Each electrodes (electrodes 3 , 4 , and central member 5 ) can be activated independently one from the other to get a first pole (first electrode) and an second pole (second electrode), “activated” meaning that a current is applied into the electrode.
In on embodiment the first and the second pole are helical electrodes. In another embodiment, the first pole is a helical electrode 3 and the second pole is the central member 5 .
When applying a current to at least one electrode of the RF surgical instrument according to the present invention, the surgical instrument works by a cage effect ( FIG. 4 ). The heating created into the tissue goes from the closest electrode to the centre to the furthermost electrode. The tissue, which is in the cage formed by the electrodes, is thus destroyed, while the tissue outside the cage is safe.
The different combination between the type of electrodes (helical and/or straight), and the different diameter of the helix formed by helical electrodes, present the advantage of having a RF surgical instrument which can be easily adapted to the size of the tissue to treat. Furthermore, the use of the central member 5 presents the advantage of having the possibility to treat a smaller tissue volume, for example in combination with a smaller helical electrode (electrode 4 ). It may further present the advantage of modifying the shape of the treated zone, from a square like shape, in case of use of helical electrodes, to a sharper shape.
The electrode guiding device 6 according to the invention presents the advantage to maintain the dimensional stability of the electrodes by preventing their deformation during the perforation of the skin or the organ. Thus the confinement of the lesion created is precise and the tissue treated is as predicted. The precision of the treatment achieved is below 1 mm. It further enables an easier penetration of the helical electrodes 3 and 4 by making easier the penetration screw like movement.
The electrode guiding device 6 of the RF surgical instrument according to the invention comprises a main body 7 comprising at least two holes 8 and 81 ( FIG. 5 ) or 8 and 82 ( FIG. 6 ), or three holes 8 , 81 and 82 ( FIG. 7 ), extending through the body 7 .
The body 7 comprises a front side 71 , a back side 72 , a proximal end 73 and a distal end 74 .
The body 7 has any suitable shape, preferably it is substantially round, but may also have, for example, a polygonal or a square shape. It is made of any metal, or of polymeric material. Preferably, it is made of titanium or stainless steel, or of a poly-ether-ether-ketone (PEEK), polycarbonate, or polyamide.
The body 7 comprises at least two holes 8 and 81 , or 8 and 82 , extending through the body 7 from the front side 71 to the back side 72 . Preferably, the holes are arranged at the primal end 73 of the body 7 .
Through the body 7 , and on the surfaces defined by the front side 71 and the back side 72 , the holes 8 , 81 , and/or 82 have a shape and a diameter enabling the electrodes 3 , 4 , 5 to go through. Preferably, their shape and diameter correspond substantially to the shape and the diameter of the RF electrodes 3 , 4 , 5 to guide and which pass thought.
Through the body 7 , the hole for a straight electrode is substantially straight, and the hole for a helical electrode is substantially helical or substantially of a corkscrew shape, with either a left-handed or a right-handed pitch depending of the pitch of the helical electrodes. On the surfaces defined by the front side 71 and the back side 72 , the hole 82 may be round, square, oval, or octagonal.
The diameter of the holes 8 and 81 is substantially equal, or corresponding, to the diameter of the helix formed by the corresponding electrodes 3 and 4 . The size of the opening forming the holes 8 and 81 is substantially equal, or corresponding, to the diameter of the corresponding electrodes 3 and 4 , preferably the size of the opening do not exceed 10% of the diameter of the electrodes 3 or 4 .
The diameter of the hole 82 is substantially equal, or corresponding, to the diameter of the central member 5 , and preferably do not exceed 10% of the diameter of the central member 5 .
In a preferred embodiment, the body 7 of the guiding device comprises two helical holes 8 and 81 ( FIG. 5 ).
In another preferred embodiment, the body 7 of the guiding device comprises one helical 8 and one straight hole 82 ( FIG. 6 ).
In another preferred embodiment, the body 7 comprises two helical holes 8 , 81 and one straight hole ( FIG. 7 ).
However, the number of holes and their shape are not limited to those disclosed here as examples. The guiding device may comprise as many holes, and as different, as RF electrodes are.
Preferably, the guiding device 6 according to the present invention cooperates with the RF electrodes as described. However, the electrode guiding device may be used with any RF surgical instrument having at least two RF electrodes, straight and/or helical, being either hollow to deliver a conductive fluid, or dry, and having any size and any length. Nevertheless, the electrode guiding device is well suited to devices comprising two helical electrodes wounded parallel one to the other.
The body 7 of the electrode guiding device has an overall size at least higher than the external diameter of the furthermost helical electrode from the centre of said body 7 (electrode 3 in FIGS. 1 to 3 ). Preferably, the body 7 has a size and a shape enabling his use with a catheter.
Preferably, the body 7 has a overall size of between 8 and 30 mm, a thickness of between 1 and 3 cm. The spacing between two helical holes is around 20 mm.
In another preferred embodiment of the electrode guiding device 6 according to the invention, the body 7 may comprise at least one supplementary hole 10 arranged at the distal end 74 of the body 7 . Preferably, the body 7 comprises several straight holes 10 laid in a tangential manner at its periphery. More preferably, the body 7 comprises two series of straight holes 10 , 11 , laid in a tangential manner at its periphery, the holes 10 of the first series being tangent to the periphery of the body 7 , and the holes 11 of the second series being tangent to the holes 10 of the first series of holes ( FIGS. 5 to 7 ).
The supplementary hole 10 and/or 11 guide any other electrode, an anchoring member, or a needle, for example a straight needle, to introduce a conductive fluid or chemotherapeutic agent into the tissue before, during, or after ablation, or a needle biopsy aspiration device or any sensor, for example temperature sensors, or any optical device, or illumination fibres.
In a preferred embodiment, the supplementary holes 10 and/or 11 guide a straight RF electrode. Preferably, the straight RF electrode is of the type of the central member 5 .
When the tissue to treat is bigger than the diameter of the biggest helix formed by the outermost helical electrode 3 , at least one straight RF electrode can be used, said straight RF electrode being guided precisely where wanted, thanks to the specific arrangement of the supplementary holes 10 and/or 11 into the guiding device 6 . To widen the volume of tissue to treat, the RF current is applied either between the helical electrode 3 and the supplementary straight electrode, or between the central member 5 and the supplementary straight electrode.
Optionally, the guiding device further comprises a fixing part 9 , to allow the guiding device 6 to be handheld, or to be fixed to a percutaneous surgical instrument or a laparoscopic surgical instrument.
The body 7 of the electrode guiding device may be made either of one piece, or made of the assembly a two elements, one corresponding to the front side 71 and the other corresponding to the back side 72 of the device, the two elements being assembled by any suitable method.
The one piece body 7 , or the two elements body 7 , may be produced by any suitable method, for example by extrusion, by moulding or by stereolytography.
In a preferred embodiment, the hole 8 , 81 , 82 and the supplementary hole 10 or 11 are formed during the process to manufacture the body 7 . In another embodiment, the hole 8 , 81 , 82 and the supplementary hole 10 or 11 are drilled, by any suitable means, into the mass of the one piece body 7 , or in the two elements corresponding to the front side 71 and the back side 72 of the body 7 , the holes being drilled before or after the assembly of the two elements of the body 7 .
In another embodiment, the holes 8 , 81 or 82 are not drilled but are formed by the assembly of a one piece body 12 , or a front side and back side elements assembly, having a circular opening 13 , and a threaded rod 14 engaged in said circular opening 13 ( FIG. 8 ). Preferably, the threaded rod 14 is engaged by force in the opening 13 and fixed to the body 7 , for example by heat welding or by mean of a biocompatible glue.
Preferably, the threaded rod 14 is made of the same material as the one of the body 7 , or as the one of the front side and back side elements, for example, made of PEEK.
The diameter of the opening 13 and the external diameter of the threaded rod 14 are chosen to fit the external diameter of the helical electrode to guide. Furthermore, the length of the threaded rod 14 substantially corresponds to the thickness of the body 7 , and its pitch substantially corresponds to the pitch of the helical electrode, in terms of dimension and type of pitch (either left-handed or right-handed thread).
Preferably, the threaded rod 14 further comprises a hole 82 , which may be an helical hole or a straight hole. The threaded rod 14 may comprise a helical and a straight hole. The hole 82 may be drill in the threaded rod 14 , or may be formed by the engagement a threaded rod in an opening at the centre of the threaded rod 14 .
The guiding device 6 may be fastened by any suitable means to a laparoscopic instrument, for example an endoscope, to a positioning head of a percutaneous surgical instrument, or to be held by hand. Preferably, this fastening is achieved by a fixing part 9 of the guiding device 6 .
Preferably, the electrode guiding device is disposable.
The RF surgical instrument, and the electrode guiding device, according to the invention, may be parts of a more complex surgical instrument.
In a preferred embodiment, the RF surgical instrument, and the electrode guiding device, according to the invention, may be parts of a laparoscopic surgical instrument, for example an endoscope device. Therefore, the electrode guiding device 6 may be fixed to the head of the endoscope by, for example, a fixing part 9 , which may have any suitable shape and size. The front side 71 of the guiding device 6 is place against the organ to treat and the electrodes extend out through the head of the endoscope device, engage, and extend out through, the electrode guiding device 6 , and penetrate into the organ in a screw-like movement for helical electrodes, or a straight movement for a straight electrode, as deep as necessary to reach the zone to treat.
The laparoscopic surgical instrument may further comprise a RF current generator, and optionally, spatial location means, optical means, biopsy aspiration means, sensors and/or computer means.
In a preferred embodiment, the RF surgical instrument, and the electrode guiding device, according to the invention, may be parts of a percutaneous surgical instrument. Therefore, the surgical instrument further comprises a RF current generator, and optionally, positioning means, controlling means, location means, imaging means, and computer means.
In percutaneous applications, the front side 71 of the guiding device 6 is place against the skin and is hand-held, for example by the fixing part 9 , said fixing part 9 having any suitable shape and size. Then, the electrodes 3 , 4 and/or 5 are engaged into the holes of the guiding device, and extend out through the guiding device 6 to penetrate through the skin in a screw-like movement for helical electrodes, or a straight movement for the straight electrode, as deep as necessary to reach the zone to treat. However, this operation may be more automated by using positioning means and controlling means. The RF surgical device may further comprise location means and imaging means.
Preferably, the positioning means comprise a “X, Y” head 12 ( FIG. 9 ), or a robot arm, to which the electrode guiding device 6 is fixed, for example by using the fixing part 9 of any suitable shape and size allowing its fastening to the “X, Y” head 12 or robot arm.
The location means, comprising for example a ultrasound probe coupled to imaging means, allow to get the exact position of the tissue to treat and give a reference point to insure the precise positioning of the electrodes using the “X, Y” head 12 , before and after the penetration of the electrodes 3 , 4 , 5 . Preferably, the location means are controlled by the computer means.
The front side 71 of the guiding device 6 , fastened to the “X, Y” head 12 , for example by the fixing part 9 , is place against the skin precisely at the point of entry determined by location means, at the level of the tissue to treat, or the area chosen for the treatment. Then, the electrodes 3 , 4 and/or 5 extend out through the electrode guiding device 6 , and penetrate through the skin as deep as necessary to reach the zone to treat.
The “X, Y” head 12 , and/or the movement of the electrodes 3 , 4 , 5 , may be hand-operated, for example by the operator of the surgical instrument, or automatically operated using the controlling means, which may comprise for example a stepper motor which may be controlled by the computer means.
Preferably, in either the laparoscopic or percutaneous embodiments, the treatment of the tissue or the organ may be followed by the location means coupled to the imaging means.
If necessary, to widen the volume of the area to treat, without being obliged to remove the electrodes and to readjust the position with the “X, Y” head 12 , one or more straight electrodes may be used. These supplementary electrodes are precisely positioned thanks to the supplementary hole 10 and/or 11 of the guiding device 6 . Thus, the area treated is widened while the skin perforation is reduced to a minimum.
The electrode guiding device 6 according to the invention presents the advantage of allowing thus a precise electrodes positioning in respect to the tissue to treat, as it is an alternate solution to the traditional grid used to guide straight electrodes of percutaneous surgical instrument.
It has also the advantage of giving the possibility to widen the treated area by guiding at precise locations supplementary electrodes.
The RF surgical instrument, according to the invention comprising the guiding device 6 , presents the advantage of having enhanced performances. It also has the advantage of being adaptable to any size or shape of tumours to treat. It also has the advantage of being minimally invasive.
The RF surgical instrument, according to the invention, may preferably been used to treat prostate, kidney or breast cancer. | The present invention relates to a surgical system. Specifically, the surgical system comprises a percutaneous and laparoscopic surgical instrument and an electrode-guiding device. The percutaneous and laparoscopic surgical instrument having at least two dry rigid electrodes that are capable of percutaneous insertion to provide non-invasive radiofrequency (RF) therapy on a selected region of organ or tissue. For example, the percutaneous and laparoscopic surgical instrument may be used to ablate tumors from different organs, e.g., breast, colon, lungs, pancreas, prostate, kidney. The percutaneous and laparoscopic surgical instrument can be used in concert with an electrode-guiding device having a main body with insertion holes that correspond to the shape and size of the dry rigid electrodes. The dry rigid electrodes are removably engageable in the insertion holes, which allow the user to manipulate the dry rigid electrodes via the electrode-guiding device during percutaneous insertion and RF therapy. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a DIV. of Ser. No. 09/898,584 filed on Jul. 2, 2001 now U.S. Pat. No. 6,789,290.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable.
FIELD OF THE INVENTION
This invention relates to cleaning machines, carpet cleaning solutions, the system incorporating the cleaning machines and carpet cleaning solutions, and methods of cleaning carpet. Specifically, the carpet cleaning machine of the present invention is capable of operating in either a surface cleaning mode and a deep cleaning mode, or alternatively, a fast drying mode and a longer drying mode.
BACKGROUND OF THE INVENTION
Currently, machines for cleaning carpets consist of a system for delivering a cleaning solution, typically a hot aqueous detergent solution, to a carpet and a system for vacuuming the applied cleaning solution from the carpet. Many of these machines also have rotating brushes or beater bars to work the cleaning solution into the carpet and to aid in the dislodging of dirt and other debris from the carpet fibers.
The system for delivering the cleaning solutions in these machines usually includes a tank for holding the solution and a pump for pumping solution from the tank to a spray nozzle chamber. The spray nozzle chamber then distributes the cleaning solution to the carpet. The system for vacuuming generally comprises a vacuum chamber disposed in a cleaning head positioned over the carpet (The term “carpet” is defined to also include rugs.). The brushes then scrub the carpet. Next, a vacuum pump in fluid communication with the vacuum chamber and nozzle generates suction to remove the solution applied to the carpet.
These cleaning systems come in various varieties. The first variety is a deep clean system in which the tanks, the delivery system, the removal system and the brush are all contained on a moveable cart. A cleaning solution is applied to the carpet through various applying mechanisms that allow the solution to penetrate to the carpet backing material and remove unwanted dirt. The dirt/solution mix is subsequently removed by the vacuum. U.S. Pat. Nos. 5,473,792, 4,809,397 and 4,803,753 are examples of these machines. In this deep cleaning variety, the carpet is first administered a high pressure stream of cleaning solution, then scrubbed or otherwise agitated, and finally subjected to a vacuum to remove the solution and unwanted soil. This type of application provides thorough cleaning, and penetrates to the carpet backing material with the cleaning solution. As a result the carpet takes usually at least four to seven hours, or longer to dry. Long drying times make it logistically difficult to deep clean carpets in high traffic areas. As a result, many businesses are unable to deep clean carpets more than once a year.
Other varieties of cleaning systems include petroleum powder, dry cleaning, SORI (Spray On Rub In), and shampoo. The petroleum powder system involves spraying on a petroleum powder that binds to dirt. However, powder removal is never complete, and the remaining powder residue continues to attract dirt, making the carpet dirtier. The dry cleaning system involves applying dry cleaning chemicals to the carpet which can create environmental concerns. The SORI system is for spot cleaning where carpet cleaner is sprayed onto carpeting, and hand scrubbed. The shampoo system requires a shampoo solution containing a relatively small amount of water to be applied to the carpet. A bonnet on a machine is used to absorb the solution-dirt mixture from the surface of the carpet.
Currently, a machine does not exist that can be used for both a traditional deep cleaning application and a faster drying surface cleaning application. In addition, a cleaning solution does not exist that is designed for use in both a deep cleaning application and a surface cleaning application. Although numerous examples of cleaning solutions and powders are known in the art, none are specifically formulated to be used in both deep cleaning and surface cleaning varieties.
Additionally, neither a system using a dual mode carpet cleaning machine using a fast drying solution, nor methods of using such a system exist in the art. Therefore, what is needed is 1) a dual mode carpet cleaning machine that operates in a fast drying, surface cleaning mode and a longer drying, deep cleaning mode; 2) a fast drying carpet cleaning solution that will penetrate the carpet to the carpet backing mixed at one concentration and that will not penetrate the carpet to the carpet backing at another concentration; 3) a system using the dual mode carpet cleaning machine and fast drying carpet cleaning solution; and 4) methods of using such a system. Each of these features result in faster carpet drying times while retaining high cleaning efficiency.
BRIEF SUMMARY OF THE INVENTION
The present invention is drawn to the next generation of carpet cleaning machines and cleaning agents. The invention solves the above mentioned problems and will allow a user the ability to use the same machine and the same cleaning solution to either deep clean or surface clean a carpet, resulting in faster drying times while retaining high cleaning efficiencies. The invention empowers the user of the carpet cleaning machines and carpet cleaning solutions of the invention to choose whether they want to clean the surface of a carpet and quickly have the carpet available for use, or deeply clean the carpet for sanitary or other reasons when time has been allowed for longer drying times. Hotels and other businesses would greatly benefit from such an invention when carpets need to be cleaned quickly between guests or business hours, but provide the hotel or other business the option of deep cleaning carpets using the same machine and carpet cleaning solution when time is not of the essence.
One aspect of the invention is to provide an improved machine that allows the easy selection of either a deep cleaning mode or a surface cleaning mode, or alternatively a longer drying time mode or a faster drying time mode. By the simple change of the selection mechanism, the machine will adjust the physical characteristics of the delivered cleaning solution and thus the manner in which the cleaning solution interacts with the rug or carpet, prior to being removed by the vacuum. This in turn enables the user to control the carpet drying time.
Another aspect of the invention is to provide a new cleaning solution. The new cleaning solution has characteristics that allow it to be diluted into a mixture for use in both a longer-drying, deep-cleaning application as well as a fast-drying, surface-cleaning application by changing the solution concentration in the water. Even with a single mode, deep cleaning machine, the improved cleaning solution shows faster carpet drying times over prior art mixtures, without the use of alcohol or other volatile flammable solvents.
The cleaning solution of the present invention is formed by diluting a specific amount of cleaning mixture with clean water. The cleaning mixture has a combination of surfactants, detergents and wetting agents optimized for use in a surface cleaning application, but also formulated to deep clean carpets. An additional benefit of the solution of the invention is that it imparts cleaning efficiencies that are similar to the efficiencies of prior art cleaning solutions while at the same time providing for a substantial reduction in carpet drying time over the prior art. A key property of the carpet cleaning mixture is that it creates a foam when mixed with water at a lower concentration, but creates a gel-like higher viscosity foam when mixed with water in a higher concentration. Preferably, the higher concentration is about twice as concentrated as the lower concentration. The gel-like foam produced upon agitating the solution at this concentration imparts increased foam stability while other components enhance sheeting action. The combination of the lower application rate and the creation of this foam prevents deep penetration of the cleaning solution into the carpet prior to removal by the vacuum system. This results in a surface-cleaned carpet that typically dries in less than two hours as compared to four-to-seven hours or more of current carpet cleaning systems.
Yet another aspect of the invention is to provide a dual mode carpet cleaning system using the dual mode cleaning machine and the fast drying cleaning mixture.
A further aspect of the invention is to provide a method of cleaning carpet. The method comprises the steps of mixing the concentrated carpet cleaning solution at a concentration such that a foam produced by agitating the carpet cleaning solution does not penetrate the carpet to the carpet backing, placing the mixed carpet cleaning solution into the dual mode carpet cleaning machine, selecting a fast dry mode of the carpet cleaning machine, and applying the carpet cleaning solution to the carpet fibers.
Further features and advantages of the present invention as well as the structure, composition and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 illustrates an elevated perspective view of the carpet cleaning machine of the present invention;
FIG. 2 illustrates an elevated, perspective exploded view of a removal section of the carpet cleaning machine of the present invention;
FIG. 3 illustrates an elevated, perspective exploded view of a storage section and an application and extraction section of the carpet cleaning machine of the present invention;
FIG. 4 illustrates a detailed perspective view of jet tip nozzles of the carpet cleaning machine of the present invention;
FIG. 5 is a chart which illustrates the results of a cleaning efficiency test;
FIG. 6 is a chart which illustrates the results of a second cleaning efficiency test; and
FIG. 7 is a chart which illustrates the results of a drying time test.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the accompanying drawing in which like reference numbers indicate like elements, the machine, the cleaning mixture and the system of the present invention are set forth below.
A. The Machine
Referring now to FIGS. 1–4 it can be seen a portable self-contained carpet cleaning machine is shown generally at 10 in accordance with the present invention. Machine 10 includes a main support housing, shown generally at 12 , having an application and extraction section shown generally at 14 , a storage section 16 , and a removal section shown generally at 18 . A handle 20 is attached to the support and wheels 24 allow machine 10 to be rolled.
As shown in FIG. 3 , the application and extraction section 14 includes a vacuum nozzle 30 attached to a removal conduit 32 , a brush assembly shown generally at 34 , solution pump 38 , spray nozzle chamber 40 and a ball valve 42 . The brush assembly 34 uses a motor 46 with off-center drive shaft 48 to drive link member 50 linked to a brush 52 (bristles not shown in this top view) which drives the brush 52 back and forth between the vacuum nozzle 30 and the spray nozzle chamber 40 . The solution pump 38 pumps cleaning solution (not shown) to the spray nozzle chamber 40 through solution pump outlet 55 . The machine 10 may be produced using a range of nozzle spraying patterns, varying in length, width, dispersion, and other geometrical configurations. The spray nozzle chamber 40 is equipped with both a deep cleaning jet tip 60 (preferably model H1/8 VV-KY11010 for narrower width spraying such as in a Rug Doctor Mighty Pack machine or model 1/8HVV KY11006 for wider spraying such as in a Rug Doctor Wide Track machine, available from Spraying Systems Co., Wheaton, Ohio) and a fast dry jet tip 62 (preferably model 1/8K SS1.5 for narrower width spraying or model 1/8K SS2.5 for wider spraying, available from Spraying Systems Co., Wheaton, Ohio). The deep cleaning jet tip 60 is pointed downward and forcefully propels a stream of cleaning solution. Preferably, the surface cleaning (fast dry) jet tip 62 has a deflector surface (in the preferred model specified) and covers the same area of carpet as the deep cleaning jet tips 60 . However, the presence of a deflector surface in fast dry tip 62 is also dependent upon the geometrical orientation of the jet tips 60 , 62 . Other tips with or without deflector surfaces can be used according to geometrical constraints.
A ball valve 42 is continuously fed diluted cleaning solution from the solution pump 38 and can be switched between first and second outlets, 70 and 72 , respectively . When the ball valve 42 is aligned with the first outlet 70 , cleaning solution is fed to a deep cleaning jet tip 60 , and when the ball valve 42 is aligned with the second outlet 72 cleaning solution is fed to the fast dry jet tip 62 .
The ball valve 42 of machine 10 is actuated by an actuator (shown generally at 78 ). The actuator comprises an indicator 76 and a shaft 77 . The indicator 76 can be rotated between a first position 79 (shown) and a second position 80 (shown in shadow). Movement of the indicator 76 between the two positions 79 , 80 selectively places the two types of jet tips 60 , 62 in fluid communication with the cleaning solution.
In the first position 79 , cleaning solution is fed to the deep cleaning jet tip 60 . The machine 10 (e.g., the Rug Doctor Mighty Pack machine) may be configured to deliver a carpet-covering spray pattern at a rate of preferably between 0.52 to 0.55 GPM (gallons per minute), more preferably 0.54 GPM through the deep clean jet tip 60 . A machine 10 configured to deliver a wider spray pattern, (e.g., the Rug Doctor Wide Track machine), may be configured to deliver preferably 0.60 to 0.70 GPM, more preferably 0.65 GPM. Other configurations may be used depending on the geometrical configuration requirements of different machines.
The second position 80 provides cleaning solution to a fast dry jet tip 62 . A carpet cleaning machine (e.g., Rug Doctor Mighty Pack machine) may be configured to deliver preferably between 0.13 to 0.24 GPM, more preferably 0.17 to 0.21 GPM, and still more preferably 0.19 GPM. A carpet cleaning machine (e.g. Rug Doctor Wide Track machine) configured to deliver a wider spray pattern may be configured to deliver preferably between recovery tank 108 . The air inlet 109 side (under the motor and not shown) of vacuum motor 102 is attached to an inlet conduit 118 which passes through an aperture 134 in the vacuum cover 104 and connects to one side of a dome 120 . The vacuum motor creates suction to pull air and dirty water recovered from the carpet through nozzle 30 (best seen in FIG. 3 ). Dirty water and air travel through the removal conduit 32 (best seen in FIG. 3 ), up through the first conduit 112 (best seen in FIG. 2 , FIG. 2 and FIG. 3 hoses match up at x and y), through an aperture 114 in the vacuum cover 104 and into dome 120 . The dirty water and air hit a baffle (inside the dome 120 and not shown) and the dirty water drops into the recovery bucket 108 ( FIG. 3 ). After traveling through the inlet conduit 118 into the vacuum motor 102 , the air leaves through exhaust 110 and is directed into hose 126 . Hose 126 goes down the main support 12 and exits out of the bottom of the machine (best seen in FIG. 2 ). The dome 120 has a gasket 124 about its base and is sealed about an aperture 130 in the top of recovery tank 108 . The seal between the dome 120 and the recovery tank 108 is maintained by a bale 132 that doubles as a carrying handle for the recovery tank 108 .
In a preferred embodiment, the vacuum nozzle 30 includes a pair of spaced triangular plates 140 , 142 , joined on two sides and open on the bottom, the rear plate of which has a fitting for attachment to the first conduit 112 (alternatively called removal conduit 32 ). The vacuum nozzle 30 preferably has an ear 144 and is held in the grooves 146 with a single screw not shown. It will be appreciated by those skilled in the art, however, that the vacuum nozzle 30 may be attached by any suitable means known in the art.
The top of the cavity has a hollow extending into a notch 148 up the rear wall 150 of the clean water tank for receipt of the first conduit 112 . A second notch 152 is provided in the rear wall 150 for receipt of the hose 126 which is vented through a rear panel 160 . The rear panel 160 is attached to the pan 162 and the rear wall 150 of the clean water tank 82 with screws (not shown) or any other suitable means.
In use, as machine 10 is pulled rearwardly on wheels 24 by handle 20 , premixed cleaning solution is drawn through strainer 90 in clean water tank 82 through first tube 164 into the inlet 92 of solution pump 38 . The cleaning solution is then forced from the outlet 55 of solution pump 38 into second tube 166 , through selection mechanism 168 (comprising ball valve 42 , indicator 76 , and actuator 78 ) and delivered under pressure to spray nozzle chamber 40 . Spray nozzle chamber 40 directs a spray of the solution onto a carpet just behind vibratory brush assembly 34 . The wetted carpet is given a brief scrubbing and the cleaning solution immediately recovered with vacuum nozzle 140 . Spent cleaning solution is sucked through conduit 112 , into dome 120 , where it is stopped by a baffle (not shown) and falls under gravity to the bottom of recovery tank 108 .
B. The Cleaning Mixture
The carpet cleaning solution of the invention is a mixture comprising a detergent, foam stabilizer and an emulsifying agent. The solution is preferably a concentrate that can be diluted to different concentrations for use in different carpet cleaning modes of a dual mode carpet cleaning machine. A single compound may provide all three functions—detergency, stabilization, and emulsification—but it is preferred that at least two and more preferably three distinct compounds provide each individual function. In one embodiment, the carpet cleaning solution combines 1) an active detergent which may also function as a foaming agent, corrosion preventer, and a foam bubble-size reducer, and 2) an emulsifying agent which may also function as a profoamer, sheeting agent, and dispersing agent. These agents are referred to as the active agents of the invention. In addition, agents such as optical brighteners, deodorizers, water softeners, acid/base buffers, preservatives, and suspending agents may be added to optimize the carpet cleaning performance.
More preferably, the solution additionally includes: 3) a suspending agent which may also function as an incrustation inhibitor, an anti-redeposition agent, and a detergency booster; 4) a non-bleach optical brightener; and 5) a sequestering agent which may also function as an acidic/alkaline buffer and a soil dispersing agent. Finally, the solution may additionally include: 6) a preservative; 7) a water softener which may also function as an alkaline buffer; and 8) a fragrance or odor absorber.
The Active Detergent
The active detergent is preferably sodium lauryl sulfate (available from Para-Chem, Inc., Dalton, Ga.), but may also comprise an anionic detergent such as alkyl glyceryl ether sulfonates, alkyl sulfonates, alkyl monoglyceride sulfates or sulfonates, alkyl polyethoxy ether sulfonates, alkyl aryl sulfonates, aryl sarcosinates, aryl esters of isothionates, alkyl esters of sulfosuccinic acid, and alkyl phenol polyethoxy sulfonates. They are used in the form of water-soluble salts, such as, by way of example only, sodium, potassium and ammonium salts. Specific examples of the anionic organic detergents include sodium lauryl sulfate, sodium dodecyl sulfonate and sodium lauroyl sarcosinate.
The active detergent is more preferably a mixture of sodium lauryl sulfate and sodium lauroyl sarcosinate (available from Stephan Chemicals, Chicago, Ill.). It is believed the sodium lauroyl sarcosinate stabilizes the foam produced from agitating the carpet cleaning solution resulting in a drier foam with smaller and more uniform bubble size. The mixture of active detergents and the emulsifying agent below produces the unique properties of the invention upon increasing the concentration of the solution, e.g., from 4 oz./gallon to 8 oz./gallon, thereby imparting cleaning properties typical of current carpet cleaners at a lower concentration, but reduced drying time, cleaning activity with a drier, more stable foam, and increased sheeting action at higher concentrations. This also provides the advantage that the same carpet cleaning solution may be used in different concentrations in the same carpet cleaning machine to perform different functions.
The Emulsifying Agent
The emulsifying agent is preferably Silwet L-7608 (polyethyleneoxide modified trisiloxane copolymer, available from Osi Specialties, Inc., Greenwich, Conn.), but may comprise other compounds that increase the adhesion of the carpet cleaning solution to the carpet or increase the cross-link density of the carpet cleaning solution. It is believed that Silwet L-7608 aids foaming and foam stability and increases other properties such as viscosity, adhesion to the carpet, increased wetting of the carpet, and increased cross-linking of compounds within the foam. The emulsifying agent is also believed to function as a profoamer, sheeting agent, and dispersing agent.
The Sequestering Agent
The sequestering agent is preferably sodium tripoly-phosphate (Na 5 P 3 O 10 , available from Solutia, Inc., St. Louis, Mo.), but may also comprise other agents that provide sequestration of multivalent metal ions. The sequestering agent may also function as an acidic/alkaline buffer and a soil dispersing agent.
The Suspending Agent
The suspending agent is preferably Sokalan CP-9 (available from BASF, A.G., Germany), but may also comprise other polycarboxylate copolymers such as carboxylic acid copolymers, acrylic acid homopolymers, carboxymethyl cellulose, and nonionic copolymers such as polyvinylpyrrolidone. The suspending agents may also function as incrustation inhibitors, anti-redeposition agents, and as detergency boosters.
The Non-Bleach Optical Brightener
The non-bleach optical brightener is preferably Tinopal® (available from Ciba Specialty Chemicals, Greensboro, N.C.), but may also comprise other agents that absorb incipient, invisible UV light and convert it into visible light, e.g., UVITEX® (available from Ciba Specialty Chemicals, Greensboro, N.C.) or other agents that make the carpet appear brighter than the light which strikes it.
The Preservative
The preservative is preferably Dowicil-75 (1-(3-chloroallyl)-3,5,7-triaza-1-azoniaadamantane chloride, available from Dow Chemical Company, Midland, Mich.), but may comprise other compounds which provide antimicrobial activity.
The Water Softener
The water softener is preferably sodium sesqui-carbonate (Na 2 CO 3 .NaHCO 3 2H 2 O available from Solutia, Inc., St. Louis, Mo.) which may also function as an alkaline buffer. Other water softening agents may be used which provide a reduction in calcium or magnesium hardness.
The Fragrance
The fragrance is preferably a lemon scent (available from Chemia Corp., St. Louis, Mo.), but may also provide other agents which provide a pleasant scent or odor absorbance.
As one skilled in the art will observe from the above descriptions of the preferred agents of the carpet cleaning solution, the foam generated by agitation of the solution applied to a carpet will acquire different properties when applied in different concentrations. For example, when applied in a 4 oz./gallon concentration, the cleaning solution easily penetrates to the carpet backing material. It is believed that the foam stabilizer and emulsifier are dilute enough at this concentration to reduce foam persistence and viscosity so that the cleaning solution may easily penetrate the lower layers of the carpet fiber thereby providing excellent cleaning power.
When applied in an 8 oz./gallon concentration, however, the foam does not easily penetrate the carpet backing, but remains substantially in the upper layer of carpet fibers. It is believed that the foam stabilizer and emulsifier become increasingly cross-linked as concentrations increase so that the foam takes on the consistency of a gel rather than loosely organized and compacted bubbles. Thus, the agents mixed in the carpet cleaning solution form a more viscous and concentrated mass of foam staying on the upper layer of carpet fiber thereby concentrating the active agents on the upper layer. Thus, the benefit of the carpet cleaning solution of the invention is not only the ability to use the same carpet cleaning solution applied in different concentration to perform two different cleaning tasks, but concentrating the carpet cleaning solution and foam on the upper layer of carpet fibers allows the user to clean more quickly, using less carpet cleaning solution, with greater ease, and allowing faster drying times.
The carpet will be substantially dry within two hours of applying the carpet cleaning solution of the invention to the carpet, preferably in less than two hours, and more preferably less than one hour. As used herein, the term “substantially dry” is preferably defined to mean dry to the human touch. As used in the EXAMPLES below, however, substantially dry can be objectively determined by measuring the moisture content of a carpet using an RF monitor (model “Protimeter Aquant”, available from Protimeter PLC, Marlow, United Kingdom). On a scale from 0 where no moisture is detected and 15 where 100% moisture saturation is detected, “substantially dry” is more preferably defined to mean obtaining less than a “level 3” reading on a scale of 15 of the RF Protimeter Aquant under normal temperature and humidity conditions, but in no case less dry than ambient humidity.
The preferred active agents of the carpet cleaning solution may be combined in different ranges depending on the desired characteristics the manufacturer may wish the solution and foam to embody. Generally, the formulation may comprise the eight agents mixed in amounts defined in TABLE 1 below. It will be appreciated, however, that the active agents may be applied alone in one embodiment of the invention.
TABLE 1
Ingredient
Percent Weight
Percent Weight
Carboxylate Copolymer
0.100
1.000
Non-Bleach Optical Brightener
0.001
0.0025
1-(3-chloroallyl)-3,5,7-Triaza-
0.012
0.012
1-Azoniaadamantane Chloride
Sodium Tripoly-Phosphate
3.000
6.000
Sodium Sesqui-Carbonate
3.000
6.000
Sodium Lauryl Sulfate(30%)
0.400
1.500
Sodium Lauroyl Sarcosinate
0.400
1.500
Fragrance (Lemon)
0.0375
0.075
Polyethyleneoxide Modified
0.250
2.000
Trisiloxane Copolymer
Water
Remainder
Remainder
Total
100.00
100.00
While the formulation of the carpet cleaning solution may comprise individual components within the ranges specified in TABLE 1, the preferred concentrations of the components are listed in TABLE 2 as follows:
TABLE 2 Ingredient Percent Weight Carboxylate Copolymer 0.2500 Non-Bleach Optical Brightener 0.0015 1-(3-chloroallyl)-3,5,7-Triaza-1- 0.0120 Azoniaadamantane Chloride Sodium Tripoly-Phosphate 4.8000 Sodium Sesqui-Carbonate 4.8000 Sodium Lauryl Sulfate (30%) 0.5000 Sodium Lauroyl Sarcosinate 0.5000 Fragrance 0.0375 Polyethyleneoxide Modified 0.5000 Trisiloxane Copolymer Water Remainder Total 100.00
The solution of TABLE 2 is hereinafter referred to as the “Preferred Solution.”
C. The System
The invention contemplates a system which combines the machine of Part A with the Mixture of Part B. When the machine is set up for a deep clean operation, the cleaning solution is formed by mixing about 4 ounces of cleaning mixture per gallon of clean water. When the machine is set up for a Fast Dry surface clean operation the cleaning solution is formed by mixing about 8 ounces of cleaning mixture per gallon of clean water.
After cleaning in the Deep Clean mode, a typical carpet is, on average, approximately 91% clean and takes longer than 2 hours to dry. After a cleaning in the Fast Dry Surface Clean mode the typical carpet is, on average, approximately 86% clean and takes less than 2 hours to dry. The testing parameters and standards used to determine the above characteristics are discussed in the Part E Testing section below.
D. The Method
A method of cleaning is disclosed by the invention. After a survey of the area to be cleaned a user chooses to proceed with a Deep Clean application or a Surface Clean application. The machine is then set up for the application. First the user moves selection mechanism 168 to the proper position. Second the user prepares the cleaning solution tank by mixing 4 ounces of cleaning mixture per gallon of clean water when the Deep Clean application is selected or 8 ounces of cleaning mixture per gallon of clean water when the Fast Dry surface application is selected. Finally the area to be cleaned is cleaned.
E. Testing
To define terms, the term “Standard Machine” is a standard “Mighty Pack” machine, available from Rug Doctor, L.P., Fenton, Mo. and a “Fast Dry Machine” is a modified 0.19 gallon per minute delivery rate (“GPM”) Mighty Pack machine. The track width of these machines is approximately 10.5 inches. Similar tests results were obtained using a modified 0.28 GPM “Wide Track” machine (available from Rug Doctor, L.P., Fenton, Mo.). The track width of this machine is approximately 12.5 inches. A 4 oz. per gallon solution of Steam Cleaner carpet cleaning solution (hereinafter “Steam Cleaner”, available from Rug Doctor, L.P., Fenton, Mo.) and a 4 oz. per gallon concentration of the Preferred Solution (defined below) of the invention were compared to hot water.
Extensive testing was performed on carpets made from different materials of construction. The solutions were tested on a ⅜ inch pile height Nylon Saxony Plush carpet ( FIG. 7 ), the most common type of carpet currently on the market. Similar results were derived from tests on Olefin loop and Nylon loop carpets. The carpet gauge was about 1/10 inch with 10 stitches per inch. The diluted solutions tested were approximately 110° F., ambient relative humidity between 21 to 32% and ambient temperature between 70 to 73° F.
The tests show in FIG. 7 that the carpet cleaning system, when used with the Preferred Solution of the invention, at a concentration of 8 oz. per gallon dried in periods ranging from one to two hours, depending on the type of carpet tested. When the same carpets were cleaned with the standard Steam Cleaner solution in the Standard Machine at 4 oz. per gallon, the drying time was 3 to 7 hours depending on the type of carpet cleaned. When the carpets were cleaned with exactly the same concentration of the two cleaning solutions using the same machine, i.e., the Preferred Solution and the Steam Cleaner, the carpet cleaned with the Preferred Solution dried about 15% faster than that cleaned with the Steam Cleaner. This is believed to be due to the sheeting agent that allows the Preferred Solution to be spread into a thin film on the surface of the carpet fiber. The spreading of this film increases the surface area of the Preferred Solution and helps it dry quicker. The Active Detergent is also believed to be involved as the increased foam stability, increased viscosity, more uniform bubble size, and increased cross-linking between the polymers of the Emulsifying Agent and the Active Detergent act to keep the foam close to the top of the carpet fibers without penetrating to the carpet backing. Thus, the tests show that the combination of reduced flow and improved sheeting and foam characteristics of the Preferred Solution reduces drying time considerably.
Clean carpet strips were color measured using a Minolta Spectrophotometer (available from Minolta Corporation, Ramsey, N.J.) to determine an original color value. A standardized method of applying uniform soil to the carpet strips was developed to obtain precise and accurate measurements across data sets. The standardized method uses ajar mill with a Standard Soil mixture. The strips were then removed, vacuumed and color measured using the Minolta Spectrophotometer to determine a “Soil color” value. The soiled strips were then affixed to the floor. The carpet strips were then cleaned with the carpet cleaning solutions using a Deep Clean machine and a Surface Clean machine.
The carpet strips were cleaned with the Steam Cleaner and Preferred Solution using a Standard Machine for comparison. A linear cleaning rate of 30 feet per minute was used whenever possible. A pre-measured lateral overlap of two inches was allowed between strokes. The % Cleaning Efficiency was calculated after using the Minolta Spectrophotometer to determine the “clean color” value using the formula:
%
Cleaning
Efficiency
=
(
Clean
Color
value
-
Dirty
Color
value
)
(
Original
Color
value
-
Dirty
Color
value
)
×
100
Although the fast dry jet tips (delivering 0.19 GPM in the Mighty Pack machine and 0.28 GPM in the Wide Track machine) and deep clean jet tips (delivering 0.54 GPM in the Mighty Pack machine and 0.64 GPM in the Wide Track machine) of the invention are affected by the viscosity of the cleaning solutions and the pressure generated by the solution pump, the most important variable that was kept constant in the EXAMPLES below was the spray pattern. Different track widths, spray pattern widths, and liquid delivery rates are encompassed within the scope of the invention so long as the solution delivered by a dual mode machine is capable of producing the fast drying times presented in the invention. Other track widths, spraying patterns, spraying pattern widths, and jet tips may be used as one skilled in the art will observe.
EXAMPLE 1
Methods
A Standard Machine and a Fast Dry Machine were compared. A 4 oz. per gallon solution of Steam Cleaner and a 4 oz. per gallon Preferred Solution were used in the Standard Machine (applying the cleaning solutions at 0.54 GPM, or in the “deep cleaning mode”) and Fast Dry Machine (applying the cleaning solutions at 0.19 GPM, or in the “surface cleaning mode”) and were compared to hot water. The track width of these machines is approximately 10.5 inches. Similar tests results were obtained using a modified 0.28 GPM “Wide Track” machine (available from Rug Doctor, L.P., Fenton, Mo.). The track width of this machine is approximately 12.5 inches.
An acceptable cleaning standard for the Preferred Solution was arbitrarily targeted to be within 5% of the % cleaning efficiency result obtained from the Np machine using 4 oz./gallon of Steam Cleaner (87.33%−5%=82.33%). Test results show that the Preferred Solution in the preferred concentration actually improves the carpet cleaning results when comparing both the Preferred Solution of the invention and Steam Cleaner in the Standard Machine.
FIG. 5 shows the results of this test:
(a) Cleaning with a 4 oz./gallon concentration of the Preferred Solution in the deep cleaning mode, the average % cleaning efficiency is 91.03%. Cleaning with Steam Cleaner showed an average % cleaning efficiency of 87.33% compared to a baseline level of 54.1% using hot water in the deep cleaning mode.
(b) Cleaning with a 4 oz./gallon concentration of the Preferred Solution in the surface cleaning mode, the average % cleaning efficiency is 75.84%. However, using 4 oz/gallon concentration of the Steam Cleaner in the surface cleaning mode, the average cleaning efficiency drops to 52.36%, while plain hot water can only show baseline cleaning efficiency of 31.92% in the surface cleaning mode.
Results
From EXAMPLE 1(a), it is clear that the Preferred Solution outperforms the standard Steam Cleaner in the deep cleaning mode at 4 oz./gallon. This dilution is the preferred use level for the Preferred Solution in the deep cleaning mode.
From EXAMPLE 1(b), the results demonstrate that the cleaning performance of the Preferred Solution declines when used at 4 oz./gallon in the surface cleaning mode. However, the performance of the standard Steam Cleaner, at the same dilution decreases far more than that of the Preferred Solution. This demonstrates that a higher concentration of detergent is required for efficacious cleaning in the reduced flow mode.
EXAMPLE 2
Methods
A Standard Machine and a Fast Dry Machine were compared. An 8 oz. per gallon solution of Steam Cleaner and an 8 oz. per gallon Preferred Solution were used in the Standard Machine and the Fast Dry Machine, and were compared to hot water. FIG. 6 shows the results of this test:
(a) Cleaning with a 8 oz./gallon concentration of the Preferred Solution in the deep cleaning mode, the average % cleaning efficiency is 94.0%. In comparison, cleaning with 8 oz./gallon concentration Steam Cleaner gave an average % cleaning efficiency of 90.0% and a baseline level of 54.1% using hot water, both in the deep cleaning mode.
(b) Cleaning with an 8 oz./gallon concentration of the Preferred Solution in the surface cleaning mode, the average % cleaning efficiency is 86.12%. However, using 8 oz./gallon concentration of Steam Cleaner in the surface cleaning mode, the average cleaning efficiency is merely 61.26%, while hot water can only show a baseline level of 31.92% in the surface cleaning mode.
Results
From EXAMPLE 2(a), the results show that the cleaning performance of the Preferred Solution and the standard Steam Cleaner is high (accepted performance levels when compared to the 82.33% benchmark of EXAMPLE 1) when used at 8 oz./gallon in the deep cleaning mode. However, from EXAMPLE 2(b), at 8 oz./gallon, the performance of the standard Steam Cleaner decreases to a “below acceptable” (below the 82.33% benchmark of EXAMPLE 1) level in the surface cleaning mode. At the same 8 oz./gallon concentration, the Preferred Solution shows an average cleaning efficiency that is acceptable in the surface cleaning mode. This dilution is the preferred use level for the Preferred Solution in the reduced flow mode.
Further experiments were run using carpets soiled in real-life conditions to obtain similar results. For example, cleaning a soiled carpet from a typical residence with an 8 oz./gallon concentration of the Preferred Solution in the surface cleaning mode, the average % cleaning efficiency improved to 88.42% from 86.12% in the controlled experiments. Thus, the slight variation in this result suggests that the results obtained in the laboratory will be comparable, if not better, in a real world environment.
A Nylon Saxony Plush carpet was used in this test, but similar results were obtained for various carpet fibers including Nylon Loop and Olefin Loop carpets.
Overall, it can be deduced from the above EXAMPLES that the Preferred Solution 1) provides acceptable cleaning in both the deep cleaning and surface cleaning modes of the carpet cleaning machine; 2) the preferred dilution ratios for the Preferred Solution are unique to the carpet cleaning machine of the invention; and 3) the combined performance of reduced drying time and cleaning efficiency cannot be achieved by using the standard Steam Cleaner solution.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, ball valve 42 of selection mechanism 168 could be any multi-positional valve. In addition the two deep clean jet tips 60 could be replaced with a single jet tip 60 . Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. | A dual mode carpet cleaning method is capable of being used in both a deep cleaning mode and a fast drying surface cleaning mode. The method utilizes a carpet cleaning apparatus that provides selective communication with different sets of cleaning jets. One set of cleaning jets is operated to deliver a first cleaning solution that penetrates deeply into a carpet in the deep cleaning mode. A second set of cleaning jets is operated to deliver a lower flow rate of a second cleaning solution that does not penetrate as deeply into the carpet and dries quickly. The method involves manually operating a valve on the apparatus to selectively communicate a source of cleaning fluid of the apparatus with one of the first set of cleaning jets and the second set of cleaning jets, and discharging the cleaning liquid from the selected one of the first set of cleaning jets and second set of cleaning jets onto a carpet to be cleaned. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a silver halide photographic material and in particular to a silver halide photographic material exhibiting superior print stability and capable of providing prints with superior image quality when printed onto printing paper.
BACKGROUND OF THE INVENTION
[0002] Based on recent progress in techniques for silver halide photographic materials used as general negative film for camera use (hereinafter, also denoted simply as photographic materials or negative film), photographic materials having a higher speed than the common speed of ISO 100 have become commercially available, one after another. Furthermore, the use of zoom lenses of a long focal length has increased along with popularization of compact cameras for amateur photographers. Thus, the full open value (lightness) of a lens has become smaller and the percentage of under-exposed scenes has increased compared to the past, resulting in lowering print productivity and finished print quality in photofinishing laboratories, and consequently, an immediate solution thereof is therefore desired.
[0003] When printing from an under-exposed negative film, high-light and shadow portions of the main subject in the under-exposed scene show poor density representation (tone reproduction), so that when the density of the subject is increased, the overall density increases, resulting in an excessively dark print; on the contrary, when the overall density is decreased, the density of the subject becomes lighter, resulting in blurred images and leading to print images not acceptable to customers. In such situations, the acceptable range of proper print density becomes narrower, resulting in printing difficulty.
[0004] Such appearance of under-exposed scenes often occur not only in the case of indoor photography, night photography, scenes having a relatively high dark proportion and photographing by using darker lenses such as a zoom lens, but also in the case of so-called photographing against light, such as a dark subject against the light background of the sky. It was proved from a survey that in such photography against light, few photographers realized that dark scenes were really photographed, often resulting in cases that the photographers discovered under-exposed photography when they obtained their prints from under-exposures. It was further proved that the difference between realization or expectation of the photographer and the real finished print quality was wide, often producing dominant causes of complaints for poor quality.
[0005] The speed in the foregoing photography system is generally called effective speed. It is commonly known that the effective speed in the negative-positive system using color negative film and color paper is more or less related with but is not simply connected to the commonly used color negative film speed as defined in ISO standards (hereinafter, also denoted simply as ISO speed).
[0006] Means for solving print quality problems of under-exposed scenes include, for example, enhancement of the ISP speed of color negative film. The silver halide emulsion speed is mainly dependent on silver halide crystal size and a technique of using a large grain silver halide emulsion to achieve enhanced speed, which is readily feasible and commonly practiced, as is known in the prior art or reported in literatures.
[0007] In fact, enhanced ISO speed can be achieved by the use of such a large silver halide grain emulsion, thereby also enhancing the effective speed in printing to some extent; however, the effect of solving the foregoing problems is low and on the contrary, the use of large silver halide grains produces rough graininess of the subsequent printed image. Specifically in cases when printed at a large magnification such as a 2L size or panorama size, printed images become coarse, producing complaints of prints being unacceptable by the photographers.
[0008] A single channel printer built-in with a scanner (hereinafter, also denoted as “1 ch. printer”) can faithfully scan negative images using a CCD camera (i.e., image scanning) and can also conduct appropriate exposure control taking account of pattern analysis of the respective scenes. However, the fact remains that the print yield cannot be enhanced enough even by use of such printers and finished print quality by no means reaches satisfactory levels.
[0009] As described above, the print yield can be enhanced to some extent by recent progress in printer technique but further improvements are desired.
[0010] As a result of analysis by the inventors of this application using various types of printers and photographic materials to explore causes for the foregoing problems, it was proved that variation in color reproduction, specifically in under-exposures greatly affect variation in finished print quality (which is also called print level variation) and secondly, variation in color reproduction at a normal exposure level was also explored. It was further proved from a survey of print quality on the market that users complained that image quality of under-exposures did not meet the given quality standard for the respective film speeds.
[0011] To improve the print level variation of under-exposures, an attempt of stabilizing the density balance along with exposure variation over the range of the under-exposed region to the over-exposed region have been made through enhancement of photographic material speed by applying techniques proposed or disclosed in photographic literature and patents, but marked effects have not been achieved by anyone thereof. The correct printing exposure condition set in the printer is set by attaching importance to an average value on the market for each of various film speeds. Consequently, in response to variation of color temperature in the respective scenes (for example, according to a photographing environment such as fine weather, cloudy weather, shade and electric flash light), exposure conditions for a specified film speed, e.g., ISO 800 often results in a calculated value corresponding to a film speed of ISO 200 to 400, so that delicate exposure control is not achieved.
[0012] Appearance of under-exposed scenes accounts for approximately 20% in the current negative-positive system. However, total image quality of the thus under-exposed scenes is markedly inferior to normal- or over-exposure scenes accounting for 80% and therefore, enhancement in image quality of the under-exposed scenes is desired together with enhancement in total print image quality and print yield. As described in literature, for example, “Shashin-Kogaku no Kiso Ginene-Shashin” (Fundamentals of Photographic Engineering of Silver Salt Photography), published by Corona Publishing Co., it is known that sharpness and graininess greatly affect total image quality. For example, JP-A No. 10-268467 (hereinafter, the term, JP-A refers to Japanese Patent Application Publication) discloses a method of enhancing image quality by RMS granularity at a normal exposure or in vicinity thereof. However, total image quality in under-exposed scene, which differs from that of normal-exposure scenes cannot be accounted for only in terms of sharpness and graininess. Using a large amount of silver coverage or a dye forming coupler for enhancement of image quality results in an increase in cost, therefore, it cannot be said to be an efficient method.
[0013] Recently, besides the above-described printers of a conventional exposure control system, digital type or hybrid type printers are on the rise, in which image density information is obtained as digital information by scanning developed negative images and after being subjected to image processing, printing is performed based on that information.
[0014] In cases when using such printers, in addition to the foregoing problems in exposure control at under-exposure, problems arose with compression or deficiency of information when digitizing (or quantizing) information. This is due to the fact that negative film usually has information of a density of up to 3.5 (or gradation number of more than 300 levels) and contrary to that, an image in the standard format has to be compressed to a 256 level gradation at the time of quantization and a part of the information is often not properly transformed.
[0015] However, one disadvantage thereof is that when an under-exposed, low contrast scene is converted to proper contrast, incompatibility of the density range of the negative film (hereinafter, also denoted as negative density range) and the range of quantization excessively enhances contrast to a level higher than necessary for most people, resulting in deteriorated graininess or producing problems in that an excessive decrease of contrast is caused in high contrast scenes having a main subject differing in luminance from the background. Consequently, it was proved that the dynamic range was not fully employed, often producing an unnatural image print and tending to cause print level variation. In this regard, an improvement was made using a complicated algorithm with respect to some of phenomena, but it lowered productivity per hour and proved to be unacceptable in practice.
[0016] It was further proved that rapid access and diversification of photographic processing, according to recent market trend in the photographic industry, caused lowering in the SN ratio at the stage of digitization in silver halide photographic materials using silver above a given amount. This is assumed to be due to insufficient desilvering, in which metallic silver is retained in the coat due to an exhausted bleaching solution, resulting in lowering in SN ratio at the stage of negative-positive conversion of negative images in the process of digital printing. In cases when metallic silver was retained in processed negative film, location for the respective pictures was not accurately set up at the stage of scanning the negative film in a printer. Specifically in a scene taken with a low-priced camera which was poor in film-transport accuracy, even data of portions not relevant to the real scene (minimum density portions) were read in image processing, so that the dynamic range of positive image data (8 to 16 bits) was not effectively employed to perform positive image processing, resulting in a print exhibiting contrast, which was incongruity with a print obtained by a conventional analog type printer.
SUMMARY OF THE INVENTION
[0017] In view of the foregoing problems, the present invention was achieved. Thus, it is an object of the invention to provide a silver halide photographic material, which exhibits improved color stability and superior image quality when used in printing under-exposed scenes on printing paper by using an analog type printer and which also exhibits superior graininess, improved color stability and scanner suitability, and superior tone reproducibility when printed by using a digital type printer.
[0018] Specifically, the present invention was accomplished by the following constitution.
[0019] 1. A silver halide photographic light sensitive material which is in the form of a roll film packaged in a cartridge, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the photographic material satisfies the following equation (1):
QC≦ 15.982 ×S −0.378 (1)
[0020] wherein S represents a nominal speed of the photographic material, provided that 100≦S≦1600; and QC represents a quality value and is defined as follows;
[0021] when a Macbeth color checker chart (having 24 colored squares including 6 neutral gray areas and 18 color areas) having been photographed with the photographic material using a camera under a light source having a color temperature of 4800° K. at an under-exposure of 3 stops-down from normal exposure in which the aperture of the camera is reduced by 3 steps from the normal exposure and after having been processed, the photographic material is exposed to obtain a print under the exposure condition so that N5 gray of the Macbeth color checker chart (gray chart of 18% reflectance) gives values of L*=50, a*=0 and b*=0 and 18 colors other than gray are subjected to chromaticity measurement, the quality value of QC is calculated according to the following equation (2):
QC= ( Cr+Ch )/2 (2)
[0022] wherein Cr and Ch are defined in the following equations (3) and (4):
Cr= 20×log 10 ( Cr 0) (3)
Ch= 7.0−3×log 10 ( Ch 0) (4)
[0023] wherein Cr0 represents a ratio of a mean chroma value calculated from chromaticity values of 18 colors of the Macbeth color checker chart to a mean chroma value calculated from chromaticity values of 18 colors of the print of the Macbeth color checker chart; and when from color vectors of the 18 colors of the Macbeth color checker chart and the respective color vectors of the print corresponding to the Macbeth color checker chart, chromaticity fluctuations for the respective colors are represented by an angle between the foregoing color vectors for each of the 18 colors, a mean value of the chromaticity fluctuations is designated as Ch0;
[0024] 2. A silver halide photographic light sensitive material which is in the form of roll film packaged in a cartridge, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the photographic material satisfies the following equation (5):
QT≧ 11.544 ×S −1.2752 (5)
[0025] wherein S represents a nominal speed of the photographic material, provided that 100≦S≦1600; and QT represents a quality value and is defined by the following equation (6):
QT= ( QC+QG )/2 (6)
[0026] wherein QC is the same as defined in 1. above; and QG is defined as follows;
QG=( 0.413 ×M −3.4 +0.422 ×R −3.4 ) −1/3.4 −0.53
[0027] wherein M and G are defined by the following equations:
M= 7.0×log 10 ( Mg× 0.7 +Mr× 0.3)−10 (12)
Mg=Mg 0 ×γg ×100 (10)
Mr=Mr 0 ×γr× 100 (11)
[0028] wherein Mg0 and Mr0 are MTF values at a spatial frequency of 15 cycle/mm of magenta and cyan images obtained at normal exposure, respectively; when the photographic material is exposed at an under-exposure in which the aperture is reduced by 3 steps from the normal exposure and after being processed, the density of the area corresponding to a Neutral 5 (N5) gray area of the Macbeth Color Checker chart is determined, which is designated as Dg 1 and Dr 1 and when the photographic material is exposed and processed to prepare a characteristic curve comprised of an ordinate of density (D) and abscissa of exposure (logE) for each of magenta and cyan images, γg and γr are a slope (tanθ) of a straight line connecting two points corresponding Dg 2 and Dg 3 or Dr 2 and Dr 3 on the magenta or cyan characteristic curve is determined for magenta and cyan images, in which when an exposure at density Dg 1 or Dr 1 on the characteristic curve is designated as logEg 1 or logEr 1 , Dg 2 and Dr 2 are respectively densities corresponding to exposures of logEg 2 =logEg 1 −0.3 and logEr 2 =logEr 1 −0.3 on the magenta and cyan characteristic curves, and Dg 3 and Dr 3 are respectively densities corresponding to exposures of logEg 3 =loggE 1 +0.3 and logEr 3 =loggrE 1 +0.3 on the characteristic curve;
R= (7 ×Rg+ 4 ×Rr )/11 (9)
Rg=− 7.0×log 10 (3.4 ×Rgav )+15.5 (7)
Rr=− 7.0×log 10 (3.4 ×Rrav )+15.5 (8)
[0029] wherein Rgav is an average value of RMS granularities RMSg 1 , RMSg 2 and RMSg 3 at densities Dg 1 , Dg 2 and Dg 3 on the characteristic curve of the magenta image; and Rrav is an average value of RMS granularities RMSr 1 , RMSr 2 and RMSr 3 at densities Dr 1 , Dr 2 and Dr 3 on the characteristic curve of the cyan image;
[0030] 3. A silver halide photographic light sensitive material which is in the form of a roll film packaged in a cartridge, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the photographic material satisfies the following equation (14) and exhibits a cyan minimum density of less than 0.20 after having been processed:
QTN≧ 14.838 ×S −0.274 (14)
[0031] wherein S represents a nominal speed of the photographic material, provided that 100≦S≦1600; and QTN represents a quality value and is defined by the following equation (15):
QTN= ( QCN+QGN )/2 (15)
[0032] wherein QCN is a value which is obtained similarly to the foregoing QC value, except that a Macbeth color checker chart (comprised of 24 colored squares) has been photographed with the photographic material using a light source having a color temperature of 4800° K. at a normal exposure; and QGN is a value which is obtained similarly to the foregoing QG value, except that a Macbeth color checker chart (comprised of 24 colored squares) has been photographed with the photographic material using a light source having a color temperature of 4800° K. at a normal exposure;
[0033] 4. The silver halide photographic material described in 1. or 2., wherein the photographic material satisfies the following equation (14) and exhibits a cyan minimum density of less than 0.20 after having been processed;
[0034] 5. The silver halide photographic material described in any of 1. through 4., wherein the photographic material satisfies the following equation (16):
B≦ 10−10 (−0.005×S+0.85 )
[0035] wherein B represents a total silver coverage, expressed in g/m 2 ; S represents a nominal speed of the photographic material, provided that 100≦S≦1600;
[0036] 6. The silver halide photographic material described in any of 1. through 5., wherein the photographic material contains an infrared dye having a main absorption at the wavelength of 700 to 1100 nm;
[0037] 7. The silver halide photographic material described in any of 1 through 6., wherein the photographic material has a nominal speed of 100 to 400.
[0038] The inventors of this application have made studies in light of the problems described earlier and as a result of detailed analysis of density distribution of photographed scenes taken by general users, it was proved that in algorithm for exposure control at specified speed of a printer, normal exposure conditions were easily determined when color reproduction of under-exposed photographic material was higher than a given value for the film speed.
[0039] Efficient achievement of enhancement of image quality has been a proposition for years and development of a method thereof has been consistently desired. As a result of the inventors' study, it was further proved that a dominant factor of print quality of under-exposures was not only graininess but also when a quality value relating to color reproduction, QC value and a quality value (or QT value) including graininess and sharpness both of which were more than prescribed values, print quality was recognized as being superior; and the quality values depend of nominal speed of the used film. Thus, the present invention is presented based on the foregoing.
DETAILED DESCRIPTION OF THE INVENTION
[0040] One aspect of the invention is that a silver halide photographic light sensitive material, which is packaged in a cartridge in a roll form, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the quality value QC, as defined earlier satisfies the equation (1).
[0041] The quality value, QC is a parameter indicating the extent of color balance of a finished print of an under-exposed scene, that is, print level variation.
[0042] As a result of the study of methods for decreasing print level variation of commercially available printers and enhancing finished print quality, it was proved that normal exposure conditions not being determined in the printer was a factor of increasing the print level variation. From analysis of a problem of finished print quality, it was further proved that low contrast of the obtained print image was a cause thereof.
[0043] However, allowing both problems described above to exist simultaneously means treating the under-exposed scene and the correctly exposed scene as the same characteristic, leading to an increase of the silver content of a photographic material for picture-taking (or camera material) and producing problems such as silver retention, increased fog density and increased cost, which are by no means effective. As a means for increasing contrast in the toe portion on a characteristic curve which is used in the under-exposed cameral material is cited a method of using large silver halide grains to increase the ISO speed. In fact, enhancing the effective speed in printing can be achieved to some extent; however, on the contrary, the use of large silver halide grains produces rough graininess of the subsequent printed image, often producing complaints of prints being unacceptable by the photographer. It was further proved that even if the effective speed was enhanced by the foregoing method, color contrast was insufficient and proper printing conditions could not be determined, which was not so effective to reduce the print level variation.
[0044] The invention was made in view of the foregoing problems. Thus, exposure conditions of a printer are set up, as follows: the overall exposure condition has been controlled up to now based on neutral densities so as to raise or lower the finished density. In the invention, when separated color densities, specifically those in under-exposures are different, a correction value is calculated and the relationship between quality value QC as the correction value and the nominal speed of the photographic material is specified to provide a print exhibiting a stable color balance even when photographed at an under-exposure. In the invention, quality value QC is represented by rounding a calculated value to one decimal.
[0045] According to equation (1) described above, the quality value QC relating to the invention is 2.8 or more for photographic material of the nominal speed of 100, 2.2 or more for photographic material of the nominal speed 200, 1.7 or more for photographic material of the nominal speed 400, 1.3 or more for photographic material of the nominal speed 800, and 1.0 or more for photographic material of the nominal speed 1600.
[0046] Unless satisfying the foregoing condition, determination of the proper density and calculation of printing conditions in cases when color temperature or background vary at the time of taking-picture cannot be definitely achieved, making it difficult to finish human skin color within acceptable levels of tolerance.
[0047] Next, quality value QC will be described. In the invention, the QC value satisfies the following equation:
QC≧ 15.982 ×S −0.378 (1)
[0048] wherein S represents a nominal speed of a photographic material, provided that 100≦S≦1600; and QC is determined in accordance with the process comprising the steps of:
[0049] (i) photographing a Macbeth color checker chart which is a checkerboard array of 24 colored squares in a wide range colors (including 6 grades of neutral gray and 18 kinds of colors other than gray) with the photographic material under a light source having a color temperature of 4800° K. using a camera at an under-exposure of 3 stops-down from normal exposure in which the aperture of the camera is reduced by 3 steps from that of the normal exposure;
[0050] (ii) processing the thus exposed photographic material in a prescribed color processing, for example, the process described in paragraph [0220]-[0227] of JP-A No. 10-123652, as described later;
[0051] (iii) printing the processed photographic material on a color paper to produce a color print, under such an exposure condition that an area on the print, corresponding to Neutral 5 (or N5) gray area of the Macbeth color checker chart (which is a neutral gray area exhibiting a reflectance of 18%) gives values of L*=50, a*=0 and b*=0,
[0052] (iv) subjecting the color print to chromaticity measurement to determine chroma values of areas on the print corresponding to 18 colors other than the 6 grades of gray of the Macbeth color checker chart, and
[0053] (v) calculating the foregoing QC value according to the following equation (2):
QC= ( Cr+Ch )/2 (2)
[0054] wherein Cr and Ch are defined in the following equations (3) and (4):
Cr= 20×log 10 ( Cr 0) (3)
Ch= 7.0−3×log 10 ( Ch 0) (4)
[0055] wherein Cr0 is the ratio of the mean value of chroma values of 18 colors of the Macbeth color checker chart to the mean value of chroma values of the areas on the print corresponding to the 18 colors of the Macbeth color checker chart; and the absolute value of the difference in angle between a color vector of each of the 18 colors of the Macbeth color checker chart and that of an area on the print corresponding to each of the 18 colors is determined and the average value of the thus determined absolute values of the 18 colors is defined as Ch0.
[0056] In the invention, the L*, a* and b* values are color coordinates represented by CIE 1976 (L*, a*, b*) space, and calorimetric calculation is made using standard light source C as an observation light to obtain tristimulus values. The L*, a* and c* values are commonly known in the art, as described, for example, in U.S. Pat. No. 5,362,616, and can also be determined by the method described in “Shikisai Kagaku Handbook (New Edition)”, pages 83-146, 182-255 (edited by Nippon Shikisai-Gakkai, published by Tokyo Daigaku Shuppankai). Thus, chromaticity of a photographic material for camera use is measured using a color analyzer (e.g., CMS-1200, produced by Murakami Shikisai Co., Ltd.) and the chromaticity point in the L*a*b* space is determined using a color matching function at a visual field of 20 and a standard light source, C light source.
[0057] The nominal speed, designated as “S”, refers to a numeral indicated subsequent to designation “ISO” on the outside of a cartridge (or patrone) or a vessel having photographic film of commonly known 135 size, IV 240 Type and the like. Alternatively, on the outer surface of the metallic container of 135 size roll film (also called cartridge), a portion comprised of a conductive section and non-conductive section, so-called CAS portion is provided to detect the film speed, and the nominal speed is a speed value indicated when the cartridge is loaded in a camera. Speed of photographic material is represented in various ways in different countries. The nominal speed in the invention (designated as “S”) is expressed in ISO speed, which is used as an international designation. In the case of the ISO speed designation being 100/21°, the ISP speed is to be 100. In the invention, S is not less than 100 and not more than 1600, and preferably not less than 100 and not more than 400.
[0058] The normal exposure in general refers to the exposure condition which can be determined by means of a commercially available exposure meter, in which the film speed, and the aperture (stop) and shutter speed (exposure time) in photographing (picture-taking). The designated values therein are often determined based on N5 gray chart (of Macbeth color checker chart), exhibiting 18% reflectance. In this invention, the normal exposure is defined as an exposure amount of 10/S l×·sec, where S is the nominal speed. In the case of the film speed of 100, for example, the normal exposure is to be the exposure condition giving an exposure amount of 0.10 l×·sec. Furthermore, as described earlier, expression “having been photographed at an under-exposure of 3 stops-down from normal exposure in which the aperture of the camera is reduced by 3 steps from the normal exposure” means that photographic is performed in an exposure amount of ⅛ of the normal exposure amount, as defined above.
[0059] One aspect of this invention is that a silver halide photographic light sensitive material which is in the form of a roll film packaged in a cartridge, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the quality value QT, as defined earlier satisfies the equation (5). The quality value QT is a parameter indicating image quality of a print, that is, graininess and sharpness of an underexposed scene.
[0060] It is generally said that sharpness and graininess affect image quality of finished prints. It is really difficult to achieve an appropriate image quality design at the same level as the normal exposure region and it is the status quo that effective means therefore are few. As described earlier, deteriorated contrast is cited as print quality of under-exposures. Specifically, from reflection density and visual assessment values of graininess and image quality of finished prints, it was proved that image quality of under-exposed scenes was affected by color reproduction to a greater extent than that of normally exposed scenes. It was further proved that a product of RMS granularity as a barometer of graininess, MTF as a barometer of sharpness and neutral contrast was also an important factor. It was found that the object of the invention was achieved when the quality value QT which was determined by the contrast of an under-exposed scene, QG approximated by a hyperbolic curve having a parameter of graininess and color space of the QC value described earlier, and the nominal speed of a photographic material meet the relationship represented by equation (5). In this invention, the QT value was rounded to one decimal.
[0061] According to the equation (5) described earlier, the preferred quality value QT relating to the invention is 3.3 or more for photographic material of the nominal speed of 100, 2.7 or more for photographic material of nominal speed 200, 2.2 or more for photographic material of nominal speed 400, 1.8 or more for photographic material of nominal speed 800, and 1.5 or more for photographic material of nominal speed 1600.
[0062] It is unclear problems in the design of a photographic material for camera use that how graininess, sharpness, contrast and color reproduction are balanced to obtain a best print and therefore, extensive trial-and error experimentation was conducted to achieve optimum design. Development of silver halide photographic materials optimized to the respective nominal speeds can be efficiently achieved by advancing design based on the quality value QT relating to this invention, thereby leading to enhanced image quality of finished prints.
[0063] Next, the quality value QT will be detailed. In the invention, the photographic material satisfies the following equation (5):
QT≧ 11.544 ×S −0.2752 (5)
[0064] wherein S represents the nominal speed of the photographic material for camera use, provided that 100 ≦S≦ 1600; and QT represents the quality value and is defined by the following equation (6):
QT= ( QC+QG )/2 (6)
[0065] In the equation (6), QC is the same as quality value QC as described earlier and QG is defined as follows;
[0066] when a Macbeth color checker chart (comprised of 24 colored squares) has been photographed with the photographic material using a camera under a light source having a color temperature of 4800° K. at an under-exposure of 3 stops-down from the normal exposure in which the aperture of the camera is reduced by 3 steps from the normal exposure and after processing the photographic material, the density of the area corresponding to a Neutral 5 (N5) gray area of the Macbeth Color Checker chart is designated as D 1 (or Dg 1 and Dr 1 for magenta and cyan densities, respectively). Separately, the photographic material is exposed and processed to prepare a characteristic curve for each of magenta and cyan dye images. The characteristic curve, as is well known in the art, is comprised of ordinate of density (designated as D) and abscissa of logarithmic exposure (designated as logE). A granularity at the density of D 1 (or Dg 1 and Dr 1 ) is determined and designated as RMS 1 (or RMSg 1 and RMSr 1 ). When an exposure at density D 1 on the characteristic curve (or densities Dg 1 , and Dr 1 on the magenta and cyan characteristic curves) is designated as logE 1 (logEg 1 and logEr 1 ), a granularity at a density D 2 corresponding to an exposure of logE 2 =logE 1 −0.3 on the characteristic curve is determined and designated as RMS 2 (or RMSg 2 and RMSr 2 ), and a granularity at a density D 3 corresponding to an exposure of logE 3 =logE 1 +0.3 on the characteristic curve is determined and designated as RMS 3 (or RMSg 3 and RMSr 3 ), the average value of granularities at the foregoing three densities (Dg 1 , Dg 2 and Dg 3 ) on the characteristic curve of a magenta dye image is determined and designated as Rgav; and the average value of granularities at the foregoing three densities (Dr 1 , Dr 2 and Dr 3 ) on the characteristic curve of a cyan dye image is designated as Rrav; Rg and Rr are determined by the following equations (7) and (8):
Rg=− 7.0×log 10 (3.4 ×Rgav )+15.5 (7)
Rr=− 7.0×log 10 (3.4 ×Rrav )+15.5 (8)
[0067] A characteristic curve can be prepared in the following manner. A photographic material for camera use is exposed to light for {fraction (1/200)} sec. through an optical wedge using light source having a color temperature of 4800° K. and processed, for example, according to the process described in JP-A No. 10-123652, col. [0220] through [0227] and the processed photographic material is subjected to densitometry using a densitometer, for example, a densitometer produced by X-rite Co. to prepare characteristic curves comprised of an ordinate of density (D) and an abscissa of logarithmic exposure (logE) for yellow, magenta and cyan images, respectively. Specifically, the density at a portion in the processed photographic material, which corresponds to the Neutral 5 (N5 gray) square in the Macbeth Color Checker chart is measured to obtain density D 1 and the RMS granularity at density D 1 is determined and designated as RMS 1 . Furthermore, when exposure (logE) corresponding to density D 1 on the characteristic curve as obtained above is designated as logE 1 , RMS granularities at exposures of logE 2 =logE 1 −0.3 and logE 3 =logE 1 +0.3 on the characteristic curve are determined, which are designated as RMS 2 and RMS 3 , respectively, and which are determined for each of magenta and cyan dye images.
[0068] The granularity (RMS) is measured in such a manner that densitometry is made by scanning with a micro-densitometer at an aperture area of 750 μm 2 (a 5 μm wide, 150 μm long slit) and 1000 times a standard deviation of density variation of at least 1000 densitometry samples is defined as a RMS value of this invention. Magenta and cyan densities are measured using Wratten filters W-99 and W-20 (available from Eastman Kodak Co.), respectively.
[0069] From the thus obtained Rg and Rr values, R is determined in accordance with the following equation (9):
[0070] Equation (9)
R= (7 ×Rg+ 4 ×Rr )/11 (9)
[0071] Next, MTF values at a spatial frequency of 15 cycle/mm of magenta and cyan images obtained at normal exposure are designated as Mg0 and Mr0, respectively. Thus, the photographic material is exposed to light through a pattern wedge for MTF measurement and after being processed, the photographic material is subjected to densitometry using a microdensitometer to determine MTF values at a spatial frequency of 15 cycle/mm of magenta and cyan images obtained under the normal exposure.
[0072] Further, slope (tanθ) of a straight line connecting two points corresponding D 2 (Dg 2 or Dr 2 ) D 3 (Dg 3 or Dr 3 ) on the foregoing characteristic curve is determined for magenta and cyan images and designated as γg and γr. Thus, when the density at the portion corresponding to N5 gray (or Neutral 5) of the Macbeth color checker chart is designated as D 1 and an exposure at density D 1 on the characteristic curve is designated as logE 1 , D 2 and D 3 are densities corresponding to exposures of logE 2 =logE 1 −0.3 and logE 3 =logE 1 +0.3 on the characteristic curve, respectively. Furthermore, using the foregoing values Mg0, Mr0, γg and γr, Mg and Mr are determined in accordance with the following equations (10) and (11):
Mg=Mg 0× γg× 100 (10)
Mr=Mr 0× γr× 100 (11)
[0073] Furthermore, M is determined in accordance with the following equation (12):
M= 7.0×log 10 ( Mg× 0.7 +Mr× 0.3)−10 (12)
[0074] Measurement of the MTF value is commonly known and can readily be made. Details thereof, including the principle and method of the measurement, calculation equations and meaning as a photographic image are described in, for example, “Shashin-Kogaku no Kiso of Gineneshashin” (Fundamentals of Photographic Engineering of Silver Salt Photography, published by Corona Publishing Co.) on page 414-421.
[0075] Using the thus obtained M and R, QG is calculated in accordance with the following equation (13):
QG= (0.413 ×M −3.4 +0.422 ×R −3.4 ) −1/3.4 −0.53 (13)
[0076] In one preferred embodiment of this invention, a silver halide photographic light sensitive material which is packaged in a roll form in a cartridge, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer is characterized in that quality value QTN described earlier satisfies equation (14) and the minimum cyan density of the processed photographic material is less than 0.20. The quality value QTN is a barometer representing relationship of graininess, sharpness and color reproduction in the normal exposure region, specifically concerning scanner suitability for backlight scenes in digital printers or hybrid printers.
[0077] Next, improvements of graininess and contrast in backlight scenes, when using digital or hybrid printers will be described.
[0078] As a result of analysis of negative film picture-taken by amateur photographers, it was proved that when compressing or quantizing information at densities up to 3.5 (or gradation of more than 300 levels) to an image in the standard format having gradation of 256 levels, part of the information was not properly transformed. Specifically, transformation of low contrast scenes such as under-exposed scenes or backlight scenes to a proper contrast disadvantageously results in deteriorated image quality.
[0079] This was partially due to sharpness and graininess in normal exposures, and it was proved to be necessary to make correction of color information of negative film in contrast transformation to inhibit excessive transformation. As a result, it was concluded that chroma of blue, green and red densities and hue reproduction are significant to inhibit excessive transformation in negative film, and unless both, chroma and density fall within the specific range, contrast transformation in quantization of respective densities at the time when printer software computes the average density unnecessarily modulates contrast of silver halide photographic material. Thus, it was proved that the foregoing problems could be overcome by setting the QTN quality value and the nominal speed of photographic material for camera use so as to meet the relationship defined in equation 14.
[0080] According to equation (14) described below, the quality value, QTN is preferably 4.2 or more for photographic material of the nominal speed of 100, 3.5 or more for photographic material of the nominal speed 200, 2.9 or more for photographic material of the nominal speed 400, 2.4 or more for photographic material of the nominal speed 800, and 2.0 or more for photographic material of the nominal speed 1600.
[0081] This was proved to be due to the fact that photographic color film usually has a minimum density (corresponding to a mask density) and unnecessary data in the minimum density area affect digital quantization of uncompressed analog information.
[0082] Analysis of effects of respective mask densities on blue, green and red densities revealed that the respective mask densities affected images substantially at an equal level. It was further proved that when the minimum red density is less than 0.2 to reproduce flesh tone, the combination of the QTN value therewith results in prints with natural contrast in the normal exposure region and superior graininess even when employing functions such as local printing in digital prints.
[0083] Next, quality value QTN relating to this invention will be detailed below. The quality value QTN is represented by the following equation (14):
QTN≧ 14.838 ×S −0.274 (14)
[0084] wherein S is a nominal speed, provided that 100≦S≦1600; and QTN is defined by the following equation (15):
QTN= ( QCN+QGN )/2 (15)
[0085] wherein QCN is the same as defined earlier, except that a Macbeth color checker chart (comprised of 24 varyingly colored squares) is photographed at a normal exposure with the photographic material using a light source having a color temperature of 4800° K.; and QGN is the same as defined earlier, except that a Macbeth color checker chart (comprised of 24 colored squares) is photographed at a normal exposure with the photographic material using a light source having a color temperature of 4800° K.
[0086] In one preferred embodiment of this invention, the total silver coverage, which is represented as calculated in terms of silver (i.e., coating weight of silver), is the silver content, B (g/m 2 ) meeting the following equation (16):
B≦ 10.0−10 (−0.005×S+0.85) (16)
[0087] wherein S is a nominal speed, provided 100≦S≦1600.
[0088] When the content of silver used in a photographic material and the nominal speed of the photographic material meet the foregoing equation (16), the state of speed and the state of image quality of the photographic material are optimized and optimizing desilvering ability in various processes leads to an enhanced S/N ratio in negative to positive conversion of negative film at the stage of digital printing.
[0089] According to equation (16), silver content B is 3.4 (g/m 2 ) or less for photographic material of the nominal speed of 100, 3.8 (g/m 2 ) or less for photographic material of nominal speed 200, 4.6(g/m 2 ) or less for photographic material of nominal speed 400, 5.9(g/m 2 ) or less for photographic material of nominal speed 800, and 7.7 (g/m 2 ) or less for photographic material of nominal speed 1600.
[0090] In one preferred embodiment of this invention, the silver halide photographic material relating to the invention contains an infrared absorbing dye having its main absorption at wavelengths of 700 to 1100 nm. Thus, the infrared transmission density is preferably increased in the photographic material relating to this invention, whereby positioning for individual pictures, for example, scenes taken by film with lens or a low price camera can be precisely conducted at the stage of scanning processed negative film and image processing is conducted without reading a portion not relevant to the real scene (minimum density) to perform positive image processing by effectively using the dynamic range of positive image data (8 to 16 bits), leading to finished prints having superior (not unpleasant) contrast, which is close to that performed by an analog printer.
[0091] Any infrared absorbing dye having an absorption maximum within the wavelength region of 700 to 1100 nm is applicable to this invention. Such infrared absorbing dyes have been used in infrared-recording silver halide photographic material, semiconductor laser, optical filter, LB membranes, photoelectric conversion, and vinyl resin structures in agricultural application. Examples of specific infrared dyes include cyanine type dyes, methine type dyes, quinone type dyes, naphthoquinone type dyes, quinonediimine type dyes, phthalocyanine type dyes and 1,2-dithiol complex type dyes.
[0092] Cyanine Dye
[0093] Cyanine type near-infrared absorbing dyes useable in this invention preferable are compounds represented by the following formula (1) or (3):
[0094] In the formula, Y 11 , Y 12 , Y 21 , and Y 22 are each independently an non-metallic atom group necessary to form a 5- or 6-membered nitrogen-containing heterocyclic ring, such as a benzothiazole ring, naphthothiazole ring, benzoselenazole ring, naphthoselenazole ring, benzoxazole ring, naphthoxazole ring, quinoline ring, 3,3-dialkylindolenine ring, benzimidazole ring and pyridine ring. The heterocyclic ring may be substituted by substituent groups such as low alkyl group, alkoxy group, hydroxy group, aryl group, alkoxycarbonyl group and halogen atom. R 11 , R 12 , R 21 and R 22 are each independently a substituted or unsubstituted alkyl aryl or aralkyl group. R 13 , R 14 , R 15 , R 23 , R 24 , R 25 , and R 26 are each independently a substituted or unsubstituted alkyl, alkoxy, phenyl, benzyl group or —N<W 1 W 2 , in which W 1 and W 2 are each a substituted or unsubstituted alkyl (comprised of an alkyl portion having 1 to 18, and preferably 1 to 4 carbon atoms) or aryl group, provided that W 1 and W 2 may be linked together with each other to a 5- or 6-membered nitrogen containing heterocyclic ring. R 13 and R 15 , or R 23 and R 25 may be linked together with each other to form a 5- or 6-membered ring. X 11 − and X 21 − are each an anion; n11, n12, n21 and n22 are each 0 or 1.
[0095] Representative examples of the compounds represented by formula (1) or (3) are shown below, but the present invention is by no means limited to these compounds.
Exam- ple No. Y 1 Y 2 B 1 C 1 B 2 C 2 R 11 R 12 V 1 X − D 1 D 2 1-1 Se Se H H H H C 2 H 5 C 2 H 5 H I H H 1-2 S S H H H H C 2 H 5 C 2 H 5 H I H H 1-3 Se Se H H H H (CH 2 ) 2 OCH 3 (CH 2 ) 2 OCH 3 H Br H H 1-4 Se S H H H H (CH 2 ) 3 SO 3 H C 2 H 5 H — H H 1-5 S S H OCH 3 H H C 2 H 5 C 2 H 4 OH C 2 H 5 Br H H 1-6 S S C 2 H 5 H C 2 H 5 H C 5 H 11 C 5 H 11 C 2 H 5 Br H H 1-7 S S C 2 H 5 H C 2 H 5 H C 5 H 11 C 5 H 11 C 4 H 9 Br H H 1-8 S S OCH 3 OCH 3 OCH 3 OCH 3 C 2 H 5 C 2 H 5 CH 3 I H H 1-9 S S OCH 3 H OCH 3 H C 2 H 5 C 2 H 5 H I OCH 3 OCH 3 1-10 S S OCH 3 H OCH 3 H CH 2 CH═CH 2 CH 2 CH═CH 2 H I OCH 3 OCH 3 1-11 S S OCH 3 H OCH 3 H CH 2 CH═CH 2 CH 2 CH═CH 2 C 2 H 5 Br OCH 3 OCH 3
[0096] [0096] Exam- ple No. Y 3 Y 4 B 3 C 3 B 4 C 4 R 13 R 14 — 2-1 S S H H H H C 2 H 5 C 2 H 5 Br 2-2 S S CH 3 H H H C 2 H 5 C 2 H 5 Br 2-3 S S CH 3 H CH 3 H C 2 H 5 C 2 H 5 I 2-4 S S H H H H C 2 H 5 C 3 H 7 I 2-5 S S H H H H C 2 H 5 C 4 H 9 I 2-6 S S H H H H C 2 H 5 C 5 H 11 Br 2-7 S S H H H H C 2 H 5 C 7 H 15 Br 2-8 S S H H H H C 2 H 5 C 10 H 21 Br 2-9 S S H H H H C 3 H 7 C 3 H 7 Br 2-10 S S H H H H C 4 H 9 C 4 H 9 PTS − * 2-11 S S H H H H C 5 H 11 C 5 H 11 Br 2-12 S S H H H H C 7 H 15 C 7 H 15 Br 2-13 S S CH 3 H H H C 2 H 5 C 5 H 11 Br 2-14 S S CH 3 H CH 3 H C 2 H 5 C 5 H 11 Br 2-15 S S OCH 3 H H H C 2 H 5 C 2 H 5 Br 2-16 S S OCH 3 H H H C 2 H 5 C 5 H 11 Br 2-17 S S CH 3 CH 3 CH 3 CH 3 C 2 H 5 C 2 H 5 Br 2-18 S S C 3 H 7 (i) H C 3 H 7 (i) H C 2 H 5 C 2 H 5 Br 2-19 S S H H H H C 2 H 5 (CH 2 ) 3 SO 3 − — 2-20 S S CH 3 H CH 3 H C 2 H 5 (CH 2 ) 4 SO 3 − — 2-21 S S CH 3 H CH 3 H (CH 2 ) 3 SO 3 HN(C 2 H 5 ) 3 (CH 2 ) 3 SO 3 − — 2-22 S S H H H H C 2 H 5 (CH 2 ) 4 SO 3 − — 2-23 S S CH 3 H CH 3 H C 2 H 5 C 5 H 11 Br 2-24 Se Se H H H H C 2 H 5 C 2 H 5 Br 2-25 Se Se CH 3 H CH 3 H C 2 H 5 C 2 H 5 Br
[0097] [0097]
[0098] The foregoing infrared absorbing dyes can be readily synthesized in accordance with methods described in F. M. Hamer, The Chemistry of Heterocyclic Compounds, vol. 18, The CYanine Dyes and Related Compounds (A. Weissberger ed., Interscience, New York, 1964).
[0099] Next, silver halide photographic materials relating to this invention will be described.
[0100] As silver halide grains used in the silver halide photographic material of this invention, tabular silver halide grains having an aspect ratio of 8 or more, which account for at least 50% of the total grain projected are preferably used to achieve enhanced sensitivity and superior image quality. Tabular grains having an aspect ratio of 15 or more and accounting for at least 15% of the total grain projected area are specifically preferred.
[0101] In the photographic materials relating to the invention are usable silver halide emulsions described in Research Disclosure NO. 308119 (hereinafter, also denoted simply as RD308119). Relevant portions are shown below.
Item RD 308119 Iodide composition 993, I-A Preparation method 993, I-A; 994, I-E Crystal habit (regular crystal) 994, I-E Crystal habit (twinned crystal) 993, I-E Epitaxial 993, I-E Homogeneous halide composition 993, I-B Inhomogeneous halide composition 993, I-B Halide conversion 994, I-C Halide substitution 994, I-C Metal occlusion 994, I-D Monodispersibility 995, I-F Solvent addition 995, I-F Latent image forming site (surface) 995, I-G Latent image forming site (internal) 995, I-G Photographic material (negative) 995, I-H Photographic material (positive, including internally fogged grains) 995, I-H Emulsion blending 995, I-I Desalting 995, II-A
[0102] Silver halide emulsions according to the invention are subjected to physical ripening, chemical ripening and spectral sensitization. As additives used in these processes are shown compounds described in Research Disclosure RD 17643, RD 18716 and RD 308119), as below.
Item RD 308119 RD 17643 RD 18716 Chemical Sensitizer 996, III-A 23 648 Spectral Sensitizer 996, IV-A-A, B, C, 23-24 648-9 D, H, I, J Super Sensitizer 996, IV-A-E, J 23-24 648-9 Antifoggant 998, VI 24-25 649 Stabilizer 998, VI 24-25 649
[0103] Photographic additives usable in the invention are also described, as shown below.
Item RD 308119 RD 17643 RD 18716 Anti-staining Agent 1002, VII-I 25 650 Dye Image-Stabilizer 1001, VII-J 25 Britening Agent 998, V 24 U.V. Absorbent 1003, VIII-C, 25-26 XIII-C Light Absorber 1003, VIII 25-26 Light-Scattering 1003, VIII Agent Filter Dye 1003, VIII 25-26 Binder 1003, IX 26 651 Anti-Static Agent 1006, XIII 27 650 Hardener 1004, X 26 651 Plasticizer 1006, XII 27 650 Lubricant 1006, XII 27 650 Matting Agent 1007, XVI Developing Agent 1001, XXB (incorporated in photographic material)
[0104] A variety of couplers can be employed in the invention and examples thereof are described in research Disclosures described above. Relevant description portions are shown below.
Item RD 308119 RD 17643 Yellow coupler 1001, VII-D VII-C˜G Magenta coupler 1001, VII-D VII-C˜G Cyan coupler 1001, VII-D VII-C˜G Colored coupler 1002, VII-G VII-G DIR coupler 1001, VII-F VII-F BAR coupler 1002, VII-F PUG releasing coupler 1001, VII-F Alkali-soluble coupler 1001, VII-E
[0105] Additives used in the invention can be added by dispersion techniques described in RD 308119 XIV. In the invention are employed supports described in RD 17643, page 28; RD 18716, page 647-648; and RD 308119 XIX. There are also employed polyester supports described in JP-A No. 6-102623 and 7-306496. In the photographic material relating to the invention, there can be provided auxiliary layers such as a filter layer and interlayer, as described in RD 308119 VII-K, and arranged in a variety of layer orders such as normal layer order, reverse layer order and a unit layer arrangement.
[0106] The photographic material relating to this invention can be processed using commonly known developers described in T. H. James “The Theory of The Photographic Process” Forth Edition, pp. 291-334; and J. Am. Chem. Soc. Vol. 73, pp. 3100 (1951), according to the conventional methods, as described in, cited above, RD38957, items XVII through XX and RD40145, item XXII.
EXAMPLES
[0107] The present invention will be further described, based on examples, but the invention is by no means limited to these embodiments.
Example 1
[0108] Preparation of Sample 101
[0109] On a 120 μm thick, subbed triacetyl cellulose film support, the following layers having composition as shown below were formed to prepare a multi-layered color photographic material sample 101. The addition amount of each compound was represented in term of g/m 2 , unless otherwise noted. The amount of silver halide or colloidal silver was converted to the silver amount and the amount of a sensitizing dye (denoted as “SD”) was represented in mol/Ag mol.
1st Layer: Anti-Halation Layer Black colloidal silver 0.13 UV-1 0.30 CM-1 0.11 OIL-1 0.23 Gelatin 1.20 2nd Layer: Interlayer OIL-3 0.267 Gelatin 0.89 3rd Layer: Low-speed Red-sensitive Layer Silver iodobromide emulsion a 0.31 Silver iodobromide emulsion k 0.22 SD-1 1.28 × 10 −4 SD-2 1.78 × 10 −5 SD-3 8.40 × 10 −5 C-1 0.324 CC-1 0.056 D-1 0.014 AS-2 0.002 OIL-4 0.320 Gelatin 1.06 4th Layer: Medium-speed Red-sensitive Layer Silver iodobromide emulsion j 0.08 Silver iodobromide emulsion l 0.40 SD-1 2.56 × 10 −4 SD-2 3.50 × 10 −5 SD-4 1.72 × 10 −4 C-1 0.219 CC-1 0.044 D-1 0.024 D-3 0.002 AS-2 0.002 OIL-4 0.001 Gelatin 0.84 5th Layer: High-speed Red-sensitive Layer Silver iodobromide emulsion l 0.10 Silver iodobromide emulsion o 0.38 SD-1 7.11 × 10 −5 SD-2 9.78 × 10 −6 SD-3 4.72 × 10 −5 C-1 0.046 C-3 0.041 CC-1 0.019 D-3 0.003 AS-2 0.001 OIL-4 0.088 Gelatin 0.84 6th Layer: Interlayer AS-1 0.20 OIL-1 0.25 Gelatin 0.91 7th Layer: Low-speed Green-sensitive Layer Silver iodobromide emulsion j 0.23 Silver iodobromide emulsion k 0.10 SD-4 1.17 × 10 −4 SD-5 1.28 × 10 −5 SD-6 1.61 × 10 −5 M-1 0.275 CM-1 0.085 D-2 0.003 D-3 0.001 AS-2 0.001 X-2 0.069 AS-3 0.033 OIL-1 0.410 Gelatin 1.14 8th Layer: Medium-speed Green-sensitive Layer Silver iodobromide emulsion k 0.09 Silver iodobromide emulsion l 0.33 SD-4 3.83 × 10 −4 SD-5 4.00 × 10 −5 SD-6 5.00 × 10 −5 M-1 0.101 CM-1 0.039 D-2 0.001 D-3 0.012 AS-2 0.001 X-2 0.014 AS-3 0.007 OIL-1 0.280 Gelatin 1.06 9th Layer: High-speed Green-Sensitive Layer Silver iodobromide emulsion j 0.02 Silver iodobromide emulsion n 0.48 SD-4 1.01 × 10 −4 SD-5 3.78 × 10 −5 SD-6 6.33 × 10 −6 M-1 0.058 CM-1 0.029 AS-2 0.001 X-2 0.015 AS-3 0.007 OIL-1 0.141 Gelatin 1.11 10th Layer: Yellow Filter Layer Yellow colloidal silver 0.06 AS-1 0.07 OIL-1 0.09 Gelatin 0.90 11th Layer: Low-speed Blue-sensitive Layer Silver iodobromide emulsion j 0.11 Silver iodobromide emulsion l 0.17 Silver iodobromide emulsion m 0.17 SD-7 2.78 × 10 −4 SD-8 7.17 × 10 −5 Y-2 0.925 AS-2 0.003 OIL-1 0.371 Gelatin 1.91 12th Layer: High-sped Blue-sensitive Layer Silver iodobromide emulsion m 0.03 Silver iodobromide emulsion p 0.25 SD-7 2.78 × 10 −5 SD-8 1.83 × 10 −5 Y-2 0.078 AS-2 0.001 D-4 0.038 OIL-1 0.047 Gelatin 0.61 13th Layer: First Protective Layer Silver iodobromide emulsion i 0.22 UV-1 0.10 UV-2 0.06 X-1 0.04 AF-6 0.003 Gelatin 0.70 14th Layer: Second protective Layer PM-1 0.10 PM-2 0.018 WAX-1 0.02 Gelatin 0.55
[0110] In addition to the above composition were added coating aids SU-1, SU-2 and SU-3; a dispersing aid SU-4; viscosity-adjusting agent V-1; stabilizer ST-1; two kinds polyvinyl pyrrolidone of weight-averaged molecular weights of 10,000 and 1.100,000 (AF-1, AF-2); calcium chloride; inhibitors AF-3, AF-4, AF-5, Af-6 and AF-7; hardener H-1; and antiseptic Ase-1.
[0111] Characteristics of silver iodobromide emulsions used in sample 101, which were prepared in accordance with conventional method are below, in which the average grain size of silver iodobromide emulsions k, l, m, n, o, and p refers to an edge length of a cube having the same volume as that of the grain. Silver iodobromide emulsions were each in accordance with the method described in emulsion Em-2 in Examples of JP-A 2001-290232, provided that the pAg at the stage of ripening and growth, and flow rates of silver nitrate and halide solutions were respectively varied. Silver iodobromide emulsion i was comprised of octahedral grains having an average size of 0.043 μm and average iodide content of 1.9 mol%.
Emul- Av. Grain Av. Iodide Av. Aspect sion Size (μm) Content (mol %) Ratio i 0.28 2.0 — k 0.61 3.1 5.43 l 0.89 3.7 6.10 m 0.95 8.0 3.07 n 1.43 3.9 6.76 o 1.50 3.1 6.60 p 1.23 7.9 2.85
[0112] With regard to the foregoing emulsions, except for emulsion i, after adding the foregoing sensitizing dyes to each of the emulsions and ripening the emulsions, triphenylphosphine selenide, sodium thiosulfate, chloroauric acid and potassium thiocyanate were added and chemical sensitization was conducted according to the commonly known method until relationship between sensitivity and fog reached an optimum point.
[0113] Chemical structures for each of the compounds used in the foregoing sample are shown below.
[0114] Preparation of Samples 102 Through 125
[0115] Samples 102 through 125 were prepared similarly to Sample 101, provided that the average grain size, aspect ratio, chemical sensitization condition and amount of silver iodobromide emulsion and coupler amounts used in individual light-sensitive layer were adjusted so that the nominal speed, quality values QC and QT were those shown in Table 1.
[0116] Exposure
[0117] The thus prepared Samples 101 through 125 were each packed into a cartridge and loaded into a commercially available single-lens reflex camera. Using the camera, a Macbeth Color Checker Chart (comprised of 24 colored squares) was photographed under a light source having a color temperature of 4800° K. with varying an exposure in which the aperture of the camera is reduced by 4 steps from the normal exposure (hereinafter, also referred to as −4 under-exposure) to an exposure in which the aperture was increased by 1 step from the normal exposure (hereinafter, also referred to as +1 over-exposure). Further, 100 shots for each of an outdoor scene against light and a stroboscopic (electronic-flashed) scene were photographed with varying an object distance by 4 steps and changing background colors of gray, white, black, green and yellow at varying exposure from =2 under-exposure to +1 over-exposure, while varying the number of objects from one person to five persons. Furthermore, scenes with a lighter background than the object, such as white wall or blue sky were photographed through center-weighted metering at an exposure ranging from −1 under-exposure to +1 over-exposure, including normal exposure. In addition to the foregoing, Samples 101 through 125 were each exposed through an optical wedge or a pattern wedge for MTF measurement for {fraction (1/200)} sec. using a light source having a color temperature of 4800° K.
[0118] Processing
[0119] The thus exposed samples were subjected to color processing in accordance with processing steps described in JP-A No. 10-123652, col. [0220] through [0227], as shown below.
Process: Temper- Replenish- Processing step Time ature ing rate* Color developing 3 min. 15 sec. 38 ± 0.3° C. 780 ml Bleaching 45 sec. 38 ± 2.0° C. 150 ml Fixing 1 min. 30 sec. 38 ± 2.0° C. 830 ml Stabilizing 1 min. 38 ± 5.0° C. 830 ml Drying 1 min. 55 ± 5.0° C. —
[0120] A color developer, bleach, fixer and stabilizer each were prepared according to the following formulas.
Color developer solution Worker Replenisher Water 800 ml 800 ml Potassium carbonate 30 g 35 g Sodium hydrogencarbonate 2.5 g 3.0 g Potassium sulfite 3.0 g 5.0 g Sodium bromide 1.3 g 0.4 g Potassium iodide 1.2 mg — Hydroxylamine sulfate 2.5 g 3.1 g Sodium chloride 0.6 g — 4-Amino-3-methyl-N-(β-hydroxyethyl)- 4.5 g 6.3 aniline sulfate Diethylenetriaminepentaacetic acid 3.0 g 3.0 g Potassium hydroxide 1.2 g 2.0 g
[0121] Water was added to make 1 liter in total, and the pH of the developer and replenisher were adjusted to 10.06 and 10.18, respectively, using potassium hydroxide and 20% sulfuric acid.
Bleaching solution Worker Replenisher Water 700 ml 700 ml Ammonium iron (III) 1,3-diamino- 125 g 175 g propanetetraacetic acid Ethylenediaminetetraacetic acid 2 g 2 g Sodium nitrate 40 g 50 g Ammonium bromide 150 g 200 g Glacial acetic acid 40 g 56 g
[0122] Water was added to make 1 liter in total and the pH of the bleach and replenisher was adjusted to 4.4 and 4.0, respectively, using ammoniacal water or glacial acetic acid.
Fixer solution (worker and replenisher) Water 800 ml 800 ml Ammonium thiocyanate 120 g 150 g Ammonium thiosulfate 150 g 180 g Sodium sulfite 15 g 20 g Ethylenediaminetetraacetic acid 2 g 2 g
[0123] Water was added to make 1 liter in total and the pH of fixer and replenisher was adjusted to 6.2 and 6.5, respectively, using ammoniacal water or glacial acetic acid.
Stabilizer solution (worker and replenisher): Water 900 ml p-Octylphenol/ethyleneoxide 2.0 g (10 mol) adduct Dimethylolurea 0.5 g Hexamethylenetetramine 0.2 g 1,2-benzoisothiazoline-3-one 0.1 g Siloxane (L-77, product by UCC) 0.1 g Ammoniacal water 0.5 ml
[0124] Water was added to make 1 liter in total and the pH thereof was adjusted to 8.5 with ammoniacal water or sulfuric acid (50%).
[0125] Calculation of Quality Values QC, QG and QT
[0126] Using the thus processed samples, quality values, QC, QG and QT were each determined in the manner described earlier and obtained results are shown in Table 1. Thus, according to equation (1) described earlier, the quality value QC of the invention is 2.8 or more for photographic material of a nominal speed of 100, 2.2 or more for photographic material of nominal speed 200, 1.7 or more for photographic material of nominal speed 400, 1.3 or more for photographic material of nominal speed 800, and 1.0 or more for photographic material of nominal speed 1600. Further, as defined in the equation (5) described earlier, the preferred QT value is 3.3 or more for photographic material of the nominal speed of 100, 2.7 or more for photographic material of nominal speed 200, 2.2 or more for photographic material of nominal speed 400, 1.8 or more for photographic material of nominal speed 800, and 1.5 or more for photographic material of nominal speed 1600. Furthermore, as defined in the equation (14) described earlier, it is preferred that QTN be 4.2 or more for photographic material of the nominal speed of 100, 3.5 or more for photographic material of the nominal speed 200, 2.9 or more for photographic material of the nominal speed 400, 2.4 or more for photographic material of the nominal speed 800, and 2.0 or more for photographic material of the nominal speed 1600.
[0127] To calculate quality values of QC, QG and QT, preparation of characteristic curves and determination of granularity (RMS) and sharpness (MTF) were carried out in accordance with the following procedure.
[0128] Preparation of Characteristic Curve
[0129] Samples which were exposed through an optical wedge and processed in color processing were subjected to densitometry using a densitometer produced by X-rite Co. and characteristic curves comprised of an ordinate of density (D) and abscissa of exposure (logE) were prepared for each of yellow, magenta and cyan images.
[0130] Measurement of Granularity (RMS)
[0131] Scanning each of the processed samples with a microdensitometer was made at a scanning aperture area of 750 μm 2 (5 μm wide and 150 μm long slit) and the value of 1000 times a standard deviation of fluctuation in density for at least 1,000 density values was defined as RMS. In the measurement of RMS granularity of the green-sensitive layer (magenta image), Wratten filter W-99 (available from Eastman Kodak Co.) was used to separate green light. In the measurement of RMS granularity of the red-sensitive layer (cyan image), Wratten filter W-26 (available from Eastman Kodak Co.) was used to separate red light.
[0132] Measurement of MTF
[0133] Pattern wedge images for MTF measurement were subjected to densitometry using a microdensitometer and MTF values at 15 cycle/mm of magenta and cyan images were determined.
[0134] Variation of Color and Image Quality of Print
[0135] Evaluation (1-1): Analog Print of Under-Exposed Scene
[0136] Portrait scenes including outdoor scenes against light and stroboscopic scenes, which were photographed at an exposure varying from −2 under-exposure to +1 over-exposure of both sides of the normal exposure, based on center-weighted metering, while varying the object distance at 4 steps and background colors (gray, white, black, green and yellow), were printed on color print paper (Color Paper QA Type A7, produced by Konica Corp.) using an analog printer (Nice Print System NPS 858, one-channel type, produced by Konica Corp.) and processed (by Konica CPK-2-21) to output 100 prints per sample. The thus obtained prints were evaluated by 10 people having experience in using the printer with respect to color image quality of finished prints (print level), taking account of occurrence of variation of print level from the preferred neutral level, based on the following criteria:
[0137] A: excellently finished prints within less than 5% of color correction in printer;
[0138] B: occurrence of prints necessary to make 5 to 10% correction based on color buttons being less than 10%, leading to almost favorable finished prints;
[0139] C: occurrence of prints necessary to make 5 to 10% correction based on color buttons being 10 to 30%, falling within levels acceptable in practice;
[0140] D: occurrence of prints necessary to make 10 to 30% correction based on color buttons being within 30%, leading to unacceptable levels in practice.
[0141] Evaluation (1-2): Analog Print of Under-Exposed Scene
[0142] Portrait scenes with a lighter background than the object such as white wall or blue sky, which were photographed at varying exposure from −1 under-exposure to +1 over-exposure of both sides of the normal exposure, based on center-weighted average-metering, while varying the object distance in 4 steps and background colors (gray, white, black, green and yellow), were printed on color print paper (Color Paper QA Type A7, produced by Konica Corp.) using an analog printer (Nice Print System NPS 858, one-channel type, produced by Konica Corp.) and processed (by Konica CPK-2-21) to output 100 prints per sample. The thus obtained prints were visually evaluated by 10 amateur photographers with respect to color image quality of finished prints (print level), based on the following criteria:
[0143] A: excellent image quality including graininess and contrast over under-exposed scenes to normal exposure scenes;
[0144] B: slightly coarse graininess or slightly insufficient contrast being observed in under-exposed scenes but levels of almost favorable image quality;
[0145] C: slightly coarse graininess and slightly insufficient contrast being observed in under-exposed scenes but levels of almost favorable image quality and being acceptable in practice;
[0146] D: deteriorated graininess and lowered contrast being apparent and levels unacceptable in the market.
[0147] Total Evaluation of Image Quality of Analog Print
[0148] Combining the foregoing results of evaluations (1-1) and (1-2), total evaluation was made based on the following criteria:
[0149] 5: A and B, or A and A in both evaluation results,
[0150] 4: B and B in both evaluation results,
[0151] 3: B and C in both evaluation results,
[0152] 2: C and C in both evaluation results,
[0153] 1: D in at least one evaluation result,
[0154] wherein suitability for marketing is at a grade of 2 or more, and preferably 3 or more.
[0155] Results are shown in Table 1.
TABLE 1 Analog Printer: Under- exposed Scene Sam- Evalua- Evalua- Total ple Nominal Quality Value tion tion Evalua- No. Speed QC QG QT (1-1) (1-2) tion Remark 101 100 2.8 3.7 3.3 B B 4 Inv. 102 200 2.2 3.2 2.7 B B 4 Inv. 103 400 1.7 2.8 2.2 B B 4 Inv. 104 800 1.3 2.4 1.8 B B 4 Inv. 105 1600 1.0 2.0 1.5 B B 4 Inv. 106 100 3.1 4.0 3.6 A A 5 Inv. 107 200 2.5 3.5 3.0 A A 5 Inv. 108 400 2.0 3.1 2.5 A A 5 Inv. 109 800 1.6 2.7 2.1 A A 5 Inv. 110 1600 1.3 2.3 1.8 A A 5 Inv. 111 100 2.8 3.1 3.0 B B 4 Inv. 112 200 2.2 2.6 2.4 B B 4 Inv. 113 400 1.7 2.2 1.9 B B 4 Inv. 114 800 1.3 1.8 1.5 B C 3 Inv. 115 1600 1.0 1.4 1.2 B C 3 Inv. 121 100 2.5 3.4 3.0 D D 1 Comp. 122 200 1.9 2.9 2.4 D D 1 Comp. 123 400 1.4 2.5 1.9 D D 1 Comp. 124 800 1.0 2.1 1.5 D D 1 Comp. 125 1600 0.7 1.7 1.2 D D 1 Comp.
[0156] As can be seen from Table 1, it was proved that samples meeting the quality value QC as defined in the invention resulted in superior finished print color quality and print image, specifically in the under-exposure region when printed using an analog printer.
Example 2
[0157] Preparation of Samples 201 Through 225
[0158] Samples 201 through 225 were prepared similarly to Sample 101 in Example 1, provided that the average grain size, aspect ratio, chemical sensitization condition and amount of silver iodobromide emulsion and amounts of coupler and colored coupler used in individual light-sensitive layer were varied so that the nominal speed, quality values QTN and minimum cyan density, as shown in Table 2, were achieved.
[0159] Exposure
[0160] The thus prepared samples 201 through 235 were each packed into a cartridge and loaded into a commercially available single-lens reflex camera. Using the camera, a Macbeth Color Checker chart (comprised of 24 colored squares) was photographed under a light source having a color temperature of 4800° K. at varying exposure in which the aperture of the cameral is reduced in 4 steps from the normal exposure (hereinafter, also referred to as −4 under-exposure) to an exposure in which the aperture was increased by 1 step from the normal exposure (hereinafter, also referred to as +1 over-exposure). Further, scenes with a lighter background than the object, such as white wall or blue sky were photographed through center-weighted metering at an exposure ranging from −1 under-exposure to +1 over-exposure, including normal exposure. In addition to the foregoing, Samples 201 through 235 were each exposed through an optical wedge or a pattern wedge for MTF measurement for {fraction (1/200)} sec. using a light source having a color temperature of 4800° K.
[0161] Processing
[0162] The thus exposed samples were processed similarly to Example 1.
[0163] Calculation of Quality Value QTN
[0164] Using the thus processed samples, quality values, QTM value was determined in accordance with the manner as described earlier and obtained results are shown in Table 2. To calculate quality value QTN, preparation of characteristic curves and determination of granularity (RMS) and sharpness (MTF) were carried out similarly to Example 1.
[0165] Variation of Color and Image Quality of Print Evaluation (2-1): Graininess of Digital Print
[0166] Portrait scenes with a lighter background than the object, such as white wall or blue sky, which were photographed through center-weighted metering at a normal exposure, were printed on color print paper (Color Paper QA Type A7, produced by Konica Corp.) at a L print size (printing magnification: 4.5 times) or a panorama print size (printing magnification: 7.5 times) using a digital printer (KONICA QD21, produced by Konica Corp.) and processed (by Konica CPK-2-21) to obtain 100 prints of each size. The thus obtained prints were visually evaluated by 10 people (general users) with respect to color image quality of finished prints, compared to prints obtained by an analog printer in Example 1, and were graded based on the following criteria:
[0167] A: superior graininess in almost prints of L size and panorama size prints, compared to analog prints,
[0168] B: superior graininess in at least 50% of each of L size and panorama size prints, compared to analog prints,
[0169] C: superior graininess in 30 to 50% of each of L size and panorama size prints, compared to analog prints,
[0170] D: equivalent graininess in L and panorama size prints to analog prints and no improvement was noted.
[0171] Evaluation (2-2): Contrast of Digital Print
[0172] L size prints used in the foregoing graininess evaluation were visually evaluated by 10 people (general users), comparing to analog prints, based on the following criteria:
[0173] A: superior contrast conversion having been achieved in at least 30% of scenes and no problem in other print qualities, compared to analog prints,
[0174] B: superior contrast conversion having been achieved in 10 to 30% of scenes and no problem in other print qualities, compared to analog prints,
[0175] C: equivalent contrast to analog prints and no problem in finishing,
[0176] D: Comparing analog prints, contrast having been excessively enhanced, leading to unnatural prints and being unacceptable.
[0177] Total Evaluation of Image Quality of Digital Print
[0178] Combining the foregoing results of the evaluations (2-1) and (2-2), total evaluation was made based on the following criteria:
[0179] 5: A and B, or A and A in both evaluation results,
[0180] 4: B and B in both evaluation results,
[0181] 3: B and C in both evaluation results,
[0182] 2: C and C in both evaluation results,
[0183] 1: D in at least one evaluation result,
[0184] wherein no problem in suitability for marketing is at a grade of 2 or more, and preferably 3 or more.
[0185] Results thereof are shown in Table 2.
TABLE 2 Digital Print/ Correct-exposed Scene Sample Nominal Dmin Total Image No. Speed QC QTN (cyan) Graininess Contrast Quality Remark 201 100 2.8 4.2 0.19 B B 4 Inv. 202 200 2.2 3.5 0.19 B B 4 Inv. 203 400 1.7 2.9 0.19 B B 4 Inv. 204 800 1.3 2.4 0.19 B C 3 Inv. 205 1600 1.0 2.0 0.19 C C 2 Inv. 206 100 3.1 4.5 0.19 A B 5 Inv. 207 200 2.5 3.8 0.19 A B 5 Inv. 208 400 2.0 3.2 0.19 A B 5 Inv. 209 800 1.6 2.7 0.19 B B 4 Inv. 210 1600 1.3 2.3 0.19 B B 4 Inv. 211 100 2.8 4.2 0.16 B A 5 Inv. 212 200 2.2 3.5 0.17 B A 5 Inv. 213 400 1.7 2.9 0.17 B A 5 Inv. 214 800 1.3 2.4 0.17 B A 5 Inv. 215 1600 1.0 2.0 0.17 B B 4 Inv. 221 100 2.5 3.9 0.19 D D 1 Comp. 222 200 1.9 3.2 0.19 D D 1 Comp. 223 400 1.4 2.6 0.19 D D 1 Comp. 224 800 1.0 2.1 0.19 D D 1 Comp. 225 1600 0.7 1.7 0.19 D D 1 Comp.
[0186] As can be seen from Table 2, it was proved that samples meeting quality value QTV, as defined in equation (14) and having a minimum cyan density, Dmin (cyan) of less than 0.20 resulted in finished prints with superior graininess and contrast when printed using an analog printer.
Example 3
[0187] Using processed Samples 101, 102, 103, 106 through 110, 111 through 113, and 116 through 118 of Example 1, evaluation was made as follows.
[0188] Evaluation (3-1): Color Quality of Digital Print of Under-Exposed Scene
[0189] Portrait scenes used in Example 1, including outdoor scenes against light and stroboscopic scenes, which were photographed at varying exposure from −2 under-exposure to +1 over-exposure of both sides of the normal exposure, based on center-weighted metering, while varying the object distance at 4 steps and background colors (gray, white, black, green and yellow), were printed on color print paper using an analog printer (KONICA QD21, produced by Konica Corp.). The digital printer was run under the condition that correction for local printing was automatically made. The thus obtained prints were evaluated by 10 people having experience in using the printer with respect to color image quality of finished prints (print level), taking account of occurrence of variation of print level from the preferred neutral level, based on the following criteria:
[0190] A: excellently finished prints within less than 5% of color correction in the printer;
[0191] B: occurrence of prints necessary to make 5 to 10% correction based on color buttons being less than 10%, leading to almost favorably finished prints;
[0192] C: occurrence of prints necessary to make 5 to 10% correction based on color buttons being 10 to 30%, falling within acceptable levels in practice;
[0193] D: occurrence of prints necessary to make 10 to 30% correction based on color buttons being within 30%, leading to levels unacceptable in practice.
[0194] Evaluation (3-2): Image Quality of Digital Print of Under-Exposed Scene
[0195] Portrait scenes with a lighter background than the object such as white wall or blue sky, which were photographed at varying exposure from −1 under-exposure to +1 over-exposure of both sides of the normal exposure, based on center-weighted average-metering, while varying the object distance in 4 steps and background colors (gray, white, black, green and yellow), were printed on color print paper (Color Paper QA Type A7, produced by Konica Corp.) using an analog printer (Nice Print System NPS 858, one-channel type, produced by Konica Corp.) and a digital printer (KONICA QD21, produced by Konica Corp.) at a 2L print size (printing magnification: 5.6 times). The digital printer was run under the condition that correction for local printing was automatically made.
[0196] The thus obtained prints were visually evaluated by 10 people with respect to graininess and contrast of finished prints, based on the following criteria:
[0197] A: superior graininess and contrast having been achieved in at least 30% of the scenes and no problem in other print qualities, compared to analog prints,
[0198] B: superior graininess and contrast having been achieved in 10 to 30% of scenes and no problem in other print qualities, compared to analog prints,
[0199] C: equivalent graininess and contrast to analog prints and no problem in finishing,
[0200] D: Comparing analog prints, contrast having been excessively enhanced and graininess having been roughened, falling outside acceptable levels.
[0201] Results are shown in Table 3.
TABLE 3 Digital Print/ Quality Under-exposed Scene Sample Nominal Value Color Image No. Speed QC QT Quality Quality 101 100 2.8 3.3 B B 102 200 2.2 2.7 B B 103 400 1.7 2.2 B B 111 100 2.8 3.0 B C 112 200 2.2 2.4 B C 113 400 1.7 1.9 B C 106 100 3.1 3.6 A A 107 200 2.5 3.0 A A 108 400 2.0 2.5 B A 109 800 1.6 2.1 C B 110 1600 1.3 1.8 C C
[0202] As can be seen from Table 3, it was proved that prints printed by a digital printer from silver halide photographic material meeting the quality values QC and QT, as defined earlier exhibited little color variation and superior graininess and contrast, even in under-exposed scenes.
Example 4
[0203] Preparation Samples 501 through 509
[0204] Samples 501 through 509 were prepared similarly to Sample 101 in Example 1, provided that the average grain size, aspect ratio, chemical sensitization conditions, total silver coating amount and coupler amount used in individual light-sensitive layer were adjusted so that the nominal speed, quality values QC and QT, as shown in Table 1, were achieved, and infrared dyes were further added thereto.
[0205] Exposure and Processing of Samples
[0206] The thus prepared samples 501 through 509 were each packed into a cartridge and loaded into a commercially available single-lens reflex camera and a Macbeth Color Checker chart (comprised of 24 colored squares) was photographed under a light source having a color temperature of 4800° K. at an under-exposure (under-exposed scenes) and at a normal exposure (normal scenes) and processed similarly to Example 1.
[0207] Evaluation of Noise Level in Digital Print
[0208] The thus processed samples were scanned by a digital printer (KONICA QP21, produced by Konica Corp.) to read image data for each of the colored squares. Image unevenness was calculated from bit values with respect to each of the 24 colored squares, the noise level of the under-exposed scene and that of the normal scene were each evaluated, based on the following criteria:
[0209] A: the noise level for under-exposed scenes or normal scenes being not more than 0.5% and being superior,
[0210] B: the noise level for under-exposed scenes or normal scenes being within 0.5 to 1%, with an average of not more than 1% and being superior,
[0211] C: the noise level for under-exposed scenes or normal scenes being within 1 to 2%, with an average of not more than 1.5% and superior, falling within acceptable levels in practice,
[0212] D: the noise level for under-exposed scenes or normal scenes being more than 2%, with an average of more than 1.5%, leading to unacceptable levels in practice.
[0213] Tone Reproduction of Digital Print
[0214] The foregoing processed samples were printed on color paper using a digital printer (KONICA QD21, produced by Konica Corp.) and an analog printer (NPS858, produced by Konica Corp.) at an L size print (printing magnification: 4.7 times). The digital printer was run under the condition that correction for local printing was automatically made. Evaluation was made with respect to under-exposed and normal scenes.
[0215] The thus obtained digital prints were visually evaluated by 10 people with comparing analog prints, based on the following criteria:
[0216] A: at least 50% of the prints being superior in tone reproduction and the remainder being close to the analog prints and superior as finished prints,
[0217] B: 20 to 50% of prints being superior in tone reproduction and the remainder being close to the analog prints and superior as finished prints,
[0218] C: at least 80% of the prints being close in tone reproduction to analog prints,
[0219] D: at least 50% of the prints being unpleasing in tone reproduction and no improved contrast being noted, leading to prints with unnatural image quality.
[0220] Results are shown in Tables 4 and 5.
TABLE 4 Digital Print/ Under-exposed Total Scene Quality Silver Infra- Tone Sample Nominal Value Coverage red Repro- No. Speed QC QT (g/m 2 ) Dye Noise duction 501 100 2.8 3.3 3.4 — B C 502 200 2.2 2.7 3.8 — B C 503 400 1.7 2.2 4.6 — B C 504 100 2.8 3.3 4.2 — C B 505 200 2.2 2.7 4.6 — C B 506 400 1.7 2.2 5.4 — C B 507 100 2.8 3.3 3.4 3-26 B B 508 200 2.2 2.7 3.8 3-26 B B 509 400 1.7 2.2 4.6 3-26 B B
[0221] [0221] TABLE 5 Digital Printer: Total Normal scene Silver Infra- Tone Sample Nominal Dmin Coverage red Repro- No. Speed QTN (cyan) (g/m 2 ) Dye Noise duction 501 100 4.2 0.19 3.4 — B C 502 200 3.5 0.19 3.8 — B C 503 400 2.9 0.19 4.6 — B C 504 100 4.2 0.19 4.2 — C B 505 200 3.5 0.19 4.6 — C B 506 400 2.9 0.19 5.4 — C B 507 100 4.2 0.19 3.4 3-26 B B 508 200 3.5 0.19 3.8 3-26 B B 509 400 2.9 0.19 4.6 3-26 B B
[0222] As can be seen from Tables 4 and 5, it was proved that samples according to the invention produced prints exhibiting superior noise resistance and tone reproduction in both under-exposed and normal scenes, when printed using a digital printer, and the use of infrared dyes enhanced effects thereof. | A silver halide photographic material which is in the form of a roll film packaged in a cartridge, and which exhibits superior print stability and is capable of providing prints with superior image quality when printed onto printing paper is disclosed, comprising on a support a red-sensitive layer, a green-sensitive layer and a blue-sensitive layer, wherein the quality value (QC) satisfies the following requirement
QC ≧15.982× S −0.378 (100≦ S ≦1600 )
where S is the nominal speed of the photographic speed. | 6 |
BACKGROUND
Image sensors and displays are generally formed from crystalline silicon substrates, glass, or other somewhat rigid and brittle materials. These materials result in displays such as liquid crystal displays (LCD), and imaging arrays, such as charge-coupled devices (CCD), that are generally flat. Flat image sensors have limitations as to the field of view, and rely upon complex and expensive optical systems to widen the field of view, while a spherically curved sensor gives a wide field of view with simple optics. Curved displays may be required in certain applications depending on the positions from which it is intended to be viewed and the form of the structure that supports the display.
The ability to curve these arrays would allow for wide angle imaging systems, whether for sensing or viewing. Forming a curved array of pixels for either sensing or display gives rise to a number of issues. The advent of flexible electronics has made possible conical or cylindrical array surfaces, mostly based upon bending rectangular arrays. Formation of a spherical array is much more complex in several aspects, including manufacture, addressing, and image processing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a segmented three-dimensional surface.
FIG. 2 shows an embodiment of a segment having subsegments.
FIG. 3 shows an alternative embodiment of a segment having subsegments.
FIG. 4 shows an embodiment of a layout of addressing circuitry for a segment.
FIG. 5 shows an embodiment of a pixel array having a transition between blocks.
FIG. 6 shows an embodiment of a segmented, two-dimensional structure prior being formed into a three-dimensional structure.
FIG. 7 shows an embodiment of a base pixel structure for a subsegment.
FIG. 8 shows an embodiment of a transform to transform a base pixel structure into a subsegment pixel.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Forming three-dimensional electronic devices directly on a curved surface causes difficulties because there is little or not processing equipment available that can process curved surfaces. For the purposes of the discussion here, ‘three-dimensional’ will refer to three-dimensional surfaces which are not flat. Obviously, a ‘flat’ electronics device has three-dimensions, but the surface upon which it is formed is flat and appears two-dimensional from a top view. For example, an array of pixels has an x component and a y component, but there is no z component.
‘Pixel,’ or picture element, as that term is used here refers to both display pixels, the individual cells of a display used to render an image, or an individual sensor element used in a sensor device. Examples of pixels include liquid crystal device (LCD) elements, or charge-coupled devices (CCD).
Some three-dimensional surfaces, such as cylinders may be formed using flat structures, such as by curling a rectangular device around to form a cylinder. However, forming an electronics device on a flat surface that can be formed into a three-dimensional device such as a sphere or hemisphere is far more complex. At any point on a cylinder there is always one direction on the surface which is straight and other directions which are curved. This discussion concerns fabricating the more general case in which the surface curves in all directions at any point. Such surfaces cannot be made by simply bending a flat sheet. It is possible to use a shape such as a geodesic dome to segment the surface into smaller two-dimensional shapes. These two-dimensional segments may then be laid out on a flexible substrate, an array of pixels formed on each segment and then the flexible substrate may be cut and shaped into the desired three-dimensional shape. Various aspects of this are discussed below.
It must be noted in the following discussions that reference may be made to a three-dimensional surface. This is not intended to imply that the device is actually formed around or on a three-dimensional surface. The three-dimensional surface is used as a model to determine the layout of the pixels; it is not necessarily an actual surface. Furthermore, when the discussion refers to a sphere or hemisphere, it is intended to apply to a spherical shape that might be only a portion of the spherical surface, and may be only an approximation to this shape.
This invention solves the problem of making the curved electronic array by choosing a shape that allows the array to be fabricated on a flat surface such that the surface can be cut and bent to form a sufficiently good approximation to the desired three-dimensional curved shape. One embodiment is based on the design of a geodesic dome.
FIG. 1 shows a geodesic dome 10 segmented into triangles. At the vertex of the dome 12 , one can see 5 larger triangles that come together to form the vertex. Each of these triangles has a symmetrical shape, as can be seen by triangle segment 14 defined by the vertices A-A, having sides of lengths A+F+F+A. Each letter designates a different length, A-F. These combinations of lengths for sides, as well as the combination of different lengths to form the various triangles are merely examples and no limitation should be implied from any particular structure used in this discussion.
Each of these sides is then divided into 4 further triangular subsegments. For example, the left side of the triangle 14 is divided to form left edges of the triangles 16 , 18 , 20 and 22 . This is generally noted as a ‘4V’ structure, because the original side of A+F+F+A is divided to form 4 new sides, A, F, F, A. If it were divided into two sides, for example, it would be noted as a 2V structure. This notation of mV may also be referred to as dome order.
It must be noted that this model employs triangles as both the segments such as 12 and the subsegments such as 16 . Other shapes are of course possible. For example, a common segmentation of a sphere uses hexagons and pentagons, as in a soccer ball. Other shapes for both the segments and the subsegments include rectangles, squares, hexagons, pentagons, etc. There is no requirement that the segments and subsegments have the same shape. For example, a hexagon segment may have triangular subsegments.
One particular aspect of the geodesic dome, or half-dome, is that increasing the number of segments further increases the approximation of a spherical shape. In this example, the dome has 5-fold symmetry at the vertices. Some domes have 6-fold symmetry. Generally, the smallest dome that makes a reasonable approximation of a sphere is a 3V structure, which tiles a sphere with 180 subsegments, increasing to 720 subsegments for a 6V structure. FIG. 1 shows a 4V structure with triangular subsegments.
It is possible to make a useful curved back plane using less than a hemisphere and the angle at which the segments come together to form the curved surface may vary depending upon the desired final shape. The number of subsegments used for an array of elements in an electronic device depends upon the desired angle of the spherical surface and the dome order. The below table provides some data as to the numbers of subsegments and the angle achievable using various sizes of triangles for different dome orders.
Number of
Dome
triangles
2 × 2 (20T)
3 × 3 (45T)
4 × 4 (80T)
order
in sphere
fraction, angle
fraction, angle
fraction, angle
3V
180
0.111; 39°
0.25; 60°
0.44; 83°
4V
320
0.0625; 29°
0.141; 44°
0.25; 60°
5V
500
0.04; 23°
.09; 34°
0.16; 47°
6V
720
0.028
.0625; 29°
0.111; 39°
The large triangular segments of the geodesic dome of FIG. 1 have a curved shape and hence require cuts in order to be laid on a flat surface. FIGS. 2 and 3 show 3×3 and 4×4 triangular segments with the cut lines used to reshape the segments into curved segments. FIG. 2 shows an example of a 3×3 triangular segment 30 . It is possible to use 2×2 triangles as a segment, as shown by the outlined triangular region 32 . The 2×2 segment can be manufactured flat as it only consists of four triangles. This would result in a dome with 20 triangles. Generally, this may not be sufficient to give a good enough spherical approximation unless the angle is small.
The 3×3 unit of FIG. 2 makes a 45 triangle structure and is the smallest triangular segment that needs a cut to make it flat. The cut is shown at 34. The 4×4 segment 36 of FIG. 3 makes an 80 triangle structure and requires more cuts to ‘make it flat.’ Actually, the structure will be manufactured in a flat shape and then cut and shaped into the three-dimensional curved shape. An example of the cuts are shown at 38 and 40
As can be seen by the table, the angle subtended by the spherical section decreases with increasing dome order up the progression 3V, 4V, 5V. The basic 3×3 triangle can be used to make a spherical arc of different angles. The table above provides the dome orders for designs that are close approximations to a complete sphere. If one is interested in just the spherical section, then the triangle sizes can be chosen to give any arbitrary angle. For example, sixty degree segments can be made with a 3×3 triangle in the 3V dome, or a 4×4 segment in the 5V dome. Generally, the higher order, more triangles segments provide better approximations to a sphere, but are harder to design because of their increased complexity.
Similar to the use of other shapes for the segments and subsegments, the same triangular design can be transformed into other curved shapes with some loss in the symmetry. For example, an oval shape may be made by a simple scaling of the triangles, and many arbitrary cured surfaces can be done the same way.
The number of triangles and the dome order, whether applied to a dome or other curved shapes, determine how accurately the structure approximates a spherical section. Given a line segment of length x on a circle of radius, R, the deviation of the center of the line from the arc, for small lengths x, is x 2 /8R. Considering the curved image sensor application, in which the imaging optics forms a spherical shaped focus, if one assumes the focal plane is equally between the maximum and minimum deviation, then the depth error is half this amount,
Δ= x 2 /16 R.
This can be expressed in terms of the number, N, of triangles needed to create a sphere for a particular geodesic dome, as shown in the table,
Δ=π R/ 2N.
For the 4V dome with 320 triangles, Δ˜R/70, so the for a 3 centimeter (cm) radius, the deviation is 0.4 millimeters (mm).
Alternatively, a designer can require that Δ is no more than the pixels size, D P , which is essentially the condition for perfect imaging with an f1 imaging lens. This condition sets a limit on the number of pixels along one side of the triangle, (x=N P D P ),
D P /R< 16 /N P 2 .
For a radius of 3 cm and pixel size of 0.3 mm, the limit would be 40 pixels, corresponding to an edge length of 1.2 cm for the 4V structure. This condition also relates the maximum number of pixels in a hemispherical sensor for a particular dome order, for the hemispherical example,
N MAX <4 N 2 /π.
Therefore, a design that requires 500×500=250,000 pixels ideally requires a 5V dome. Larger f-number optics allows more pixels for a particular dome order.
The pixel array can be fabricated using the techniques of large area electronics on a flexible substrate such as plastic or metal foil. A typical pixel contains one or more thin film transistor (TFT) which can be fabricated from amorphous silicon, polycrystalline silicon, an organic semiconductor or other suitable material. In the case of an image sensor, the pixel also contains a photodiode made from similar materials. For active matrix addressing, there are address lines, typically contacting the gate and drain of one of the pixel TFTs.
Hence, in order to address the individual pixels in the array, they should be laid out in a (n×m) matrix and there should be access to the address lines to connect to the external electronics. In this particular example, the triangular structure provides a solution to this problem. FIG. 4 shows how this is done for a 3×3 structure 50 .
The address lines run parallel to the sides of the triangles so that they cover the whole surface and lead to the bottom free edge. In the example of FIG. 4 , the gate lines 52 , 54 , 56 and 58 run down to the bottom edge parallel to the left edge of the triangle segment. Similarly, the data lines 60 , 62 , 64 and 66 run down to the bottom edge parallel to the right edge of the triangle segment.
It may be advantageous to lay out the pixels in four bocks as shown in FIG. 4 . Each of the 3 triangle section blocks A, B and C is designed with the gate and data lines parallel to the opposite sides of the triangle. These are ‘triangle’ blocks in that they are at least a portion of a triangle. By using one fewer pixels in each row from the bottom row of the blocks to the top row of the blocks, the layout fits the structure.
The trapezoidal structure D does not layout the same as the opposite sides are nearly but not quite parallel. The adjustment could be done by adjusting the number of pixels in the rows to make a best fit. Alternatively, the pixels in that block could be shrunk slightly in size in each row to match the slow change in distance between the two sides.
As yet another alternative, one could depart from the dome structure. If the trapezoidal shape is given sides of a length that matches the length of the side 68 of the triangular subsegment adjacent the cut, it can be laid out very precisely. The bottom left structure is adjusted in size, such that the bottom length A+B changes in size to 2A+B−C. This may result in a less than precise approximation of the spherical shape, but a better organization of the pixels. FIG. 5 shows a close-up of the pixel structure at the transition between two blocks, in this case the transition between blocks A and B, noticeable at region 70 .
The layout also has to accommodate the cuts that will allow the flat structure to be shaped and curved. It may be desirable for the address lines that move from left to right, for example line 56 in FIG. 4 , should continue through the cut. Several options may solve this problem. In one embodiment, the gate line 56 would loop around the center of the triangle. This may or may not require an additional metal layer in the manufacturing process so as to not interfere with the routing of the pixels.
In another embodiment, extra address lines could come out to the bottom of the lower right segment. This may also require extra metal during the manufacturing process. In yet another alternative, the lines could be routed in the cut area. The array could be designed with a flap where the segments overlap, and the flap could contain the address lines. In either case, the upper portion of line 56 would be connected to the contact area of block D and the lower portion of line 56 would be connected to the contact area of block C. The two portions can be connected together in the external electronics.
FIG. 6 shows an embodiment of a complete layout of the 3×3 triangle, 3V dome structure and is a picture of the array design on a flat substrate. The unmarked white areas of the picture indicate the areas that will be cut out to allow the substrate to be bent to the curved shape. The five sections, such as 82 , are joined near the apex and the gate and data address lines can be seen around the edge at 84 and 86 . In this particular example, the segments such as 82 are laid out on a square or rectangular electronics substrate.
Some of the electronics may be included on the substrate with the address/data lines and the pixels. These electronics may include the gate shift register, a data multiplexer (MUX), data amplifiers, etc. The join of the five sections could also be made around the outer perimeter, rather than at the vertex. The sections could also be fabricated independently on individual pieces of flexible substrate and then joined together. A center join as shown in FIG. 6 results in the most compact structure. An outer perimeter join may result in easier contacts with the address lines. Further, the independent fabrication of the sections may result in higher yield, but have more issues in assembly.
As can be seen in FIG. 6 , the array of pixels has a non-rectangular shape, making a non-trivial problem of rendering the array. For the sensor, the image is created in the n×m pixel matrix and displayed in an appropriate x,y form, such as on a flat screen. The transformation needed is:
( n×m )→(θ,φ)→( x,y ),
where (θ,φ) are radial and azimuthal angels of the spherical surface.
The second transformation is:
x=N cos φ tan θ,
y=N sin Φ tan θ,
where N is an index which determines the pixel size of the display. The first transformation would be easy if the pixels in the triangular section were all identical, as it can be derived from the pixel size and angle. The transformation may still be calculated for pixels of different sizes and angles.
FIG. 7 shows an n×m pixel arrangement for one of the segments, such as shown in FIG. 4 , as it would appear on a regular x,y display. The position of the different block of pixels denoted A-D are indicated FIG. 8 illustrates the different shape of this section of pixels when it is shaped and the different shape from FIG. 7 represents the transformation (n×m)→(θ,φ). For a display, the transformation would go from the flat x,y array to the curved n×m pixel arrangement on the three-dimensional surface. While this transformation is used for matrix-addressed devices, it may be applied to other types of electronic devices as well.
After processing of the arrays, where the arrays are laid out to correspond to the desired three-dimensional shape, cuts are made between the segments, such as cut 88. Cuts may also be made within each segment as necessary, such as 90. The substrate can then be ‘lifted’ out of the plane and shaped and bonded into the desired three-dimensional shape.
To manufacture such a device, a flexible substrate is provided. The process then forms at least one segment on the flexible substrate, the segments being from the three-dimensional shape. While the segments are not formed in the three dimensional structure prior to manufacture, the segments would more than likely modeled to cover the desired three-dimensional surface. The segments would then be divided into the subsegments. The subsegments and the segments determine how the arrays are laid out on the flexible substrate.
After the formation of the addressing lines on the substrate, and the formation of the pixel structures corresponding to the addressing lines, the flexible substrate is then cut along at least one cut line. The cut line corresponds to an edge of at least one of the subsegments within the segment. The cut lines are made to allow the flexible substrate to be curved and shaped to the desired three-dimensional shape.
It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | A method of forming a three-dimensional electronic device includes forming an array of pixels on a flexible two-dimensional surface, the array being formed according to a three-dimensional structure, the pixels having addressing lines accessible from at least one edge of the array, cutting the two-dimensional surface, the cuts being located to allow the two-dimensional surface to be shaped, and shaping the two-dimensional surface to form the three-dimensional surface, the array of pixels forming the three-dimensional electronic device. A three-dimensional electronic device has a flexible substrate containing an array of pixels, the substrate fabricated as a flat surface, then cut and shaped to form a three-dimensional surface, the array of pixels covering the three-dimensional surface in subarrays corresponding to segments of the three-dimensional surface, and addressing lines for each subarray being accessible along an edge of the three-dimensional surface. A method of forming a three-dimensional electronic device includes providing a flexible substrate, forming address lines on the substrate such that the address lines are accessible at an edge of the substrate, forming pixels on the address lines, the pixels being laid out in subarrays, the subarrays being determined by segments of a three-dimensional surface, and accommodating any cuts that will allow the flexible substrate to form the three-dimensional electronic device in the forming of addressing lines and pixels. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
None
STATEMENT REGARDING GOVERNMENT SPONSORED RESEARCH
None
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to door hinges generally; more particularly, the invention relates to a pin for a door hinge that overcomes the problem of a door's swinging away, under the influence of gravity, from a user's chosen open position for the door to some other position.
2. Background Art
Doors mounted on hinges over wall openings in buildings, cabinetry, motor vehicles, et cetera, tend to develop malfunctions over time. Of particular interest for the present invention are door hinges of the kind that comprise two hinge plates or leaves that are assemblable to form a butt hinge, each hinge leaf having one or more pintle journals or knuckles, wherein the knuckles are complementarily spaced apart so as to be interleaveable on a common axis, and wherein each of the knuckles defines an open chamber for receiving a hinge pin. In the case of doors mounted on two or more such butt hinges that are vertically aligned to permit the door to swing about a vertical axis, the hinges may become misaligned and/or the hinges may become so worn by use that the hinges develop excessive play; in either case, an attempt to leave the door in a desired open position may result in the door's swinging by gravity to some other position.
U.S. Pat. No. 1,900,081 issued to Swerer disclosed an adjustable hinge having a first set of vertically-spaced knuckles attachable by a jamb plate to a door jamb and a second set of vertically-spaced knuckles attachable by a door-engaging plate to a door. The knuckles within each set were concentrically aligned with each other, but the two sets of knuckles were ordinarily positioned out of axial alignment with each other. A hinge pin, preferably of hexagonal transverse cross-section, carried cylindrically-shaped eccentrics such that rotational adjustment of a lower, protruding end of the pin would alter the distance between the door and the jamb.
U.S. Pat. No. 1,908,383 issued to Vice disclosed an adjustable hinge comprising a pair of cooperating hinge plates having interleaved pintle journals that extended into the spaces between the journals. A lower portion of the hinge pin was of non-circular cross-section and adapted to insert into slots or grooves formed in eccentrics. One eccentric was provided for insertion and retention within each of the pintle journals, and each eccentric consisted of a cylindrical body. To install the eccentric pin structure, the hinge plates of a standard butt hinge were separated and the journals reamed out to receive the eccentrics in order to relatively adjust the plates of the hinge and thereby to properly adjust the position of the door within a wall opening.
U.S. Pat. No. 2,533,502 to Philips disclosed a hinge pin that could be employed as a replacement unit for hinge pins already installed. The replacement pin had bearing portions axially aligned to form bearings in the knuckles of one of the hinge leaves; alternately disposed, reduced-diameter crank portions formed on the pin for positioning in the knuckle bores of the companion hinge leaf; and eccentric bushings mounted on the crank portions of the pin. Each bushing was longitudinally split open to permit seating upon a reduced-diameter crank portion of the pin. Means was provided for rotating the pin once it was installed within a hinge, such as a kerf in the head of the pin, rotatable by a coin or screwdriver.
U.S. Pat. No. 4,864,690 to Chen disclosed a butt hinge intended to substantially eliminate the friction that results when two or more hinges on a door become misaligned and to permit up to at least a 5° deviation of the hinge pin in either direction. The hinge mainly comprised a set of hinge butts, a center shaft insertable through the cylinder of the hinge butts and having a ball-shaped part in a mid-portion thereof, and two sets of ball bearings mounted on upper and lower ends of the ball-shaped part to provide a rolling friction between the center shaft and the butts.
U.S. Pat. No. 6,591,450 B2 to Gardner disclosed a door hinge comprising a knuckle with a cylindrical opening and having a mounting plate for mounting to a door; a mounting bracket for attachment to a door frame and having a pair of apertured flanges spaced apart to receive the knuckle therebetween; and a hinge pin insertable through the flange apertures and through the knuckle opening when the apertures and the knuckle opening were coaxially aligned, thereby to connect the knuckle and attached door to the mounting bracket. The pin had an intermediate ball part that fit snugly within the knuckle opening and opposing extended shanks that were fitted freely to permit transverse movement of the shanks within the knuckle opening. Consequently, a door mounted on two or more such hinges could swing freely and without excessive friction even if the hinges were misaligned.
The foregoing references do not adequately address the problem of a waywardly swinging door that is mounted somewhat askew to a door frame by butt hinges. To minimize time, labor and expense, it is desirable to be able to retain the existing butt hinges in position and to replace only the hinge pins with hinge pins that, merely by rotational adjustment of the pins, will introduce just enough friction into the hinges to eliminate the problem. Vince required reaming out the journals to receive his eccentrics. The solutions offered by Swerer, Chen and Gardner would require replacement of the existing butt hinges with their own novel hinges. Phillips teaches replacement of only the hinge pin, but his hinge pin is unnecessarily complicated for the limited purpose addressed by the present invention.
SUMMARY OF THE INVENTION
There remains, therefore, a need, for which the present invention provides a solution, for a replacement hinge pin that, by rotational adjustment of the replacement pin will introduce just enough additional friction into a butt hinge to cure the problem of a hinged door that swings waywardly under the influence of gravity—a door that, when open, just will not stay put; a pin, moreover, that is simple in construction, inexpensive, and foolproof to install. In a preferred embodiment, the replacement hinge pin is intended for use with the type of door hinge that has two hinge leaves assemblable to form a butt hinge, wherein each leaf has knuckles complementarily spaced apart to permit interleaving alignment of the knuckles on a common longitudinal axis and each knuckle defines an open pin chamber. The pin chambers in this type of butt hinge are not cylindrical, however; instead, they are elliptical in transverse cross-section due to the manner in which the knuckles are roll-formed during manufacture. The replacement hinge pin includes a cylindrical shank, a head at a free end of the pin, and a collar intermediate the head and the shank. Distributed longitudinally at intervals along the shank are oppositely disposed and oppositely-directed pairs of bulges—a pair of bulges for at least one knuckle of the hinge, and preferably a pair for each of the knuckles. When the knuckles of the two leaves are interleaved and aligned, and the pin is inserted through the pin chambers, rotational adjustment of the pin, such as by a screwdriver inserted into a kerf in the head of the pin, causes the bulges to force the oppositely-disposed, inner surfaces of the pin chambers apart. In this manner, just enough additional friction can be introduced into the hinge to compensate for a skew-mounted door's tendency to swing under the influence of gravity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front face view of a type of butt hinge of the prior art that has roll-formed knuckles;
FIG. 2 is a transverse, cross-sectional view thereof taken along line 2 - 2 of FIG. 1 .
FIG. 3 is a front face view of a butt hinge with roll-formed knuckles from which the original equipment hinge pin has been removed and the hinge leaves separated for clarity of view, and showing how the bulges of my replacement hinge pin are disposed along the pin to correspond to the locations of the knuckles; and
FIG. 4 is a frontal perspective view of the same wherein the knuckles are now interleaved and aligned and ready for insertion of my replacement hinge pin.
FIG. 5A is an enlarged, transverse cross-sectional view of the butt hinge of FIG. 3 after the knuckles of the mating hinge leaves have been aligned and interleaved and my replacement hinge pin inserted through the pin chambers of the knuckles, taken along line 5 A, and with the leaves in a closed position;
FIG. 5B is the same view as FIG. 5A except that the leaves are here shown in an open position.
FIG. 6 is an enlarged, fragmentary perspective view of a version of my pin having a hexagonal-faced head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A butt hinge 10 of the prior art is depicted in FIGS. 1 and 2 , comprising a first hinge leaf 12 having two knuckles 16 , 18 , a second hinge leaf 20 having three knuckles 22 , 24 , 26 interleaved on a common axis A-A with the knuckles 16 , 18 , and a hinge pin 15 inserted through pin chambers within the knuckles 16 , 18 , 22 , 24 , 26 . The hinge pin 15 has a cylindrical shaft of uniform diameter and terminates at an upper end in a head 14 into which has been cut a kerf 36 . Representative of all the knuckles is knuckle 22 , shown in transverse cross-section in FIG. 2 , wherein it may be seen that in this type of butt hinge the knuckles are roll-formed; that is, a leading edge 30 of a tab extension 32 of a hinge leaf 20 has been rolled around and back upon itself to form the knuckle 22 . Consequently, the pin chambers defined by the knuckles 16 , 18 , 22 , 24 , 26 are slightly elliptical in transverse cross-section, having major axis B-B and minor axis C-C, as depicted in FIG. 2 .
As depicted in FIGS. 3 , 4 , 5 A and 5 B, my hinge pin 40 comprises a cylindrical shank 42 , a head 44 at an upper, free end of the pin, and a collar 46 intermediate the head and the shank. The pin 40 further includes pairs of oppositely-disposed and oppositely-directed bulges 48 uniformly distributed along the shank 42 —one pair corresponding to the location of each of the knuckles 16 , 18 , 18 , 22 , 24 , 26 when the pin 40 is fully inserted into all the pin chambers thereof; see FIG. 3 . The pin further includes index means—e.g., a kerf 50 cut into the head 44 —to facilitate alignment of the bulges 48 coplanar with the major axes B-B of the knuckles. In a first rotational disposition of the pin 40 , the bulges 48 can be oriented by an installer along the major elliptical axis B-B of a representative knuckle 16 , as shown in FIG. 5A , for the situation in which the hinge leaves 12 , 20 are in a closed position (i.e., the fixed hinge leaf 20 is attached to a door frame, the movable hinge leaf 12 is attached to a door, and the door is closed). Thereafter, as depicted in FIG. 5B , rotation of the hinge leaf 12 to an open position (i.e., the door is open) causes the pin 40 to rotate such that the bulges 48 align more or less with the minor axis C-C of the knuckles, thereby forcing the oppositely-disposed inner surfaces of the pin chambers apart. This action opens a gap G in the knuckle 16 at the leading edge 30 thereof due to the inherent resiliency of the material from which the knuckles are formed—typically, brass sheet metal. The result is increased friction between the pin 40 and the interior surfaces of the knuckles 16 , 18 , 22 , 24 , 26 , which reduces or eliminates the tendency of a door to swing waywardly under the influence of gravity. The amount of increase in friction can be adjusted by rotating the pin 40 , when the door is open, throughout a range—namely, from a position in which the bulges 48 are aligned with the major axes B-B to a position in which they align with the minor axes C-C, or to any position in between those extremes. Methods for manufacture of my pin are within the skill and knowledge person experienced in the manufacture of door hinges and can include, for example, drop force, casting and/or machining.
From the foregoing description, it will be clear that the present invention may be embodied in other specific forms without departing from the sprit or essential characteristics thereof. It will be understood for instance, that the number of pairs of bulges 40 may be increased or decreased from the five pairs described above, to match the number of knuckles of the butt hinge needing a replacement pin. Further, the index means could be either a kerf or a radially-directed, inscribed line 50 in the head, but the head itself could be a hexagonally-shaped head 44 ′ with hexagonal faces 114 and adjustable with a hex wrench; see FIG. 6 . Moreover, the preferred embodiment of the pin has a collar intermediate the head the shank, but the pin can be made to work even without the collar. The collar tends to keep the pin stationary with respect to whichever leaf has the knuckle that surrounds the collar. Thus, the presently disclosed embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and not limited to the foregoing description. | A replacement hinge pin to cure the problem of an open door that swings waywardly under the influence of gravity. The pin has a pair of oppositely-disposed and oppositely-directed bulges for frictional engagement with the roll-formed knuckles of a butt hinge. Rotational adjustment of the pin increases the friction in the hinge enough to prevent a door from swinging waywardly. | 8 |
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The invention lies in the mechanical arts and relates, more specifically, to a thread which extends along a thread axis, with a thread structure for engagement into a counterthread with a counterthread structure for making a screw connection. The invention relates, furthermore, to a screw connection for high application temperatures, i.e., to assembly structures with screw connections to be exposed to high temperatures.
[0003] Screw connections consisting of a screw with a bolt thread and with a counterthread (nut thread) are employed in a multiplicity of technical areas, such as mechanical engineering, plant construction, and electrical engineering. They serve, as a rule, for connecting and fastening two parts to one another. There exist, in one extreme, small screw connections which are used at room temperature and need to transmit low forces and, in the other extreme, large screw connections which have to transmit high forces at high temperatures.
[0004] The publication “Schraubenvademecum” [“Screw manual”] by Illgner and Blume, 1976, Fa. Bauer & Schaurte Karcher, Neuss, Germany, in particular section 3.5, discloses that, under elastic deformations of threads of a screw connection, different notch fatigue factors prevail at different notch points and influence the fatigue strength. The initial region, in which the thread and counterthread engage one into the other in the loading direction determines the fatigue strength. In order to reduce the super-proportionally high loads occurring in this initial region, while retaining the same thread structure of the thread and counterthread, the shape of the nut thread can be changed. In this change of shape, the outside diameter of the nut body is smallest in the initial region and increases monotonically opposite to the loading direction (tension nut, nut screwed in annularly). Other methods for relieving the initial region involve providing an overlapping nut thread, a countersinking of the nut thread and relief notches in the initial region.
[0005] A thread connection between parts having different linear thermal expansion coefficients may be gathered from European patent EP 0 008 766 B1. In order to minimize stresses in the threaded connection and use the threaded connection at increased working temperatures a taper is provided at ambient temperature. In this case, the taper is produced by means of a linear change in the radial play along the thread axis, radial play increasing in the direction of the loading of the part with the higher linear thermal expansion coefficient. This conical design of the taper over the entire length of the threaded part makes it possible to have a reliable tensioning of the threaded connection in the hot state only. By contrast, in the cold state, that is to say at ambient temperature, there is no efficient transmission of the screw force to the threaded connection and reliable absorption of the prestressing force.
[0006] U.S. Pat. No. 2,770,997 describes a cylindrical screw connection with a nut thread and with a bolt thread which is in engagement with a nut thread. The material of the nut thread and of the bolt thread have, in this case, different thermal expansion coefficients, for example a ceramic material for the nut thread and a material with a higher thermal expansion coefficient, a metal, for the bolt thread. In order to make it possible for the ceramic/metal screw connection to be used over a wide temperature range of about 20° C. to 900° C., an adaptation of the thread rise angle of the nut thread and bolt thread is provided in the cylindrical screw connection along the cylinder axis, so that maladaptions at high temperatures can be partially compensated.
[0007] For this purpose, the thread lead and rise angle of the nut thread and bolt thread is configured in such a way that an adaption of the thread rise occurs at an upper temperature limit.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide a thread and screw connection which overcomes the above-noted deficiencies and disadvantages of the prior art devices and methods of this general kind, and wherein the thread, which extends along a thread axis, for a component, is provided with an essentially homogenous load distribution along the thread axis. Another object of the invention is to specify a screw connection for high application temperatures.
[0009] With the above and other objects in view there is provided, in accordance with the invention, a thread assembly for making a screw connection between a first component and a second component having mutually different elastic and/or thermal deformation behavior, comprising:
[0010] a thread, extending along a thread axis, formed in a first component with a thread structure for engagement into a counterthread of a second component formed with a counterthread structure;
[0011] the thread having a cylindrical thread segment of constant diameter; and
[0012] a further thread segment, axially adjacent the cylindrical thread segment, the further thread segment having a diameter varying along the thread axis for compensating for an anticipated elastic and/or thermal deformation under a predetermined thermomechanical load.
[0013] In other words, the above and othere objects directed at a thread are satisfied with a thread of a first component, the thread extending along a thread axis, with a thread structure for engagement into a counterthread of a second component with a counterthread structure for making a screw connection, the elastic and/or thermal deformation behavior of the first component and of the second component being different from one another, the thread structure having an anticipation of deformation, in order to compensate elastic and/or thermal deformation under a elastic and/or thermal deformation under a predeterminable thermomechanical load, and a cylindrical thread segment of constant diameter, a further thread segment being provided, which adjoins the cylindrical thread segment axially, the diameter varying along the thread axis in the further thread segment.
[0014] The different deformation behavior may, in this case, be brought about by a different rigidity of the components, for example even with regard to essentially identical materials of the components with the same modulus of elasticity, and even when the components are in the cold state. The first component has a first material in the vicinity of the thread and the second component has a second material in the vicinity of the counterthread. The two materials may possess identical, similar or markedly different elastic, plastic and/or thermal material properties. The materials are preferably materials with a different chemical composition or alloys with at least different material properties. However, alloys with an identical material composition or identical material properties may also be used.
[0015] By means of the thread according to the invention, there is, for the first time, a controlled anticipation of deformation, as compared with the previous practice of achieving merely a reduction in the expected stress excesses by matching the rigidity of a nut to the rigidity of a screw. Simultaneously, for the first time, reliable force transmission and load absorption by the thread, even in the undeformed state, that is to say in the mounting state at room temperature, are ensured.
[0016] Where thermal deformation is concerned, the invention proceeds, here, from the recognition that, for screw connections at high temperatures, considerable requirements are placed on the screw materials used. Above particular temperature limits, for example above 500° C., in particular 580° C., in the case of steam turbines, screw materials based on iron can no longer or (because of insufficient strength) no longer appropriately be used. The screw materials which then come into consideration have different (substantially higher) thermal expansion coefficients from the high-temperature nut materials, for example flange materials, based on iron which are normally used at these temperatures. In the event of a temperature increase, differential thermal expansions in the thread segment cause the load to be shifted to the first thread segment (initial engagement region) which in any case is subjected to high load. This forestalls the use of screw materials of higher thermal expansion, since inadmissibly high stress values may thus occur. According to the invention, therefore, a deformation-compatible configuration of the thread is specified for the first time, so that the additional stress on the thread at high temperatures is prevented or at least reduced and, consequently, it also becomes possible for materials with a different thermal expansion behavior to be used for the thread and counterthread.
[0017] This is advantageous, in particular, in the case of use in steam turbines at steam temperatures of above 550° C., in particular above 580° C. At these high application temperatures, therefore, it is possible to dispense with material pairings of flange and screw-connection materials which are identical in terms of their thermal expansion behavior or the thermal expansion behavior of which is such that, in the event of a temperature increase, the stress on the thread is not concentrated inadmissibly at specific locations. To be precise, with an increase in temperature, it would be necessary to provide larger screw cross sections for such material pairings. This is limited, however, by the long-term strength of the materials, which decreases against the temperature, and by possible limits to the use of the materials, for example as a result of material-related effects which occur, such as long-period notch impact embrittlement. This disadvantage of identical materials is now eliminated by the possibility of using different materials.
[0018] At high temperatures and when high-temperature materials are used, for example in the case of 10%-chromium steels for flanges for nickel-based screws, for example made from Nimonic 80A, where conventional threads and counterthreads are concerned a thermal expansion difference arises which causes greater stress on the first thread segment (initial engagement region) as a result of a load shift. The consequence of this is that the bolt material has a higher thermal expansion than the flange material; starting from the first load-bearing thread flank of a screw connection, this brings about an elongation of the bolt thread relative to the nut thread. This leads to a relief of the following flanks and, under some circumstances, to a disengagement of flanks lying further in the screw connection, due to the thermally induced pitch errors, and therefore to additional load on the first thread segment (initial engagement region). Under some circumstances, this could necessitate a marked reduction in load and be detrimental to the operating reliability of the screw connection as a whole. This problem, too, is solved by the thread's anticipation of deformation which takes into the account the differential thermal expansion according to the invention, so that the initial engagement region is reliably subjected to a lower load than a permissible critical load up to the application temperature and higher temperatures.
[0019] The thread of the screw connection has, in this case, a deformation-compatible configuration such that, at the application temperature, a favorable load-bearing behavior generated by virtue of thermal deformation itself is established as a result of thermal expansion. In this case, the thermal thread deformation is compensated at the outset. The thread is manufactured in such a way that there are, as compared with the conventional thread, controlled deviations, for example in thread shape, amount of taper, pitch or thread profile, which are compensated completely or partially by the thermal expansion at the intended application temperature. A more uniform distribution of the load-bearing behavior is thus established as a result of the different thermal expansions.
[0020] It is possible in a simple way, for the outset, to take into account the thermal expansion for each application temperature and application load (force transmission) and for each counterthread analytically or via commercially obtainable computing programs, for example based on the Finite-Element Method (FEM), the Boundary Element Method (BEM) or the Finite Difference Methods. In this context, to design the thread, the computing methods can make use of the known thermomechanical material equations, in which the different moduli of elasticity and thermal expansion coefficients are taken into account. The manufacture of the thread with the thread shape may, particularly for cut bolt threads, be carried out in a simple way by means of numerically controlled machine tools.
[0021] It goes without saying, therefore, that the anticipation of deformation according to the invention can be used, even in the case of purely elastic and elastoplastic deformations, at an essentially constant temperature. Thus, even in the case of pure elastic or elastoplastic deformations, there is an improvement in the fatigue strength of the initial engagement region which is critical for the fatigue strength of the entire screw connection. Depending on the embodiment, an improvement in this initial engagement region up to a factor of two may be achieved, so that another region of the screw is critical for the fatigue strength of the screw connection. The thread is therefore also suitable in broad areas of conventional screw technology in the case of relatively small or simply designed screw connections in which there is merely a different elastic deformation behavior of the thread and counterthread of the components screwed together. Anticipation of deformation with regard to thermal and elastic or elastoplastic deformations may, of course, also be taken into account.
[0022] In the cold state, that is to say at normal temperature, the thread, by virtue of the geometry which takes into account the change of shape, has a load-bearing behavior which differs from a conventional thread and may also be concentrated on a few thread flights. This is acceptable, inter alia, because the load-bearing capacity of the screw and flange materials is substantially higher in the cold state than at high application temperatures. Moreover, in application in a steam turbine, the maximum stress on the screw connections, occurs, as a rule, in the case of screwed-together pressure-carrying parts (for example, turbine casing, screwed-together covers), only under the full action of pressure. In a steam turbine, this full action takes place, by virtue of the principle adopted, at increased temperature, for which the thread geometry is deliberately improved.
[0023] Measures may nevertheless also be taken, which reduce the effect of the higher stresses in the cold state in a controlled way. Preferably, in this case, one thread segment is designed as a normal thread, by means of which the screw force is borne reliably in the cold state. In the event of a temperature increase, this thread segment is relieved by other deformation-anticipating thread segments. As a result of this design, an equalization of the load-bearing behavior of the thread over an extended temperature range, that is to say, for example from room temperature up to the application temperature, is achieved.
[0024] In accordance with a further preferred embodiment, the thread has, along the thread axis, a diameter which varies at least in regions, in particular increases monotonically. In this case, the thread structure may have a curved design, at least in one thread segment, a tangent to an enveloping curve of the thread forming an acute angle with a line parallel to the thread axis. This angle decreases continuously, in particular monotonically. It may approach zero. The thread structure may at the same time, at least in one thread segment, also have a tapered design with a taper angle which is acute in relation to the thread axis. Such a taper angle amounts, preferably, to between 0.1° and 1.0°, in particular to about 0.3°. The tapered thread segment is followed, preferably opposite to a loading direction, that is to say in the direction away from the initial engagement region, by the cylindrical thread segment of constant diameter.
[0025] In this case, preferably, a controlled withdrawal of the first thread flight radially out of the thread takes place (the diameter of the external thread reduced at the thread start or the diameter of the internal thread increased in this region). The radial withdrawal of the flanks from the thread teeth which is caused thereby gives rise to play between two adjacent flanks of the thread and the counterthread in the first thread segment (initial engagement region). In the case of an undeformed (ideal) thread, the thread teeth configured in this way do not come into engagement; when the screws are tensioned, the flanks can come into contact again, but this is not mandatory. As a result, even in the event of purely elastic deformations, an equalization of the loads in the thread along the thread axis is achieved. With a corresponding embodiment of the thread, in the case of thermal and/or elastic deformation, the thread teeth come into engagement and assume part of the screw force. The flanks within the screw connection which are subjected to higher load due to the changed shape are therefore relieved, as compared with the cold state. In this case, the thread stress on the first thread segment does not attain the value which would occur in the case of normal thread configuration.
[0026] The effects of thermal expansion can be compensated effectively by a suitable choice of the taper angle or by another suitable variation in diameter. The tapered thread segment may have different leads and be combined with cylindrical thread segments, in order, for example, to achieve a better load-bearing behavior in the cold state. Furthermore, additional compensation of the high stress on the first thread flight which occurs with normal threads (and which is due to elastic deformation) can be achieved as a result. A preferred taper angle for thermal compensation at an application temperature of about 600° C. in the case of a 10%-chromium-steel for a nut thread and a nickel-based alloy, for example Nimonic 80A, for a bolt thread (600° C.) amounts to approximately 0.3°. The taper angle is, in this case, selected preferably in such a way that the first thread segment (initial engagement region) comes into engagement and comes to bear at the application temperature.
[0027] As compared with tapered threads, which serve for achieving a sealing effect in the thread or as an unscrewing safeguard by radial clamping and in which, for this purpose, either two tapered threads of the same taper angle are paired or one tapered thread is paired with one cylindrical thread, in such a way that the thread play decreases with progressive screwing-in, in the above tapered thread the thread play in relation to the first thread teeth is greater, in order to relieve these in a controlled way in the operating state.
[0028] In accordance with another preferred embodiment, the thread has at least one thread segment with a pitch which changes along the thread axis. Also preferably, the thread segment with a changing pitch is followed opposite to the loading direction by a thread segment with constant pitch.
[0029] Preferably, a controlled introduction of a pitch deviation between the thread and the counterthread is carried out, in order to compensate the pitch deviation occurring as a result as thermal and/or elastoplastic expansion. In this case, the pitch of a bolt thread is smaller than that of the associated nut thread which has a lower thermal expansion coefficient. At the application temperature, an equalization of the pitch is established due to the greater thermal expansion of the bolt. The pitch may vary over the thread length. Preferably, a thread segment without pitch deviation is provided for a favorable behavior in the cold state and a thread segment with increased pitch deviation at the thread start is provided for compensating the additional load on the first thread segment. The mountability and demountability of the bolt may, in this case, be ensured, for example, by applying a temperature difference between the bolt thread and nut thread, for example a heating of the bolt before screwing-in, or by the provision of correspondingly increased flank plays.
[0030] In a further embodiment, the thread has a thread segment with a changing thread profile. For this purpose, the flank angle of a flank may change along the thread axis. The change may take place monotonically or in steps, in the latter case two regions, each with a constant but different thread profile, adjoining one another. It is also possible for the falling flank and the rising flank of a thread tooth to have a flank angle which is different in each case. Preferably, the thread segment with a changing thread profile is followed by an, in particular, cylindrical thread segment with a constant thread profile.
[0031] The rigidity and the engagement of the individual flanks can be influenced by an adaptation of the thread profile. Thus, for example, changes to the flank angle, different part flank angles or other geometrical changes to the thread teeth are possible.
[0032] It is also possible for a thread to contain a combination of individual or all the measures for the anticipation of deformation, such as change of pitch, change of thread profile and diameter configuration. They may be carried out in each case on one thread of a screw-connection partner (bolt thread or nut thread) or on both.
[0033] Preferably, the thread is designed for use at an application temperature of above 500° C., in particular above 580° C.
[0034] It is preferably a bolt thread on a screw composed of an nickel-based alloy. For a component, a cobalt-based alloy or an austenitic steel may be provided, as an alternative to a nickel-based alloy, at least in the vicinity of the thread or of the counterthread.
[0035] The object directed at a screw connection is achieved by means of a screw connection for a high application temperature, with a thread, in which, when the thread and the counterthread engage one into the other at a normal temperature below the application temperature, play remains, in an initial engagement region, between the thread structure of the thread and the counterthread structure of the counterthread or there is, at least, a relief of the flanks which are in contact. The screw connection is preferably made on a flange of a steam turbine. The flange consists preferably of a chromium steel with a fraction of 9% by weight to 12% by weight of chromium.
[0036] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0037] Although the invention is illustrated and described herein as embodied in a thread and screw connection for a high application temperature, it is nevertheless not intended to be limited to the details shown, since 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.
[0038] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] [0039]FIG. 1 is a longitudinal section through a screw connection with a bolt screwed into a flange;
[0040] [0040]FIGS. 2A, 3A, 4 A, 5 A are sectional details of a screw connection similar to that of FIG. 1 in the cold state; and
[0041] [0041]FIGS. 2B, 3B, 4 B and 5 B are sectional views each showing the corresponding detail at a high application temperature.
[0042] Identical and functionally equivalent parts are identified with the same reference symbols throughout the figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a longitudinal section through a screw connection in a flange 12 of a steam turbine. The latter is referenced as an example only and is, therefore, not illustrated. The flange 12 has a counterthread 4 designed as a nut thread.
[0044] A bolt or screw 13 extending along a screw axis 2 is screwed into the counterthread 4 (nut thread 4 ). The screw 13 has a thread 1 which is designed as a bolt thread and which meshes with the nut thread 4 . The bolt thread 1 has a thread structure 3 and the nut thread 4 a counterthread structure 5 . By virtue of the rotational symmetry of the screw 13 with respect to the screw axis 2 , only half of the longitudinal section through the screw 13 is illustrated. The screw 13 has an end face 17 which is perpendicular to the screw axis 2 and with which the screw 13 is screwed farthest into the flange 12 . The region, starting from which the screw 13 projects from the nut thread 4 of the flange 12 , is designated as the initial engagement region 14 of the thread 1 into the counterthread 4 . In conventional threads, this region is the region which is critical for the fatigue strength of the screw connection.
[0045] The following numerical computation results were achieved for a screw connection illustrated in FIG. 1, with a M120x6 setscrew 13 under an assumed shank tension of 250 N/mm 2 at a temperature of 600° C. In these computations, the thermal expansion behavior of a 10%-chromium steel (X12CrMoWVNbN10-1-1) was assumed for the flange 12 . This steel has a mean thermal expansion coefficient of 12.7·10 −6 /K at a temperature of between 20° C. and 600° C. When an 11%-chromium steel (X19CrMoVNbN11-1) is used for the screw 13 , local stress excesses are exhibited in the initial engagement region 14 , but these do not impair the load-bearing behavior of the thread 1 at temperatures below the limit temperature of the high-temperature non-austenitic screw steel of about 560° C. These local stress excesses result from the different rigidities of the screw 13 and of the flange 12 .
[0046] When a nickel-based material is used for the screw, for example Nimonic 80A, with a conventional thread, a pronounced stress excess is exhibited in the initial engagement region 14 as a result of the different thermal expansion coefficients. As shown by finite element computations, which include the plastic material behavior, this leads to pronounced plastic expansions in the flange 12 which may correspond to the breaking expansion of the flange material. Under thermal load changes, this could lead, under some circumstances, to a failure of the thread flights in the flange 12 . The mean thermal expansion coefficient of Nimonic 80A is approximately 15·10 −6 /K at 600° C.
[0047] When a screw 13 made from the material Nimonic 80A is used, with a tapered design of the thread 1 (bolt thread 1 ) having a taper angle of about 0.3°, the result is, in the initial engagement region 14 , a stress state which corresponds to the stress state when an 11%-chromium steel is used for the screw 13 . In this case, a taper angle of about 0.3° corresponds, in the initial engagement region 14 , to a reduction in diameter of about 0.6 mm. Further homogenization of the load-bearing behavior, that is to say relief of the initial engagement region 14 , may take place by virtue of a slight increase in the taper angle in order to compensate the rigidity differences between the screw 13 and flange 12 . In the case of the tapered design of the thread 1 , increased loads arise in the further-in thread flights, that is to say in the region of the end face 17 , at low temperatures of about 20° C. (mounting state), but these loads are not critical due to the higher load-bearing capacity of the screw material and of the flange material in the cold state. These increased loads may be reduced by a conventional cylindrical thread, preferably with a constant diameter D, being used in the region of the end face 17 .
[0048] [0048]FIG. 2A shows a detail through a screw connection with a bolt thread 1 and with a nut thread 4 in the cold state in which the thread teeth 3 A of the bolt thread 1 bear with a flank 11 on a respective flank 16 of an associated thread tooth 5 A of the nut thread 4 . The bolt thread 1 consists, in this case, of a material with a higher thermal expansion coefficient than the material of the nut thread 4 . In the event of an increase in the temperature, for example to an application temperature of 600° C., the different thermal expansion of the screw 13 in relation to the flange 12 leads to the further-lying thread teeth 3 A to lift off with their flanks 11 from the associated flanks 16 of the thread teeth 5 A or at least to be relieved (see FIG. 2B). The result of this is that not all the thread teeth 3 A and 5 A are any longer load-bearing, but, instead, the load is shed virtually completely via the thread teeth 3 A and 5 A of the initial engagement region 14 . This leads, at increased temperatures to an occasionally critical load on the initial engagement region 14 . The screw connection is preferably prestressed even in the cold state.
[0049] [0049]FIG. 3A illustrates a thread 1 with a variation in diameter, in engagement with a counterthread 4 (nut thread 4 ), in the cold state. The thread 1 has a cylindrical thread structure of constant diameter D in the thread segment 7 facing the end face 17 . In the thread segment 7 , those flanks 11 of the thread teeth 3 A facing away from the end face 17 bear directly on the respective flanks 16 of the associated thread teeth 5 A of the nut thread 4 . In the vicinity of the initial engagement region 14 , the thread 1 has a tapered thread segment 6 , the taper angle β of which is dimensioned according to the expected thermal and elastic expansions at a predetermined application temperature of the thread 1 . Between the thread segment 6 and the thread segment 7 is located a thread segment 6 A, in which the thread 1 likewise has a tapered construction. In this case, the associated taper angle is dimensioned according to expected thermal expansions.
[0050] The variation in diameter D in the region of the tapered thread segments 6 , 6 A as illustrated has been greatly exaggerated for the sake of clarity. At an increased temperature, in particular the application temperature of the thread 1 , different thermal expansions of the screw 13 (higher thermal expansion coefficient) and of the flange 12 (lower thermal expansion coefficient) take place. In the thread segment 6 , the flanks 11 and 16 come into full engagement under elastic and thermal deformation (see FIG. 3B). In the thread segment 6 A, the flanks 11 and 16 come into full engagement under thermal expansion. An equalization of the load-bearing behavior and, as a result, a partial or complete relief of the initial engagement region 14 are thereby achieved. At increased temperature, the flanks 11 and 16 , which, in the cold state, are load-bearing in the thread segment 7 , lift off from one another or are at least relieved.
[0051] [0051]FIG. 4A illustrates a screw connection in which the thread 1 has a variation in pitch. In the initial engagement region 14 , there is a thread segment 8 A with a varied pitch which is determined according to expected thermal and elastic expansion. The thread segment 8 A has adjoining it a thread segment 8 B, the pitch of which is varied in light of an expected thermal expansion. The thread segments 8 A and 8 B form a thread segment 8 in which there is a varied pitch of the thread 1 . The thread segment 8 is followed, toward the end face 17 , by a thread segment 9 with a normal pitch, so that, in the cold state, the flanks 11 and 16 bear on one another and thereby shed a load determined by prestress. The flanks 11 and 16 in the thread segment 8 are at least (partially) relieved or even spaced from one another. The variation in pitch is likewise illustrated as being exaggerated for the sake of clarity. In the event of an increase in temperature, the effect, already described above, occurs (see FIG. 4B), whereby flanks 11 , 16 in the thread segment 8 come into full engagement as the result of elastic and thermal or only thermal expansions and an equalized load-bearing behavior and a relief of the initial engagement region 14 are thus achieved. In the event of an increase in temperature, the flanks 11 and 16 in the thread segment 9 are relieved or even lift off from one another.
[0052] [0052]FIG. 5A illustrates a detail of thread 1 with a variation in the thread profile, the variation in the thread profile being achieved here, using an unequal part flank angle of the thread teeth 3 A. The flanks 11 B (rising flanks) facing away from the end face 17 have a flank angle γB which is larger than the flank angle γA of the flanks 11 A (falling flanks) facing the end face 17 . In a thread segment 15 which adjoins the end face 17 , the thread profile of the thread 1 is selected conventionally, so that, under prestress in the elastic state, the flanks 11 and 16 bear on one another and shed the load caused by the prestress. The thread segments 10 A, 10 B following the thread segment 15 have thread teeth with a different part flank angle γ. In the thread segment 10 A assigned to the initial engagement region 14 , the thread profile is determined according to the expected thermal or elastic expansions. In the thread segment 10 B located between the thread segments 10 A and 15 , the thread profile is determined according to the expected thermal expansion. As already explained above with regard to FIGS. 3B and 4B, in the event of an increase in temperature (see FIG. 5B), the flanks 11 and 16 come into full engagement under elastic and/or thermal deformation, with the result that an equalization of the load-bearing behavior is obtained. In this case too, the flanks 11 and 16 in the thread segment 15 are relieved or lift off completely from one another.
[0053] It goes without saying that the embodiments described above and other possibilities for the configuration of the thread segments may be combined with one another, depending on requirements and choice of material. Depending on the design of the screw 13 and of the flange 12 , thread segments 7 , 9 , 15 may be used with an unmodified profile, omitted or modified, as required, for the purpose of the shedding of load in the cold state.
[0054] The invention is distinguished by a thread which is manufactured in such a way that, at least at the intended application temperature and/or under the intended elastic load, it has a shape which brings about an equalized load-bearing behavior. This achieves a relief of the initial engagement region which is otherwise subjected to high load and which is critical for fatigue strength. Furthermore, the thread preferably has a thread segment of conventional type, which ensures an improved capacity for the transmission of the screw force in the cold state. An equalization of the load absorption and load distribution in the thread over the entire thread length and over an extended temperature range is thereby ensured. | The thread of a first component extends along a thread axis and has a thread structure for meshing engagement into a counterthread of a second component having a counterthread structure, for making a screw connection. The elastic and/or thermal deformation behavior of the first component and of the second component are different from one another. The thread structure is configured with an anticipation of deformation, in order to compensate for an elastic and/or thermal deformation under a predeterminable thermomechanical load, and a cylindrical thread segment of constant diameter. There is provided a thread segment, axially adjacent to the cylindrical thread segment, with a diameter that varies along the thread axis. The thread assembly is utilized in a screw connection for a high application temperatures. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a plate for a heat exchanger tank and more particularly to a plate for a heat exchanger tank having integrated fluid turbulation features.
BACKGROUND OF THE INVENTION
[0002] Heat exchanger tanks are designed to transport a heat transfer fluid, such as in a motor vehicle for example. Typically, opposed plates carry the fluid such as oil, for example, in passageways formed therebetween. It is known to provide corrugated fins between pairs of plates, wherein the fins act as a turbulator to increase the heat transfer coefficient of the heat exchanger.
[0003] One known method of making such a construction is to physically insert a corrugated fin between the plates after the plates have been manufactured. This has proved to be a difficult process since the corrugated fins are extremely thin and subject to deformation and damage during the insertion process. Further, inserting the fins can be a time consuming and costly process.
[0004] It is also known to provide beaded plates for heat exchangers, wherein the beads define a plurality of passageways between adjacent plates for the passage of a fluid therethrough. An example of the beaded plates is disclosed in commonly owned U.S. Pat. No. 6,364,006, hereby incorporated herein by reference in its entirety. The beaded plates increase the surface area of conductive material available for heat transfer and cause turbulence of the fluid carried between the plates. Prior art plates include a plurality of beads formed thereon. The beads of the plates contact each other and are bonded together to force the flow of fluid therearound. The beads are aligned in rows, wherein a first row has an “A” pattern and the adjacent row has a “B” pattern. The rows are repeated in an A-B pattern, in which the beads in the A rows are aligned longitudinally or downstream from each other and the beads in the B rows are aligned longitudinally or downstream from each other.
[0005] Although the above heat exchangers have worked well, it is desirable to eliminate the use of a turbulator between plates of a heat exchanger. It is also desirable to provide beaded plates for a heat exchanger wherein a turbulation of fluid flowing on both sides of the plate is caused to enhance heat transfer between the fluids.
[0006] It is therefore considered desirable to produce a beaded plate for a heat exchanger tank, wherein the walls of the plate include integrated fluid turbulation features formed thereon for maximizing a turbulation of fluids flowing through the tank on both sides of the plate.
SUMMARY OF THE INVENTION
[0007] Harmonious with the present invention, a beaded plate for a heat exchanger tank, wherein the walls of the plate include integrated fluid turbulation features formed thereon for maximizing a turbulation of fluids flowing through the tank on both sides of the plate, has surprisingly been discovered.
[0008] In one embodiment, a plate for a heat exchanger comprises: an elongate first main body having a first surface, a second surface, and a lip extending laterally outwardly from a peripheral edge of the main body; a plurality of spaced apart first beads formed on the second surface of the plate, wherein a depth of the lip is larger than a depth of the first beads; and a plurality of spaced apart second beads formed on the first surface of the plate.
[0009] In another embodiment, a stack for a heat exchanger comprises: a first plate having a first surface and a second surface, the second surface including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surface including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads; and a second plate having a first surface and a second surface, the second surface including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surface including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads, wherein the lip of the first plate is connected to the lip of the second plate.
[0010] In another embodiment, a stack for a heat exchanger comprises: a plurality of plates having first surfaces and second surfaces, the second surfaces including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surfaces including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads, wherein the lips of pairs of plates are connected and the second beads of the pairs of plates are connected, and wherein a first plurality of flow passages is formed between the first surfaces of adjacent plates, and a second plurality of flow passages is formed between the second surfaces of adjacent plates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings in which:
[0012] FIG. 1 is a top plan view of a beaded plate for a heat exchanger in accordance with an embodiment of the invention;
[0013] FIG. 2 is a sectional view of the beaded plate for a heat exchanger illustrated in FIG. 1 taken along line 2 - 2 ;
[0014] FIG. 3 is a side elevational view of a stack of beaded plates illustrated in FIG. 1 ;
[0015] FIG. 4 is a top plan view of a beaded plate for a heat exchanger in accordance with another embodiment of the invention; and
[0016] FIG. 5 is a sectional view of the beaded plate for a heat exchanger illustrated in FIG. 4 taken along line 4 - 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.
[0018] FIGS. 1 and 2 show a beaded plate 10 for a heat exchanger (not shown) in accordance with an embodiment of the invention. The plate 10 is formed from a metal material such as aluminum or an aluminum alloy, for example. The plate 10 extends longitudinally from a first end 12 to a second end 14 , and includes a first surface 11 and an opposed second surface 13 . A main body portion 16 of the plate is disposed between the first end 12 and the second end 14 , and has a substantially rectangular shape in plan.
[0019] The first end 12 of the plate 10 includes a raised lip 18 surrounding an aperture 20 . The raised lip 18 forms a circular shaped channel (not shown) in the second side 13 of the plate 10 . A plurality of raised portions 21 is formed in the first end 12 . The raised portions 21 form channels (not shown) in the second side 13 of the plate 10 . The channels extend from the channel opposite the raised lip 18 to the main body portion 16 . It is understood that more or fewer channels can be formed in the first end 12 as desired.
[0020] The second end 14 of the plate 10 includes a raised lip 22 surrounding an aperture 24 . The raised lip 22 forms a circular shaped channel (not shown) in the second side 13 of the plate 10 . A plurality of raised portions 25 is formed in the second end 14 . The raised portions 25 form channels (not shown) in the second side 13 of the plate 10 . The channels extend from the main body portion 16 to the channel opposite the raised lip 22 . It is understood that additional or fewer channels can be formed in the second end 14 as desired.
[0021] As more clearly shown in FIG. 2 , the second surface 13 of the plate 10 includes a laterally outwardly extending lip 26 having a depth d 0 that extends outwardly from a peripheral edge of the plate 10 . The plate 10 also includes a plurality of spaced apart first beads 32 extending laterally outwardly from the second surface 13 . The first beads 32 are generally dome shaped and have a predetermined radius such as 1.5 millimeters, for example. It is understood that a larger or smaller radius can be used. The first beads 32 have a depth d 1 . In the embodiment shown, the depth d 0 of the lip 26 is substantially similar to the depth d 1 of the first beads 32 , although other depths can be used as desired.
[0022] The plate 10 also includes a plurality of spaced apart second beads 36 extending laterally outwardly from the first surface 11 of the plate 10 . The second beads 36 are generally trapezoid shaped and have a predetermined width such as five millimeters, for example. It is understood that a larger or smaller width can be used. The second beads 36 have a depth d 2 . In the embodiment shown, the depth d 2 of the second beads 36 is larger than the depth d 1 of the first beads 32 , although other depths can be used. A distal end 40 of the second beads 36 is generally flat. It is understood that the second beads 36 can be dome shaped or have other shapes as desired.
[0023] The plate 10 includes a plurality of spaced apart third beads 42 that are substantially ovoid or football shaped, and extend laterally outwardly from the first surface 11 . The third beads 42 have a depth (not depicted) extending from the first surface 11 and terminating in a substantially flat distal end 45 . It is understood that the distal end 45 of the third beads 42 can be curved as desired. In the embodiment shown, the depth of the third beads 42 is larger than the depth d 2 of the second beads 36 .
[0024] In the embodiment shown, the first beads 32 , the second beads 36 , and the third beads 42 are formed in a pattern of a plurality of rows. It is understood that the beads 32 , 36 , 42 can be formed in other configurations as desired. Each row contains a plurality of a predetermined number of the first beads 32 , the second beads 36 , and the third beads 42 , wherein the number of the second beads 36 and the third beads 42 in certain rows is zero (0). The rows of the beads 32 , 36 , 42 are spaced longitudinally on the main body portion 16 of the plate 10 a predetermined distance.
[0025] When assembled, a pair of plates are brazed together to form a heat exchange plate 50 , as shown in FIG. 3 . One of the plates 10 is oriented as shown in FIGS. 1 and 2 , and the other of the plates is inverted from the orientation of FIGS. 1 and 2 to permit corresponding lips 26 to abut one another. The lips 26 of the pair of the plates 10 are brazed together. Thus, the first surfaces 11 of the pairs of plates 10 are exposed. The first surfaces 11 of the pair of brazed plates 10 are then brazed together at the raised lips 18 , 22 , the second beads 36 , and the third beads 42 to form a stack 44 . A gap 45 is formed between the first surfaces 11 of adjacent heat exchanger plates 50 .
[0026] The first apertures 20 of the heath exchanger plates 50 in the stack 44 are aligned and cooperate to form a first conduit (not shown). The second apertures 24 of the plates 10 in the stack 44 are aligned and cooperate to form a second conduit (not shown). A first plurality of flow passages (not shown) is formed in the heat exchange plates 50 between the second surfaces 13 of brazed adjacent plates 10 . A second plurality of flow passages is formed within the gaps 45 formed by the first surfaces 11 of adjacent plates 10 . The second plurality of flow passages formed by the gaps 45 between adjacent heat exchanger plates 50 is in fluid communication with a pair of flow headers (not shown).
[0027] A first mounting plate 54 is disposed on and brazed to the plate 10 at a first end of the stack 44 . A second mounting plate 56 is disposed on and brazed to the plate 10 at a second end of the stack 44 . The first mounting plate 54 includes a first aperture (not shown) that is aligned with the first conduit and a second aperture (not shown) that is aligned with the second conduit. The stack 44 includes a fluid inlet conduit 66 in fluid communication with the first conduit and a fluid outlet conduit 68 in communication with the second conduit.
[0028] In use a first fluid (not shown) such as radiator fluid or oil, for example, flows through the fluid inlet conduit 66 into the first conduit. The first fluid flows through the channels 21 and into the first plurality of flow passages formed in the heat exchanger plates 50 between the second surfaces 13 of brazed adjacent plates 10 . As the first fluid travels through the first plurality of flow passages, the first fluid flows around the first beads 32 , which cause the first fluid to be turbulated. Thereafter, the first fluid flows through the channels 25 into the second fluid conduit and out of the stack 44 through the fluid outlet conduit 68 .
[0029] A second fluid (not shown) such as a coolant, for example, is caused to flow through the gaps 45 . As the second fluid flows through the gaps 45 , the second fluid flows across the first surfaces 11 including the first beads 32 , which cause the second fluid to be turbulated. Additionally, heat is transferred from the first fluid to the second fluid. It is understood that heat can also be transferred from the second fluid to the first fluid.
[0030] The turbulation caused by the first beads 32 to the first fluid and the second fluid minimizes a need for a separate turbulating fin to be disposed between the plates 10 . Accordingly, a cost of materials and a weight are minimized.
[0031] It should be appreciated that the plates 10 could be used for heat exchangers in other applications besides motor vehicles.
[0032] FIGS. 4 and 5 show a beaded plate 110 for a heat exchanger (not shown) in accordance with an embodiment of the invention. The plate 110 is formed from a metal material such as aluminum or an aluminum alloy, for example. The plate 110 extends longitudinally from a first end 112 to a second end 114 , and includes a first surface 111 and an opposed second surface 113 . A main body portion 116 of the plate is disposed between the first end 112 and the second end 114 , and has a substantially rectangular shape in plan.
[0033] The first end 112 of the plate 110 includes a raised lip 118 surrounding an aperture 120 . The raised lip 118 forms a circular shaped channel (not shown) in the second side 113 of the plate 110 . A plurality of raised portions 121 is formed in the first end 112 . The raised portions plate form channels (not shown) in the second side 113 of the plate 110 . The channels extend from the channel opposite the raised lip 118 to the main body portion 116 . It is understood that more or fewer channels can be formed in the first end 112 as desired.
[0034] The second end 114 of the plate 110 includes a raised lip 122 surrounding an aperture 124 . The raised lip 122 forms a circular shaped channel (not shown) in the second side 113 of the plate 110 . A plurality of raised portions 125 is formed in the second end 114 . The raised portions 125 form channels (not shown) in the second side 113 of the plate 110 . The channels extend from the main body portion 116 to the channel opposite the raised lip 122 . It is understood that additional or fewer channels can be formed in the second end 114 as desired.
[0035] As more clearly shown in FIG. 5 , the second surface 113 of the plate 110 includes a laterally outwardly extending lip 126 having a depth d 10 that extends outwardly from a peripheral edge of the plate 110 . The plate 110 also includes a plurality of spaced apart first beads 132 extending laterally outwardly from the second surface 113 . In a preferred embodiment, the first beads 132 are general wave shaped. The first beads 132 have a depth d 11 . In the embodiment shown, the depth d 10 of the lip 126 is substantially similar to the depth d 11 of the first beads 132 , although other depths can be used as desired.
[0036] The plate 110 also includes a plurality of spaced apart second beads 136 extending laterally outwardly from the first surface 111 of the plate 110 . The second beads 136 are generally trapezoid shaped and have a predetermined width such as five millimeters, for example. It is understood that a larger or smaller width can be used. The second beads 136 have a depth d 12 . In the embodiment shown, the depth d 12 of the second beads 136 is larger than the depth d 11 of the first beads 132 , although other depths can be used. A distal end 140 of the second beads 136 is generally flat. It is understood that the second beads 136 can be dome shaped or have other shapes as desired.
[0037] The plate 110 includes a plurality of spaced apart third beads 142 that are substantially ovoid or football shaped, and extend laterally outwardly from the first surface 111 . The third beads 142 have a depth (not depicted) extending from the first surface 111 and terminating in a substantially flat distal end 145 . It is understood that the distal end 145 of the third beads 142 can be curved as desired. In the embodiment shown, the depth of the third beads 142 is larger than the depth d 12 of the second beads 136 .
[0038] In the embodiment shown, the first beads 132 , the second beads 136 , and the third beads 142 are formed in a pattern of a plurality of rows. It is understood that the beads 132 , 136 , 142 can be formed in other configurations as desired. Each row contains a plurality of a predetermined number of the first beads 132 , the second beads 136 , and the third beads 142 , wherein the number of the second beads 136 and the third beads 142 in certain rows is zero (0). The rows of the beads 132 , 136 , 142 are spaced longitudinally on the main body portion 116 of the plate 110 a predetermined distance.
[0039] When assembled, a pair of plates 110 are brazed together to form a heat exchange plate (not shown) as discussed above. One of the plates 110 is oriented as shown in FIGS. 4 and 5 , and the other of the plates is inverted from the orientation of FIGS. 4 and 5 to permit corresponding lips 126 to abut one another. The lips 126 of the pair of the plates 110 are brazed together. Thus, the first surfaces 111 of the pairs of plates 110 are exposed. The first surfaces 111 of the pair of brazed plates 110 are then brazed together at the raised lips 118 , 122 , the second beads 136 , and the third beads 142 to form a stack (not shown). A gap (not shown) is formed between the first surfaces 111 of adjacent heat exchanger plates.
[0040] The first apertures 120 of the heath exchanger plates in the stack are aligned and cooperate to form a first conduit (not shown). The second apertures 124 of the plates 110 in the stack are aligned and cooperate to form a second conduit (not shown). A first plurality of flow passages (not shown) is formed in the heat exchange plates between the second surfaces 113 of brazed adjacent plates 110 . A second plurality of flow passages (not shown) is formed within the gaps formed by the first surfaces 111 of adjacent plates 110 . The second plurality of flow passages formed by the gaps between adjacent heat exchanger plates is in fluid communication with a pair of flow headers (not shown).
[0041] Use of the plates 110 is substantially similar to use of the plates 10 as discussed above for FIGS. 1-3 . The turbulation caused by the first beads 132 to the first fluid and the second fluid minimizes a need for a separate turbulating fin to be disposed between the plates 110 . Accordingly, a cost of materials and a weight are minimized.
[0042] It should be appreciated that the plates 110 could be used for heat exchangers in other applications besides motor vehicles.
[0043] From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. | A plate for a heat exchanger is disclosed, wherein surfaces of the plate have integrated turbulation features formed thereon. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a system for testing digital circuits and, more particularly, relates to a system for high speed testing of both integrated logic and array circuits.
2. Description of the Prior Art
The testing of electrical characteristics of integrated circuits is of prime importance in the manufacture of electronic devices, especially for use in data processing equipment which requires extremely high reliability. Because of the large number of circuits in an integrated circuit chip, it is very desirable to test the chip or wafer during development, before releasing the chip design to manufacturing. However, the trends today in integrated circuits of increasing even more the number of circuits per chip and of merging logic and memory arrays on the same chip make testing of these chips a difficult and complex problem. As the number of circuits change, the pin count also changes and the tester must be sufficiently flexible to handle a variable pin count. Today, there exists slow speed DC testers which can handle variable pin counts, and high speed functional testers with limited and fixed pin counts. However, there is need for a combination tester (DC and functional) which will handle variable pin counts and operate in a mixed mode by testing both array and logic circuits.
SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to provide a tester which has the flexibility of a slow speed DC tester by being able to handle variable pin counts, and also is operable as a mixed mode high speed functional tester.
A further object of the present invention is to provide a tester with expanded pin count capability, without a degradation in testing throughput due to the increased time needed to store additional data for the expanded pins.
Another object of the present invention is to provide a tester with the ability to time each pin individually and independently.
These and other objects are achieved by the tester of the present invention which is designed with separate electronics for test data storage, test data movement and high speed test application with the electronics being divided into a plurality of blocks. Each block is self sufficient during test and operates in parallel with the other blocks, the self-sufficiency being obtained by storing and applying the test data assigned to that block. This is accomplished at a high speed rate with unique timing control on a per pin basis.
To achieve the flexibility of being able to handle variable pin counts on a high speed tester without degrading performance, the tester of the present invention is designed with local mass storage in each block sufficient to store a working days supply of test data and the necessary electronics to move that data to the high speed electronics behind each pin. As a result, the data rate to the high speed electronics increases as the tester pin requirement increases by adding additional blocks thus maintaining a fixed setup time essentially independent of the pin count.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which
FIG. 1 is a generalized diagram of the test system of the present invention, showing the plurality of blocks.
FIG. 2 is a diagram of the system configuration of a block.
FIG. 3 is a diagram of the components of a block controller.
FIG. 4 is a diagram of a read/write controller.
FIG. 5 is a diagram of the pin electronic card.
FIG. 6 is a diagram of the setup buffer of the pin electronic card.
FIG. 7 is a diagram of the high speed logic of the pin electronic card.
FIG. 8 is a diagram showing the timing logic in the pin electronic card.
FIG. 9 is a diagram of the high speed buffer of pin electronic card.
FIG. 10 is a diagram of the address generator portion of the pin electronic card.
FIG. 11 is a partial diagram of the selection circuitry of the selection block of FIG. 7.
FIG. 12 is the remaining portion of the selection circuitry of the selection block of FIG. 7.
FIG. 13 is a diagram of the high speed system controller of FIG. 1.
FIG. 14 is a diagram of the driver and receiver circuit of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 generally shows the test system of the present invention which comprises a host computer 10 a plurality of blocks 11a, 11b, 11c, 11n, a high speed system controller (HSSC) 12, a probe 13, and a device under test (DUT) 14. The host computer 10 controls the entire system and sends information to each block. Each block stores that information and controls a set of probe points 15 which will be used simultaneously to test the device 14, herein an integrated circuit chip. The HSSC 12 comprises an oscillator which, when testing the device 14, performs the function of synchronizing the test system.
Turning now to a more detailed description of one of the blocks 11 (FIG. 1), FIG. 2 shows the host computer 10 communicating with a block controller 20 of the block. The block controller 20 is connected via a system bus 21 to a block controller program store 22 and a plurality of mass storage units 23a, 23n which are expandable in 64K increments to 16 megabytes. In addition, the controller 20 is connected via the system bus 21 to high speed buffer 24a and setup buffer 24b on the Pin Electronic Card (PEC) 25.
The details of the block controller 20 (FIG. 2) are shown in FIG. 3. The controller comprises a microprocessor 30, direct memory access unit (DMA) 31, two parallel input/output ports 33, 34, a read/write controller 35 and a decoder 36 all interconnected by a bus containing CONTROL 37, ADDRESS 38, and DATA 39 lines. All but the read/write controller 35, which will be described in more detail in connection with FIG. 4, are commercially available.
FIG. 4 shows a more detailed look at the read/write controller 35 of FIG. 3. The microprocessor 30 (FIG. 3) will set up READ ADDRESS and the WRITE ADDRESS via the parallel input/output ports 34a, 34b. Each one of these addresses represents which block is to be the source or destination of a data transfer. The decoders 40 feed the AND circuits 41 which switch the read and write address stipulated by the parallel input/ output port to address the block controller program store 22 (FIG. 2). This is done by the memory request line, which is set when the microprocessor wishes to access the block controller program store.
To cite an example how the read/write control is used to move information, reference is made to FIGS. 2 and 3. If 20,000 bytes of information are to be moved from mass storage unit 23a (FIG. 2) to the set up buffer 24b (FIG. 2) the microprocessor 30 (FIG. 3) instructs direct memory access unit 31 (FIG. 3) to move 20,000 bytes of information. Next, the microprocessor instructs the parallel input/output port 34 to set up mass storage, herein 23a, as the READ 42 address and set up buffer 24b as the WRITE address. The microprocessor 30 then instructs the direct memory access unit 31 to control the busses, whereby DMA 31 performs the move operation and then instructs the microprocessor that the job is done. At this point, the microprocessor 30 then gains control of the system bus. A block move of this type can only be accomplished via the direct memory access unit 31 which does not have control over the memory request line shown in FIG. 4. Conversely, when the microprocessor generates a read or write signal, it will always set the memory request line.
As was shown in FIG. 2 the pin electronics card 25 comprises a high speed buffer 24a and a set up buffer 24b. In addition, it includes card logic 50, which contains the high speed buffer, a phase lock loop timing block 51, and a driver and receiver block 52 as shown in FIG. 5.
In operation, the setup buffer 24b stores the information necessary to run the pin electronics card and communicate with and control the driver and receiver block 52, phase lock loop timing block 51, and the card logic block 50. The driver and receiver block 52 receives the information from the setup buffer 24b as to what voltage is defined to be a 1 or 0. The phase lock loop block 51 of FIG. 5 is commercially available, and is used to determine pulse width and position of the data being fed into the device under test, or to position the strobe (not shown) used to sample the data being received from the device under test 14. Analog signals are used to control phase lock loop block 51.
In order for the direct memory access unit 31 (FIG. 3) of the block controller 20 (FIG. 2) to choose a particular register for writing, circuitry is provided on the set up buffer 24b (FIG. 2) which is shown in more detail in FIG. 6.
Essentially, the buffer comprises a plurality of different registers 60a, 60b, 60c, 60n, whose outputs either feed digital to analog converters 61a, 61b or are connected to the card logic 50 (FIG. 5). The 16 bits of the address are split into low order bits, which are fed in as ADDRESS LOW on line 62 to one of a plurality of decoders 63, and high order bits, which are fed in as ADDRESS HIGH on line 64 to comparator 65. A compare is made with an input from register identity switches 66 and the output of the comparator 65 is anded with the WRITE input in AND circuit 67 whose output is fed to decoder 63. Data from DATA BUS is buffered by buffer 68 and then distributed to the registers 60a-n along with inputs from decoder 63.
The card logic (FIG. 7) comprises address generator logic 70, selection circuitry 71, and the high speed buffer 24a (FIG. 2). Timing circuitry 72 is necessary to run the card logic which will be described in conjunction with FIG. 8. In operation, the SYSTEM RESET input, resets counter 80, the SYSTEM CLOCK input is from the oscillator in the high speed system controller 12 (FIG. 1). Register 83 and 84 are in the setup buffer 24b (FIG. 2), and are shown in this diagram for clarity. Counter 80 and register 83 and the compare circuitry 85 which they both input are used to delay the acceptance of the SYSTEM CLOCK for a number of cycles. Counter 80 counts up the cycles initiated by the SYSTEM CLOCK and register 83 stores the number of cycles the electronics card 25 (FIGS. 2 and 5) is to wait. When counter 80 equals register 83, the SYSTEM CLOCK will be gated off into counter 80 and will be allowed to propagate into the rest of the timing circuitry. The pin electronics card 25 then continues to complete the test at which point the SYSTEM CLOCK input stops.
Counter 86 feeds a multiplexer 87, which is controlled by register 84. The combination of this counter, multiplexer and register, is used to frequency divide SYSTEM CLOCK into CLOCK output 88. As an example, if the multiplexer 87 is programmed to pass port 0 0 to its output, SYSTEM CLOCK equals CLOCK output 88. If the multiplexer 87 passes port 0 1, CLOCK output 88 is at half the frequency of the SYSTEM CLOCK and so on. Port 1 0 divides the SYSTEM CLOCK by 4 and port 1 1 divides the SYSTEM CLOCK by 8. The width of the READ/WRITE output 89 is determined by the delay of the delay circuit 90 feeding the input of the AND circuit 91, the frequency of the pulse being equal to CLOCK output 88. Register 84 controls whether the READ/WRITE output was propagated or not. System clock also feeds into AND circuit 81 to provide a GATED CLOCK output 82.
Turning now to the memory block 24a of FIG. 7, it is fed by READ/WRITE output 89 from the timing block of FIG. 8 and the WRITE input 92, which comes from the decoder 36 (FIG. 3), two DATA IN inputs 93 and 94 from an 8 bit data bus, and a SECTION address 95 which is the low order 12 bits of the address bus. Since only two data bits from the data bus are required to feed a pin electronics card 25, (FIGS. 2 and 5) four cards are paralleled for an 8 bit bus system. If those four cards equal a section, each block supports 16 sections.
Further details of the memory block will be understood with reference to FIG. 9. SECTION address 95 and the AWAY address 96 feed a multiplexer 100 which is controlled by a SETUP bit 97 from the setup buffer 24b (FIGS. 2 and 6). WRITE input 92 and READ/WRITE input 89 both feed a multiplexer 101 controlled by the same SETUP BIT 97 as multiplexer 100. The SETUP BIT 97 provides a path for the direct memory access to write into, herein, two 4 k×1 buffers 102a, 102b. DATA IN 93 and 94 again come from two bits of the data bus.
The address generation block 70 (FIG. 7) is shown in more detail in FIG. 10. The inputs to the address generation block are CLOCK 88 and 16 bits of setup buffer information. Counter 110 and register 111, both feed compare circuitry 112. When counter 110 equals register 111, counter 110 presets to the contents of register 113. This permits pin electronics to loop within an address base. The output of counter 110 is referred to as the AWAY address, and provides the AWAY input 96 in FIG. 9. The output of the compare circuitry 112 fed by register 111 and counter 110 is called WORD LENGTH 116. Counter 110 and counter 114 are herein configured into one 32 bit counter. The output of counter 114 is called the HOME address. The output of counter 110 and counter 114 are compared using compare circuitry 115 to yield either HOME<AWAY output 117, HOME=AWAY output 118 or HOME>AWAY output 119.
The selection block 71 (FIG. 7) is now shown in more detail in reference to FIGS. 11 and 12. As shown in FIG. 11 control of the selection circuitry is SYSTEM SETUP BITS 97 which input into counter 120 along with CLOCK 2 and SYSTEM RESET input 91. The counter 120 determines the number of steps per address in the test program and its output is fed into a series of multiplexers 121a, 121b and 121c, each of which are associated with registers 122a, 122b, 122c, respectively, which identify the sequence of TRUE/COMPLEMENT generation at specific intervals indicated by HOME/AWAY inputs. These inputs are fed to AND circuits 123a, 123b, 123c along with the outputs from multiplexer 121a, 121b, and 121c. The output of the AND circuits are fed into OR circuit 124. GATED CLOCK 82 input is ANDed with WORD LENGTH input, which identifies the size of the memory under test, in AND circuit 125 whose output feeds a toggle flip flop or complement by pass flip flop 126. The output of flip flop 126 is fed together with the output of OR circuit 124 into Exclusive OR 127 which provides a TRUE/COMPLEMENT output.
Turning to FIG. 12, the TRUE/COMPLEMENT output is fed, together with DATA OUT 1, into an Exclusive OR 128 whose output is fed into input 2 of multiplexer 129 which computes the DATA output. The computation is based on input 1-5 of multiplexer 129. Input 1 of the multiplexer receives set up bits, and input 4 is an AND function from AND circuit 134 of DATA OUT 1 and HOME=AWAY inputs. Input 3 is a direct input of DATA OUT 1.
In array testing using a ping pong pattern, multiplexer 130 is fed by a bit either from (HOME address) multiplexer 131 or (AWAY address) multiplexer 132, both of which receive a setup bit coming from setup buffer 24b (FIGS. 2 and 6). The output of multiplexer 130 is fed into input 5 of multiplexer 129. DATA OUT 2 along with a SET UP bit also inputs AND circuit 133 whose output feeds the driver and receiver logic 52 shown in FIG. 5. The INSTRUCTION OUT bit controls whether that circuitry is either driving the device under test 14 or receiving information from the device 14, and permits the use of a bidirectional channel to and from the device 14.
To further understand the high speed system controller 12 (FIG. 1), a detailed discussion will now be given in conjunction with FIG. 13. A variable controlled oscillator 140, which receives an input from a digital to analog converter 141, determines the clock frequency at which all pin electronic cards 25 (FIGS. 2 and 5) will execute. Register 142 stores the counter 143 precondition, and a PRESET bit loads the precondition into the counter. Register 144 contains the number of cycles of the test. A START input into AND circuit 145 will propagate the frequency of the oscillator 140 as the SYSTEM CLOCK to all pin electronic cards 25 and to the counter 143. When the number in counter 143 equals the number of cycles in register 144 by a compare in comparator 146, a STOP signal will be fed to the AND circuit 145 and the SYSTEM CLOCK will be turned off.
To further understand the tester of the present invention, a logic and an array test will now be described. The test program, whether it be for a logic test or an array test, resides in the host computer 10 (FIG. 1). This test program is distributed to preselected blocks 11a-11n (FIG. 1) via block controllers 20 (FIG. 2 and FIG. 3). A segment test data is first stored in the block controller program store 22 and is later transferred to mass storage 23a-23n (FIG. 2) via direct memory access 31 (FIG. 3) and the read/ write controller 35 (FIG. 3). In this manner, the entire test data enters mass storage. It should be recognized that the host computer 10 (FIG. 1) has been programmed with the block configuration. That is, the host computer knows how many blocks are in the tester and which block controls which pin in the device under test. Further, the analog calibration data and additional setup information is stored in mass storage 23a-23n (FIG. 2).
At the time of executing a test, the block controller 20 (FIGS. 2 and 3) instructs that the high speed buffer 24a (FIGS. 2 and 7) and the setup buffer 24b (FIGS. 2 and 6) be loaded with data values which were previously stored in mass storage 23a-23n (FIG. 2). This is achieved by the previously described memory segment move. At this point, the block controller 20 signals the host computer 10 that the preselected blocks of blocks 11a-11n (FIG. 1) are ready. Now, the high speed system controller 12 (FIG. 1) transmits via the system clock 81 (FIG. 7) a predetermined number of pulses to all pin electronic cards 25 (FIGS. 2 and 5).
The driver and receiver block 52 (FIG. 5) is shown in greater detail in FIG. 14. Inputs comprise SET UP ANALOG signals and include DATA LEADING EDGE, DATA TRAILING EDGE, STROBE POSITION into phase lock loops 150, 151, 152 respectively, and DRIVER UP LEVEL and DRIVER DOWN LEVEL into driver 153 and V REFERENCE into comparator 154. The analog input comes from the digital to analog converter output of the setup buffer as shown in FIG. 6. The DATA LEADING and TRAILING EDGE inputs control data position and pulse width while the STROBE POSITION input determines strobe timing. DRIVER UP LEVEL and DRIVER DOWN LEVEL inputs set the pulse amplitude and offset of the driver 153. V REFERENCE input sets the reference level of comparator 154.
DATA input to flip flop or pulse shaper 155 and delay compensator 156 in FIG. 14 is from the output of multiplexer 129 (FIG. 12) and serves (1) as a data source for the driver in those pin electronic cards 25 (FIGS. 2 and 5) which are used to generate DUT 14 inputs, and (2) as a compare input in those pin electronic cards 25 which are used to receive and check DUT 14 outputs. The same pin electronic card 25 may serve both functions in a bidirectional mode. The INST. OUT input to driver 153 and AND circuit 157 is from AND circuit 133 (FIG. 12) and is used to determine whether the pin electronic card 25 (FIGS. 2 and 5) is driving or receiving at any given time. For example, when driving the FAIL output of AND circuit 157, which is an AND of the input INST. OUT and the output from comparator 158, is blocked and the driver 153 is enabled. When receiving, the FAIL output is enabled and the driver blocked or disabled. When it doesn't matter whether the pin electronic card 25 is driving or receiving, this condition is masked by INST. OUT to drive and DATA to zero so that no driver 153 output occurs and the FAIL output is disabled.
The pulse shaper 155, along with phase lock loops 150 and 151, latch the DATA input and establish its leading and trailing edge before it reaches driver 153. The driver, in turn, establishes proper up and down levels before it sends the DATA input to the DUT 14 via the probe 13 (FIG. 1). The comparator 154 compares the DUT 14 output or the driver 153 output with a reference level and feeds the results to a sample flip flop 159 where it is time sampled by the strobe (not shown) previously positioned by phase lock loop 153. The sample flip flop 159 output then is compared with a delayed DATA input in comparator 158 and the results gated by INST. OUT in AND circuit 157 whose output is fed to an error buffer 160 where it is stored. At the end of a test, the error buffers 160 on all the pin electronic cards 25 (FIGS. 2 and 5) which were used to check DUT 14 outputs are read by the host computer 10 (FIG. 1) and the results analyzed.
In performing a logic test, DATA OUT (FIG. 9) contains the logical value information for the test. DATA OUT 1 contains an instruction as to whether the pin electronic card 25 is driving to (1) or receiving from (0) the device under test 14 (FIG. 1). Counter 110 (FIG. 10) generates a sequence of addresses necessary to step through the high speed memory 24a (FIGS. 2 and 9). DATA (FIG. 12), which is gated from DATA OUT 1 via the third input to the multiplexer 129, is fed to compare circuitry of driven receiver block 52 (FIG. 5).
For testing an array, herein, a 1K RAM the addressing sequence is a commonly known ping pong pattern, the data format being complementary by pass. The test comprises the following steps:
1. All locations in the test RAM are preconditioned to 1.
(a) In pin electronic cards used for address, the setup chooses the weight of AWAY address (FIG. 12) which is gated through to DATA output;
(b) In pin electronics cards used for data the setup bits makes the DATA=1;
(c) In pin electronics used for control lines (i.e. read/write) the setup causes DATA output to be of proper value to write.
2. Execute test
(a) In pin electronic cards used for address in
register 111 (FIG. 10) equals size of the RAM under test (i.e.--1K)
register 113 (FIG. 10) equals 0
multiplexer 131 and 132 (FIG. 12) are set up to proper address weight (i.e.--2 3 ) multiplexer 130 selects HOME or AWAY address under control of DATA OUT
DATA OUT contains ping (HOME) or pong (AWAY) information in which four step ping pong herein comprises
Read HOME address
Read AWAY address
Write HOME address
Read AWAY address
(b) In pin electronic cards used for data
generation
buffer 102a (FIG. 9) is loaded with 1's;
register 111 (FIG. 10) equals size of the address of the RAM under test;
register 113 (FIG. 10) 122a, 122b and 122c (FIG. 11) equal 0;
DATA OUT (FIG. 12) is gated through input 2 of multiplexer 129;
(c) In pin electronics cards used for write control in which
store the write control sequence in memory (FIG. 9) (i.e.--1,1,0,1,1,1,0,1 et seq.)
register 111 equals size of the address of the RAM;
register 113, (FIG. 10) 122a, 122b, 122c, (FIG. 11) equals 0;
(d) In pin electronics cards used for receiving and checking DATA from RAM under test;
register 113 equals size of RAM under test;
register 111 equals 0;
buffer 102a (FIG. 9) is loaded with all 1's;
counter 120 (FIG. 11) equals 3 for a four-step per address pattern;
registers 122a, 122b and 122c are loaded with a true complement pattern necessary to insure correct data polarity of the compare circuit input (FIG. 14);
DATA OUT (FIG. 12) is gated to input 2 of multiplexer 129.
While our invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that changes in form and detail may be made without departing from the spirit and scope of our invention. | A test system for testing circuits in integrated circuit chips includes a host computer for controlling the test system, and a plurality of blocks operable in parallel and each including a controller, storage for test programs and test data, and plurality of electronic units or pin electronics cards, one unit being associated with one of the pins of a device under test. Each of the electronic units include timing circuitry for timing its associated pin independent of the timing of any other electronics unit. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to thermal ink jet printers, and, more particularly, to control of the temperature of the print head ejectors of such printers during printing operations.
Printers are devices that print characters onto a printing medium such as a sheet of paper or a polyester film. Printers of many types are available, and are commonly controlled by a computer that supplies the images, in the form of text or figures, that are to be printed.
Some printers used a colored liquid, such as an ink or a dye, but generally termed herein a colorant, to form the images on the printing medium. (By contrast, other printers use a dry toner to form the image.) Such printers deliver the colorant to the medium using a print head that creates the proper patterning of colorant to record the image.
One important type of printer is the thermal ink jet printer, which forms small droplets of colorant that are ejected toward the printing medium in the pattern of dots. The droplets are formed when an electrical current is passed through an electrical resistor in the ejector, vaporizing a small volume of colorant. The vaporized colorant expands, driving a droplet of colorant out of a nozzle to deposit as a dot on the printing medium. When viewed at a distance, the collection of dots form the image, in much the same manner that images are formed in newspapers. Ink jet printers are fast, producing a high output of printed image, and quiet, because there is no mechanical impact during formation of the image except for the droplets of ink striking the printing medium.
Typically, a thermal ink jet printer has an ejector with a large number of individual colorant ejection nozzles in a print head, with one resistor for each nozzle, supported in a carriage and oriented in a facing, but spaced-apart, relationship to the printing medium. The carriage and supported print head traverse relative to locations on the surface of the medium, with the nozzles ejecting droplets of colorant, at appropriate times under command of the controller, to produce a swath of droplets. The droplets strike the medium and then dry to form "dots" of color that, when viewed together, form one swath of the permanently printed image. The carriage is then moved an increment in the direction normal to the traverse (or, alternatively, the printing medium is advanced), and the carriage again traverses the page with the print head droplet ejector operating to deposit another swath of dots. In this manner, the entire pattern of dots that form the image is progressively deposited by the print head during a number of traverses of the page. To achieve the maximum output rate, the printing is preferably bidirectional, with the print head ejecting colorant during traverses from left-to-right and right-to-left.
One of the key operating parameters of the print head and ejector is its temperature of operation. Thermal energy is generated with each operation of an ejection resistor. Some of the energy leaves the printer in the ejected droplet, but some remains in the print head to heat it. The print head is constantly cooled by conduction to the surrounding air. The actual temperature of the print head is the result of a balancing of heating and cooling of the print head.
A typical thermal ink jet printer has specified minimum and maximum operating temperatures of the ejector, that define its operating range. If the operating temperature is less than the minimum, the ejection resistors cannot impart enough energy to each droplet to achieve proper ejection. If the operating temperature is greater than the maximum, there may be spurious ejection, irregularities in the ejected droplets, and choking of the nozzles as gas dissolved in the ink leaves solution to form bubbles in the ink flow channels.
These minimum and maximum values are temperatures measured at the ejector of the print head, and do not correspond directly to the air temperature where the printer is operated. However, the air temperature plays a part in determining whether the printer can stay within the specified temperature range. That is, a cold air temperature tends to cause the ejector to be nearer the low end of its range, and a warm air temperature tends to cause the ejector to be nearer the high end of its range. To be a viable commercial product, the thermal ink jet printer must be able to operate over a range of air temperatures, and still maintain the ejector temperature within the acceptable range.
It is known to use heaters and fan coolers within the printer, operating under control of a temperature sensor, to assist in maintaining the temperature of the ejector within the proper operating range. See, for example, U.S. Pat. No. 4,704,620, which emphasizes that the temperature control of the print heads must be carefully controlled, and provides a method for ensuring that the heaters will not overheat the print head and that the fans will not overcool the print head. The approach described therein utilizes a calculation of the heat transfer coefficients of the heaters and the fan in an attempt to keep the heat flowing into or out of the ejector within preconceived limits that will result in maintenance of the temperature range. The ejector itself is small and has very low thermal mass, and therefore careful attention is required to avoid overheating or overcooling. The use of heaters and a fan encourages increasing the thermal mass to avoid temperature swings through and out of the acceptable operating range, but the general principles of print head design call for reduced mass that must be supported on and moved by the carriage.
Although the system described in the `620 patent and available in the art is presumably operable, there is a need for an improved thermal control system for a thermal ink jet printer. Such a control system would preferably not use a fan to cool the ejector, since this component adds cost and weight to the printer, and increases the chances of a breakdown. The control system would also preferably achieve more precise temperature control than possible using heaters and a fan, without increasing the thermal mass of the ejector. The present invention fulfills this need, and further provides related advantages.
SUMMARY OF THE INVENTION
The present invention provides a thermal ink jet printer, print head, and thermal control methodology that achieve excellent control of the temperature of the ejector without the need for a fan. Thermal control is responsive to the actual printing demands of the printer and heat loading imposed thereby, and to temperature measurements at the ejectors, and not just to a preconceived heat loading pattern. The thermal control system of the invention does not add significantly to the cost or weight of a printer having no thermal control system, and is less costly than prior thermal control systems requiring separate heaters and fans.
In accordance with the invention, a thermal ink jet printer comprises print head means for ejecting droplets of colorant, the print head means including an ejection heater that heats the colorant; means for supporting the print head means; means for sensing the temperature of the print head means; means for predicting the extent of future operation required of the ejection heater; and means for establishing the temperature of the print head responsive to the means for predicting.
More specifically, a thermal ink jet printer comprises a print head having a plurality of ejection nozzles from which droplets of colorant may be ejected, and a thin film electrical resistance heater associated with each nozzle, the resistance heaters being deposited upon a substrate; a carriage that supports the print head and traverses it across a printing medium in a series of passes; a thin film temperature sensor deposited upon the same substrate as the thin film resistance heaters of the print head; means for predicting the heat loading of the ejector during a pass, prior to the initiation of the pass; and means for controlling the temperature of the print head responsive to the means for predicting.
The invention also extends to a process for maintaining the ejector temperature within an acceptable range. In accordance with this aspect of the invention, a process for controlling the temperature of the ejector portion of the print head of a thermal ink jet printer comprises the steps of sensing the temperature of the ejector; predicting the future temperature of the ejector from the amount of printing to be accomplished by the ejector during a future period; and controlling the temperature of the ejector responsive to the prediction of future temperature so that the actual temperature of the ejector is maintained within an acceptable operating range.
An important feature of the present invention is the thin film temperature measurement resistor that is deposited upon the ejector substrate, and provides an accurate, current measurement of the temperature at the substrate and the ejector. In accordance with this aspect of the invention, a thermal ink jet printer comprises a print head having a plurality of ejection nozzles from which droplets of colorant may be ejected, and a thin film electrical resistance heater associated with each nozzle, the resistance heaters being deposited upon a substrate; a carriage that supports the print head and traverses it across a printing medium in a series of passes; and a thin film temperature sensor deposited upon the same substrate as the thin film resistance heaters of the print head. Since the print head is often provided as a separable unit that is replaced as necessary, the print head itself utilizing the thin film temperature sensor is novel. In accordance with this aspect of the invention, a thermal ink jet print head comprises colorant ejector means including a plurality of thin film resistors deposited upon a substrate; and thin film sensing means for sensing the temperature of the colorant ejector means, the thin film sensing means being deposited upon the same substrate as the thin film resistors.
The temperature of the ejector of a thermal ink jet printer print head is determined by a balancing of heat flows in and out of the ejector. Heat flows into the ejector when the ejection resistors are operated during the printing operation to eject droplets of colorant that are then ejected toward the printing medium, and from the general thermal transfer from the environment if it is warmer than the ejector. Heat flows out of the print head with the droplets of ejected colorant, and by radiation and conduction if the ejector is warmer than its environment. Intentional heating and cooling, if any, also influence the temperature of the ejector.
Accurate temperature control is not readily achieved unless these various components of heat transfer are considered. However, the various heat flows are not easily modeled by any preestablished set of criteria, because a major influencing factor is the rate of production of heat and loss of heat by the ejector itself, which is in turn determined by the amount of printing that is performed. Where there is much printing (that is, many droplets ejected over a short period of time), for example, the heat loading into the ejector is high, and the rate of heat transfer out of the ejector through the droplets is also high.
The present invention therefore incorporates a temperature control system that utilizes the current temperature of the ejector, measured very accurately at a location on the ejector substrate, together with predictions of heat flow during the immediate future period of time. Such prediction is possible because of the mode of operation of ink jet printers, wherein the print to be deposited subsequently is decomposed into a droplet pattern that may be analyzed to determine the future droplet demand and thence heat loading.
The thermal control of the print head ejector involves several considerations. The temperature of the print head may be measured at different locations, and in different manners. Prior approaches measure the print head temperature at locations remote from the ejector, an approach that is unacceptable where precise information and control are required. The temperature at the ejector may differ from that in other portions of the print head, because the temperature of the ejector can vary over a range in a short time due to printing demands and because of the relatively low thermal conductivity of the remainder of the print head. The present approach preferably utilizes the thin film temperature measurement resistor deposited directly upon the same substrate upon which the ejection resistors are deposited. The substrate, which is normally silicon, has a high thermal diffusivity, so that the temperature measured by the thin film resistor is very nearly that at the ejector nozzles. Moreover, the thin film resistor and its associated circuitry can be deposited upon the substrate at the same time that the ejector resistors and related circuitry are deposited, so that there is virtually no additional cost in providing the temperature measurement resistor.
Another key consideration in controlling the temperature of the ejector is the future demand for ejection of droplets. In the normal mode of operation of a thermal ink jet printer, the print head is moved back-and-forth across the face of a printing medium in a series of passes by the carriage, while the printing medium is moved in a perpendicular direction relative to the print head between passes. On each pass, the print head ejector prints a pattern of dots, termed a swath. In this manner, the entire image is built up as a series of swaths deposited side-by-side on the printing medium.
The pattern of dots to be printed during any swath is determined by the driving computer or by a microcomputer built into the printer itself. That is, prior to the commencement of a swath, the pattern of dots, and thence the number of droplets required to form the swath, is calculated and known. The number of droplets to be deposited during the swath is the printing demand for the ejector during that swath. If the number of droplets or demand is high, then there will be a predictably large amount of heating of the ejector by ejection pulses to the ejection resistors during the swath. Conversely, if the number of droplets or demand is low, then there will be a predictably small amount of heating during the swath.
From this information, and an accurate measurement of the temperature of the ejector at the commencement of the swath, the final temperature of the ejector under various printing patterns can be predicted. If a normal printing mode causes the predicted temperature at the end of the swath to exceed an acceptable maximum limit, then the start of the printing of that swath can be delayed or the printing mode can be modified. If the temperature at the start of the swath is below the minimum permissible temperature, then the ejector can be heated before commencement of the swath by passing a small current through the ejection resistors. This heating current is calculated to be too small to cause ejection of colorant, but large enough to heat the ejector to at least the minimum acceptable operating temperature. Alternatively, a small current can be passed through the sensing resistor itself to heat the ejectors, between temperature measurements.
The precise method of predicting the temperature during any swath depends upon the specific printer, and a preferred approach is presented subsequently. However, in each case the future printing demand is utilized to predict the temperature at the end of the swath and possibly at intermediate points along the swath, to be certain that the temperature does not stray from the permitted range. By utilizing a swath by swath approach, the heating or cooling demand for a reasonable period of time into the future is predicted, obviating the need for highly precise thermal models. That is, on a swath by swath basis, relatively simple linear thermal models may be used and are normally acceptable. However, more complex models reflecting an advanced understanding of the effects of thermal inputs and losses may also be utilized.
The present invention provides an important advance in the thermal control of ink jet printers, that improves the performance of the printers. A predictive process provides the predicted heat loading for a future period of time, which is used in conjunction with the current temperature, measured very accurately at the ejector, to determine the temperature of the ejector in the future. The printing behavior can then be modified, if necessary, to ensure that the temperature limits of operation are not exceeded. Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a thermal ink jet print head assembly;
FIG. 2 is a schematic side view of an ejector;
FIG. 3 is a plan view of a portion of an ink jet printer;
FIG. 4 is a side sectional view of the printer of FIG. 3, taken along lines 4--4;
FIG. 5 is a plan view of the electrical leads for the ejector resistors and the thermal measurement resistor deposited upon the substrate; and
FIG. 6 is a flow chart illustrating the process for thermal control of the ejector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The approach of the present invention is used in conjunction with a thermal ink jet printer. A thermal ink jet printer utilizes as the basic print head an assembly that creates and ejects microdroplets of ink by vaporization of a small bubble of colorant. A thermal ink jet print head assembly 10, used to eject droplets of colorant toward a print medium in a precisely controlled manner, is illustrated in FIG. 1. Such a print head assembly is discussed in more detail in U.S. Pat. No. 4,635,073whose disclosure is incorporated by reference.
The print head assembly 10 includes an ejector 12 having a silicon substrate 14 and a nozzle plate 16, depicted in FIG. 2. The nozzle plate 16 has a plurality of nozzles 18 therein. Droplets of colorant are ejected from the individual nozzles 18. (As used herein, the term "colorant" means generally a fluid that is deposited upon a printing medium to produce images, including but not limited to inks and dyes, and is not restricted to any narrow sense of that term as may be found in other arts.)
Droplets of colorant are ejected through the nozzles 18 by localized heating of the silicon substrate 14 with a heater 20. To effect such heating, the silicon substrate 14 has deposited thereon a plurality of tantalum-aluminum alloy planar resistors 22 with gold leads 24, one of the resistors being located adjacent each nozzle 18. An electrical current is passed through the portion of the resistor 22 between the ends of the leads 24 rapidly heating the resistor. A small volume of colorant adjacent the resistor 22 is thereby rapidly heated and vaporized, causing some of the colorant 26 in a reservoir 28 to be ejected through the nozzle 18 and thereafter to be deposited as a dot 30 on a printing medium 32 (such as paper or polyester). An optional passivation layer 34 overlies the resistor 22, to p protect it from corrosion and cavitation damage by the colorant.
Returning to FIG. 1, the ejector 12 is mounted in a recess 36 in the top of a central raised portion 38 of a plastic or metal manifold 40. The raised portion has slanted side walls 44, and end tabs 46 which facilitate its handling and attachment to a carriage mechanism in the printer, to be described subsequently.
External electrical connection to the leads 24 and thence to the resistors 22 is supplied through a set of traces 48 on the silicon substrate 14, connected to a flexible interconnect circuit 50, which may be of the type sometimes known as a TAB circuit. The circuit 50 fits against the side walls 44, with one end extending to the traces 48 and the other end to external connections to the controllable current source that supplies current to the resistors 22. The general features, structure, and use of such flexible interconnect circuits 50, and their fabrication, are described in U.S. Pat. No. 3,689,991, whose disclosure is incorporated by reference.
FIGS. 3 and 4 illustrate a portion of one type of ink jet printer 60, which can utilize print heads of the type just discussed. The printer 60 includes platens 62 between which a sheet of the printing medium 32 is captured. One or both of the platens 62 are rotatably driven by a stepping motor 64 that causes them to controllably rotate in either direction. Rotation of the platens 62 advances the printing medium in the selected direction.
A carriage 66 is supported above the printing medium 32 on bearings 68 from rails 70. The carriage 66 slides along the rails 70 under the control of a traversing motor 71 acting through a wire or belt 72 that extends from the motor 71 to the carriage 66. The direction of movement of the carriage 66 along the rails 70 is termed the "traversing direction", indicated by numeral 73. The traversing direction 73 is perpendicular to the direction of the advance of the printing medium through rotation of the platens 62, termed the "paper advance direction" and indicated by numeral 74.
One or more of the print heads 10 is supported in the carriage 66, in a generally facing but spaced apart relationship to the printing medium 32, in the manner illustrated in FIGS. 2 and 4, so that ink droplets ejected from the ejector 12 strike the printing medium. If the printer is only for printing of single colors, then only one print head is required. Multiple print heads are needed where a variety of colors are to be printed. The present invention is applicable whether one or multiple print heads are used, but is discussed herein in relation to a single print head for simplicity. Where multiple print heads are used, then the most limiting conditions must be considered in determining a printing strategy.
The print head 10 is mounted in a support 76 on the carriage 66. The support 76 preferably includes a body 78 and an aperture 80 therethrough. The print head 10 slides into the aperture 80 to rest against a shoulder 82. A retainer clip 84 holds the print head 10 in position within the aperture 80 and against the shoulder 82. Plug-in electrical connectors 86 extend to the print head 10 from the control circuitry of the printer.
FIG. 5 presents an enlarged plan view of a detail of the substrate 14 with traces 48 to the ink ejection resistors 22 shown thereon (and the nozzle plate 16 removed). A thermal sensing resistor 94 is deposited upon the same substrate 14, with measurement leads 96 extending thereto. The resistor 94 is made of a material whose temperature coefficient of resistance is sufficiently high that measurements of resistance can be converted directly to a temperature value for the resistor 94. An acceptable resistor material is aluminum or an aluminum-copper alloy with less than about 5 percent by weight copper. Because the resistor 94 is positioned directly adjacent the ejector 12 on a substrate of relatively high thermal conductivity, its temperature provides a close approximation to that of the ejector 12. For the same reason, the temperature of the resistor 94 follows changes in the temperature of the ejector 12 quite closely. The illustration of FIG. 5 depicts the presently preferred approach wherein the resistor 94 is deposited as a single length or resistance material at one end of the ejector. Alternatively, the resistor 94 may be deposited with portions in different locations around the ejector, as on the sides and at both ends, to provide an even more accurate measurement of the actual temperature in the neighborhood of the nozzles 18. At the present time, the configuration of FIG. 5 has been found satisfactory for temperature measurement and control. In any event, the leads 96 to the resistor 94 are attached to the flexible interconnect circuit 50 in the same manner as the traces 48, so that the temperature can be measured externally.
To accomplish the measurement of temperature externally to the print head, the four-wire measurement technique is preferably used, requiring that there be four leads 96, two to each end of the resistor 94. A current is passed through the resistor 94 using one pair of the leads 96, and the voltage drop across the resistor 94 is measured with the second pair of leads at the opposite ends of the resistor 94. The voltage drop and current are converted to electrical resistance, which is a known function of temperature and is stored in the computer as a formula or table.
FIG. 6 illustrates the presently preferred process for determining the printing strategy that permits printing without exceeding the allowed temperature range, on either the high end or the low end. From the image to be printed 100, which is supplied by the computer, the dot pattern to be deposited is calculated from well known algorithms. See, for example, "Principles of Interactive Computer Graphics", by William M. Newman and Robert F. Sproull, McGraw Hill, 1979, pages 213-243 and the "Hardware Support Manual for Hewlett Packard 7600 Series Printers, For Models 240D and 240E Electrostatic Plotters", Hewlett Packard Corp., 1988, at pages 5-1 to 5-4, both of which publications are incorporated by reference. Those procedures are well known, and performed by existing ink jet printers as a matter of course.
The printing demand is calculated, numeral 102, from the number of dots required for the swath. It has been found convenient to define an area fill fraction as the number of dots printed during a swath divided by the total number of possible dots in a swath. The area full fraction provides a direct indicator of the printing demand during the swath, which in turn is used to predict heat loadings. The area fill fraction can be determined as a function of position in a similar manner, so that the printing demand as a function of position is known. This information would be particularly useful where images appear on one side of the page, and large portions of the other side of the page are blank, for example. However, at the present time it has been found sufficient to determine the overall area fill fraction during a pass, and work with only the beginning and ending temperatures.
The current or beginning value of temperature T b is measured, numeral 104, prior to the initiation of the printing of the swath using the thermal sensing resistor 94 and the measurement procedure previously described.
The predicted temperature T f at the end of the swath is then calculated, numeral 106, using the following formulation:
T.sub.f =T.sub.b +dT.sub.print +dT.sub.environment.
where dT print is the change in temperature due to the printing demands, and dT environment is the change in temperature that would normally occur due to heating or cooling of the print head as it is moved through the ambient air.
dT print is determined from a table lookup or corresponding formula expressing the relationship between printing demand and the heat flow during printing. The ejector normally heats during printing. Heat flows into the ejector in the form of electrical energy that is converted to heat by the resistors 22. Some of that heat flows out of the ejector as heated colorant and heated gas, during ejection of each droplet. The net heat flow per droplet (the heat input less the heat lost per droplet) and the increase in temperature of the ejector are calculated or measured, and expressed as a function of the area fill fraction. For example, an increase in the area fill fraction means that the total net heat retained in the ejector will increase, and that the temperature of the ejector will increase. The preferred approach is to establish a calibration table or curve of dt print by direct measurement of print head operation as a function of area fill fraction for the print head, and store that calibration in the computer for use in finding dt print . Such measurements are performed by the manufacturer prior to sale to the user, so that the thermal control is not apparent to the user.
dT environment is similarly determined from a table lookup or corresponding formula expressing the heat flow into or out of the ejector as it moves through the ambient air. The temperature of the ambient air is measured by a temperature resistor positioned well away from the ejector, preferably on the frame of the printer, such as the resistor 95 illustrated in FIG. 3. The resistor 95 is used to sense ambient air temperature using the same four-point measurement technique previously described in relation to the resistor 94. For example, if the air temperature is cool and the print head moves through it without any ink ejection, the print head and ejector are expected to cool down. The value of dT environment is ascertained from the table of calibration measurements or a formula wherein the average coefficient of thermal transfer is multiplied by the difference in temperature of the ejector and the environment. Again, the preferred method for establishing this relationship is measurements conducted by the printer manufacturer prior to sale of the product to the user, so that the calibration procedures need not be of concern to the user.
The three components of temperature are added according to the above formula to predict the final temperature T f , numeral 106. The beginning temperature T b and final temperature T f are then compared to the permissible temperature range of operation, numeral 108, and a printing strategy is determined, numeral 110. Normally, dt print is positive and causes a temperature increase, and dT environment is negative and causes a temperature decrease. Thus, a balancing of temperature to within the acceptable range is achieved by an appropriate strategy involving the printing rate, the time permitted for cooling without printing, and heating pulses introduced, as required.
In the preferred approach wherein only the beginning and ending temperatures are considered, there are five possible conditions of operation, which are not mutually exclusive. In the first, both the beginning and predicted final temperatures are within limits, and the printing proceeds with no modifications to the printing cycle.
In the second, the beginning temperature is below the acceptable minimum temperature. In that event, the computer commands the printer to send low level electrical warming currents through the resistors 22 or 94 to warm the ejector. The currents are too small to cause ejection of colorant, but cumulatively warm the ejector to a temperature greater than the minimum acceptable operating temperature.
In the third, the temperature of the ejector is initially too high. In that event, the starting of the printing swath is delayed until natural cooling of the ejector reduces its temperature to below the maximum permitted temperature.
In the fourth, the predicted temperature of the ejector at the end of the swath is too low. In that event, small electrical warming currents may be passed through the resistors 22 during the pass and printing of the swath at intermediate times when particular resistors 22 are not operating, or through the resistor 94 when temperature measurements are not taken. As described previously, the warming currents are too small to cause colorant ejection, but are sufficient to warm the ejector so that it does not fall below the minimum acceptable temperature.
In the fifth, the predicted temperature of the ejector at the end of the swath is too high. In that event, printing of the swath is commenced but an alternative printing strategy is used. Many different approaches are possible to reduce the temperature rise during the swath resulting from printing, and three exemplary strategies are listed. In one, where the beginning temperature is near the high end of the range or perhaps exceeding the maximum temperature, the initiation of printing is delayed to permit cooling, so that both the beginning and final temperatures are within the acceptable temperature range. In a second, printing of the swath is initiated immediately but at a reduced rate of carriage movement and droplet output, permitting environmental cooling to balance the heat input from the printing demand. In a third, printing of the swath is initiated immediately at the normal rate of carriage movement, but only a fraction, typically half, of the dots are printed on the pass, and the remaining dots are printed on the next pass without advancing the printing medium. Of course, other and more complex printing strategies can be envisioned.
As noted previously, more complex strategies regarding the temperature distribution of the ejector at points along the swath can also be adopted, but these consume processing and memory of the computer. At the present time, the outlined approach of beginning and ending temperature determinations has been found sufficient and is preferred.
As a further diagnostic aid in assessing the operation of the printer, the predicted temperature at the end of the swath T f is compared with the measured temperature at the beginning of the next swath. Or alternatively, the ending temperature at the end of the swath is measured using the resistor 94, and compared with the predicted ending temperature T f . If the actual measured temperature is significantly greater than the predicted temperature, a plugged nozzle or deprimed nozzle is indicated. Such a problem causes a degraded printed image. That is, where no colorant is ejected from a particular nozzle even though heating pulses are sent to its ejection resistor 22, the temperature of the ejector rises much faster than predicted by the model, because some of the heat produced by the ejection resistors 22 is not being carried away from the ejector as in normal operation. This information of an unexpectedly large temperature rise can be used to indicate to other automated systems in the printer the need to correct the problem, or to signal the user if the problem cannot be corrected automatically by the printer.
The present invention provides a thermal control system and strategy that permits the ejector of a thermal ink jet printer to be maintained within acceptable operating limits without the need for a fan or other expensive cooling device. Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | The temperature of the ejector (12) of a thermal ink jet print head (10) is maintained within acceptable operating limits by measuring the current temperature, predicting the heat loading on a subsequent pass over a printing medium (32), and adjusting the temperature of the ejector (12), as necessary, by heating the ejector (12) or modifying the operation of the printer (60) to permit cooling of the ejector (12). The temperature of the ejector (12) is preferably measured by a thin film temperature measurement resistor (94) codeposited onto a substrate (14) with the thin film ejection resistors (22) that generate the droplets ejected from the ejector (12). Heating of the ejector (12) is preferably accomplished by passing a low level current through the ejection resistors (22). Cooling is preferably accomplished without the use of a fan by delaying the printing pass, or reducing the heat load during the printing pass by slowing the printing rate during that pass only. | 1 |
This is a Continuation-in-Part application of Ser. No. 09/727,570 filed Nov. 30, 2000, now U.S. Pat. No. 6,356,788 which is a Continuation-in-Part of Ser. No. 09/178,060 filed Oct. 26, 1998, now U.S. Pat. No. 6,205,359. Priority is claimed from these applications, and the prior applications being incorporated herein by reference. Further, this application is related to the following applications filed Apr. 17, 2001, entitled
a) Apparatus and method for adjunct (add-on) treatment of coma and traumatic brain injury with neuromodulation using an external stimulator.
b) Apparatus and method for adjunct (add-on) treatment of Diabetes by neuromodulation with an external stimulator.
c) Apparatus and method for neuromodulation therapy for obesity and compulsive eating disorders using an implantable lead-receiver and an external stimulator.
FIELD OF INVENTION
This invention relates generally to medical device system for therapy of cardiovascular disorders, more specifically to adjunct (add-on) treatment of certain cardiovascular disorders by neuromodulation of a selected nerve or nerve bundle, utilizing an implanted lead-receiver and an external stimulator.
BACKGROUND
Electrical stimulation of the vagus nerve, and the profound effects of electrical stimulation of the vagus nerve on the central nervous system (CNS) activity extends back to the 1930's. Medical research has furthered our understanding of the role of nervous control of body functions. In the human body there are two vagal nerves (VN), the right VN and the left VN. The innervation of the right and left vagus nerves is different. The innervation of the right vagus nerve is predominately to the sinus (SA) node of the heart, and its stimulation results in slowing of the sinus rate. The cardiac innervation of the left vagus nerve is predominately to the AV node, and its stimulation results in delaying the conduction through the atrioventricular (AV) node.
The system and method of the current invention utilizes an implanted lead-receiver, and an external stimulator for adjunct (add-on) treatment or alleviation of symptoms for certain cardiovascular disorders, such as atrial fibrillation, inappropriate sinus tachycardia, and refractory hypertension. The system of this invention delivers neuromodulation pulses according to a limited number of predetermined programs, which are stored in the external stimulator, and can be activated by pressing a button. The predetermined programs contain unique combinations of pulse amplitude, pulse width, frequency of pulses, on-time and off-time. In one embodiment, the system contains a telecommunications module within the external stimulator. In such an embodiment, the external stimulator can be controlled remotely, via wireless communication.
Nervous Control of the Heart
FIGS. 1A and 1B are simplified schematic diagrams showing nervous control of cardiovascular function. As shown in FIG. 1A, The cardiovascular (CV) center 222 located in the medullary center in the brain influences and controls cardiovascular functions such as heart rate, contractactility, and blood vessels. The cardiovascular center 222 in the brain 220 , receives input from the higher centers in the brain 224 and from receptors 226 such as baroreceptors and propriocepters. The cardiovascular (CV) center 222 of the brain 220 controls the effector organs in the body by increasing the frequency of nerve impulses. The CV center 222 decreases heart rate by parasympathetic stimulation via efferent impulses carried by the 10 th cranial nerve or the vagus nerve. The CV center can also increase heart rate and cause vasoconstriction via sympathetic stimulation. Thus, the CV center 222 in the brain 220 exerts its control via the opposing actions of the sympathetic and parasympathetic stimulation.
Further, as shown in FIG. 1B baroreceptors located in the aortic arch 262 , and in the carotid sinus 260 send blood pressure information to the cardiovascular (CV) center 222 located in Medulla Oblongata 240 of the brain 220 . This information is carried by afferent fibers of Glossopharyngeal Nerve 55 and Vagus Nerve 54 .
Additionally of interest to the current patent application, the efferent fibers of the right vagus nerve predominately innervate the sinus node 252 and stimulation of these fibers will be used to control (slow-down) heart rate for Inappropriate Sinus Tachycardia Syndrome. The efferent fibers from the left vagus nerve predominately innervate the A-V node 256 of heart, and efferent stimulation of the left vagus nerve 54 will be used for controlling heart rate as adjunct (add-on) therapy for atrial fibrillation in this invention.
Atrial Fibrillation
Atrial fibrillation (AF) is both the most common sustained arrhythmia encountered in clinical practice, and the most common arrhythmia-related cause of hospital admission. Although health utilization costs related to AF are significant, little is known about its incidence and prevalence. Estimates indicate that 2.2 million Americans have AF and that 160,000 new cases are diagnosed each year. The incidence is higher in older adults, whose risk for developing AF is associated with advanced age. During atrial fibrillation, the atria of the heart discharge at a rate between 350 and 600 per minute. The ventricular rate during atrial fibrillation is dependent on the conducting ability of the AV node which is itself influenced by the autonomic system. Atrioventricular conduction will be enhanced by sympathetic nervous system activity and depressed by high vagal tone. In patients with normal atrioventricular conduction, the ventricular rate ranges from 100 to 180 beats per minute.
AF is characterized by a rapid, irregular ventricular rate, the irregularity being in rhythm and arterial pulse pressure amplitude. This can occur to such an extent that multiple pulse deficits (absence of an arterial pulse following ventricular excitation) are present. Current therapies are designed to extinguish the fibrillation activity or to control or abolish atrioventricular (AV) conduction.
Thus, the two components of acute management of patients with atrial fibrillation include control of ventricular rate and conversion to sinus rhythm. The traditional first step in acute treatment of patients with symptomatic AF who have a rapid ventricular response is to slow the ventricular rate. The first line of defense is usually drugs such as Digoxin, Metoprolol, Esmolol and verapamil etc. Drugs typically have side effects, and some patients may be refractory to drugs. Non-pharmacologic adjunct therapy such as nerve stimulation offers an alternative mode of therapy.
In a paper published by Van den Berg et al in the Aug. 19, 1997 issue of Circulation, the authors showed that heart rate variability in patients with atrial fibrillation is related to vagal tone. In an abstract published at the American Heart Association meeting, by Tabata et al from the Cleveland Clinic Foundation, the authors presented the results of heart rate reduction by vagus nerve stimulation on left ventricular systolic function. Their data showed a dramatic decrease in ejection fraction and stroke volume as atrial fibrillation was induced. Then, while still in atrial fibrillation, a return towards baseline of both ejection fraction and stroke volume, with vagus nerve stimulation of the atrio-ventricular (AV) node.
Thus, with the system of the present invention where an implanted lead-receiver is implanted within the body, and a stimulator with predetermined programs is external to the body, would be useful. The implantable and external components are inductively coupled. With turning the stimulator “on”, the symptoms of atrial fibrillation would be alleviated by decreasing the heart rate and increasing the stroke volume and ejection fraction.
Inappropriate Sinus Tachycardia
Inappropriate Sinus Tachycardia is a clinical syndrome with a relative or absolute increase of heart rate at rest or an exaggerated heart rate response inappropriate to the degree of physical or emotional stress. On the surface electrocardiogram, P-wave morphology during tachycardia is nearly identical to the P-wave morphology during normal sinus rhythm. The clinical manifestations of this syndrome complex are diverse. Young women make up most of the patient population, and clinical symptoms can range from intermittent palpitations to multiple system complaints.
Clinical signs and symptoms associated with inappropriate sinus tachycardia are often refractory to medical therapy with drugs. Drugs, such as β-adrenergic blockers or calcium channel blockers, usually either are not effective in controlling symptoms or are poorly tolerated. It is hypothesized that the inappropriate sinus tachycardia response in these patients is due to underlying autonomic dysregulation. The electrophysiologic findings are consistent with the diagnosis of inappropriate sinus tachycardia in the following circumstances: Gradual increase (warm-up) and decrease (cool-down) in heart rate during initiation and termination of isoproterenol infusion, consistent with an automatic mechanism of sinus node function; Surface P-wave morphology similar to that observed during sinus rhythm; and Earliest endocardial activation along the crista terminalis estimated from fluoroscopic images. Clinically, Inappropriate Sinus Tachycardia is divided into 2 subsets, a) postural orthostatic tachycardia syndrome (POTS), and b) non-postural orthostatic tachycardia syndrome (non-POTS). The second category, non-POTS would be alleviated by decreasing the heart rate by the system and method of the current invention.
Hypertension
Blood pressure (BP) is the hydrostatic pressure exerted by blood on the walls of a blood vessel. The arterial blood pressure is determined by physical and physiological factors. Mean arterial pressure is the pressure in the large arteries, averaged over time. Systolic and diastolic arterial pressures are then considered as the upper and lower limits of periodic oscillations about this mean pressure. The pressure of the blood in arteries and arterioles reaches a peak, called systolic pressure, with each contraction of the heart and then gradually decreases to a minimum, the diastolic pressure before the next contraction. Blood pressure is always expressed as two figures, for example, 120/80 in healthy young adults, representing respectively the systolic and diastolic pressures in millimeters of mercury (mm Hg).
About 20% of the adult population is afflicted with hypertension, the most common single disorder seen in the office of an internist. It is a major risk factor for coronary artery disease and a common cause of heart failure, kidney failure, stroke, and blindness. For adults over 50 years of age, the diagnosis is usually based on repeated resting levels of greater than 160/95 mm Hg in adults over 50 years of age. It is more common among males than females and far more common among blacks than whites. In refractory hypertension, the BP stays at these levels despite treatment with at least two anti-hypertensive drugs for a period of time that is normally adequate to relieve the symptoms.
There is considerable evidence that the nervous system is much involved in the regulation of arterial pressure. For example, hypertension can be induced in experimental animals by transection of arterial baroceptor nerves, by lesion of the nucleus tractus solitarius (NTS). For refractory hypertension where pharmacologic therapy either is not effective, or is not tolerated because of the side effects of drugs, non-pharmacologic therapy such as afferent nerve stimulation may be another alternative for adjunct (add-on) therapy. The neuromodulation of the vagus nerve is designed to control the patient's blood pressure, in the system and method of this invention.
Neuromodulation
One of the fundamental features of the nervous system is its ability to generate and conduct electrical impulses. These can take the form of action potentials, which is defined as a single electrical impulse passing down an axon, and is shown schematically in FIG. 2 . The top portion of the figure shows conduction over mylinated axon (fiber) and the bottom portion shows conduction over nonmylinated axon (fiber). These electrical signals will travel along the nerve fibers.
The nerve impulse (or action potential) is an “all or nothing” phenomenon. That is to say, once the threshold stimulus intensity is reached an action potential 7 will be generated. This is shown schematically in FIG. 3 . The bottom portion of the figure shows a train of action potentials.
Most nerves in the human body are composed of thousands of fibers of different sizes. This is shown schematically in FIG. 4 . The different sizes of nerve fibers, which carry signals to and from the brain, are designated by groups A, B, and C. The vagus nerve, for example, may have approximately 100,000 fibers of the three different types, each carrying signals. Each axon or fiber of that nerve conducts only in one direction, in normal circumstances.
In a cross section of peripheral nerve it is seen that the diameter of individual fibers vary substantially. The largest nerve fibers are approximately 20 μm in diameter and are heavily myelinated (i.e., have a myelin sheath, constituting a substance largely composed of fat), whereas the smallest nerve fibers are less than 1 μm in diameter and are unmyelinated. As shown in FIG. 5, when the distal part of a nerve is electrically stimulated, a compound action potential is recorded by an electrode located more proximally. A compound action potential contains several peaks or waves of activity that represent the summated response of multiple fibers having similar conduction velocities. The waves in a compound action potential represent different types of nerve fibers that are classified into corresponding functional categories as shown in the table below,
Conduction
Fiber
Fiber
Velocity
Diameter
Type
(m/sec)
(μm)
Myelination
A Fibers
Alpha
70-120
12-20
Yes
Beta
40-70
5-12
Yes
Gamma
10-50
3-6
Yes
Delta
6-30
2-5
Yes
B Fibers
5-15
<3
Yes
C Fibers
0.5-2.0
0.4-1.2
No
The diameters of group A and group B fibers include the thickness of the myelin sheaths. Group A is further subdivided into alpha, beta, gamma, and delta fibers in decreasing order of size. There is some overlapping of the diameters of the A, B, and C groups because physiological properties, especially in the form of the action potential, are taken into consideration when defining the groups. The smallest fibers (group C) are unmyelinated and have the slowest conduction rate, whereas the myelinated fibers of group B and group A exhibit rates of conduction that progressively increase with diameter.
Compared to unmyelinated fibers, myelinated fibers are typically larger, conduct faster, have very low stimulation thresholds, and exhibit a particular strength-duration curve or respond to a specific pulse width versus amplitude for stimulation. The A and B fibers can be stimulated with relatively narrow pulse widths, from 50 to 200 microseconds (μs), for example. The A fiber conducts slightly faster than the B fiber and has a slightly lower threshold. The C fibers are very small, conduct electrical signals very slowly, and have high stimulation thresholds typically requiring a wider pulse width (300-1,000 μs) and a higher amplitude for activation. Because of their very slow conduction, C fibers would not be highly responsive to rapid stimulation. Selective stimulation of only A and B fibers is readily accomplished. The requirement of a larger and wider pulse to stimulate the C fibers, however, makes selective stimulation of only C fibers, to the exclusion of the A and B fibers, virtually unachievable inasmuch as the large signal will tend to activate the A and B fibers to some extent as well.
The vagus nerve is composed of somatic and visceral afferents and efferents. Usually, nerve stimulation activates signals in both directions (bi-directionally). It is possible however, through the use of special electrodes and waveforms, to selectively stimulate a nerve in one direction only (unidirectionally). The vast majority of vagus nerve fibers are C fibers, and a majority are visceral afferents having cell bodies lying in masses or ganglia in the skull. The central projections terminate largely in the nucleus of the solitary tract, which sends fibers to various regions of the brain (e.g., the thalamus, hypothalamus and amygdala).
Vagus nerve stimulation is a means of directly affecting central function. As shown in FIG. 6, cranial nerves have both afferent pathway 19 (inward conducting nerve fibers which convey impulses toward the brain) and efferent pathway 21 (outward conducting nerve fibers which convey impulses to an effector). The vagus nerve 54 is composed of 80% afferent sensory fibers carrying information to the brain from the head, neck, thorax, and abdomen. The sensory afferent cell bodies of the vagus reside in the nodose ganglion and relay information to the nucleus tractus solitarius (NTS).
FIG. 7 shows the nerve fibers traveling through the spinothalamic tract to the brain. The afferent fibers project primarily to the nucleus of the solitary tract (shown schematically in FIG. 8) which extends throughout the length of the medulla oblongata. A small number of fibers pass directly to the spinal trigeminal nucleus and the reticular formation. As shown in FIG. 8, the nucleus of the solitary tract has widespread projection to cerebral cortex, basal forebrain, thalamus, hypothalamus, amygdala, hippocampus, dorsal raphe, and cerebellum.
In summary, neuromodulation of the vagal nerve fibers exert their influence on refractory hypertension via Afferent stimulation. And, neuromodulation of the vagal nerve fibers exert their influence on atrial fibrillation and in Inappropriate Sinus Tachycardia Syndrome via Efferent stimulation of the left and right vagus nerve respectively.
PRIOR ART
One type of non-pharmacologic, medical device therapy for cardiovascular disorders is generally directed to the use of an implantable lead and an implantable pulse generator technology or “cardiac-pacemaker like” technology.
U.S. Pat. No. 5,707,400 (Terry et al) is generally directed to using an implantable device like a “cardiac pacemaker” for treating refractory hypertension by nerve stimulation. The implanted pulse generator of this patent is programmed by an external personnel computer based programmer with a modified wand, shown in FIG. 9 A. Each parameter is independently programmable. Therefore, millions of different combinations of programs are possible. In the current patent application, a limited number of programs are pre-selected. This patent neither anticipates practical problems with an inductively coupled system, nor suggests any solutions for the same.
U.S. Pat. No. 5,690,681 (Geddes et al) is directed to a closed-loop implanted vagal stimulation apparatus for control of ventricular rate during atrial fibrillation. In this patent, implanted cardiac leads, and implanted pulse generator are used for sensing signals from atrial and ventricular electrograms and an adaptive control system (controller) is used for closing the loop for output stimulation to the vagus nerve. The communication to the fully implanted system of this patent is via an external programmer. In the current patent application, the patient acts as the feedback loop.
U.S. Pat. No. 5,916,239 (Geddes et al) is directed to apparatus and method for automatically and continuously adjusting the frequency of nerve stimulator as a function of signals obtained via atrial and ventricular electrograms.
U.S. Pat. No. 5,700,282 (Zabara) is directed to simultaneously stimulating vagus efferents and cardiac sympathetic nerve efferents. The rationale being to employ the brain's natural mechanisms for heart rhythm control.
U.S. Pat. No. 5,522,854 (Ideker et al) is generally directed to monitoring parasympathetic and sympathetic nerve activity and stimulating the afferent nerves with an implanted device, with the goal of preventing arryhthmias.
U.S. Pat. No. 5,199,428 (Obel et al) is directed to an implantable electrical nerve stimulator/pacemaker for decreasing cardiac workload for myocardial ischemia. The methodology involves stimulating the carotid sinus nerves or the stellate gantglion.
U.S. Pat. No. 5,330,507 (Schwartz) is generally directed to stimulating right or left vagus nerve with an implanted device which is an extension of a dual chamber cardiac pacemaker. The system is shown in FIG. 9 B.
U.S. Pat. No. 3,796,221 (Hagfors) is directed to controlling the amplitude, duration and frequency of electrical stimulation applied from an externally located transmitter to an implanted receiver by inductively coupling. Electrical circuitry is schematically illustrated for compensating for the variability in the amplitude of the electrical signal available to the receiver because of the shifting of the relative positions of the transmitter-receiver pair. By highlighting the difficulty of delivering consistent pulses, this patent points away from applications such as the current application, where consistent therapy needs to be continuously sustained over a prolonged period of time. The methodology disclosed is focused on circuitry within the receiver, which would not be sufficient when the transmitting coil and receiving coil assume significantly different orientation, which is likely in the current application. The present invention discloses a novel approach for this problem.
U.S. Pat. Nos. 4,702,254, 4,867,164 and 5,025,807 (Zabara) generally disclose animal research and experimentation related to epilepsy and the like and are directed to stimulating the vagas nerve by using “pacemaker-like” technology, such as an implantable pulse generator. The pacemaker technology concept consists of a stimulating lead connected to a pulse generator (containing the circuitry and DC power source) implanted subcutaneously or submuscularly, somewhere in the pectoral or axillary region, and programming with an external personal computer (PC) based programmer. Once the pulse generator is programmed for the patient, the fully functional circuitry and power source are fully implanted within the patient's body. In such a system, when the battery is depleted, a surgical procedure is required to disconnect and replace the entire pulse generator (circuitry and power lo source). These patents neither anticipate practical problems of an inductively coupled system, nor suggest solutions to the same for an inductively coupled system for neuromodulation therapy.
U.S. Pat. No. 5,304,206 (Baker, Jr. et al) is directed to activation techniques for implanted medical stimulators. The system uses either a magnet to activate the reed switch in the device, or tapping which acts through the piezoelectric sensor mounted on the case of the implanted device, or a combination of magnet use and tapping sequence.
U.S. Pat. No. 4,573,481 (Bullara) is directed to an implantable helical electrode assembly configured to fit around a nerve. The individual flexible ribbon electrodes are each partially embedded in a portion of the peripheral surface of a helically formed dielectric support matrix.
U.S. Pat. No. 3,760,812 (Timm et al.) discloses nerve stimulation electrodes that include a pair of parallel spaced apart helically wound conductors maintained in this configuration.
U.S. Pat. No. 4,979,511 (Terry) discloses a flexible, helical electrode structure with an improved connector for attaching the lead wires to the nerve bundle to minimize damage.
Apparatus and method for neuromodulation, of the current application has several advantages over the prior art implantable pulse generators. The external stimulator described here can be manufactured at a fraction of the cost of an implantable pulse generator. The stimulation therapy can be freely applied without consideration of battery depletion, and surgical replacement of the pulse generator is avoided. The programming is much simpler, and can be adjusted by the patient within certain limits for patient comfort. And, the implanted hardware is much smaller.
SUMMARY OF THE INVENTION
The system and method of the current invention also overcomes many of the disadvantages of the prior art by simplifying the implant and taking the programmability into the external stimulator. Further, the programmability of the external stimulator can be controlled remotely, via the wireless medium, as described in a co-pending application. The system and method of this invention uses the patient as his own feedback loop. Once the therapy is prescribed by the physician, the patient can receive the therapy as needed based on symptoms, and the patient can adjust the stimulation within prescribed limits for his/her own comfort.
The stimulation is to the right vagus nerve for controlling Inappropriate Sinus Tachycardia, and to the left vagus nerve for adjunct (add-on) treatment of atrial fibrillation and refractory hypertension.
The system consists of an implantable lead-receiver containing passive circuitry, electrodes, and a coil for coupling to the external stimulator. The external stimulator, which may be worn on a belt or carried in a pocket, contains electronic circuitry, power source, predetermined programs, and primary coil. The external primary coil and subcutaneous secondary coil are inductively coupled. The patient may selectively activate stimulation corresponding to symptoms, or leave the stimulation on according to predetermined program.
In one aspect of the invention, the pulse generator contains a limited number of predetermined programs packaged into the stimulator, which can be accessed directly without a programmer. The limited number of programs can be any number of programs even as many as 100 programs, and such a number is considered within the scope of this invention. For patient convenience, less than 20 programs are currently incorporated.
In another feature of the invention, the system provides for proximity sensing means between the primary (external) and secondary (implanted) coils. Utilizing current technology, the physical size of the implantable lead-receiver has become relatively small. However, it is essential that the primary (external) and secondary (implanted) coils be positioned appropriately with respect to each other. The sensor technology incorporated in the present invention aids in the optimal placement of the external coil relative to a previously implanted subcutaneous coil. This is accomplished through a combination of external and implantable or internal components.
In another feature of the invention, the external stimulator has predetermined programs built into the stimulator, as well as, a manual “on” and “off” button. Each of these programs has a unique combination of pulse amplitude, pulse width, frequency of stimulation, on-time and off-time. After the therapy has been initiated by the physician, the patient has a certain amount of flexibility in adjusting the intensity of the therapy (level of stimulation). The patient has the flexibility to decrease (or increase) the level of stimulation (within limits). The manual “on” button gives the patient flexibility to immediately start the stimulating pattern at any time. Of the pre-determined programs, patients do not have access to at least one of the programs, which can be activated only by the physician, or an appropriate person.
Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there are shown in accompanying drawing forms which are presently preferred, it being understood that the invention is not intended to be limited to the precise arrangement and instrumentalities shown.
FIG. 1A is a schematic diagram showing inputs and outputs to the cardiovascular center in the brain.
FIG. 1B is a simplified schematic diagram showing nervous control of the heart.
FIG. 2 is a schematic diagram of myelinated and nonmyelinated axon.
FIG. 3 is a schematic diagram of a single nerve impulse and a train of nerve impulses.
FIG. 4 is a diagram of the structure of a peripheral nerve.
FIG. 5 is a diagram showing recordings of compound action potentials.
FIG. 6 is a schematic diagram of brain showing afferent and efferent pathways.
FIG. 7 is a schematic diagram showing pathways along the spinothalamic tract.
FIG. 8 is a schematic diagram showing relationship of Nucleus of the Solitary Track and how it relays information to other parts of the brain.
FIG. 9A is a prior art figure showing an implantable neurocybernetic prosthesis, and a personnel computer based programmer along with an external sensor.
FIG. 9B is a diagram of another prior art pulse generator.
FIG. 10 is a schematic diagram of a patient with an implanted lead-receiver and an external stimulator with predetermined programs.
FIG. 11A is a diagram showing the implanted lead-receiver in contact with the vagus nerve at the distal end.
FIG. 11B is a diagram showing two coils along their axis in a configuration such that the mutual inductance would be maximum.
FIG. 12 shows external stimulator coupled to the implanted unit.
FIG. 13 is a top-level block diagram of the external stimulator and proximity sensing mechanism.
FIG. 14 is a diagram showing the proximity sensor circuitry.
FIG. 15 is a block diagram of programmable array logic interfaced to the programming station.
FIG. 16 is a block diagram showing details of programmable logic array unit.
FIG. 17 is a diagram showing details of the interface between the programmable array logic and interface unit.
FIG. 18 is a diagram showing the circuitry of the pulse generator.
FIG. 19 shows the pulse train to be transmitted to the implant unit.
FIG. 20 shows the ramp-up and ramp-down characteristic of the pulse train.
FIG. 21 is an overall schematic diagram of the external stimulator, showing wireless communication.
FIG. 22 is a schematic diagram showing application of Wireless Application Protocol (WAP).
FIG. 23A is a diagram of the implanted lead receiver.
FIG. 23B is a schematic diagram of the proximal end of the lead receiver implanted lead receiver.
FIG. 24 is a schematic of the passive circuitry in the implanted lead-receiver.
FIG. 25A is a schematic of an alternative embodiment of the implanted lead-receiver.
FIG. 25B is another alternative embodiment of the implanted lead-receiver.
FIG. 26 is a diagram of a hydrogel electrode.
FIG. 27 is a diagram of a lead-receiver utilizing a fiber electrode at the distal end.
FIG. 28 is a diagram of a fiber electrode wrapped around Dacron polyester.
FIG. 29 is a diagram of a lead-receiver with a spiral electrode.
FIG. 30 is a diagram of an electrode embedded in tissue.
FIG. 31 is a diagram of an electrode containing steroid drug inside.
FIG. 32 is a diagram of an electrode containing steroid drug in a silicone collar at the base of electrode.
FIG. 33 is a diagram of an electrode with steroid drug coated on the surface of the electrode.
FIG. 34 is a diagram of cross sections of implantable lead-receiver body showing different lumens.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the current embodiment 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 the general principles of the invention. The scope of the invention should be determined with reference to the claims.
The system and method of neuromodulation therapy of this invention consists of delivering pulsed electrical stimulation, using an implanted lead-receiver and an external stimulator with predetermined programs of stimulation. The implanted lead-receiver and external stimulator are inductively coupled. The predetermined programs contain unique combination of stimulation parameters for neuromodulation, and differ in the aggressiveness of the therapy. Some of the predetermined programs are “locked-out” to the patient or caretaker, and can be accessed and controlled by the physician only.
Referring now to FIG. 10, which shows a schematic diagram of a patient 32 with an implantable lead-receiver 34 and an external stimulator 42 , clipped on to a belt 44 in this case. The external stimulator 42 , may alternatively be placed in a pocket or other carrying device. The primary (external) coil 46 of the external stimulator 42 is inductively coupled to the secondary (implanted) coil 48 of the implanted lead-receiver 34 . As shown in FIG. 11A, the implantable lead-receiver 34 has circuitry at the proximal end 49 , and has two stimulating electrodes at the distal end 61 , 62 . The negative electrode (cathode) 61 is positioned towards the brain and the positive electrode (anode) 62 is positioned away from the brain. During the surgical implant procedure, the stimulating electrodes are tunneled subcutaneously and the spiral shaped electrodes are wrapped around the vagus nerve 54 which is surgically isolated from the carotid artery 56 and jugular vein 58 . The incisions are surgically closed and the chronic stimulation process can begin when the tissues are healed from the surgery.
For therapy to commence, the primary (external) coil 46 is placed on the skin on top of the surgically implanted (secondary) coil 48 . An adhesive tape is then placed on the skin 60 and external coil 46 such that the external coil 46 , is taped firmly to the skin 60 . For efficient energy transfer to occur, it is important that the primary (external) and secondary (internal) coils 46 , 48 be positioned along the same axis and be optimally positioned relative to each other (FIG. 11 B). In the present embodiment, the external coil 46 is connected to proximity sensing circuitry 50 . The correct positioning of the external coil 46 with respect to the internal coil 48 is indicated by turning “on” of a light emitting diode (LED) on the external stimulator 42 .
Optimal placement of the external (primary) coil 46 is done with the aid of proximity sensing circuitry incorporated in the system. Proximity sensing occurs utilizing a combination of external and implantable or internal components. The internal components contains a relatively small magnet composed of materials that exhibit Giant Magneto-Resistor (GMR) characteristics such as Samarium-cobalt, a coil, and passive circuitry. As shown in FIG. 12, the external coil 46 and proximity sensor circuitry 50 are rigidly connected in a convenient enclosure which is attached externally on the skin. The sensors measure the direction of the field applied from the magnet to sensors within a specific range of field strength magnitude. The dual sensors exhibit accurate sensing under relatively large separation between the sensor and the target magnet. As the external coil 46 placement is “fine tuned”, the condition where the external (primary) coil 46 comes in optimal position, i.e. is located adjacent and parallel to the subcutaneous (secondary) coil 48 , along its axis, is recorded and indicated by a light emitting diode (LED) on the external stimulator 42 .
FIG. 13 shows an overall block diagram of the components of the external stimulator and the proximity sensing mechanism. The proximity sensing components are the primary (external) coil 46 , supercutaneous (external) proximity sensors 198 , 202 (FIG. 14) in the proximity sensor circuit unit 50 , and a subcutaneous secondary coil 48 with a Giant Magneto Resister (GMR) magnet 53 associated with the proximity sensor unit. The proximity sensor circuit 50 provides a measure of the position of the secondary implanted coil 48 . The signal output from proximity sensor circuit 50 is derived from the relative location of the primary and secondary coils 46 , 48 . The coil sub-assemblies consist of the coil and the associated electronic components, that are rigidly connected to the coil.
The proximity sensors (external) contained in the proximity sensor circuit 50 detect the presence of a GMR magnet 53 , composed of Samarium Cobalt, that is rigidly attached to the subcutaneous secondary coil 48 . The proximity sensors, are mounted externally as a rigid assembly and sense the actual separation between the coils, also known as the proximity distance. In the event that the distance exceeds the system limit, the signal drops off and an alarm sounds to indicate failure of the production of adequate signal in the secondary implanted circuit 167 , as applied in the present embodiment of the device. This signal is provided to the location indicator LED 140 .
FIG. 14 shows the circuit used to drive the proximity sensors 198 , 202 of the proximity sensor circuit. The two proximity sensors 198 , 202 obtain a proximity signal based on their position with respect to the implanted GMR magnet 53 . This circuit also provides temperature compensation. The sensors 198 , 202 are ‘Giant Magneto Resistor’ (GMR) type sensors packaged as proximity sensor unit 50 . There are two components of the complete proximity sensor circuit 51 . One component is mounted supercutaneously 50 , and the other component, the proximity sensor signal control unit 57 is within the external stimulator 42 . The resistance effect depends on the combination of the soft magnetic layer of magnet 53 , where the change of direction of magnetization from external source can be large, and the hard magnetic layer, where the direction of magnetization remains unchanged. The resistance of this sensor varies along a straight motion through the curvature of the magnetic field.
A bridge differential voltage is suitably amplified and used as the proximity signal. The Siemens GMR B6 (Siemens Corp., Special Components Inc. New Jersey) is used for this function in the present embodiment. The maximum value of the peak-to-peak signal is observed as the external magnetic field becomes strong enough, at which point the resistance increases, resulting in the increase of the field-angle between the soft magnetic and hard magnetic material. The bridge voltage also increases. In this application, the two sensors 198 , 202 are oriented orthogonal to each other.
The distance between the magnet and sensor is not relevant as long as the magnetic field is between 5 and 15 KA/m, and provides a range of distances between the sensors 198 , 202 and the magnetic material 53 . The GMR sensor registers the direction of the external magnetic field. A typical magnet to induce permanent magnetic field is approximately 15 by 8 by 5 mm 3 , for this application and these components. However, the sensors 198 , 202 are sensitive to temperature, such that the corresponding resistance drops as temperature increases. This effect is quite minimal until about 100° C. A full bridge circuit is used for temperature compensation, as shown in temperature compensation circuit 50 of FIG. 14 . The sensors 198 , 202 and a pair of resistors 200 , 204 are shown as part of the bridge network for temperature compensation. It is also possible to use a full bridge network of two additional sensors in place of the resistors 200 , 204 .
The signal from either proximity sensor 198 , 202 is rectangular if the surface of the magnetic material is normal to the sensor and is radial to the axis of a circular GMR device. This indicates a shearing motion between the sensor and the magnetic device. When the sensor is parallel to the vertical axis of this device, there is a fall off of the relatively constant signal at about 25 mm. separation. The GMR sensor combination varies its resistance according to the direction of the external magnetic field, thereby providing an absolute angle sensor. The position of the GMR magnet can be registered at any angle from 0 to 360 degrees.
The external stimulator shown in FIG. 13, with indicator unit 140 which is provided to indicate proximity distance or coil proximity failure (for situations where the patch containing the external coil 46 , has been removed, or is twisted abnormally etc.). Indication is also provided to assist in the placement of the patch. In case of general failure, a red light with audible signal is provided when the signal is not reaching the subcutaneous circuit. The indicator unit 140 also displays low battery status. The information on the low battery, normal and out of power conditions will forewarn the user of the requirements of any corrective actions.
As was shown in FIG. 13, the programmable parameters are stored in a programmable logic 304 . The predetermined programs stored in the external stimulator are capable of being modified through the use of a separate Programming Station 77 . FIG. 15 shows the Programmable Array Logic Unit 304 and interface unit 312 interfaced to the programming station 77 . The programming station 77 can be used to load new programs, change the predetermined programs, or the program parameters for various stimulation programs. The programming station is connected to the Programmable Array Unit 75 , shown in FIG. 16 (comprising programmable array logic 304 and interface unit 312 ) with an RS232-C serial connection. The main purpose of the serial line interface is to provide an RS232-C standard interface. This method enables any portable computer with a serial interface to communicate and program the parameters for storing the various programs. The serial communication interface receives the serial data, buffers this data and converts it to a 16 bit parallel data. The Programmable Array Logic 304 component of Programmable Array Unit 75 receives the parallel data bus and stores or modifies the data into a random access matrix 340 (FIG. 16 ). This array of data also contains special logic and instructions along with the actual data. These special instructions also provide an algorithm for storing, updating and retrieving the parameters from long-term memory. The Programmable logic Array Unit 304 , interfaces with Long Term Memory to store the predetermined programs 71 . All the previously modified programs can be stored here for access at any time, as well as, additional programs can be locked out for the patient. The programs consist of specific parameters and each unique program will be stored sequentially in long-term memory. A battery unit 310 is present to provide power to all the components shown above. The logic for the storage and decoding is stored in the Random Addressable Storage Matrix (RASM) 340 (FIG. 16 ).
FIG. 16 shows greater details for the Programmable Logic Array Unit 304 . The Input Buffer block 343 is where the serial data is stored in temporary register storage. This accumulation allows for the serial to parallel conversion to occur. The serial to 16 bit parallel block 346 sets up 16 bits of data, as created from the RS232-C serial data. This parallel data bus will communicate the data and the address information. The decoder block 344 decodes address information for the Random Addressable Logic Storage Matrix 340 from which to access the data i.e. programmer parameters. The Output Buffer 342 provides an interface to the Long Term Memory 71 .
FIG. 17 shows schematically the details of the interface between the Programmable Array Logic 304 and Interface Unit 312 which is connected to the Predetermined Programs block (Long Term Memory) 71 . The patient override 73 is essentially a control scheme for initializing or starting a program at any intermediate point. The Programmable array provides a reconfigurable mechanism to store data and associated instructions for the programs. It supports adding, modifying or retrieving the data from a Random Addressable Logic Storage Matrix 340 . This is also a widely accepted scheme for treating “flexible” logic description and control. It is flexible by providing the ability to reprogram and even redesign existing programs previously installed as predetermined programs. It allows the manufacturer or authorized user to create, and modify the programs for execution.
The pulse generator circuitry, shown schematically in FIG. 18, exhibits typical multivibrator functionality. This circuit produces regularly occurring pulses where the amplitude, pulse width and frequency is adjustable. The battery 310 is the main external power source for this circuit. The capacitor 450 is connected in parallel with the battery 310 . The combination of transistors 412 , 442 and 425 , and resistors 410 , 444 , 446 and 448 acts as a constant current source generated at the collector of transistor 426 . The transistor 412 has collector connected to the emitter of transistor 442 and base of transistor 425 . The transistors 412 and 442 are connected to provide a constant voltage drop. Likewise, transistor 426 also acts as a diode with a resistor 428 connected in series and further connected to the negative terminal of the line at terminal 460 . Capacitor 416 provides timing characteristics and its value helps determine pulse width and pulse frequency. The output of the oscillator appears at terminal 458 .
Initially, the capacitor 416 gets charged with current from the path of resistor 434 and 436 while all the transistors are turned off. As the capacitor charges up transistor 432 will become forward biased and current will flow via resistors 430 and 436 from the base to emitter resistors. This action turns on the transistor 418 and the positive voltage from the power supply 310 is made available at the base of transistor 438 through resistor 440 . This results in the transistor 438 getting turned on. The conduction of transistor 438 causes capacitor 416 to discharge. The time constant for the charge and discharge of capacitor 416 is determined by value of the resistors 428 and 440 and capacitor 416 . After the time constant, transistor 432 turns off, and this in turn turns off transistors 438 and 418 . A reset mechanism for this multivibrator can be provided by setting a positive voltage, for example 2.5 volts, to the base of transistor 420 . This positive increase in voltage turns on transistor 420 followed by transistor 438 . The turning on of transistor 438 discharges the capacitor 416 and the reset operation is complete.
Conventional microprocessor and integrated circuits are used for the logic, control and timing circuits. Conventional bipolar transistors are used in radio-frequency oscillator, pulse amplitude ramp control and power amplifier. A standard voltage regulator is used in low-voltage detector. The hardware and software to deliver the pre-determined programs is well known to those skilled in the art.
The pulses delivered to the nerve tissue for stimulation therapy are shown graphically in FIG. 19 . As shown in FIG. 20, for patient comfort when the electrical stimulation is turned on, the electrical stimulation is ramped up and ramped down, instead of abrupt delivery of electrical pulses.
The number of predetermined programs can be any number, say 100, and such a number is considered within the scope of the invention. For patient convenience, less than 20 programs are practical. One embodiment contains nine predetermined programs.
In one arrangement, the predetermined programs are arranged in such a way that the aggressiveness of the therapy increases from program #1 to Program #9. Thus the first three programs provide the least aggressive therapy, and the last three programs provide the most aggressive therapy.
The following are examples of least aggressive therapy.
Program #1:
1.0 mA current output, 0.2 msec pulse width, 15 Hz frequency, 15 sec on-time, 1.0 min off-time, in repeating cycles.
Program #2:
1.5 mA current output, 0.3 msec pulse width, 20 Hz frequency, 20 sec on-time, 2.0 min off-time, in repeating cycles.
The following are examples of intermediate level of therapy.
Program #5:
2.0 mA current output, 0.3 msec pulse width, 25 Hz frequency, 20 sec on-time, 1.0 min off-time, in repeating cycles.
Program #6:
2.0 mA current output, 0.4 msec pulse width, 25 Hz frequency, 30 sec on-time, 1.0 min off-time, in repeating cycles.
The following are examples of most aggressive therapy.
Program #8:
2.5 mA current output, 0.3 msec pulse width, 30 Hz frequency, 40 sec on-time, 1.5 min off-time, in repeating cycles.
Program #9:
3.0 mA current output, 0.5 msec pulse width, 30 Hz frequency, 30 sec on-time, 1.0 min off-time, in repeating cycles.
The majority of patients will fall into the category that require an intermediate level of therapy, such as program #5. The above are examples of the predetermined programs that are delivered to the vagus nerve. The actual parameter settings for any given patient may deviate somewhat from the above. As shown schematically in FIG. 13, new predetermined programs can be loaded into the external stimulator 42 .
In one embodiment, the external stimulator can also have a telecommunications module, as described in a co-pending application, and summarized here for reader convenience. The telecommunications module has two-way communications capabilities.
FIG. 21 shows conceptually the communication between the external stimulator 42 and a remote hand-held computer. A desktop or laptop computer can be a server 500 which is situated remotely, perhaps at a physician's office or a hospital. The stimulation parameter data can be viewed at this facility or reviewed remotely by medical personnel on a hand-held personal data assistant (PDA) 502 , such as a “palm-pilot” from PALM corp. (Santa Clara, Calif.), a “Visor” from Handspring Corp. (Mountain view, Calif.) or on a personal computer (PC) available from numerous vendors. The physician or appropriate medical personnel, is able to interrogate the external stimulator 42 device and know what the device is currently programmed to, as well as, get a graphical display of the pulse train. The wireless communication with the remote server 500 and hand-held PDA 502 would be supported in all geographical locations within and outside the United States (US) that provides cell phone voice and data communication service. The pulse generation parameter data can also be viewed on the handheld devices (PDA) 502 .
The telecommunications component of this invention uses Wireless Application Protocol (WAP). The Wireless Application Protocol (WAP) is a set of communication protocols standardizing Internet access for wireless devices. While previously, manufacturers used different technologies to get Internet on hand-held devices, with WAP devices and services interoperate. WAP promotes convergence of wireless data and the Internet. The WAP programming model is heavily based on the existing Internet programming model, and is shown schematically in FIG. 22 . Introducing a gateway function provides a mechanism for optimizing and extending this model to match the characteristics of the wireless environment. Over-the-air traffic is minimized by binary encoding/decoding of Web pages and readapting the Internet Protocol stack to accommodate the unique characteristics of a wireless medium such as call drops. Such features are facilitated with WAP.
The key components of the WAP technology, as shown in FIG. 22, includes 1) Wireless Mark-up Language (WML) 400 which incorporates the concept of cards and decks, where a card is a single unit of interaction with the user. A service constitutes a number of cards collected in a deck. A card can be displayed on a small screen. WML supported Web pages reside on traditional Web servers. 2) WML Script which is a scripting language, enables application modules or applets to be dynamically transmitted to the client device and allows the user interaction with these applets. 3) Microbrowser, which is a lightweight application resident on the wireless terminal that controls the user interface and interprets the WML/WMLScript content. 4) A lightweight protocol stack 402 which minimizes bandwidth requirements, guaranteeing that a broad range of wireless networks can run WAP applications. The protocol stack of WAP can comprise a set of protocols for the transport (WTP), session (WSP), and security (WTLS) layers. WSP is binary encoded and able to support header caching, thereby economizing on bandwidth requirements. WSP also compensates for high latency by allowing requests and responses to be handled asynchronously, sending before receiving the response to an earlier request. For lost data segments, perhaps due to fading or lack of coverage, WTP only retransmits lost segments using selective retransmission, thereby compensating for a less stable connection in wireless. The above mentioned features are industry standards adopted for wireless applications and greater details have been publicized, and well known to those skilled in the art.
In this embodiment, two modes of communication are possible. In the first, the server initiates an upload of the actual parameters being applied to the patient, receives these from the stimulator, and stores these in its memory, accessible to the authorized user as a dedicated content driven web page. The physician or authorized user can make alterations to the actual parameters, as available on the server, and then initiate a communication session with the stimulator device to download these parameters.
The physician is also able to set up long-term schedules of stimulation therapy for their patient population, through wireless communication with the server. The server in turn communicates these programs to the neurostimulator. Each schedule is securely maintained on the server, and is editable by the physician and can get uploaded to the patient's stimulator device at a scheduled time. Thus, therapy can be customized for each individual patient. Each device issued to a patient has a unique identification key in order to guarantee secure communication between the wireless server 502 and stimulator device 42 .
The second mode of communication is the ability to remotely interrogate and monitor the stimulation therapy on the physician's handheld (PDA) 502 .
Moving now to the implantable portion of the system, FIG. 23A shows a diagram of the implanted lead-receiver 34 , and FIG. 23B shows a diagram of the proximal end 49 of the lead-receiver 34 . The proximal end 49 is a relatively flat portion and contains the electrical components on a printed circuit board. The distal end has the two spiral electrodes 61 and 62 for stimulating the nerve. The passive circuitry and electrodes are connected by electrically insulated wire conductors running within the lead body 59 . The lead body 59 is made of reinforced medical grade silicone in the presently preferred embodiment.
The circuitry contained in the proximal end 49 of the implantable lead-receiver 34 is shown schematically in FIG. 24, for the presently preffered embodiment. In this embodiment, the circuit uses all passive components. Approximately 25 turn copper wire of 30 gauge, or comparable thickness, is used for the primary coil 46 and secondary coil 48 . This wire is concentrically wound with the windings all in one plane. The frequency of the pulse-waveform delivered to the implanted coil 48 can vary and so a variable capacitor 152 provides ability to tune secondary implanted circuit 167 to the signal from the primary coil 46 . The pulse signal from secondary (implanted) coil 48 is rectified by the diode bridge 154 and frequency reduction obtained by capacitor 158 and resistor 164 . The last component in line is capacitor 166 , used for isolating the output signal from the electrode wire. The return path of signal from cathode 61 will be through anode 62 placed in proximity to the cathode 61 for “Bipolar” stimulation. In the current embodiment bipolar mode of stimulation is used, however, the return path can be connected to the remote ground connection (case) of implantable circuit 167 , providing for much larger intermediate tissue for “Unipolar” stimulation. The “Bipolar” stimulation offers localized stimulation of tissue compared to “Unipolar” stimulation and is therefore, used in the current embodiment. Unipolar stimulation is more likely to stimulate skeletal muscle in addition to nerve stimulation. The implanted circuit 167 in this embodiment is passive, so a battery does not have to be implanted. It is however possible to implant a battery source for use of active component logic in the implant.
The circuitry shown in FIGS. 25A and 25B can be used as an alternative, for the implanted lead-receiver. The circuitry of FIG. 25A is a slightly simpler version, and circuitry of FIG. 25B contains a conventional NPN transistor 168 connected in an emitter-follower configuration.
The fabrication of the lead-receiver 34 is designed to be modular. Thus, several different combinations of the components can be packaged without significantly altering the functionality of the device. As shown in FIG. 23A, the lead-receiver 34 components are the proximal end 49 containing coil 48 , electrical circuitry 167 , and case 78 . The lead body 59 containing the conductor 65 , 66 and the distal end has two electrodes cathode 61 and anode 62 . In the modular design concept, several design variables are possible, as shown in the table below.
Table of lead-receiver design variables
Conductor
(connecting
Distal
Proximal
Lead
Lead body-
proximal
End
End
body-
Insulation
and distal
Electrode-
Electrode-
Circuitry
Lumens
Materials
Lead-Coating
ends)
Material
Type
Bipolar
Polurethane
Alloy of
Pure
Standard ball
Nickel-
Platinum
electrode
Cobalt
Unipolar
Double
Silicone
Antimicrobial
Platinum-
Hydrogel
coating
Iridium
electrode
(Pt/IR) Alloy
Triple
Silicone with
Anti-
Pt/Ir coated
Spiral
Polytetra-
Inflamatory
with Titanium
electrode
fluoro-
coating
Nitride
ethylene
(PTFE)
Coaxial
Lubricious
Carbon
Steroid
coating
eluting
Either silicone or polyurethane is a suitable material for the implantable lead-receiver body 59 . Both materials have proven to have desirable qualities which are not available in the other. Permanently implantable pacemaker leads made of polyurethane are susceptible to some forms of degradation over time. The identified mechanisms are Environmental Stress Cracking (ESC) and Metal Ion Oxidation (MIO). Silicone on the other hand is a softer material, therefore lead body has to be made bigger. In the presently preferred embodiment silicone re-enforced with polytetrafluroethyene (PTFE) is used.
Nerve-electrode interaction is an integral part of the stimulation system. As a practical benefit of modular design, any type of electrode described below can be used as the distal (cathode) stimulating electrode, without changing fabrication methodology or procedure significantly. When a standard electrode made of platinum or platinum/iridium is placed next to the nerve, and secured in place, it promotes an inflammatory response that leads to a thin fibrotic sheath around the electrode over a period of 1 to 6 weeks. This in turn leads to a stable position of electrode relative to the nerve, and a stable electrode-tissue interface, resulting in reliable stimulation of the nerve chronically without damaging the nerve.
Alternatively, other electrode forms that are non-traumatic to the nerve such as hydrogel, platinum fiber, or steroid elution electrodes may be used with this system. The concept of hydrogel electrode for nerve stimulation is shown schematically in FIG. 26 . The hydrogel material 100 is wrapped around the nerve 54 , with tiny platinum electrodes 102 being pulled back from nerve. Over a period of time in the body, the hydrogel material 100 will undergo degradation and there will be fibrotic tissue buildup. Because of the softness of the hydrogel material 100 , these electrodes are non-traumatic to the nerve.
The concept of platinum fiber electrodes is shown schematically in FIG. 27 . The distal fiber electrode 104 attached to the lead-receiver 34 may be platinum fiber or cable, or the electrode may be thin platinum fiber wrapped around Dacron polyester or Polyimide 106 . As shown in FIG. 28, the platinum fibers 108 may be woven around Dacron polyester fiber 106 or platinum fibers 108 may be braided. At implant, the fiber electrode 104 is loosely wrapped around the surgically isolated nerve, then tied loosely so as not to constrict the nerve or put pressure on the nerve. As a further extension, the fiber electrode may be incorporated into a spiral electrode 105 as is shown schematically in FIG. 29 . The two “pigs tail” coil electrodes are made from thin platinum coated braided yarn which is adhered to a substrate in the shape of a “pigs tail” and wraps around the nerve. The braid then continues up a silicone tube lead body.
Alternatively, steroid elution electrodes may be used. After implantation of a lead in the body, during the first few weeks there is buildup of fibrotic tissue in-growth over the electrode and to some extent around the lead body. This fibrosis is the end result of body's inflammatory response process which begins soon after the device is implanted. The fibrotic tissue sheath has the net effect of increasing the distance between the stimulation electrode (cathode) and the excitable tissue, which is the vagal nerve in this case. This is shown schematically in FIG. 30, where electrode 52 when covered with fibrotic tissue becomes the “virtual” electrode 114 . Non-excitable tissue is depicted as 120 and excitable tissue as 118 . A small amount of corticosteroid, dexamethasone sodium phosphate, which is commonly referred to as “steroid” or “dexamethasone” placed inside or around the electrode, has significant beneficial effect on the current or energy threshold, i.e. the amount of energy required to stimulate the excitable tissue. This is well known to those familiar in the art, as there is a long history of steroid elution leads in cardiac pacing application. It takes only about 1 mg of dexamethasone to produce the desirable effects. Three separate ways of delivering the steroid drug to the electrode nerve-tissue interface are being disclosed here. Dexamethasone can be placed inside an electrode with microholes, it can be placed adjacent to the electrode in a silicone collar, or it can be coated on the electrode itself.
Dexamethasone inside the stimulating electrode is shown schematically in FIG. 31. A silicone core that is impregnated with a small quantity of dexamethasone 121 , is incorporated inside the electrode. The electrode tip is depicted as 124 and electrode body as 122 . Once the lead is implanted in the body, the steroid 121 elutes out through the small holes in the electrode. The steroid drug then has anti-inflammatory action at the electrode tissue interface, which leads to a much thinner fibrotic tissue capsule.
Another way of having a steroid eluting nerve stimulating electrode, is to have the steroid agent placed outside the distal electrode 91 in a silicone collar 126 . This is shown schematically in FIG. 32 . Approximately 1 mg of dexamethasone is contained in a silicone collar 126 , at the base of the distal electrode 52 . With such a method, the steroid drug elutes around the electrode 52 in a similar fashion and with similar pharmacokinetic properties, as with the steroid drug being inside the electrode.
Another method of steroid elution for nerve stimulation electrodes is by coating of steroid on the outside (exposed) surface area of the electrode. This is shown schematically in FIG. 33 . Nafion is used as the coating matrix. Steroid membrane coating on the outside of the electrode is depicted as 128 . The advantages of this method are that it can easily be applied to any electrode, fast and easy manufacturing, and it is cost effective. With this method, the rate of steroid delivery can be controlled by the level of sulfonation.
A schematic representation of the cross section of different possible lumens is shown in FIG. 34 . The lead body 59 can have one, two, or three lumens for conducting cable, with or without a hollow lumen. In the cross sections, 132 A-F represents lumens(s) for conducting cable, and 134 A-C represents hollow lumen for an aid in implanting the lead.
Additionally, different classes of coating may be applied to the implantable lead-receiver 34 after fabrication. These coatings fall into three categories, lubricious coating, antimicrobial coating, and anti-inflammatory coating.
The advantage of modular fabrication is that with one technology platform, several derivative products or models can be manufactured. As a specific practical example, using a silicone lead body platform, three separate derivative or lead models can be manufactured by using three different electrodes such as standard ball electrode, spiral electrode, or steroid electrode. This is made possible by designing the fabrication steps such that the distal electrodes are assembled at the end, and as long as the electrodes are mated to the insulation and conducting cable, the shape or type of electrode does not matter. Similarly, different models can be produced by taking a finished lead and then coating it with lubricious coating or antimicrobial coating. In fact, considering the design variables disclosed in Table 1, a large number of combinations are possible.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention. | A system and method of neuromodulation adjunct (add-on) therapy for atrial fibrillation, refractory hypertension, and inappropriate sinus tachycardia comprises an implantable lead-receiver and an external stimulator. Neuromodulation is performed using pulsed electrical stimulation. The external stimulator contains a power source, controlling circuitry, a primary coil, and predetermined programs. The primary coil of the external stimulator inductively transfers electrical signals to the implanted lead-receiver, which is also in electrical contact with a vagus nerve. The external stimulator emits electrical pulses to stimulate the vagus nerve according to a predetermined program. In a second mode of operation, an operator may manually override the predetermined sequence of stimulation. The external stimulator may also be equipped with a telecommunications module to control the predetermined programs remotely. | 0 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the U.S. Government for government purposes without the payment to me of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates to optical scanning systems for satellites orbiting the earth. The mechanism provides a conical scan pattern which is useful in meteorological satellite radiometer applications.
Prior art scanning systems use sliding contacts such as motor brushes, grounding brushes for electrostatic noise reduction, slip ring assemblies, and flexible cables. All of these components are undesirable because they add additional mechanical complexity to the device and produce electrical noise. This invention eliminates these problems while providing complete and independent freedom of two scan motions (angular tilt and rotary motion) that can be imparted without the use of slip rings or flexible cables.
SUMMARY OF THE INVENTION
This invention presents an optical scan device for use in a satellite orbiting the earth. In it a platform rotates about an axis. A first periscope which has a longitudinal axis and first and second mirrors is attached to the rotating platform such that the first mirror is positioned with its optical axis coincident with the axis of rotation of the platform. A second periscope which has a longitudinal axis and third and fourth mirrors is pivotally attached to the platform such that the second periscope is pivoted in line with the optical centers of the second mirror and the third mirror, and such that the third mirror is in optical communication with the second mirror. This device may also further comprise means for pivoting the second periscope through an angle of α° as the platform rotates about its axis of rotation.
This invention also presents a second embodiment of an optical scan device for use in a satellite orbiting the earth. It comprises a first hollow cylinder which has a first diameter and a first central longitudinal axis of first length, and a second hollow cylinder which has a second diameter smaller than the first diameter and a second central longitudinal axis of second length. Means are provided for aligning the first hollow cylinder with the second hollow cylinder such that the first central longitudinal axis and the second central longitudinal axis are colinear to form a common central longitudinal axis. Means are also provided for rotating the first hollow cylinder and the second hollow cylinder in the same direction and at the same rate of speed about the common central longitudinal axis.
Also present in the second embodiment is a first periscope which has a longitudinal axis and a first mirror and a second mirror, and a second periscope which has a longitudinal axis and a third mirror and a fourth mirror. The first periscope is attached inside and to the first hollow cylinder such that the first mirror is positioned with its optical axis coincident with the common central longitudinal axis. The second periscope is pivotally attached inside and to the first hollow cylinder such that the second periscope is pivoted in line with the optical centers of the second mirror and the third mirror, and such that the second mirror is in optical alignment with the third mirror. Means are provided for imparting linear axial motion to the second hollow cylinder, and means further provided for imparting the linear axial motion of the second hollow cylinder to the second periscope such that the linear axial motion is converted to angular motion causing the second periscope to pivot.
A third embodiment of an optical scan device for use in a satellite orbiting the earth is also presented by this invention. It comprises a first hollow cylinder which has a first diameter, a first central longitudinal axis of first length, a first end, and a second end. Also present is a second hollow cylinder having a second diameter smaller than the first diameter, a second central longitudinal axis of second length, a first end, and a second end. The third embodiment further comprises an electric motor having a stator, and a rotor which revolves around an axis of rotation. The rotor has a hollow cylindrical shaft with a central longitudinal axis of third length smaller than the second length running through the rotor such that the axis of rotation of the rotor and the central longitudinal axis of the shaft are colinear. The hollow cylindrical shaft has a diameter large enough for the second hollow cylinder to slidably fit in it, a first end, and a second end. A first set of three axial track grooves spaced 120° apart are dispoed in the outer wall of the second hollow cylinder, and a second set of three axial track grooves spaced 120° apart are disposed in the inner wall of the hollow cylindrical shaft such that they match the first set of three axial track grooves. A first set of ball bearings is disposed in the first matched pair of axial track grooves to form a first linear ball bearing. A second set of ball bearings is disposed in the second matched pair of axial track grooves to form a second linear ball bearing. And a third set of ball bearings is disposed in the third matched pair of axial track grooves to form a third linear ball bearing.
Concentrically attached to the first end of the second hollow cylinder is the inner race of a first torque tube ball bearing. A carrier ring is concentrically attached to the outer race of the first torque tube ball bearing. Also attached to the carrier ring are a ball nut and a ball slide. The ball nut and the ball slide are spaced 180° apart. A lead screw is threaded through the ball nut, and a step motor is attached to one end of the lead screw. Rotation of the lead screw by the step motor causes the ball nut to travel along the lead screw, which imparts linear motion to the second hollow cylinder so that the second hollow cylinder travels linearly through the hollow cylindrical shaft of the rotor. The ball slide is slidably attached to a stabilizer rod. Means are included for attaching the first hollow cylinder to the rotor such that the first central longitudinal axis and the second central longitudinal axis are colinear and such that the second end of the second hollow cylinder extends into the first hollow cylinder. A first periscope is attached inside and to the first hollow cylinder. The first periscope has a first periscope tube with a first end, a second end, and a longitudinal axis. A first mirror is disposed in its first end and a second mirror is disposed in its second end. The first periscope is attached to the first hollow cylinder such that its first mirror is positioned with its optical axis coincident with the axis of rotation of the rotor. Also present is a second periscope which has a second periscope tube with a first end, a second end, and a longitudinal axis, and with a third mirror disposed in the first end of the tube and a fourth mirror disposed in the second end of the tube. Also present is a connecting tube having a central longitudinal axis, a first end, and a second end. Concentrically attached to the first end of the connecting tube is the inner race of a second torque tube bearing. The outer race of the second torque tube bearing is attached to the second end of the first periscope such that the central longitudinal axis of the connecting tube is colinear with the optical axis of the second mirror. The second end of the connecting tube is attached to the first end of the second periscope tube such that the central longitudinal axis of the connecting tube is colinear with the optical axis of the third mirror. An end bearing mount has its inner race attached to the inside of the first hollow cylinder, and the outer race of the end bearing mount is attached to the first end of the second periscope tube such that the second end of the second periscope tube can tilt when the connecting tube is rotated. A gear sector is attached to the connecting tube, and a gear rack is mounted on the outside and at the second end of the second hollow cylinder such that its teeth mesh with the teeth of the gear sector.
The electric motor in the third embodiment of the invention may be a variable speed motor, and means can be included for controlling its speed. Also, the step motor may be a variable speed motor, and means can be included for controlling its speed.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an optical scanning system for use in satellites orbiting the earth.
A further object of this invention is to provide a scanning mechanism which produces a conical scan pattern.
Another object of the invention is to provide a scanning mechanism which eliminates the need for sliding contacts such as motor brushes, grounding brushes for electrostatic noise reduction, slip ring assemblies, and flexible cables.
Another object of the invention is to provide a scanning mechanism which allows for complete and independent freedom of the two scan motions (angular tilt and rotary motion).
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional and partial cut-away view of the preferred embodiment of the invention.
FIG. 2 is a schematic of the scan optics.
FIG. 3 is a schematic of the scan optics.
FIG. 4 is a schematic of the scan optics.
FIG. 5 is a block diagram of the motor control circuitry.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is illustrated in FIG. 1. It comprises a first hollow cylinder 50. Hollow cylinder 50 has a first end 52, a second end 54, a first diameter, and a first central longitudinal axis of first length. The invention also comprises a second hollow cylinder 56. Hollow cylinder 56 has a first end 58, a second end 60, a second diameter smaller than the first diameter, and a second central longitudinal axis of second length.
An electric motor 61 is mounted in case 62. Electric motor 61 comprises a stator 64, a rotor 66, a first motor bearing 65, and a second motor bearing 67. Rotor 66 revolves around an axis of rotation, and it has a hollow cylindrical shaft 68 with a central longitudinal axis of third length smaller than the length of the second central longitudinal axis running through rotor 66 such that the axis of rotation of rotor 66 and the central longitudinal axis of shaft 68 are colinear. Hollow cylindrical shaft 68 has a diameter which is large enough for the second hollow cylinder 56 to slidably fit in it, a first end 70, and a second end 72. First motor bearing 65 comprises an inner race 69 concentrically attached to rotor 66, an outer race 73 concentrically attached to stator 64, and ball bearings 71 disposed between the two races. Second motor bearing 67 comprises an outer race 75 concentrically attached to rotor 66, an inner race 79 concentrically attached to stator 64, and ball bearings 77 disposed between the two races. First motor bearing 65 is disposed at end 59 of motor 61, and second motor bearing 67 is disposed at end 63 of motor 61.
A first set of three axial track grooves spaced 120° apart are disposed in the outer wall of second hollow cylinder 56, and a second set of three axial track grooves 120° apart are disposed in the inner wall of the hollow cylindrical shaft 68 such that they match the first set of three axial track grooves. In FIG. 1, a first pair of axial track grooves is represented by 74, and a second pair of axial track grooves is represented by 76. The third pair of axial track grooves is not illustrated. A first set of ball bearings 78 is disposed in the first pair of axial track grooves 74 such that a first linear ball bearing is formed. A second set of ball bearings 80 is disposed in the second pair of axial track grooves 76 such that a second linear ball bearing is formed. A third set of ball bearings, not illustrated, is disposed in the third pair of axial track grooves such that a third linear ball bearing is formed. The three linear ball bearings provide the necessary key relationship to assure that the second hollow cylinder rotates in unison with the first hollow cylinder, and they minimize friction between the two members upon application of an axial stroke to the second hollow cylinder.
Inner race 82, outer race 84, and a set of ball bearings 86 comprise a first torque tube ball bearing 83. Inner race 82 of the first torque tube ball bearing 83 is concentrically attached to the first end 58 of second hollow cylinder 56. The outer race 84 of the first torque tube ball bearing 83 is concentrically attached to carrier ring 88. Ball bearings 86 are disposed between inner race 82 and outer race 84 of the first torque tube ball bearing 83. Carrier ring 88 is also attached to ball nut 90 and ball slide 92. Ball nut 90 and ball slide 92 are spaced 180° apart around carrier ring 88. The ball slide 92 is slidably attached to stabilizer rod 94. Stabilizer rod 94 is attached at both ends to case 62 and is parallel to second hollow cylinder 56. Stabilizer rod 94 provides additional axial stability. A lead screw 98 is threaded through ball nut 90. Lead screw 98 is also parallel to second hollow cylinder 56. One end of lead screw 98 is attached to step motor 96, and the other end is attached to lead screw mount 100. Both step motor 96 and lead screw mount 100 are attached to case 62. Rotation of lead screw 98 by step motor 96 causes ball nut 90 to travel along lead screw 98. This in turn imparts linear motion to second hollow cylinder 56 which causes it to travel linearly through hollow cylindrical shaft 68 of rotor 66.
The first end 52 of first hollow cylinder 50 is attached to the second end 72 of the hollow cylindrical shaft 68. The two are attached such that the first central longitudinal axis of first hollow cylinder 50 is colinear with the second central longitudinal axis of second hollow cylinder 56, and such that the second end 60 of second hollow cylinder 56 extends into first hollow cylinder 50. Since second hollow cylinder 56 is connected to carrier ring 88 through first torque tube bearing 83, it can rotate freely in unison with first hollow cylinder 50.
The invention further comprises a first periscope tube 102 which has a first end 104, a second end 106, and a longitudinal axis. A first mirror 108 is disposed in first end 104, and a second mirror 110 is disposed in its second end 106. Also present is a second periscope tube 112 which has a first end 114, a second end 116, and a longitudinal axis. A third mirror 118 is disposed in its first end 114, and a fourth mirror 120 is disposed in its second end 116. A viewport 122 is attached to the second end 116 of second periscope tube 112. Viewport 122 is in optical communication with fourth mirror 120, and it is positioned so that it views the area of the earth to be scanned. The first periscope 102 is attached inside and to first hollow cylinder 50 by means of mounts 124, 128, and 130 such that first mirror 108 is positioned with its optical axis coincident with, and in optical communication with, the axis of rotation of rotor 66. Screw 126 is used to attach mount 124 to first hollow cylinder 50.
A connecting tube 132 connects the first periscope 102 with the second periscope 112. The connecting tube 132 has a central longitudinal axis, a first end 133 and a second end 135. Concentrically attached to the first end 133 of connecting tube 132 is the inner race 136 of second torque tube bearing 137. The outer race 134 of second torque tube bearing 137 is attached to the second end 106 of first periscope tube 102 such that the central longitudinal axis of connecting tube 132 is colinear with the optical axis of second mirror 110, and such that connecting tube 132 is in optical communication with second mirror 110. Ball bearings 138 are disposed between outer race 134 and inner race 136 of second torque tube bearing 137. The second end 135 of connecting tube 132 is directly attached to the first end 114 of second periscope tube 112 such that the central longitudinal axis of the connecting tube 132 is colinear with the optical axis of third mirror 118, and such that connecting tube 132 is in optical communication with third mirror 118. Also attached to the first end 114 of second periscope tube 112 is the outer race 140 of end bearing mount 141. The inner race 142 of end bearing mount 141 is attached to the inside of first hollow cylinder 50. End bearing mount 141 supports second periscope tube 112 and it allows it to tilt when connecting tube 132 is rotated. Ball bearings 144 are disposed between outer race 140 and inner race 142 of end bearing mount 141.
A gear sector 146 is attached to connecting tube 132. A gear rack 148 is mounted on the outside and at the second end 60 of second hollow cylinder 56 such that its teeth mesh with the teeth of gear sector 146. Connecting tube 132 rotates in response to the linear motion of second hollow tube cylinder 56, which is caused by step motor 96 rotating lead screw 98. The rotation of connecting tube 132 is caused by gear rack 148 driving gear sector 146. This in turn causes the second periscope tube 112 to pivot through an angle of α degrees. The rotary motion (β) of rotor 66, of first hollow cylinder 50, and of second hollow cylinder 56 is independent of the angular or tilting motion of second periscope tube 112.
The step motor-lead screw combination in conjunction with the rack and gear combination provides an ideal linear step actuator. The rotary motion of the step motor is converted to linear or axial motion by the lead screw ball nut outside the rotating first hollow cylinder and is transmitted by the second hollow cylinder to the inside of the first hollow cylinder. A reconversion to angular motion is then effected inside the first hollow cylinder by the rack gear drive and it is directly applied to the second, tilting periscope.
The magnitude of the linear stroke motion of second hollow cylinder 56 is a function of the gear sector pitch radius and the desired tilt angle. It is determined by the following equation: ##EQU1## where: S l =Linear stroke,
R p =Gear sector pitch radius, and
α=angular periscope displacement (tilt angle) in degrees.
If, for example, a gear with a one-inch pitch radius is selected and the angular displacement (tilt angle, α) is assumed to be 60° maximum, and if the angular displacement is to be advanced in 10 discrete step increments of 6° each, then the maximum stroke is 1.0472 l inches per 60°, or about 0.105 inch per each 6° increment. Further, assuming that a 200 step/revolution motor with a 1/5 pitch lead screw could be used as an actuator, then the linear index for each discrete 1.8° step that the motor advances would be about 0.001 inch. Thus, about 105 individual motor steps (or 189° step motor rotation) would be required for each 6° of tilt angle displacement. However, any suitable combination can be used as long as the actual requirements and the specified response times can be met. The linear displacement or stroke values can be derived from the following equation: ##EQU2## where: S l =Linear displacement (stroke),
Φ=Motor step angle in degrees, and
L p =Lead screw pitch.
FIGS. 2, 3, and 4 are schematics of the scan optics. Each figure shows first periscope tube 102, second periscope tube 112, first end 104 of first periscope tube 102, second end 106 of first periscope tube 102, first end 114 of second periscope tube 112, second end 116 of second periscope tube 112, first mirror 108, second mirror 110, third mirror 118, and fourth mirror 120. The arrangement of the four mirrors is in the form of two beam-twisting periscopes which compensates for the dependence of the optics to the plane of polarization of incident, partially polarized radiation. FIG. 2 shows second periscope tube 112 at the highest elevation of tilt angle α, which is represented by point A. FIG. 3 shows second periscope tube 112 at the lowest elevation of tilt angle α, which is represented by point B. FIG. 4 shows the two extreme positions of second periscope tube 112 superimposed on each other, except that second periscope tube 112 has been drawn only once.
FIG. 2 shows that when second periscope tube 112 is at point A, mirror 120 is pointing vertically downward toward the earth, as shown by light beam 150. This is the nadir position. FIG. 3 shows that when second periscope tube 112 is at point B, mirror 120 is pointing α° away from the nadir, as shown by the position of light beam 150. FIGS. 2, 3, and 4 also show that first mirror 108 is positioned with its optical axis coincident with the rotating scanning axis, which is the axis of rotation of rotor 66, as shown by β. If the scanning starts in the center, as shown by the nadir position, the circular pattern traced will increase in diameter with each rotation. The volume swept out during rotation is a cone. This type of pattern is referred to as a conical scan. In each of the drawings, beam 150 is ultimately directed to sensing means, not shown.
In the preferred embodiment motor 61 should be variable speed motor, such as a variable speed DC motor. A variable speed motor is needed since the scan pattern consists essentially of a series of circular sweeps, with each new sweep different in diameter than the previous one. In order to maintain constant sweep velocity over the surface of the earth for all sweep diameters, the rotational velocity of rotor 66 of motor 61 must be increased or decreased proportionally to each discrete change in sweep diameter. This requirement cannot be met by a single speed or synchronous motor. A standard motor control unit, as shown by 200 in FIG. 5, can be used to control the velocity of rotor 66. To meet the required accuracy and stability criteria for tilt angle control, the standard motor control unit 200 could control the angular position of lead screw 98 of step motor 96.
Because of the unusual flexibility which this scanning mechanism offers within its design parameters, diverse scan modes can be obtained and different scan patterns can be generated. It is, for instance, possible to apply unrestricted bi-directional rotation as oscillations. A quick reset to the starting position is possible with this mechanism, as well as continuing rotation in either direction. The tilt angle periscope can be operated and controlled independently of the rotating β motion to generate two axis or cross-axis scan patterns. A scan can be repeated or skipped if needed. Other combinations and variations are also possible.
While the invention has been described to make reference to the accompanying drawings, I do not wish to be limited to the details shown therein as obvious modifications may be made by one of ordinary skill in the art. | An optical scan device for use in a satellite orbiting the earth. It compes a platform rotating about an axis. A first periscope which has a longitudinal axis and first and second mirrors is attached to the platform such that the first mirror is positioned with its optical axis coincident with the axis of rotation of the platform. A second periscope which has a longitudinal axis and third and fourth mirrors is pivotally attached to the platform such that the second periscope is pivoted in line with the optical centers of the second mirror and the third mirror, and such that the third mirror is in optical communication with the second mirror. Means are provided for pivoting the second periscope through an angle of α° as the platform rotates about its axis of rotation. | 6 |
This application is a continuation-in-part of U.S. application Ser. No. 08/780,504 filed on Jan. 8, 1997, now U.S. Pat. No. 5,823,238.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a machine for clearing land, and more particularly to an environment friendly attachment mounted on an excavator which grinds trees, shrubs, concrete, tree stumps and roots, and to a method of grinding standing large trees.
2. Description of the Related Art
In the past, land has been cleared for many purposes by removing tree stumps and tree roots. Large tractors have been used to remove tree stumps and roots from the ground. After removal from the ground, tree stumps and roots have been piled for burning, or they have been hauled away for disposal. Disposal at a remote location has been by burial, or by burning.
Environmental concerns, government requirements and cost have made it necessary to find other methods for clearing land. One method for land clearing is to grind tree stumps and roots into a mulch and leave the mulch in the ground where the tree stumps and roots were originally. This procedure eliminates transportation costs and disposal costs. Leaving such shredded wood and fiber mulch on the ground improves soil fertility.
Tree stump grinders have been used to grind tree stumps following the removal of a tree from areas near buildings or other areas where it is desirable to minimize disturbance of the surface.
Known stump machines generally comminute the portion of a stump that is above the ground and the portions which are near the surface. These stump grinding machines though do not operate on standing trees, only on stumps on which the majority of the standing tree portion has been previously removed. They grind up sufficient material to allow soil to cover the remaining stump and for grass to be planted. Such stump grinders generally do not remove all of a stump or tree roots. Stump grinders designed to grind the portion of a stump that is close to the surface are relatively slow. Additionally, such grinding machines have been oriented for horizontal rotation, not vertical rotation.
SUMMARY OF THE INVENTION
The invention includes a frame movable from tree to tree, a drum and a drum support rotatably mounting the drum to the frame. The drum support rotates or swivels 360 degrees relative to the frame via a swivel motor. A hydraulic motor is attached to the drum support with a first drive pulley attached to the motor and a second drive pulley connected to the drum. A plurality of drive belts connects the first drive pulley to the second drive pulley so the hydraulic motor may rotate the drum.
The invention comprises, in one form thereof, a grinder for grinding items, such as trees, having a frame movable from location to location tree, a drum, and a drum support rotatably mounting the drum to the frame. The drum support is swivelably mounted to the frame. A drum motor is attached to the drum support while a first drive pulley is attached to the drum motor and a second drive pulley is connected to the drum. A plurality of drive belts drivingly connect the first drive pulley to the second drive pulley. In one particular embodiment, the drum support is swivelable 360 degrees.
An advantage of the present invention is that it is adaptable for grinding and shredding standing trees. The vertical orientation of the rotating drum permits the grinder to control the placement and ejection of shredded material. Further, the vertical orientation of the rotating drum and anchor assembly permit more options on grinding of trees independent of the workplace angle or grade. The system is able to collapse a tree and grind it while preventing the tree from falling on the operator.
A further advantage of the present invention is that the entire grinding system is balanced both statically and dynamically. By the use of V-belts as a drive member, in case of wear or need of replacement, no rebalancing of the system is necessary.
Yet another advantage of the present invention is that it may utilize a number of different type cutting or grinding bits depending on the material to be ground. Diamond tipped bits, flail bits attached by a pivoting connection, knife edge bits, and others may be utilized by attachment to the rotatable drum.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an elevational view of the grinder and backhoe of the present invention with the drum shown in a vertical orientation;
FIG. 2 is a side elevational view of the grinder;
FIG. 3, is a front elevational view of the grinder and backhoe stick;
FIG. 4 is a front elevational view of the grinder module of the present invention;
FIG. 5 is a side elevational view of the grinder of the present invention; and
FIG. 6 is a side sectional view of the grinder of the present invention showing the plurality of drive belts.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The tree stump grinder 10 is mounted on the stick 12 of an excavator or backhoe 14. The excavator 14, a portion of which is shown in FIG. 1, includes a base frame 16. The base frame 16 is supported by a pair of track assemblies 18. A swing frame 20 is connected to the base from 16 by a trunnion which allows the swing frame 20 to pivot about a generally vertical axis relative to the base frame 16. An operator's cab 22 is mounted on one side of the swing frame 20. An engine compartment 24 is also mounted on the swing frame 20. The engine compartment 24 houses an internal combustion engine. The internal combustion engine drives hydraulic oil pumps which drive the tracks and provide power to perform all the other standard excavator functions. Valves for directing hydraulic oil are controlled from the operator's cab 22.
A typical boom 26 is pivotally attached to the swing frame 20. A pair of hydraulic boom cylinders 28 are connected to the swing frame 20 by pins 30 and to the boom 26 by support pins 32. The operator can direct hydraulic oil to and from the double acting hydraulic boom cylinders 28 to pivot the boom 26 about the axis of its attachment to swing frame 20 to raise and lower the free end of the boom.
A stick 12 is pivotally attached to the free end of the boom 26 by a pivot pin 34. A double acting hydraulic stick cylinder 36 is connected to boom 26 by a pin 38 and to the stick 12 by a pin 40. A valve controlled from the operator's cab can direct oil to and from the hydraulic stick cylinder 46 to pivot the stick 12 relative to the boom 26 about the axis of the pivot pin 34.
Referring to FIG. 2, the tree stump grinder 10 of the present invention includes a drum support such as a yoke assembly 42. Yoke assembly 42 is swivelably attached to hydraulic swivel 43. Hydraulic swivel 43 permits yoke assembly 42 to swivel 360 degrees about the axis of the stick 12. Mounting plates 45 are affixed to hydraulic swivel 43. Mounting plates 45 are pivotally attached to stick 12 by pivot pin 44. A double acting hydraulic grinder swing cylinder 46 is attached to stick 12 by a pin 48. The hydraulic grinder swing cylinder 46 is also attached to a pair of links 50 and links 52 by a pin 54. The links 50 are attached to stick 12 by pin 55. The links 52 are attached to mounting plates 45 by a pin 56. Oil can be directed by a valve, controlled from the operator's cab, to and from the hydraulic grind swing cylinder 46 to pivot the yoke assembly 42 about the axis of the pivot pin 44. The links 50 and 52 increase the range of movement of the yoke assembly 42 about the axis of the pivot pin 44 and increase the force available to pivot the yoke assembly 42 in some portions of the yoke's range of movement. The hydraulic grinder swing cylinder 46, the links 50, and the links 52 are standard parts of a excavator 44 that normally control a bucket attached to the stick 12 during use of the support vehicle as an excavator.
Referring to FIG. 3, hydraulic swivel 43 houses swivel motor 47. Swivel motor 47 is a hydraulic motor with hydraulic oil supplied to it through oil supply line 49. During operation, swivel motor 47 powers the 360 degree swivel action of yoke assembly 42. Alternatively, an electric motor may be used in place of a hydraulic motor to actuate swivel action of yoke assembly 42. An operator can control the swivel action of yoke assembly 42 by directing the flow of hydraulic oil 47 through oil supply 49.
During the operation of the present invention, hydraulic swivel 43 is stationary relative to swiveling yoke assembly 42. Alternatively, hydraulic swivel 43 may swivel along with yoke assembly 42 about the axis of stick 12.
The drum support, i.e., yoke assembly 42, as shown in FIGS. 4-6, has a main portion 58 and a pair of arms 60 and 62. Hydraulic swivel 43 is swivelly attached to the main portion 58 of the yoke assembly 42. A pair of mounting plates 45 are rigidly secured to hydraulic swivel 43. The mounting plates 45 are used to attach the yoke 42 to the links 50 and stick 12.
A rotatable grinder drum 66 includes a shaft 68 therethrough. The ends of shaft 68 pass through bores in both arms 60 and 62 and connect with bearings 70 and 72 mounted thereon, respectively. The end of shaft 68 extending toward bearing 72, extends therethrough. Drum 66 has an axis for rotation that is oriented vertically during operation. Such vertical orientation permits the safe grinding of entire standing trees and stumps.
A hydraulic drum motor 74 is secured to a portion of yoke assembly 42, preferably to main portion 58. Hydraulic motor 74 is in fluid communication with a source of pressurized hydraulic fluid, such as an auxiliary hydraulic pump operated by a secondary internal combustion engine 76 located within engine compartment 24 or at least on the frame portion of backhoe 14. The hydraulic fluid applied to hydraulic drum motor 74 is controlled by the equipment operator using valves to control the pressure and direction of fluid flow to hydraulic motor 74. By reversing direction of hydraulic fluid, a reversal in the direction of rotation of hydraulic drum motor 74 is accomplished.
Extending from hydraulic drum motor 74 is a shaft 78 on which is attached a first drive pulley 80. On the section of drum shaft 68 that passes through bearing 72 is attached a second drive pulley 82. The preferred type of pulley 80 and 82 is that of a multi V-belt pulley able to mount at least six, but possible more, high strength V-belts 84 thereon. Other types of belts may be utilized. A plurality of V-belts 84 are used to drivingly connect first drive pulley 80 with second drive pulley 82. Use of these belts 84 reduces shock loading of hydraulic drum motor 74 during use, thereby increasing its operational life. If desired, additional gearing of hydraulic drum motor 74 may be utilized.
A plurality of grinding, cutting or shredding bit assemblies 86 are secured to the outside surface of the grinder drum 66. Such bit assemblies may include carbide tipped bits, flail type bits and hammer bits attached for pivotable connection to the grinder drum 66.
The flow of hydraulic oil to and from the hydraulic motor 74 can be stopped to prevent the grinder drum 66 from rotating.
The hydraulic boom cylinders 28, the hydraulic stick cylinder 36, and the hydraulic grinder swing cylinder 46, are all connected to the hydraulic system that is standard on the excavator 14. No modifications are required in the hydraulic system to control these cylinders.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A tree grinder movable from tree to tree. The tree grinder includes a frame movable from tree to tree, a drum and a drum support rotatably mounting the drum to the frame. The drum support rotates or swivels relative to the frame via a swivel motor. A hydraulic motor is attached to the drum support with a first drive pulley attached to the hydraulic motor and a second drive pulley connected to the drum. A plurality of drive belts connects said first drive pulley to said second drive pulley so the hydraulic motor may rotate the drum. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to a drain fitting. In particular, the invention relates to a drain fitting for use in floor and shower wastes for both commercial and domestic applications and will be described in this context. However, it should be appreciated that the drain fitting may be used for other applications.
BACKGROUND OF THE INVENTION
[0002] Waste water drain pipes have been around for thousands of years and still play an important part in most buildings throughout the world. A common problem with waste water drain pipes is that odours can be emitted from them that offend most people's olfactory senses. This is mainly due to debris, such as food, hair and/or detergent, passing into the waste water drain pipe, decomposing and creating putrid water.
[0003] A reasonably effective way in which to overcome offensive smells that are emitted from waste water drain pipes is to install an S-bend. An S-bend provides a water seal in the pipe to prevent odours from passing from upwardly from below the water seal. This water that forms the water seal is changed every time water passes through the pipe.
[0004] A difficulty with the S-bend is it is generally located a long way from the floor waste. Therefore, debris can become stuck within the drain pipe between the floor waste and S-bend to create an unpleasant odour. Further, a substantial proportion of the debris that creates odour floats in water. Therefore, it becomes trapped in the water in the S-bend. The trapped debris, as described above, creates putrid water and an offensive smell.
[0005] International Patent Application No. WO 99/27199 shows a drain fitting that is used in floor and shower wastes to assist in preventing odours from passing out of the floor and shower wastes. The drain fitting includes a conduit, a cage and a base cap. The cage is attached to the conduit and the base cap. The conduit extends through the cage such that an outlet of the conduit is located within the base cap. Apertures extend through the cage.
[0006] In order to install the drain fitting, a grate is attached to the drain fitting and the grate is placed within a waste body so that the drain fitting is located within a drain pipe. In use, water passed through the conduit to fill the base cap with water. Any excess water passes out of the base cap, through the apertures and down the drain pipe. When water stops passing through the floor waste into the conduit, water located within the base cap covers the outlet to provide a water seal to prevent odours from passing through the drain pipe and out of the grate. The water located within the base cap is replaced every time the water passes through conduit.
[0007] Unfortunately, the drain fitting disclosed in WO 99/27199 has an inherent problem. Debris that passes through the floor and shower wastes often become lodged in the base cap and/or the apertures. This debris, as it decomposes, creates putrid water in base cap which can be smelt through the floor or shower waste.
OBJECT OF THE INVENTION
[0008] It is an object of the invention to overcome and/or alleviate one or more of the above disadvantages and/or provide the consumer with a useful or commercial choice.
SUMMARY OF THE INVENTION
[0009] In one form, the invention resides in a drain fitting comprising:
a cage having a plurality of apertures extending through the cage; a conduit having an inlet and an outlet, the conduit extending at least partially through the cage; and a base cap attached to the cage, the outlet located within the base cap; wherein the conduit includes an internal surface that extends from the inlet to the outlet, the internal surface increasing the velocity of the water substantially the length of the internal surface as the water 50 passes from the inlet to the outlet.
[0014] The cage is normally a tube. The tube is typically cylindrical in shape. The surface area of the apertures is normally larger than the surface area of the remainder of the cage.
[0015] The conduit may be a funnel. The funnel may have an upper portion and a lower portion.
[0016] The internal surface may be in the form of a number of internal walls. Typically the internal walls are inclined. Preferably, the internal walls are inclined at an angle of at least 30 degrees. More preferably, the internal walls are inclined at an angle of at least 45 degrees. Still more preferably, the internal walls are inclined at an angle of at least 60 degrees.
[0017] An internal wall of the upper portion is preferably between 50 degrees and 70 degrees. More preferably, the internal wall of the upper portion is between 55 degrees and 65 degrees. Most preferably, internal wall of the upper portion upper portion is between 57.5 degrees and 62.5 degrees.
[0018] An internal wall of the lower portion is preferably at least 75 degrees. More preferably, the internal wall of the lower portion is between at least 80 degrees. Most preferably, internal wall of the upper portion upper portion is at least 82.5 degrees.
[0019] The base cap usually includes a floor. Preferably the floor is arcuate. The base cap may also include a stem which extends upwardly from the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] An embodiment of the invention will be described with reference to the accompanying drawings in which:
[0021] FIG. 1 shows a perspective view of a drain fitting according to a first embodiment of the invention;
[0022] FIG. 2 shows a further perspective view of the drain fitting of FIG. 1 ;
[0023] FIG. 3 shows a top view of the drain fitting of FIG. 1 ;
[0024] FIG. 4 shows a front view of the drain fitting of FIG. 1 ;
[0025] FIG. 5 shows a side sectional view of the drain fitting of FIG. 1 ;
[0026] FIG. 6 shows an exploded side sectional view of the drain fitting of FIG. 1 ;
[0027] FIG. 7 shows a section view of the drain fitting of FIG. 1 when attached to a shower waste;
[0028] FIG. 8 shows a sectional view of the drain fitting of FIG. 1 when water is passing through a shower waste;
[0029] FIG. 9 shows a sectional view of the drain fitting of FIG. 1 with an alternative base cap; and
[0030] FIG. 10 shows a sectional view of the drain fitting of FIG. 4 with an attached expansion member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] FIGS. 1 to 7 show a drain fitting 10 for use in a shower waste 11 to assist in preventing odours from passing out of the shower waste 11 . A typical shower waste 11 includes a grate 12 and a waste body 13 as shown in FIG. 7 . The grate 12 normally fits within the waste body 13 using a bayonet type attachment.
[0032] The drain fitting 10 includes a conduit 20 , a base cap 30 and a cage 40 . The conduit 20 , base cap 30 and cage 40 are all made from plastic. However, it should be appreciated that the conduit 20 , base cap 30 and cage 40 may be made from other materials such a metal.
[0033] The conduit 20 is used to increase the velocity of water 50 that flows through the conduit 20 . The conduit 20 is in the form of funnel that has an upper portion 21 and a lower portion 22 . The upper portion 21 of the conduit 20 has an internal wall 23 that is inclined at an angle of approximately 60 degrees. The lower portion 24 of the conduit 20 has an internal wall 24 that is inclined at approximately 85 degrees. An inlet 25 to the conduit 20 is located adjacent an end of the upper portion 21 and an outlet 26 of the conduit 20 is located adjacent an end of the lower portion 24 .
[0034] A grate attachment lip 27 is located adjacent the inlet on an external wall 28 of the upper portion 21 . A lip thread 29 extends around the grate attachment lip 27 . The grate 12 is fitted to the grate attachment lip 27 via an internal thread located on the grate 12 .
[0035] The base cap 30 is located adjacent the outlet 26 of the conduit 20 such that the outlet 26 is located within the base cap 30 . The base cap 30 is made from a foot 31 and a depending skirt 32 . The foot 31 is arcuate in shape. The depending skirt 32 extends upwardly from the foot 31 . A stem 33 extends up from the foot 31 .
[0036] The base cap 30 is integrally formed with the cage 40 . However, it should be appreciated that the base cap 30 and cage 40 may be attached to each other by different methods. For example, the base cap 30 may be attached to the cage 40 via an internal thread formed in the depending skirt.
[0037] The cage 40 is used to hold the base cap 30 so that the outlet 26 is located within the base cap 30 . The cage 40 is a cylindrical tube 41 having a series of apertures 42 and 43 that extend through the tube 41 . There are a first set of four apertures 42 extending through the tube 41 adjacent one end of the tube and a second set of four apertures 43 extending through the tube 41 adjacent the opposite end of the tube 41 . The first set of apertures 42 are offset with respect to the second set of apertures 43 . The apertures 42 and 43 are sized and arranged so that water can easily pass from one side of the tube 41 through to the other side of the tube 41 . It should be appreciated that the number, size and orientation of the apertures 42 and 43 may be varied. An internal thread 44 is located adjacent the end of the tube 41 for attachment of the base cap 30 .
[0038] FIG. 7 shows a cross-sectional view of the drain fitting 10 attached to the shower waste 11 at rest. As is shown, water 50 is located within the base cap 30 . The water 50 in the base cap 30 covers the outlet 26 and provides a water seal. This assists in preventing odours from passing up a drain pipe 15 and out of the shower waste 11 .
[0039] FIG. 8 shows a cross-sectional view of the drain fitting 10 when water is flowing through the drain fitting 10 . In use, water 50 travels along a shower floor before it passes through the grate 12 of the shower waste 11 . Hence, the water is travelling relatively slowly in a horizontal direction. When the water passes through the grate 12 and through the inlet 25 of the conduit 21 , it contacts the internal wall 23 of the upper portion 21 of the conduit 20 .
[0040] As the internal wall 23 of the upper portion 21 is angled at 60 degrees, the velocity of the water 50 increases as it passes through the upper portion 21 under the force of gravity. The water 50 then passes onto the internal wall 24 of the lower portion 22 of the conduit 20 . As the internal wall 22 of the lower portion 22 is angled at 85 degrees, the velocity of the water 50 increases further under the force of gravity.
[0041] The water 50 then passes out of outlet 26 travelling at a relatively high velocity. The water 50 then crashes into the base cap 30 . The stem 33 directs the water 50 from the outlet along the arcuate floor 31 of the base cap 30 upwardly adjacent the depending skirt 32 and into the tube 41 . The water 50 then passes through the first and second set of apertures 42 and 43 of the tube 41 . Any water 50 that is forced adjacent the external wall 28 of the upper portion 21 and is deflected out of the apertures 42 and 43 .
[0042] The drain fitting 10 is less likely to have debris becoming lodged in the base cap 30 and/or the cage 40 due to the velocity of the water 50 being increased as it passes through the conduit 20 . If debris does become lodged in the base cap 30 and/or cage 40 , the next time the drain fitting is used and water passes through the drain fitting 10 , the increased velocity of the water 50 generally flushes any old debris from the base cap 30 and/or cage 40 . Hence, the likelihood of any decomposing debris causing an odour problem is unlikely.
[0043] FIG. 9 shows an alternative base cap 30 that is large in size than the base cap 30 shown in FIGS. 1 to 3 . This base cap 30 may be used when debris is wanting to be captured. After the debris is captured in the large base cap 30 , the drain fitting 10 can be removed and cleaned. This is especially helpful if any hazardous materials, such as heavy metals or medical waste, are used on a floor that should not be washed down in the sewage system.
[0044] FIG. 10 shows an extension member 60 that is used when a larger grate 12 is required. The extension member 60 has an extension body 61 , an extension grate attachment lip 62 and a conduit attachment lip 63 . The extension grate attachment lip 61 has an external thread 64 and is used to attach a grate 12 to the extension member 60 . The conduit attachment lip 63 has an internal thread 65 and is used to attach the extension member 60 to the conduit 20 . Once the extension member 60 is attached to a grate 12 and to the conduit 20 , the drain fitting 10 operates as described above.
[0045] It should be appreciated that various other changes and modifications may be made to the embodiment described without departing from the spirit or scope of the invention. | A drain fitting comprising a cage having a plurality of apertures extending through the cage; a conduit having an inlet and an outlet, the conduit extending at least partially through the cage; and a base cap attached to the cage, the outlet located within the base cap wherein the conduit includes an internal surface that extends from the inlet to the outlet, the internal surface increasing the velocity of the water substantially the length of the internal surface as the water passes from the inlet to the outlet. | 4 |
FIELD OF INVENTION
[0001] The present invention relates to a copper complex which is advantageously employable for producing a thin metal film comprising copper or copper alloy or a thin metal film comprising a complex metal oxide containing copper by chemical vapor deposition. The invention further relates to a process for producing a thin metal film comprising copper or copper alloy or a thin metal film comprising a complex metal oxide containing copper from the above-mentioned copper complex.
BACKGROUND OF INVENTION
[0002] A metallic copper thin film (hereinafter simply referred to as “copper thin film”) is employable as a copper circuit of a silicon semiconductor. A metal oxide thin film containing copper oxide (hereinafter simply referred to as “copper oxide thin film”) is expected as material for high-critical temperature superconductors.
[0003] As the processes for producing the copper thin film or complex oxide thin film containing copper oxide by vapor deposition procedure, various processes are known. A representative process is a chemical vapor deposition process (CVD process) comprising the steps of thermally decomposing a compound containing a copper atom under specific conditions and depositing the decomposition product on a substrate to produce thereon a copper thin film or a copper oxide thin film.
[0004] For the production of a copper thin film or a copper oxide thin film in the CVD process, β-diketonato copper complexes are generally used.
[0005] JP-A-5-59551 describes a process for producing a copper thin film (to be used as a copper circuit of a silicon semiconductor) using a β-diketonato copper(I) as a copper source. The β-diketonato copper(I) is advantageously employed because it can be subjected to disproportionation reaction, to deposit metallic copper. However, it has such a defect that the β-diketonato copper (I) is thermally unstable, and that some of β-diketonato copper(I) decompose when these are heated to vaporize in the CVD process.
[0006] A typical divalent β-diketonato copper complex employed in the CVD process is dipivaloylmethanato copper(II) complex. This copper complex is more thermally stable than the monovalent β-diketonato copper complex. However, since the dipivaloylmethanato copper(II) complex has such a high melting point as 198° C., it likely deposits in a CVD system and plugs the production line. Other known β-diketonato copper complexes also have the same problem. Moreover, since the dipivaloylmethanato copper(II) complex and other known β-diketonato copper complexes have a low vapor pressure, the thin film production rate is low. Accordingly, these known β-diketonato copper complexes are not appropriate as industrially employable copper sources.
[0007] JP-A-2001-181840 describes a β-diketonato copper(II) complex having the following formula (II):
which is liquid at room temperature and solves the problems of the known material.
[0009] The above-mentioned β-diketonato copper(II) complex exists as a viscous liquid at temperature. Therefore, it is easily supplied in the CVD system and free from the problem of plugging. Nevertheless, it still shows a low film production rate, and therefore, some of the problems in the production workability are still unsolved.
DISCLOSURE OF INVENTION
[0010] It is an object of the present invention to provide a copper complex which has a low melting point and is thermally stable, so that it is favorably employable as the copper source in the CVD process for producing a copper thin film or a copper oxide thin film.
[0011] It is another object of the invention to provide a process for producing a copper-containing thin film such as a copper thin film or a copper oxide thin film in which the above-mentioned copper complex is used.
[0012] The present inventors have discovered that a copper complex having β-diketonato ligands containing a silyl ether linkage can solve the above-mentioned problems. The present inventors have been complete based on this discovery.
[0013] Accordingly, the present invention resides in a divalent copper complex having β-diketonato ligands containing a silyl ether linkage.
[0014] The invention also resides in a method of forming a copper-containing film by chemical vapor deposition using a copper(II) complex having β-diketonato ligands containing a silyl ether linkage as a copper source.
[0015] As the β-diketonato ligands containing a silyl ether linkage, a compound represented by the formula (I)′ is preferred:
in which Z is a hydrogen atom or an alkyl group having 1-4 carbon atoms; X is a group represented by the formula (I-I), in which R a is a linear or branched alkylene group having 1-5 carbon atoms, and each of R b , R c and R d independently is a linear or branched alkyl group having 1-5 carbon atoms; and Y is a linear or branched alkyl group having 1-8 carbon atoms or a group represented by the formula (I-I), in which R a is a linear or branched alkylene group having 1-5 carbon atoms, and each of R b , R c and R d independently is a linear or branched alkyl group having 1-5 carbon atoms.
[0017] As the copper complex of the invention, a compound represented by the formula (I) is preferred:
in which Z is a hydrogen atom or an alkyl group having 1-4 carbon atoms; X is a group represented by the formula (I-I), in which R a is a linear or branched alkylene group having 1-5 carbon atoms, and each of R b , R c and R d independently is a linear or branched alkyl group having 1-5 carbon atoms; and Y is a linear or branched alkyl group having 1-8 carbon atoms or a group represented by the formula (I-I), in which R a is a linear or branched alkylene group having 1-5 carbon atoms, and each of R b , R c and R d independently is a linear or branched alkyl group having 1-5 carbon atoms.
[0019] In the formulas, it is preferred that X is the same as Y. Y preferably is a linear or branched alkyl group having 1-8 carbon atoms. R a preferably is an alkylene group of 1-3 carbon atoms which may carry one or more alkyl substituents. Particularly preferred is that Z is hydrogen and each of R b , R c and R d is methyl.
BRIEF DESCRIPTION OF DRAWING
[0020] FIG. 1 is a schematic view of a CVD system which can be employed for the copper thin film production, wherein 1 denotes a glass ampul, 2 denotes a heater (vaporizer), 3 denotes a reactor, 4 denotes a heater (reactor), 5 denotes a trap, 6 denotes a heater (for pre-heating), 7 denotes a substrate, and 8 denotes a copper complex source.
DETAILED DESCRIPTION OF INVENTION
[0021] In the invention, examples of the β-diketonato ligands containing a silyl ether linkage include the compounds of the following formulas (III)′ to (XIV)′:
[0022] The above-illustrated β-diketone compounds can be obtained according to the below-illustrated scheme, in which a silylated ketone is reacted with a silylated organic acid ester in the presence of a base, or a silylated organic acid ester is reacted with a ketone in the presence of a base, and the reaction product is treated with an acid. The acid-treated product was purified by distillation or column chromatography. Other known processes also are utilizable.
[0023] The β-ketonato copper complex, i.e., a copper complex in which an enolate anion of β-diketone is coordinated to copper, can be obtained by a reaction between β-diketone and copper hydroxide (below-illustrated process 1 for copper complex synthesis) or a reaction between an enolate anion of β-diketone and a copper salt such as cupric chloride (below-illustrated process 2 for copper complex synthesis). The synthesis can be performed in most organic solvents such as hydrocarbons (e.g., hexane and toluene), ethers (e.g., tetrahydrofuran (THF) and dimethoxyethane), nitrites (e.g., acetonitrile), halogenated hydrocarbons (e.g., dichloromethane), alcohols (e.g., isopropanol), and esters (e.g., ethyl acetate). Water produced in the process 1 can be distilled off together the solvent (e.g., toluene) by azeotropic distillation. When such a solvent as THF is used, water is removed from the reaction mixture by distillation under reduced pressure at room temperature together with the solvent. Otherwise, water can be removed using a dehydrating agent such as anhydrous sodium sulfate, anhydrous magnesium sulfate, anhydrous copper sulfate, molecular sieves, or nonionic water-absorbing polymer.
[Process 1 for Copper Complex Synthesis]
[Process 2 for Copper Complex Synthesis]
[0026] The produced copper complex can be purified by column chromatography using commercially available silica gel for chromatography or a dehydrated silica gel which is prepared by dehydrating the commercially available silica gel, or by distillation, or by their combination.
[0027] An example of the copper complex having the silylether type β-diketonato ligand is represented by the following formula (III):
[0028] The copper complex of the formula (III) is a copper complex having a β-diketone enolate anion ligand of the aforementioned formula (III)′ which corresponds a compound of the aforementioned formula (I) in which X is (CH 3 ) 3 SiO—C(CH 3 ) 2 —, Y is (CH 3 ) 3 C—, and Z is H, namely, bis-(2,6,6-trimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex [hereinafter referred to as Cu(sobd) 2 ].
[0029] The β-diketones of the aforementioned formulas (IV)′ to (XIV)′ give the below-illustrated copper complexes (IV) to (XIV), respectively, which have an enolate anion of the corresponding β-diketone.
[0030] The copper complex of the invention can be employed for producing a copper-containing thin film by chemical vapor deposition in the known CVD system as illustrated in FIG. 1 .
[0031] The vaporization of the copper complex in the chemical vapor deposition process can be performed by directly supplying the copper complex into a vaporization chamber, or by diluting the copper complex with an appropriate solvent (e.g., hexane, toluene, or tetrahydrofuran) and supplying thus produced solution into a vaporization chamber.
[0032] The deposition on a substrate can be performed by the known CVD process. The copper complex is thermally decomposed under reduced pressure or in the presence of an inert gas. Otherwise, the copper complex can be decomposed and deposited in the presence of a reducing gas such as hydrogen gas. Also employable is a plasma CVD process using a hydrogen gas to deposit metallic copper. Further, thermal decomposition or plasma CVD of the copper complex in the presence of oxygen can be also employed for deposition of a copper oxide thin film.
[0033] The invention is further illustrated by the following examples.
EXAMPLE 1
[heading-0034] (1) Synthesis of 2,6-dimethyl-2,6-di(trimethylsilyloxy)-3,5-heptadione [Represented by the Formula (V)′, Hereinafter Referred to as “dsobd”]
[0035] In a 50 mL-volume flask were placed 1.80 g (45.0 mmol) of 60′ sodium hydride and 9.83 g (51.7 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate. The resulting solution was heated to 120° C., and to the heated solution was dropwise added slowly a solution of 3.00 g (17.2 mmol) of 2-(trimethylsilyloxy)-2-methyl-3-butanone in 9 mL of toluene. After the dropwise addition was complete, the reaction mixture was heated at 120° C. for one hour. Subsequently, the reaction mixture was cooled to room temperature and made weak acidic by the addition of an acetic acid-toluene mixture. The precipitated sodium acetate was removed by filtration, to obtain a yellow solution.
[0036] The obtained solution was concentrated and purified by column chromatography using dehydrated silica gel, to give 1.20 g (3.61 mmol, yield 21%) of the desired main product, i.e., 2,6-dimethyl-2,6-di(trimethylsilyloxy)-3,5-heptadione.
[0037] The product was identified by NMR, IR, and MS.
[0038] 1 H-NMR (CDCl 3 ): δ 0.15 (s, 9 H), 1.41 (s, 9 H), 4.00 (s, 0.4H), 6.43 (s, 0.8H), 15.55 (s, 0.8H)
[0039] IR (cm −1 ): 2961, 1605(br), 1252 , 1198 , 1048 , 842
[0040] MS (m/e): 332
[heading-0041] (2) Preparation of Cu(dsobd) 2 [bis(2,6-dimethyl-2,6-di(trimethylsilyloxy)-3,5-heptadionato) copper(II) Complex]
[0042] Since production of the desired β-diketone was confirmed in the above-mentioned procedure, the desired copper complex was prepared by adding a copper source to a product prepared in the same manner.
[0043] In a 50 mL-volume flask were placed 1.80 g (45.0 mmol) of 60′ sodium hydride and 9.83 g (51.7 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate. The resulting solution was heated to 120° C., and to the heated solution was dropwise added slowly a solution of 3.00 g (17.2 mmol) of 2-(trimethylsilyloxy)-2-methyl-3-butanone in 9 mL of toluene. After the dropwise addition was complete, the reaction mixture was heated at 120° C. for one hour. Subsequently, the reaction mixture was cooled to 30° C. There was produced 1.28 g (3.61 g) of 2,6-dimethyl-2,6-di(trimethylsilyloxy)-3,5-heptadionato sodium salt. To the reaction solution was added 0.24 g (1.78 mmol) of cupric chloride. The reaction solution was immediately turned to dark green. The solution was continuously stirred at 80° C. for 2 hours and cooled to room temperature. Then, the reaction solution was washed with water. The obtained organic portion was dried, and purified by column chromatography using dehydrated silica gel, to give 1.10 g (1.52 mmol, yield 85%, based on the amount of cupric chloride) of bis(2,6-dimethyl-2,6-di(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[0044] The product was identified by IR and elemental analysis.
[0045] IR (cm −1 ): 2978, 1567, 1498, 1414, 1252, 1197, 1045,
[0046] Elemental analysis for C 30 H 62 O 8 Si 4 Cu
[0047] Found: C 49.0%, H 8.99%, Cu 8.6%.
[0048] Calculated: C 49.6%, H 8.60%, Cu 8.74.
[0049] In the IR spectrum, a peak of 1,605 cm −1 assignable to β-diketone disappeared, and a peak of 1,567 cm −1 assignable to diketonato was observed. Accordingly, it was confirmed that the desired copper complex was produced. This copper complex is a new compound.
EXAMPLE 2
[heading-0050] (1) Synthesis of 2,6,6-trimethyl-2-(trimethylsilyloxy)-3,5-heptadione [Represented by the Formula (III)′, Hereinafter Referred to as “sobd”]
[0051] In a 50 mL-volume flask, 0.40 g (10.3 mmol) of sodium amide and 1.20 g (12.0 mmol) of pinacolin were suspended in 3 mL of toluene, and the resulting suspension was stirred for 30 min. at room temperature. Subsequently, a solution of 1.00 g (5.25 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate in 6 mL of toluene was dropwise added slowly. After the dropwise addition was complete, the mixture was subjected to reaction for one hour at room temperature. The reaction mixture was then made weak acidic with an acetic acid-toluene mixture. The precipitated sodium acetate was removed by filtration to give a yellow solution.
[0052] The obtained solution was concentrated and purified by column chromatography using dehydrated silica gel, to give 0.83 g (3.21 mmol, yield 61%) of the desired main product, i.e., 2,6,6-trimethyl-2-(trimethylsilyloxy)-3,5-heptadione.
[0053] The product was identified by NMR, IR, and MS.
[0054] 1 H-NMR (CDCl 3 ): δ 0.14 (s, 9 H), 1.17 (s, 9 H), 1.39 (s, 6 H), 3.86 (s, 0.3H), 6.09 (s, 0.85H), 15.72 (s, 0.85H)
[0055] IR (cm −1 ) 2966, 1600(br), 1252, 1197, 1045, 841
[0056] MS (m/e) 258
[heading-0057] (2) Preparation of Cu(sobd) 2 [bis(2,6,6-trimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) Complex, Represented by the Formula (III)]
[0058] Since production of the desired β-diketone was confirmed in the above-mentioned procedure, the desired copper complex was prepared by adding a copper source to a product prepared in the same manner.
[0059] In a 50 mL-volume flask, 0.40 g (10.3 mmol) of sodium amide and 1.20 g (12.0 mmol) of pinacolin were suspended in 3 mL of toluene, and the resulting suspension was stirred for 30 min. at room temperature. Subsequently, a solution of 1.00 g (5.25 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate in 6 mL of toluene was dropwise added slowly. After the dropwise addition was complete, the mixture was subjected to reaction for one hour at room temperature. To the reaction solution was added 0.22 g (1.60 mmol) of cupric chloride. The reaction solution immediately turned to dark green. The solution was continuously stirred for one hour at room temperature. Then, the reaction solution was washed with water. The obtained organic portion was dried, and purified by column chromatography using dehydrated silica gel, to give 0.80 g (1.38 mmol, yield 86%, based on the amount of cupric chloride) of bis(2,6,6-trimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[0060] The product was identified by IR and elemental analysis.
[0061] IR (cm −1 ) 2960, 1561, 1501, 1412, 1252, 1196, 1047,
[0062] Elemental analysis for C 26 H 50 O 6 Si 2 Cu
[0063] Found: C 54.8%, H 8.20%, Cu 11%.
[0064] Calculated: C 54.0%, H 8.71%, Cu 11.0.
[0065] In the IR spectrum, a peak of 1,600 cm −1 assignable to β-diketone disappeared, and a peak of 1,561 cm −1 assignable to diketonato was observed. This copper complex is a new compound.
EXAMPLE 3
[heading-0066] (1) Synthesis of 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione [Represented by the Formula (VIII)′, Hereinafter Referred to as “sopd”]
[0067] In a 50 ml-volume flask, 0.50 g (12.8 mmol) of sodium amide and 0.45 g (5.22 mmol) of 3-methyl-2-butanone were suspended in 1.5 g of hexane, and the resulting suspension was stirred at 15° C. for 30 min. Subsequently, a solution of 1.20 g (6.31 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate in 3 g of hexane was dropwise added slowly. After the dropwise addition was complete, the mixture was subjected to reaction at 15° C. for one hour. The reaction mixture was then made weak acidic with an acetic acid-toluene mixture. The precipitated sodium acetate was removed by filtration to give a yellow solution.
[0068] The obtained solution was concentrated and purified by column chromatography using dehydrated silica gel, to give 0.91 g (3.71 mmol, yield 71′) of the desired main product, i.e., 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione.
[0069] The product was identified by NMR, IR, and MS.
[0070] 1 H-NMR (CDCl 3 ): δ 0.14 (s, 9 H), 1.14 (s, 6 H), 1.39 (s, 6 H), 2.44-2.50 (m, 0.85H), 2.64-2.69 (m, 0.15H), 3.77 (s, 0.3H), 5.97 (s, 0.85H), 15.51 (s, 0.85H)
[0071] IR (cm −1 ) 2971, 1606(br), 1253, 1199, 1045, 842
[0072] MS (m/e): 244
[heading-0073] (2) Preparation of Cu(sopd) 2 [bis(2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) Complex, Represented by the Formula (VIII)]
[0074] Since production of the desired β-diketone was confirmed in the above-mentioned procedure, the desired copper complex was prepared by adding a copper source to a product prepared in the same manner.
[0075] In a 50 mL-volume flask, 0.50 g (12.8 mmol) of sodium amide and 0.45 g (5.22 mmol) of 3-methyl-2-butanone were suspended in 1.5 g of hexane, and the resulting suspension was stirred at 15° C. for 30 min. Subsequently, a solution of 1.20 g (6.31 mmol) of methyl 2-(trimethylsilyloxy)-2-methyl-propionate in 3 g of hexane was drop-wise added slowly. After the dropwise addition was complete, the mixture was subjected to reaction at 15° C. for one hour. To the reaction solution was added 0.25 g (1.86 mmol) of cupric chloride. The reaction solution was immediately turned to dark green. The solution was continuously stirred for one hour at room temperature. Then, the reaction solution was washed with water. The obtained organic portion was dried, and purified by column chromatography using dehydrated silica gel, to give 0.86 g (1.56 mmol, yield 84%, based on the amount of cupric chloride) of bis(2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[0076] The product was identified by IR and elemental analysis.
[0077] IR (cm −1 ): 2965, 1592, 1501, 1428, 1252, 1199, 1044,
[0078] Elemental analysis for C 24 H 46 O 6 Si 2 Cu
[0079] Found: C 53.2%, H 8.53%, Cu 11%.
[0080] Calculated: C 52.4%, H 8.42%, Cu 11.5%.
[0081] In the IR spectrum, a peak of 1,606 cm −1 assignable to β-diketone disappeared, and a peak of 1,592 cm −1 assignable to diketonato was observed. This copper complex is a new compound.
EXAMPLE 4
[heading-0082] (1) Synthesis of sopd by Different Process
[0083] In a 50 mL-volume flask, 13.7 g (0.351 mol) of sodium amide was suspended in 200 mL of hexane and then 26.7 g (0.140 mol) of methyl 2-(trimethylsilyloxy)-2-methylpropionate was added. To the resulting solution was dropwise added 12.1 g (0.141 mol) of 3-methyl-2-butanone, and the mixture was kept at 15° C. In the development of reaction, production of gaseous ammonia was observed. The reaction was continued at 15° C. for one hour. The reaction solution was then made weak acidic with acetic acid. The obtained hexane portion was washed with water and dried over anhydrous sodium sulfate. The dried portion was distilled at 101° C./8 mmHg, to give 18.8 g (0.770 mol, yield 55%) of the desired 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione.
[0084] The product was identified by NMR, IR, and MS.
[0085] H-NMR (CDCl 3 ): δ 0.14 (s, 9 H), 1.14 (s, 6H), 1.39 (s, 6H), 2.44-2.50 (m, 0.85H), 2.64-2.69 (m, 0.15H), 3.77 (s, 0.3H), 5.97 (s, 0.85H), 15.51 (s, 0.85H)
[0086] IR (cm −1 ): 2971, 1606(br), 1253, 1199, 1045, 842
[0087] MS (m/e): 244
[0088] In the below-described (2-1) to (2-3), a copper complex of Cu(sopd) 2 was prepared by three different processes.
[heading-0089] (2-1) Preparation of Cu(sopd) 2 by Azeotropic Toluene Distillation Dehydration
[0090] In 100 mL-volume flask were placed 4.43 g (45.4 mmol) of copper hydroxide, 22.2 g (90.8 mmol) of 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione, and 50 mL of toluene. The resulting mixture was heated to 130° C., and water produced by reaction was dehydrated by azeotropic toluene distillation. The amount of the produced and distilled water was confirmed by receiving and measuring it in a water receiver. The reaction was complete within approx. one hour. The obtained dark green solution was filtered and the filtrate was concentrated to give a viscous dark green solution. The solution was distilled at 179° C./0.5 Torr to give 20.2 g (36.8 mmol, yield 81%) of the desired copper complex, namely, bis-(2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[heading-0091] (2-2) Preparation of Cu(sopd) 2 at Room Temperature in THF Solvent
[0092] The desired Cu(sopd) 2 can be prepared by reacting 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione with copper(II) hydroxide in an organic solvent such as ether, acetonitrile, alcohol, ketone, ester, or hydrocarbon at room temperature. The following is a preparing procedure in a THF solvent.
[0093] In 100 mL-volume flask were placed 4.50 g (46.2 mmol) of copper hydroxide, 22.6 g (92.3 mmol) of 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione, and 50 mL of THF. The resulting mixture was stirred for one hour at room temperature in the absence of a dehydrating agent. The resulting dark blue solution was filtered, and the THF solvent was distilled off to leave a viscous dark green solution. The solution was distilled at 179° C./0.5 Torr to give 21.1 g (38.3 mmol, yield 83%) of the desired copper complex, namely, bis(2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[heading-0094] (2-3) Preparation of Cu(sopd) 2 at Room Temperature in Dimethoxyethane Solvent
[0095] The preparation in dimethoxyethane solvent is described below.
[0096] In 50 mL-volume flask were placed 1.10 g (11.3 mmol) of copper hydroxide, 5.00 g (20.5 mmol) of 2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadione, and 15 mL of dimethoxyethane. The resulting mixture was stirred for 2 hours at room temperature in the absence of a dehydrating agent. The resulting dark blue solution was filtered, and the dimethoxyethane solvent was distilled to leave a viscous dark green solution. The solution was distilled at 179° C./0.5 Torr to give 4.57 g (8.30 mmol, yield 81%) of the desired copper complex, namely, bis(2,6-dimethyl-2-(trimethylsilyloxy)-3,5-heptadionato) copper(II) complex.
[0097] The copper complex produced in (2-3) above was identified by IR and elemental analysis.
[0098] IR (cm −1 ): 3458(br), 2963, 1568, 1518, 1422, 1251, 1196, 1035, 889, 841
[0099] Elemental analysis for C 24 H 46 O 6 Si 2 Cu
[0100] Found: C 53.0%, H 8.39%, Cu 11.5.
[0101] Calculated: C 52.4%, H 8.42%, Cu 11.5%.
[0102] M.p.: 62° C.
[0103] The products of (2-1) and (2-2) showed almost same elemental analysis data.
[0104] In the IR spectrum, a peak of 1,606 cm 1 assignable to β-diketone disappeared, and a peak of 1,568 cm −1 assignable to diketonato was observed. The broad peak observed in the vicinity of 3,400 cm −1 is assignable to a water of crystallization coordinated to the copper complex. This broad peak was not observed when the product was examined just after the distillation, namely under good conditions.
[heading-0105] (3) Vapor Deposition Test
[0106] The copper complex of Cu(sopd) 2 [represented by the formula (VIII)] prepared in Example 3 was subjected to vapor deposition test according to CVD process, to examine its film forming property. For comparison, the same vapor deposition test was performed using bis(6-ethyl-2,2-dimethyl-3,5-decandionato) copper complex of the aforementioned formula (II).
[0107] The test was performed using the apparatus illustrated in FIG. 1 . The copper complex 8 placed in a vaporizer (glass ample) 1 was heated by a heater 2 for vaporization. The vaporized complex came out of the vaporizer together with helium gas. The gas coming out of the vaporizer joined a pre-heated hydrogen gas supplied through the hydrogen gas line, and entered the reactor 3 . The center portion of the glass reactor could be heated by the heater 4 . The copper complex introduced into the reactor reductively decomposed and produced a metallic copper on a surface of a substrate 7 which was set at the center part and heated to the predetermined temperature in a reducing atmosphere. The gas coming out of the reactor was exhausted to atmospheric air through the trap 5 .
[0108] The copper film-formation depends on the vapor deposition conditions such as the copper complex vaporization temperature and the substrate temperature.
[0109] Table 1 shows the vapor deposition conditions employed in the test and the results of film formation. The substrate is a rectangular substrate of 7 mm×4 mm.
TABLE 1 Example 3: copper complex - Cu(sopd) 2 Condition of vapor deposition Vaporization temperature: 140° C. Substrate: Ta—N/SiO 2 /Si Substrate temperature: 230° C. Vaporization period: 60 min. Pressure in the reaction system: atmospheric H 2 flow rate: 36 mL/min. He flow rate: 5 mL/min. Characteristics of formed film Film thickness: 200 nm Specific resistance: 4.5 μΩ cm Appearance: Smooth glossy metal surface Comparison Example 1: copper complex - bis(6-ethyl-2,2- dimethyl-3,5-decandionato) copper complex Condition of vapor deposition Vaporization temperature: 140° C. Substrate: Ta—N/SiO 2 /Si Substrate temperature: 250° C. Vaporization period: 60 min. Pressure in the reaction system: atmospheric H 2 flow rate: 36 mL/min. He flow rate: 5 mL/min. Characteristics of formed film Almost no film is produced.
[0110] The above-mentioned results indicate that the Cu(sopd) 2 of the invention shows an excellent film-forming property, as compared with the previously known copper complex.
Industrial Utility
[0111] The copper complex of the invention is a divalent copper complex which is thermally stable, as compared with the thermally unstable monovalent copper complex, and is resistant to thermal decomposition in the vaporizer. Accordingly, it is advantageously employable for industrially preparing a copper-containing film by chemical vapor deposition. Further, the copper complex of the invention can produce a film at a rate greater than that shown by the previously known divalent copper complex. This means that the copper complex of the invention is practically advantageous, and that the copper complex of the invention is favorably employable for the preparation of a copper film widely greatly utilized as the circuit material of semiconductors. | Copper-containing thin films can be industrially advantageously formed by chemical vapor deposition using as the copper source a divalent copper complex bearing β-diketonato ligands having silyl ether linkage. A representative example of the divalent copper complex is represented by the formula (I):
wherein Z is hydrogen or alkyl; X is a group represented by the formula (I-I), in which R a is alkylene, and each of R b , R c and R d is alkyl; and Y is an alkyl group or a group represented by the formula (I-I), in which R a is alkylene, and each of R b , R c and R d is alkyl. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of, and claims the benefit of the filing date of, U.S. patent application Ser. No. 10/645,024, now U.S. Pat. No. 7,496,776, entitled POWER THROTTLING METHOD AND APPARATUS filed Aug. 21, 2003.
TECHNICAL FIELD
The invention relates to a Central Processing Unit (CPU) control and, more particularly, to reducing power usage in the CPU.
BACKGROUND
In the past there have been two types of power management in computers. A first type is software based which periodically checks to see if computer parts such as the keyboard, the hard disk, the CD drive, and so forth, are being used. If items like the hard drive are no longer being used, the software will typically remove power from the drive motor after a given period of non-use. If the keyboard has not been used for a given time, the display may be removed from the screen and/or power may be removed from the monitor and/or major portions of the CPU. A second type of power control has been labeled in the art as DPM (Dynamic Power Management). Instructions being processed in the computer are monitored and when there are no more instructions to be processed, a DPM module acts to remove clock signals from appropriate portions of the CPU.
It should be noted that there are two types of power usage that occurs in advanced CMOS (Complementary Metal-Oxide Semiconductor) technology. There is active AC power and DC leakage power. As used herein, AC power is that power generated by dynamic dissipation due to switching transient current and charging and discharging of load capacitances. DC leakage power, as used herein, is that power that is generated by static dissipation due to leakage current or other current drawn continuously from the power supply. This DC leakage current, as compared to total current used, increases as CMOS component size decreases.
As noted above, there are many techniques for controlling AC power. These prior art techniques help reduce the AC power component. However, it does not help the DC leakage component because there is still voltage being applied to the circuits. Also, it does not completely shut down the AC component of power.
The architecture of some computers, such as the PowerPC of IBM (International Business Machines), defines a set of architecture control bits in an MSR (Machine State Register). These bits control various functions in the design. One control bit controls the width of the data flow (32 bit or 64 bit). Another bit controls whether there are floating point instructions active.
As known by those skilled in the art, as CPU architectures have evolved, the width of the instruction set architecture has increased to accommodate increases in desired accuracy and processing speed. Original Central Processing Units (CPUs) were 8 bits. Over time, the instruction set data width has been increased to up to 64 bits for present day CPUs. However, even though the width has increased, there remains a considerable amount of software being used which is written for a previous generation's smaller width. Although many of today's CPUs utilize a 64 bit architecture, much of the code used in operating these CPUs is still 32 bits or less. Thus, in many instances of operation, only a portion of the hardware is actively functioning. In other words, if the hardware is designed to accommodate 64 bits, and the software only demands 32 bits, half of the hardware for accommodating the software words is not being used. If the software only demands the use of 16 bits, the software may be using only one-fourth of the hardware. However, even though a portion of the instruction set hardware is not being used, it still, in all known present day CPUs, is using electrical power. The power being used is in the form of clock pulses being applied to data, computation and instruction storage registers as well as DC leakage. Since the power being used is not actively assisting the software, this power is being wasted.
In addition, there are certain workloads which contain only fixed point instructions but contain no floating point instructions.
In view of the above, it would be desirable to deactivate portions of the CPU's circuitry that are not actively engaged in accomplishing steps set forth in the software that is presently being run. Examples of such circuitry being the floating point circuits when there are no floating point instructions in the workload or portions of the computational circuitry when the software running utilizes less than the full instruction width capability of the CPU. It would be further desirable to shut down both the DC leakage power as well as the active AC power for these portions of the CPU.
SUMMARY OF THE INVENTION
The present invention comprises using a CPU architecture control mechanism which shuts down at least one of active AC power and DC leakage components of power for specific functions, or portions of the total CPU circuitry, which are not presently required for the application running on the CPU.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and its advantages, reference will now be made in the following Detailed Description to the accompanying drawings, in which:
FIG. 1 comprises a simplified block diagram of a CPU shown in more detail in FIG. 2 ; and
FIG. 2 is a more detailed presentation of a computer CPU such as shown in FIG. 1 .
DETAILED DESCRIPTION
In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. Additionally, for the most part, details concerning network communications, electro-magnetic signaling techniques, and the like, have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the understanding of persons of ordinary skill in the relevant art.
It is further noted that, unless indicated otherwise, all functions described herein may be performed in either hardware or software, or some combination thereof. In a preferred embodiment, however, the functions are performed by a processor, such as a computer or an electronic data processor, in accordance with code, such as computer program code, software, and/or integrated circuits that are coded to perform such functions, unless indicated otherwise.
In the remainder of this description, a processing unit (PU) may be a sole processor of computations in a device. In such a situation, the PU is typically referred to as a CPU (Central Processing Unit). The application of the invention may, however, be readily applied to multiprocessor installations and multiprocessor integrated circuit chips.
FIG. 1 presents a high level representation of a portion 10 of a typical general purpose computer or CPU. An instruction cache 12 fetches instructions from some type of storage (not shown). These instructions are decoded in a block 14 and are issued, via an issue block 16 and a bus 18 , to a plurality of execution units 20 , 22 , 24 and 26 . It may be noted that issue block 16 also contains an MSR (Machine State Register) block not numerically designated but discussed later in connection with FIG. 2 . The first designated execution unit 20 is shown as a SIMD (Single Instruction Multiple Data stream) VMX (Vector Multimedia Execution) device which comprises a vector register file unit, or VRF, as well as arithmetic subunits designated as 28 , 30 , 32 and 34 . Subunit block 28 is further designated as VMX SIM or simple fixed point subunit. Subunit block 30 is further designated as VMX PER or permute subunit. The subunit block 32 represents a COM or complex fixed point subunit, while subunit block 34 represents a single precision FPU. The second execution unit 22 is a scalar FPU and comprises an FPR (Floating Point Register file) portion and a double precision FPU pipeline portion further designated as FPU. The third execution unit block 24 is a fixed point unit including, as shown, a GPR (General Purpose Register) portion, an FXU (Fixed {Point Subunit) portion including an ALU (Arithmetic/Logical Subunit) portion, an LSU (Load/Store) portion and a DC (Data Cache) portion. A bus 36 connects each of the first three execution units to other parts of the computer, such as computer memory. A bus 38 connects the DC (Data Cache) portion of block 24 to the instruction cache 12 as well as to an L2 cache interface 40 . The cache 40 is interconnected to other chip components of the computer via a chip bus designated as MPI Bus. The remaining block 26 comprises a branch processing unit including CR (Condition Code Register), LR (Link Register) and CTR (Count Register) portions as well as a CR logic subunit and a BR (Branch) processing subunit. The various portions of block 26 interact with blocks 20 , 22 and 24 to process the instructions.
In FIG. 2 , a block designated as 200 provides more detail as to the contents of the FXU portion of block 24 in FIG. 1 . A block 202 , labeled FPU, provides more detail as to the contents of a similarly labeled portion of block 22 in FIG. 1 . A block 204 , further labeled MSR (Machine State Register) comprises a portion of the issue block 16 in FIG. 1 . As known in the art, the ALU (Arithmetic Logic Unit) portion of a CPU can typically, by software direction, be used in either a 32 bit or a 64 bit mode. Although more complicated to design and show, the same teachings as follows may be utilized to permit the CPU to operate in additional modes such as 16 bit and 8 bit. An architected control register, previously referred to as MSR 204 , is software accessible. A floating point (FP) bit lead, indicative of the logic value of this bit in register 204 , is supplied to a voltage control gate 206 as well as to an OR gate 208 of the FPU block 202 . A DPM (Dynamic Power Management) block 210 provides another input to OR gate 208 . An output of the OR gate 208 is used to remove DC power from a plurality of blocks in the FPU such as LCBs (Local Clock Buffers) 212 and 213 . The deactivation of the LCBs effectively deactivates (lowers the power usage) of downstream blocks, such as a multiply control block 214 and a multiply block 216 used in floating point arithmetic and unlabeled blocks 218 and 220 . When the FP bit is a given value, indicating that there is no floating point arithmetic to be performed, such as logic “1”, the entire computation portion of the FPU 202 is deactivated. A portion is deactivated through the OR gate 208 to deactivate the LCBs 212 and 213 . Further, through the voltage control block 206 , the remaining computational blocks, such as 214 , 216 , 218 and 220 , have the DC power removed. This occurs even though the DPM block 210 is indicating that there are still instructions to be processed.
A lead 222 , also labeled SF for Sixty Four bit mode, is connected to an OR gate 224 and is also used to activate another voltage control gate 226 . Gate 226 , when activated, removes power from a lead Vdd to an ANDed input of the upper half dataflow registers 228 and 230 which are further designated as RA_HI and RB_HI, respectively. Lead Vdd is also used to activate (or deactivate) an upper portion of an arithmetic logic unit (ALU_HI) 232 and supplies an input to an ANDed gate portion of a further upper half dataflow register 234 provided with a further designation of RD_HI. A dynamic power management (DPM) block 236 has an output lead 238 connected as a second input to OR gate 224 as well as providing an input to local clock buffers (LCB) 240 , 242 and 244 . An output of OR gate 224 is supplied on a lead 246 to local clock buffers (LCB) 248 , 250 and 252 . An output of LCB 248 is supplied as a second input to the AND gate portion of the dataflow register 228 . An output of LCB 250 is supplied as a second input to the AND gate portion of the dataflow register 230 . An output of LCB 252 is supplied as a second input to the AND gate portion of the dataflow register 234 . Outputs of LCB registers 240 , 242 and 244 are applied respectively to the lower half dataflow register blocks 256 , 258 and 260 , which are further labeled respectively RA_LO, RD_LO and RB_LO. An output of block 230 supplies a second input to ALU block 232 . A low side ALU_LO block 262 receives input signals from low side register blocks 256 and 260 . A carry over (CO) supplies a signal from low side ALU 262 to high side ALU 232 when the computer is in a 64 bit operational mode. Outputs of ALUs 232 and 262 are applied to high and low side registers 234 and 258 , respectively.
As may be inferred from the above, this invention provides a mechanism to use architected bits in the MSR to reduce power in the processor. As one example, and as shown in FIG. 2 , when the CPU is put in 32 bit mode, the hardware shuts off clocks from LCBs 248 , 250 and 252 for all of the upper 32 bits of the dataflow. In addition, it shuts down the power supply for all of the upper 32 bits of register and dataflow logic. Another example shown in FIG. 2 is to use the floating point available (FP) bit in the MSR to shut down power and clocks to the entire floating point unit (FPU).
In more detail, the SF bit output by MSR block 204 feeds logic which shuts down the clocks for the upper half of all registers which transfer data. As shown, these upper half registers are 228 and 230 . In addition, it deactivates the DC power supply signal (Vdd) for the registers and logic for the upper 32 bits of dataflow as applied to ALU 232 and its output register 234 . As seen in the drawing, there are LCBs for the lower 32 bits and upper 32 bits of each dataflow register. There is logic, via lead 238 , to activate (or deactivate) the LCBs 240 , 242 and 244 for the lower dataflow registers 256 , 258 and 260 . This same logic signal affects the LCBs 248 , 250 and 252 for upper dataflow registers 228 , 230 and 234 through OR gate 224 to shut down the LCBs for normal dynamic power management. For the upper 32 bits of each register, the SF signal from MSR 204 (MSR(SF)) is logically ORed with the DPM shutoff signal to turn ON clock signals coming out of the high level LCBs. In this example, a 64 bit ALU function is divided into the lower 32 bits (ALU_LO) and the upper 32 bits (ALU_HI). In 64 bit mode, the MSR(SF) bit of lead 222 is a logical “1”. In this mode, all registers and dataflow are active and the CO of the lower ALU 262 propagates to the upper ALU 232 to form an entire 64 bit result. In the 32 bit mode, the MSR(SF) bit is a logical “0”. In this mode, the upper registers and dataflow macros are not clocked and they do not receive power over lead Vdd.
The MSR(FP) bit is used in a similar manner to shut off all clocks and power to all LCBs, macros and registers in the FPU 202 .
As mentioned above, the same thought process may be used to save even more power when using a CPU with not only 32 and 64 bit software but additionally with 8 and 16 bit software.
Although the invention has been described with reference to a specific embodiment, the description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiment, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the claims will cover any such modifications or embodiments that fall within the true scope and spirit of the invention. | Disclosed is an apparatus which deactivates both the AC as well as the DC component of power for various functions in a CPU. The CPU partitions dataflow registers and arithmetic units such that voltage can be removed from the upper portion of dataflow registers when the software is not utilizing same. Clock signals are also prevented from being applied to these non-utilized components. As an example, if a 64 bit CPU (processor unit) is to be used with both 32 and 64 bit software, the mentioned components may be partitioned in equal sized upper and lower portions. The logic signal for activating the removal of voltage may be obtained from a software-accessible architected control register designated as a machine state register in some CPUs. The same logic may be used in connection with removing voltage and clocks from other specialized functional components such as the floating point unit when software instructions do not presently require same. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of Ser. No. 09/694,050 filed Oct. 20, 2000, which is a continuation-in-part of Ser. No. 09/641,820, filed Aug. 18, 2000.
INTRODUCTION
[0002] The invention disclosed and claimed in the first filed parent cross referenced above relates generally to the field of an Internet enabled business-to-business intelligent communication link allowing a first business organization to have intelligent interaction with a second fully integrated business organization to facilitate the placing of orders or reservations for business services or goods, with the services or goods provider having a computer network linking multiple levels of its organization to provide for the smooth conduct of business between the two organizations. More particularly, this field relates to an Internet enabled automatic rental vehicle transaction system to facilitate the conduct of rental vehicle transactions between two multilevel business organizations, one of which provides such rental vehicle transaction services in an integrated manner through business enterprise software to a high volume user of such rental vehicle services wherein an Internet web portal is defined by the rental vehicle service provider which interconnects the two business organizations at multiple levels, providing a graphical user interface (GUI) for the transaction of large amounts of rental vehicle services automatically and virtually without human intervention upon entry. The invention of the second filed parent continuation-in-part application extends the functionality of the first filed parent invention by providing an intelligent portal that is readily configurable to suit any particular customer and any particular provider data requirements or method of doing business. This added functionality allows the invention, for example, to provide the user with access to other suppliers in the same seamless and integrated manner. In other words, the user now has access to not just one integrated business but multiple businesses, some of which may but need not be, integrated businesses thereby extending the invention for use in a generic application to satisfy a user's needs for a good or service not just from one vendor but all vendors connected to the invention. The inventions disclosed in this application add to the functionality of the systems first disclosed in the two parent applications by providing features and advantages which increases its flexibility and adaptability to other business models as might be found in different countries for handling rental vehicle transactions.
BACKGROUND OF THE INVENTION
[0003] Computer technology has been embraced by many businesses in order to handle their ever increasing order flow as well as to mitigate the increasing blizzard of paper required to be produced to document this business. A significant benefit which often drives the implementation of technology is its further advantage in increasing productivity to thereby allow fewer people to handle greater volumes of business. One such good example demonstrating the efficiencies and value to be gained by implementing technology is the business model developed and followed by the assignee of the present invention. A rental car company at its heart, the assignee transacts an ever increasing number of time sensitive, relatively low dollar volume, vehicle rentals which in many instances require authorizations to be made in advance, reservations of vehicles from available geographic and vehicle type selections, monitoring of the rental as it progresses including possibly extending the rental under certain circumstances, communications between the various parties involved in the transaction to ensure ultimate customer satisfaction, and financial accounting for the transaction including generating invoices and processing them for payment. While a significant portion of the vehicle rental business involves rental for leisure, business travel, etc., another significant business relationship has developed with insurance companies and the like in what has been termed as the replacement car rental service business. In this business, a vehicle insurance company may have many thousands of policyholders who are eligible to be involved in accidents, and other dislocations of use, requiring that a vehicle be rented for that customer's use while his own vehicle be made ready again for use. Thus, for this business segment, a multi-tiered business organization such as a vehicle insurance company represents a significant customer for repetitive vehicle rental services. To conduct this business in an orderly, time efficient and cost efficient manner, it is necessary that this insurance company has as its business partner a vehicle rental company which is itself multi-tiered, such as the assignee of the present invention. This is because the needs, both geographically and in volume, are significant which require the dedication of a significant amount of resources. To satisfy these needs and to respond to other business growth, in its embrace of technology the assignee hereof has succeeded in developing an in-house computer system and related software which has integrated its business internally. This business integration has been massive and company-wide as is needed to integrate a company having a central office with literally thousands of individual branches located nationally, and even now internationally, with hundreds of thousands of vehicles available for rental. Furthermore, other business partners including other service providers such as vehicle repair shops have also been given access to this system to allow for input of information relating to progress of vehicle repair, extension of rental time, etc. as the rental progresses. This integrated business computer network and software generally includes a mainframe server at the heart of a wide area network (WAN) which facilitates the transfer of vehicle rental information and orders company-wide. This integrated business model is most efficient and needed in order to satisfy the vehicle rental service needs of a vehicle insurance company which itself may be national or even international in scope.
[0004] As a first step in extending the integration of technology into this business model, the present assignee has previously developed and implemented a computer system which has provided improved communication capabilities between the two business partners. This system generally comprised a second mainframe computer linked to the first mainframe of the integrated business network, with dedicated access lines being provided from this second mainframe to various levels of the multilevel business organization comprising the insurance company. In effect, with this additional mainframe and dedicated pipeline access, various individuals at the insurance company were permitted to directly interact with the integrated business computer network of the vehicle rental company as well as other selected service providers such as body shops where wrecked vehicles were being repaired. The implementation of this system provided a great step forward over the people intensive business activity previously required in order to handle the large number of transactions encountered in this business relationship. Historically, the replacement car market engendered large numbers of telephone calls being placed between the insurance company, the rental company, and the body shop where vehicle repair was being performed in order to authorize the rental, select and secure the desired replacement vehicle to be provided, monitor the progress of the repair work so that scheduling of the rental vehicle could be controlled, extending the vehicle rental in the event of delays in repair, authorizing various activities involved in the rental process including upgrades of vehicles or other charges for services, and subsequent billing of the rental service and processing the billing to the insurance company for payment.
[0005] While the implementation of this system was successful and represented a tremendous step forward in automating the business relationship between the insurance company and the vehicle rental company, it did have certain limitations. For example, a specific communication link had to be established between the rental vehicle company and the particular users at the insurance company designated to have access to this system. Thus, special attention and some modicum of expense was required to establish these “pipelines” and maintain them. Still another aspect to the system implemented was that it was not “browser” based nor did it provide graphical user interface (GUI) menus. Thus, each user had to be specifically trained in the particular “language” used by the system and learn to work with specific menus nested in a specific manner as well as codes for entering commands which were not similar to other computer software programs. This software design thus necessarily required additional training in order to insure that users could gain the full measure of advantage provided by the system and in order to minimize the opportunity for erroneous information or incorrect reservations from being entered or otherwise confusing the business transactions. Furthermore, user efficiency was not immediate and required skill beyond that ordinarily found in casual computer users, as we are all becoming in this computer age. Still another disadvantage to the system was that access was required to a designated entry point in the system in order for a person authorized to be on the system to work with it. As the nature of the insurance and replacement car business requires extreme mobility at multiple levels of both business partners, this represents a limitation to the usefulness and time efficiency with which various business functions could be performed. Therefore, while implementation of the second mainframe allowing for pipeline connections at various levels of the multi-tiered insurance company was a significant step forward in automating the business relationship between the two business partners, significant limitations to this solution were readily apparent to the users thereof.
SUMMARY OF THE INVENTION
[0006] In the first parent application cross-referenced above, the inventors herein have previously succeeded in designing and developing a means for substantially enhancing the business to business communication link between these two businesses which provide significant advantages over its prior embodiment. More particularly, the inventors have succeeded in replacing the dedicated pipeline access of the existing system with a web portal allowing Internet access to the mainframe with a browser based graphical user interface (GUI) presentation. This also made the system more readily accessible to smaller business-partners as the expense of the “pipeline” was eliminated. The first parent's invention offers several important technical advantages over the previous system. First of all, by taking advantage of the ubiquitous nature of the Internet, the ultimate in portability and connectivity for this system is now provided in a business environment where mobility and connectivity are at a premium. In other words, a claims adjuster, body shop, or any other business employee authorized to have access to the system may gain access at any site offering Internet access. In present day technology that includes many mobile devices and appliances which are Internet enabled. As technology advances, it is conceivable that this access will extend to permit “24/7” access by any authorized person at any geographic location. This is a marked improvement providing immediate benefit and advantage over the dedicated pipeline access of the prior art system.
[0007] One limitation however, is that with this embodiment, this internet access must support a stateful connection. In this context, a stateful connection refers to a “persistent” conversation, meaning that the client side and server side software components establish a connection to one anther once and multiple data transfers may occur without severing that connection. Common examples of a stateful connection include on-line chat, on-line gaming, and for virtually all on-line conferencing. This is distinguishable from the normal operation of web pages which typically establish a connection, transfer the object on the page, and then sever that connection. These types of connections are generally referred to as “stateless” connections.
[0008] A second major advantage of the first parent's invention is its graphical user interface. The inventors have taken full advantage of this browser based GUI to streamline and organize the presentation of information to a user to actually guide him as he interacts in doing his business. One such example is customized design of the menus such that the user is guided and directed to answer only those questions required to be answered in order to conduct the particular transaction being addressed, and further to present choices to the user for his selection to minimize the need for the user to rely on his own memory or to be familiar with complicated and specialized codes to enter data or request transaction activity. With the recent and continuing explosion of the Internet, more people are becoming familiar with browser programs and their operation through their own daily activities in their personal lives. This familiarity paves the way for easier training and quicker orientation of a new user to the present invention. For large business organizations communicating at multiple levels, this significant advantage cannot be minimized as there are large numbers of people who must be continuously trained due to the growth of the organizations, as well as the replacement of employees due to the inevitable attrition. Thus, the first parent's invention provides an immediate increase in worker productivity, and makes that improved efficiency available to many more workers who are not particularly skilled otherwise in computer usage.
[0009] Still another advantage provided by the first parent's invention is through the implementation of additional functionalities which are engendered by the browser/GUI interface. As the system is continuously used, and feedback is continuously monitored and analyzed, additional features that add value through providing management information as well as by speeding transaction activity over the system may be implemented. For example, several of these features include the ability of a user to create an on demand report for transaction activity including summaries of transactions handled by a particular user or group of users which might either be open or closed. Another example of additional functionality which improves the efficiency of a user is the ability to create a repair facility call back list which allows a user to sort existing open vehicle rental reservations by repair facility (body shop) and date such that a user is presented with the list of open reservations at a particular repair facility which can be readily handled in a single telephone call while at the same time having the system on line to implement any needed changes such as extensions of reservations, etc. Additional functionality has also been provided to speed the processing of invoicing which of course also speeds their payment and cash receipts. For example, it was found that even despite the built-in error checking and correction facilities provided to the users of the system, a repetitive pattern of mistakes involving incorrect claim numbers was discovered. To speed the processing of these, an additional functionality was provided as an “electronic audit” known as invoice return which returns an invoice to a particular adjuster upon detection of an incorrect claim number for his human intervention and correction of the claim number. In this manner, problem invoices exhibiting one of the most common problems encountered may be readily handled within the system and in an efficient manner, instead of manually as before.
[0010] The first parent's invention also has as a significant advantage the ability to be further customized to meet the individual business partners' needs and desires as well as to provide additional functionality by offering additional features which become desirable upon accumulation of user data based on user experience. Furthermore, once implemented, they are immediately available system wide. While this allows for consistent usage, it is limited in the sense that all of the system users are forced to use the same menus, data definitions, etc. This is not seen as a limitation for the one-to-one business application intended to be primarily addressed by the first parent's invention.
[0011] Still another advantage of the first parent's invention is that the graphical user interface incorporates point and click interaction, using buttons and tabs to present or conceal data for the user's attention or inattention as the case may be, and provide a much more robust interaction capability through the creation of menu designs that allow for access to the most commonly needed features from any point in the menu architecture. This is to be contrasted with the prior system which consisted of a main frame character based interface while the first parent's invention with its GUI interface allows a user to point and click to navigate and to make selections by pull down selection, thereby reducing errors. As users become more experienced with the system, and their confidence level grows, they are much more likely to become bored and aggravated with the rigid structure of the prior system requiring them to follow along a certain menu architecture in order to complete certain tasks. On the other hand, the first parent's invention generally increases the interest of the user in using the system. These advantages of the first parent's invention over the prior interface promote employee productivity by allowing a user more control over his work which is critical in achieving savings in human resources to operate the system which is one of its main goals.
[0012] The second parent's invention extends the first parent's invention and expands its capabilities and functionalities. With the second parent's invention, a user may not only have access to its business partner, but also one or more competitors of its business partner through the same Internet portal. In this way, at least two needs are satisfied. First, the user can have access to a variety of providers to choose from where business needs or desires require. This allows the user to use a single portal and not have to sign on to a number of different portals, even should they be available. Furthermore, the user isn't troubled to learn how to access and use different portals even should they be available. Presently, not all providers are operating an Internet portal for offering their services, so by allowing business competitors to be accessible through the same portal, independent development of other portals is forestalled. This is a benefit to the operator of the main portal as it creates and maintains a competitive advantage by handling all of the order flow which creates a data base of useful information for marketing purposes. Although initially the portal services might be offered for no additional cost to a competitor, eventually a fee might be charged which would at least partially offset the cost for owning and operating the portal.
[0013] The design of the portal is elegant and offers great flexibility for customizing not only the menus for presentation to the user, but also in the design of the data base entries needed or desired by the user and/or the competitive provider. For example, some users might not know or care about the features of a vehicle rented and so those data entries may not be provided space on the menu for the user to fill in. The data base as handled by the networked computer system then need not keep track of that data for that customer. This feature is readily accommodated by the data base programming and is conveniently implemented.
[0014] In still another aspect of the second parent's invention, the web portal has the capability to accommodate the varying data requirements also of the various competitive providers, but also the level of their sophistication as evidenced in their respective computer systems and interface facilities. For example, the web portal may be configured to communicate the user's order to the competitive provider via email, phone, or even through a connection directly to an integrated computer system having the same or substantially the same inter-operability as the integrated computer system of the assignee hereof. This capability extends to accommodating and matching the competing data requirements of the user and the competitive providers, and having the flexibility to design and implement menus that readily meet these competing needs. Furthermore, the second parent's invention allows for changes to be implemented by simple re-programming of the web portal which minimizes the effort and enhances the “user friendly” aspect to the present invention.
[0015] Not only are these “global” improvements made available with the second parent's invention, there are other more particularized improvements that add functionality within the operating framework of the second parent's invention. For example, one such improvement is the ability to “virtually” assign work groups within the user so that, for example, multiple adjusters might be made into a team with a shared work load so that all of the team members have access to the same pool of work, such as the placing of reservations for the same group of drivers. With this “virtual team” assignment capability, work groups may be readily re-assigned to match changing work loads without worrying about re-configuring hardware or internal network connections. This can be a very valuable feature to accommodate staffing issues over geographical distances that can be nationwide, with access through the web portal to reservation facilities which are themselves nationwide.
[0016] Still another feature is the ability to customize an individual user's authorization limits. As can be appreciated, one of the mixed blessings of providing enhanced functionality to the individual users of any integrated computer system is that it places great power in the hands of the user which at the same time creates the potential for abuse. There have been well publicized instances of “rogue” employees making financial decisions or placing instructions which have far reaching financial consequences well beyond the intended authority of an employee, with disastrous results. With the second parent's invention, one feature is the ability to limit the financial commitments that a user may make during any pre-selected time period. For example, the user's profile may limit his ability to make only a certain dollar limit of vehicle reservations over any certain number of work days. In this way, added safe guards may be conveniently provided, monitored by reporting capabilities, and changed as circumstances warrant, all with simple programming changes at the web portal.
[0017] There are still other features that are provided by the second parent's invention that find their genesis in the different approach taken over the first parent's invention and owing to the inherent increased flexibility of using a web based programming for the web portal to interface between the user and the providers on the web server and eliminating the need for any custom software on the user's terminal. The details of these are to be found and described in the detailed description of the preferred embodiment below. Examples include the ability to send confirmatory communications to the user that the reservation has been received and entered into the provider's system for fulfillment, custom report design including the capability to save and re-generate the custom report upon user command, increased flexibility to process and pay invoices, etc.
[0018] Still other advantages and features have been developed and are newly disclosed and claimed more particularly herein. These advantages and features relate to usage of the present invention both domestically and abroad where there are idiosyncrasies in the business model that need to be accommodated. Still other features provide entirely new functionality. One such new feature involves adapting the present invention as a tool to market replacement vehicles for sale or lease to a customer who has had an accident significant enough that repair of his vehicle is not economically feasible. This is commonly referred to “totaling” a vehicle. The insurance industry totals about 3 million cars per year, of which approximately 17% are newer models (defined as within three years of current model year). Once totaled, the owner needs to buy another car. Since car rental companies desire to sell more cars, any opportunity to tap into the total loss market will be bountiful.
[0019] The present invention provides a window into the establishment of a total loss for a renter's/insured's/claimant's automobile. Any car that is deemed to be a total loss would be indicated as such in the present invention for reporting purposes. At this point the stored information could be used to help provide economic benefit to all parties, insurance company, rental car company, and automobile owner.
[0020] Once a renter's/insured's/claimant's (owner's) car is determined to be a total loss the adjuster will try to ascertain the actual cash value (ACV) to be settled with the owner. The adjuster can use a third party tool, such as CCC's Pathways® product, to determine what ACV is. Today an adjuster must input this information manually into a separate application. The present invention contains much of the necessary information needed to determine ACV: name, car make, model series, year. The present invention need merely send the necessary information electronically to a total loss product and request an electronic response. Once the necessary information is generated, the present invention would in turn take the ACV and cross reference the car rental database of inventory. Necessary information might include but not be limited to: ACV, year, make, model series, comparable cars, etc.
[0021] The car rental inventory can be filtered by geography and “holding requirements”. As a reseller of vehicles, the car rental inventory is generally contractually required to be within the fleet as a rental for a predetermined amount of time prior to being available for sale to third parties. Once a car is past the holding requirement it is generally within the discretion of the car rental company to sell. Thus, instead of X% of cars available to the car rental company for retail sale, a virtual inventory of cars is available for retail sale to the owner of the car.
[0022] Once the filters for geography and holding requirements are active, the present invention delivers a list of available vehicles for sale. At this point the adjuster and owner review the available cars, decide the cars considered to be attractive, and the owner then decides which one he wishes to purchase.
[0023] The user then selects one or more potential vehicles and sends the request to the appropriate car rental location. The car rental location can then contact the owner of the vehicle to buy one of the selected vehicles. In addition, the list of vehicles and ACV information can be sent to the owner for further review and discussion.
[0024] Once the car rental company contacts the owner and comes to a sufficient conclusion, either to buy or not to buy, the adjuster is notified of the conclusion and the transaction is consummated either through the present invention or off-line.
[0025] Still other features are disclosed and claimed herein which extend the functionality of the present invention. These include the following. One such feature is providing for automatic extensions of existing rental authorization, so that some limited extension authority is granted to permit some flexibility to a particular user without burdening him with the need to obtain approval for the extension. Another feature could be referred to offline usage, and provides the functional advantage of permitting processing of reservation data in a computer not connected into the network, and then uploading/downloading between the offline computer as it is connected into the network, such as by dialing into the network over the internet, or through a portal. The type of data which could be processed includes virtually any related to the processing of vehicle rental transactions and other related data such as car repair scheduling, etc. This functionality provides an extension of the usability to the invention to mobile users who travel beyond the reach of the internet, which even further enhances its applicability to those places not covered by wireless coverage. Alternatively, it allows the invention to bypass special connectivity issues which are thought to be disadvantageous for any reason including cost, unavailability, inconvenience, etc. Still another feature includes further integration of the internal data bases kept by permitting a user to automatically update not just one but several data bases with a single command once that new data is entered into a single menu. For example, in what can be referred to as “power templates”, a user may enter a multiple number of rental reservations on a single menu and then click a single “approved” icon which would then enter all of them into the system. This represents an improvement over a previous implementation requiring a user to separately “approve” each reservation, and then suffer the system processing time for each reservation. This “batch” processing can result in significant improvement in throughput, and reduction of user interface time for processing multiple transactions. Still another feature provides the added functionality of processing customer satisfaction feedback through the system. This feature provides the capability for a user to enter customer feedback information, both positive and negative but perhaps more importantly negative, so that immediate awareness of any problem can be obtained and corrective action taken to mitigate or eliminate the difficulty. This feature also allows a user to indicate a suggested supervisory level of interaction, or the system may allow for automatic escalation of involvement for succeeding levels of supervisory attention as the dissatisfaction continues or even escalates. This feature can be significant to a service provider as the ultimate success of a service provider is directly dependent on the perception of satisfaction by the end customer. And, it is well known that the sooner a problem is identified and solved, the more likely a customer will have a satisfactory experience. Furthermore, from a strict economic viewpoint, the sooner some problem is addressed and solved, generally the less expensive the solution. A small accommodation can change a frown to a smile, if promptly offered.
[0026] Still other features are now disclosed that have applicability perhaps in the domestic business model, but certainly offer needed functionality in other business models found in other countries. One of these includes multiple party involvement/management of a rental transaction. While the flexibility of allowing multiple adjusters within a group to “work on” a rental transaction has been previously described, this particular feature is different in that not only may these multiple adjusters not be within the same group, they might not be employed by the same employer, might not be adjusters themselves, and might have different authority for action on the transaction as is commonly found in different countries. For example, in some countries one adjuster authorizes and manages the rental reservation for the car while another adjuster authorizes and manages the insurance coverage for the rental. Still another feature allows third party or “independent party” management of the rental. In some countries a third party other than an insurance company is involved, such as a “credit hire” or “assist companies” or “repair facility” or “lawyer” or “fleet management company”. Each of these third parties, or any other third party, may be permitted access to the system and a user profile created for them that defines their authority to process rental transactions through an administrative profile set up in advance through agreement with the authorizing agent, such as an insurance company. As an enhancement, various individualized features may also provide data indigenous to a particular country, such as electronic access to the Schwackliste book for an adjuster to conveniently view a “class” for a car to determine what replacement vehicle is legally authorized for rental. Still another example of a feature needed to accommodate international capability is a need for a tiered rate system, and an hourly rental charge instead of a daily charge which predominates the domestic market. Processing of electronic signatures to satisfy local custom or legal requirement is yet another example of a feature for which the present invention is uniquely suited to provide.
[0027] While the principal advantages and features of the invention have been discussed above, a greater understanding of the invention including a fuller description of its other advantages and features may be attained by referring to the drawings and the detailed description of the preferred embodiment which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a schematic diagram of the computer systems comprising the first parent's invention;
[0029] FIG. 2 is a flow chart of the software programs which communicate over the computer systems of FIG. 1 to implement the first parent's invention; and
[0030] FIG. 3 is a schematic diagram of the computer systems comprising the second parent's invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] The overall system architecture for the first parent's invention 20 is best shown in FIG. 1 . As shown therein, an insurance company computer system 22 , which itself may be virtually any computer configuration or even a stand alone PC accesses the Internet 24 through any convenient access point 26 such as even including an ISP (Internet service provider), as known in the art. Also connected to the Internet 24 is a web portal 28 which is preferably provided by a server appropriately programmed as explained herein below. This web portal 28 may be appropriately configured as desired to suit any particular business relationship or arrangement, although preferably the inventors herein and assignee of this invention have determined that a 24/7 or full time connection to the Internet 24 is preferable, except for scheduled downtimes for maintenance, etc. The service provider 30 which for purposes of explaining the first parent's preferred embodiment is preferably a vehicle rental organization, has itself an Internet portal mainframe 32 connected by a bi-directional communication link 34 to a second computer network 36 which may itself preferably have a mainframe server 38 . This second computer system 36 is preferably a network having a database 40 for communication with what may be thousands of branch offices each of which has its own computer interface 44 which communicates to this second mainframe server 38 to conduct the integrated business functions of a service provider organization. Instead of communicating with the branch offices directly, a reservation may be communicated to a centralized location for further processing, such as a call center, and then relayed on to an appropriate branch office. This might be desirable under certain circumstances, such as if a branch office is closed, or when a purchaser requires some specialized service such as close monitoring of the rental. This may be done electronically and automatically, or with human intervention.
[0032] It should be noted that the particular computer configuration chosen as the preferred embodiment of the first parent's invention may itself be subject to wide variation. Furthermore, the term “mainframe” as used herein refers solely to a computer which can provide large scale processing of large numbers of transactions in a timely enough manner to suit the particular business application. Preferably, as is presently used by the assignee hereof, an IBM AS/400 mainframe computer is used as each of computers 32 , 38 . However, as is well known in the art, computer technology is subject to rapid change and it is difficult if not impossible to predict how these computer systems may evolve as technology advances in this art. For example, it is not beyond the realm of possibility that in the not so distant future a network of computers would provide the processing power to conduct these business operations as presently handled by “mainframe” computers. Thus, the term “mainframe” is not used in a limiting sense but merely to indicate that it is descriptive of a computer suited to handle the processing needs for a large scale business application.
[0033] It should also be noted that the communication link 46 extending between the server 42 and each of the branch offices 44 may have alternative configurations. For example, in some applications access over the Internet may itself be adequate, recognizing the vagaries of Internet service availability, reliability, and processing speed. Alternatively, this communication link 46 could well be a dedicated pipeline providing broadband service connection full time with back up connections to ensure continuous communication between a particular branch office or groups of branch offices and the service providers business operations computer system 36 . Some branch offices might even be served through satellite links. Indeed, it is even possible that a mixture of these wide variations of service level be present within a single organization's structure depending upon communication link cost and availability balanced against service needs. It should merely be noted for present purposes that this communication link 46 serves as the electronic umbilical cord through which branch offices 44 communicate with the business computer system 36 of the invention.
[0034] Attached hereto as exhibits are functional descriptions of the software programs resident on the computers comprising the two computer systems 32 , 38 which implement the first parent's invention. More particularly, attached hereto as Exhibit A is a functional description of the software to implement the integrated business functions resident on the AS/400 or mainframe computer 38 . Attached hereto as Exhibits B and C are related flow diagrams and explanatory text, respectively, for the software resident on the mainframe AS/400 computer 32 . Attached hereto as Exhibit D is a functional description of the software resident on computer 32 but which also appears on the server 28 which creates the web portal for access to the mainframe 32 and its resident program. Server 28 may use a bi-directional GUI to character based interface translator program, well known to those skilled in the art, to present the displays and information obtained and transmitted between the user and the computer 32 . However, the software of Exhibit D could also be run on server 28 , as would be appreciated by those of skill in the art. It is believed that these functional descriptions and accompanying text as exemplified in these exhibits are adequate to enable an ordinary programmer to implement corresponding software programs for executing the preferred embodiment of the first parent's invention using ordinary programming skills and without inventive effort.
[0035] As a further example of the flow of data and the functional advantages provided by the first parent's invention, reference is made to FIG. 2 . As shown therein, a right hand column is identified as “ECARS” which represents the integrated business software implemented as part of the mainframe operation 38 in computer network 36 . The center column headed “ARMS” is resident on mainframe computer 32 and coordinates the communication of data. The left column headed “ARMS/WEB” represents the software resident on computer but which is presented on server 28 and accessible by users through the Internet. Along the left side of FIG. 2 are designated three separate sections of operational activity. These are “reservation” followed by “open” and concluded by “close”. Generally, the functional descriptions are arranged in chronological order proceeding from the top of FIG. 2 to the bottom. However, some functional features are permitted throughout the entirety of one of the three periods designated at the left side of FIG. 2 . One such example is the “message” function which allows messages to be sent between users at one business organization 22 and branch offices 44 and others connected to the other business organization 30 . Proceeding with a description of the transaction, the first set of communications allow for the reservation of the services. These can include requests for authorization or a rescind authorization request to be sent from the service provider to the service purchaser. Correspondingly, authorizations and authorization cancels can be sent from the services purchaser to the services provider. Confirmations are communicated upon confirmation of an authorized reservation request. Authorization changes may be made and communicated from the services purchaser to the service provider. Corresponding rental transaction changes may be communicated from the services provider to the services purchaser. As indicated, through the entirety of this process messages may be sent between users and others connected or having access to the integrated business software, as desired. The consummation of this portion of the transaction is a reservation that has been placed, authorized, confirmed, and provision is made for changes as necessary. During the next phase of the transaction, a reservation is opened and services intended to be provided are started. Generally, and preferably for the rental of vehicles, a start and end date are established in the reservation process. However, along the way, transactional changes may be made, such as for changing the type of vehicle provided, extensions may be requested and entered from either business partner, messages may be transmitted between the business partners, and the transaction may be terminated such as by voiding the contract by one business partner or terminating the authority by the other business partner. The term “reservation” has been used herein to refer not only to the act of placing the order but also to filling the order for services including providing the rental vehicle to the ultimate user and even invoicing for those services.
[0036] The last phase of the process involves closing the transaction. During this phase of the transaction, the contract is indicated as being closed and invoiced, the services purchaser can approve invoices, reject invoices, and also remit invoices. Such invoice remittance may also include the actual transfer of funds through an electronic funds transfer medium, or otherwise as previously arranged between the business partners.
[0037] It should be understood that this is a streamlined description of the handling of a transaction, and by no means is exhaustive. For example, much more functionality is available to the user including accessing the data base to generate production reports regarding status of open or closed reservations, preparing action item lists to allow a user to organize and prioritize his work, obtaining information available in the system from having been entered by others which would otherwise require phone conversations which are inefficient and occupy still another person's time. A more detailed explanation of the functionality provided is found in the exhibits.
[0038] In summary, the first parent's invention creates almost an illusion that the services purchaser, and the great number of users at various levels of the multi-tier purchaser users, are actually part of the services provider organization in that immediate online access is provided to significant data which enable the user to make reservations for services, monitor those services as they are being provided, communicate with those providing the services, obtain information relating to the status of services as they are being provided, and close transactions, all by interacting with the services provider-business organization over that user's PC and without human interaction required by the business providers personnel. By way of contra-distinction, for many years business has been conducted on a human level by customers picking up the telephone and calling services providers and talking to their human counterparts in order to convey information, place orders, monitor orders, including obtaining information as to status, canceling orders, questioning invoices and paying invoices, along with a myriad of other related interactions. Not only did the conduct of business in this manner entail significant amounts of human resources at both ends of the transaction, but it also led to inefficiencies, mistakes and delays all of which increase the cost of doing business and contribute to an increased risk of services being rendered in an unsatisfactory manner in many instances to the end user. The first parent's invention has taken the preexisting solution of providing electronic communication between the business partners to another level by “web enabling” this system for improved connectivity, improved usability, reduced training, enhanced mobility, and other advantages as described herein.
[0039] A schematic diagram of the second parent's invention is shown in FIG. 3 and includes three levels of architecture. As shown in the first level of the architecture 50 , a user 52 such as an insurance company or other user has access through the Internet 54 to the computer system comprising and incorporating the invention. An Internet provider provides a link 56 through which Internet connections may be made to communicate with the further described system. For convenience, this Internet connection may be considered as an Internet site or portal in that a user enters a URL and arrives at this connection. A firewall 58 as is known in the art is used for security purposes and to prevent hackers and the like from unauthorized access to the system. A first set of servers 60 are interconnected in a network 62 and may preferably include an ancillary server 64 for running load balancing software or the like to balance the load and provide redundancy amongst what may be a plurality of web servers 60 . These web servers 60 may preferably be Sun Microsystem servers running Apache web server software, or other such suitable software as would be well known to those of ordinary skill in the art. This first web server network of servers 60 , 62 process the random and disorderly communications flowing to and from this system and the Internet before passing them through a firewall 66 as a further precautionary measure. This first layer of architecture, identified as the Internet space/DMZ layer provides a secure interface and creates order out of the chaos of communications flowing between the system and others, as will be described.
[0040] With this architecture, stateless connections are accommodated, for the first time. By supporting stateless connections, this embodiment eliminates the implementation difficulties encountered with the first parent's embodiment on the client. These implementation difficulties include installing extra software on the client side computers, and eliminates the need for special configuration of the internet access method, such as proxy servers or routers. For example, many proxy server are configured to disallow stateful connections for security reasons, i.e. to prevent unauthorized programs from establishing such connections. Another example is that routers are customarily configured with most ports closed and thereby unable to support stateful connections.
[0041] The next layer of architecture 68 is noted in the figure as the “Enterprise private network” and is comprised of a plurality of servers 70 network connected with a network connection 72 . Again, although the choice of hardware is not considered critical by the inventors hereof, Sun Microsystem's server/work station hardware is preferably used to provide the platform for running the application software for processing the various rental vehicle transactions, as will now be explained. Attached hereto as Exhibit E are a series of functional design specifications for the ARMS/WEB application software resident on servers 70 and which provide the detailed description of the operational features of the software and system. With these functional design specifications for the individual modules, it would be readily apparent to those of ordinary skill in the art that programmers of ordinary skill would be able to write software to execute these functional specifications without using inventive effort. Furthermore, the details of this implementation are not considered to provide any aspect of the best mode for carrying out the invention which is defined by the claims below. Generally, the ARMS/WEB application software permits a user to sign on and, when recognized, provides the series of menus presenting choices for the user to indicate the parameters for his reservation. A plethora of information is provided and accessible to the user through the various menus provided from which the user selects and enters data to process the reservation. An important feature of the ARMS/WEB application software is that it provides the user the opportunity to select to place his vehicle rental reservation not only with the integrated business computer system represented by the third level of architecture 74 , described below, but also to route the reservation information back through the first architectural level 50 and into the Internet 54 for transmission to a competitive service provider 76 . Although the interconnection is depicted in FIG. 3 as being made through the Internet 54 , the network of servers 70 configured in accordance with the ARMS/WEB application software may utilize virtually any electronic means for transmitting the reservation information to a competitive services provider 76 . These include email, automated telephone, facsimile, and other forms of electronic communication. Of course, the competitive services provider 76 may itself comprise an integrated business such that the level of interconnectivity provided to the user 52 may parallel that disclosed and described in connection with the integrated services provider system of the invention as well as the first parent's invention. This integrated business capability is represented as the third level 74 of the architectural topography shown in FIG. 3 which parallels portions of that shown in FIG. 1 in that a pair of network mainframe computers, such as AS/400's 78 , 80 may process reservations to and from various branch offices 82 which are geographically diverse.
[0042] With the invention, the Internet portal provided by the ARMS/WEB network configured servers 70 provide an Internet portal for communication with not only the integrated computer enabled business system of the resident services provider, but also a portal for placing reservations to other competitive services providers 76 . Thus, the user 52 enjoys the capability of accessing multiple service providers for competitive services through a single Internet connection using a single set of protocols, menus, etc. for the conduct of this business activity. Furthermore, the software configured network of servers 70 is readily configured in Web Logic to adapt to changing user requirements, data requirements, unique competitive service provider requirements, and other upgrades or modifications in a convenient manner by simply modifying the software resident therein. No special browser software of other interface software is required by the user and any special interconnecting software or server/hardware requirements may be satisfied as between the service providers such that the user is presented with a seamless interconnection. As the invention is configured and works well with the integrated business and computer systems as disclosed herein, it is anticipated that such interconnection and usability may be readily translated to any other such integrated computer system as might be found in other competitive service providers, as would be apparent to those of ordinary skill in the art. Thus, with the invention, a user is provided with among other things Internet access through a single portal to a plurality of service providers and, to the extent possible, to their integrated computer business systems.
[0043] The invention is sufficiently flexible to accommodate changes which are intended to adapt it for use with other business models, and especially those encountered in other countries. Furthermore, some of these changes add features that are equally applicable domestically. One such example is an “automated extensions” feature. Typically, there are many occasions when a damaged or inconvenienced vehicle is not made available for use when originally scheduled. In the prior art, many times an extension would then need to be requested through the system, with authorization requested and provided. In order to streamline this process, and to minimize delay and involvement of supervisory authority, the system may provide for some form of automatic extension authority. Preferably, this could be provided in any one of three modalities, or some combination thereof. A first modality would be for the service provider to have automatic extension authority, upon communication to the customer, within certain pre-determined limits. For example, an initial authorization may be for 12 days of a vehicle rental. A request for an extension of 5 days may be made by the service provider and of that 5 days 3 days may be authorized automatically as being within 25% of the original rental term and a request for the additional 2 days requiring approval may be automatically generated. Still another variation would be for the insurance company to set a limit within the system of the total number of authorized days, which could be based on some other parameter such as labor hours or body shop hours or down time for the repairs to take place. Then, upon request for an extension, one may be automatically granted based on the total authority allowed or initially set into the system by the insurance company, and up to that limit. Still another variation would be for a third party service provider to be involved in the process, such as a body shop, to make direct input into the system of a need for an extension. These authorized third party providers would preferably be pre-selected and their authority limited as described above. This feature may be implemented conveniently in a separate menu, for example as shown in the attached “screen shots” headed “Extend Rental”.
[0044] Another feature is an offline usage feature which allows a user, such as an adjuster, to work with a laptop having loaded thereon a software program that emulates the connected network software for local processing of data, such as claims data. In use, an adjuster would preferably first connect to the system and download or “synch” his laptop data base with the claims data resident in the system. The adjuster would then disconnect and use his local program to work offline. Such work could include the generation of new reservations, authorization of direct billings, extension of rentals, approval of invoices, and setting of termination dates for on-going rentals, among other tasks. The user would then re-connect to the system, such as over an internet connection, sign in, and “synch” his laptop to the system which then transmits or executes his commands/communications to the central processor. The central processor checks the users “synch” data against its data file, advises the user of any “synch” data that is older than the current data, and requests the user to specify which data should be processed. After the processor is instructed by the user, it will then act on the “synch” data. For clarity, a first “screen shot” is provided that illustrates a sign in log for a user who wants to initiate a “synch”, and a second “screen shot” is provided to illustrate a listing of activity that could have been created offline and which is available to be input to the system upon “synching”. A preferences feature is provided to allow a user to establish defaults for automatic syncing of the data. Also, a history feature will allow the user to display all of the syncing activity from his connection or portal including error messages and conflicts noted.
[0045] Yet another feature allows for a user to enter, or execute, a full menu of transactions without individually opening them from a summary menu. This has been referred to as a “power template” feature. Instead, a hyperlink is provided to allow a user to jump into another menu of details for an individual item should it need to be changed and not entered as suggested, requested or listed on a user's action list.
[0046] Still another feature allows for the collection of user satisfaction feedback, and alerts to be entered for the attention to complaints, by the user right at his terminal. This capability allows for a text message to be entered as well as the name and contact information of the party making the feedback. As known in the service industry, and as discussed above, customer satisfaction is important and the faster a complaint can be registered and communicated to the proper person for correction, and then corrected, the more likely that a customer will view his experience favorably. By providing a pop up menu item capability, a user may from any one of a number of menus immediately enter the description of the problem and send it to the proper person electronically with a minimal amount of effort and a high degree of reliability. A convenient record may then be made of these “feedback” issues and entered into the system database. With this information stored electronically, it may be conveniently searched and analyzed for any recurring patterns, thereby identifying any particular person, branch, facility, or type of problem that should be addressed for action beyond the solution of the immediate problem. A “screen shot” is provided to illustrate how the “pop up” menu may appear, although it could be varied to allow for entry of other or additional information such as “trouble codes” allowing for the type of problem to be user classified, etc. A flow diagram is also provided to illustrate the flow for complaints, a methodology for processing them including escalating their importance and level of attention as the matter remains unresolved over time.
[0047] Still another feature that adds to the flexibility of the invention is a multiple adjuster feature, that can be extended to include an independent party control feature. In some countries, and in some business models either domestically or abroad, it may be preferable to have more than one adjuster be empowered to interact with or authorize certain facets of a vehicle rental transaction. In those situations, the invention can provide the flexibility and control needed to separately empower and control the interaction of multiple adjusters. For each user of the invention, an “Administration” schedule is set up by an authorizing agent, such as someone at the supervisory level of either the insurance company or the service provider, which grants authority for performing certain work activities as well as possibly limiting the amount of monetary authority allowed that adjuster. A “screen shot” is attached which exemplifies such authorization, with work activities including creating/authorizing reservations, maintain/extend rentals, pay invoices, user maintenance, receive unassigned action items, and reporting. This capability could be used to separately authorize different adjusters acting on behalf of the insurance company and the individual. In other words, the individual may need the car for 5 days but the individual's insurance coverage may only apply for 3 days while the insurance may pay for five days rental. This capability may also be further extended to independent third parties.
[0048] As extended for independent party management, this capability further adapts the invention for use with agencies such as “credit hire”, “lawyer”, “fleet management companies”, or “repair facility”, or “assist companies”, all of which are found in other than domestic markets. Included herewith is an attachment which further explains the different types of independent parties routinely found at present, and examples of “screen shots” which provide the additional functionality of customizing authorizations for each of these independent parties for interacting with a rental transaction.
[0049] Yet another feature provided by the invention is a facility for marketing cars for sale/lease to customers. As explained above, a customer will occasionally be forced to replace his vehicle at the same time that he is renting a vehicle for temporary use. Furthermore, the value of the replacement vehicle, or the approved value that an insurance company will allow under coverage, many times determines the available vehicles from which a customer will be allowed to select without personal expense. The invention is uniquely designed to provide a listing of available cars, and information about the cars, all from the existing rental car data base as is kept in routinely running the rental car company's main business of renting cars. It is a simple matter to provide a menu which allows a user to specify search through the car inventory with parameters such as zip code, vehicle category, make and model. Using any one or more of these parameters, a search inquiry will then produce a listing of available vehicles matching the parameters, along with additional information about the vehicle including mileage, selling price, and color as well as other accessories. A customer could then be advised of the search results and allowed to select a vehicle. The invention may, if agreed to by the insurance company, and possibly conditioned on the physical inspection of the car by the customer, then authorize the transfer of the vehicle to the customer as an outright settlement of his claim.
[0050] In implementing the replacement of the customers vehicle, a process preferably comprises the steps of an adjuster identifying the loss as a total loss which is preferably entered at the same time that a replacement vehicle rental is reserved, sending the vehicle data to a third party valuation tool for processing, determining the valuation of the vehicle by a suitable measure such as actual cash value (ACV), sending the ACV to the system, using the search function to identify possible replacement vehicles available for the customer, finalizing the replacement process with the customer including executing transfer of title documentation if desired, and posting the results of the vehicle replacement in the system for access by the insurance adjuster so that he can confirm that the customer's claim has been satisfied. A flow chart describing this process is attached for further explanation.
[0051] Various changes and modifications to the preferred embodiment as explained herein would be envisioned by those of skill in the art. Examples of these changes and modifications include the utilization of computer systems configured in any one of a myriad of ways using present technology alone. For example, mobile computers are presently available and wireless technology could be used to extend the integrated business network of the services provider, as well as match the mobility needed by the various users connected to and using the present invention. The particular software, and various aspects and features of its design, have been adapted for particular application to the vehicle rental business. Of course, computer software applications satisfying other business needs would necessarily require adaptation to their particular business models. Thus, it is envisioned by the inventors herein that the various software programs described herein would be matched to the particular business application to which the invention is utilized. These and other aspects of the preferred embodiment should not be viewed as limiting and instead be considered merely as illustrative of an example of the practical implementation of the present invention. These changes and modifications should be considered as part of the invention and the invention should be considered as limited only by the scope of the claims appended hereto and their legal equivalents. | An Internet enabled, business-to-business computerized transaction system is disclosed in its preferred embodiment for use in providing rental car services for high volume users and comprises an Internet web portal through which the high volume user may access a plurality of service providers including an integrated business computer network for at least one rental vehicle service provider. The rental vehicle services provider computer network is configured to interconnect a geographically diverse plurality of branch offices, cataloguing their available rental vehicles and schedules for same as well as handling all transactional data relating to its business. The Internet web portal provides ubiquitous connectivity and portability for a multi-level business organization who regularly places high volumes of rental purchases with its business partner and also those other service providers who may or may not have the same integrated business computer system and software. Utilizing the method and apparatus of the present invention large volumes of rental transactions may be placed, monitored, altered during performance, and closed out with financial accounting and payment being made virtually without human intervention. | 6 |
[0001] The present invention relates to an apparatus for providing percussive action in a rotary power tool, and to a rotary power tool incorporating such apparatus. The invention relates particularly, but not exclusively, to hammer action drills.
BACKGROUND OF THE INVENTION
[0002] Repeated hammering action is provided in drills for masonry and other hard materials. In one known type of hammer drill, a drill bit is carried in a chuck fixed to a working shaft which is driven via a gear from another shaft, the working shaft carrying the chuck being free to move axially over a small range of distances. A ratchet ring is fixed to the end of the working shaft opposite to the chuck end, and a corresponding ratchet ring is fixed to the body of the tool. One extreme of the allowable axial movement of the working shaft is set by the contact of the two ratchet rings, and this extreme is a function of the angle of rotation of the working shaft. When a user operates the tool, the working shaft is forced backwards such that the two ratchet plates come into contact with each other, and relative rotation of the ratchet rings causes a series of impulses to occur.
[0003] Ratchet ring arrangements of this type are relatively inexpensive to construct, but suffer from the drawback that the impulses acting on the working shaft and ultimately passing into the drill bit also have a reaction on the body of the tool, which results in substantial shaking of the tool. A further disadvantage is that friction losses between the two ratchet plates are relatively high.
[0004] A further known type of hammer drill which benefits from substantially lower tool body vibration, lower loss of torque at the instant of impact, and more effective impact in most cases because the impulses are generated closer to the drill bit, incorporates a flying striker mass. However, hammer drills of this type require direct axial excitation of the flying striker mass, as a result of which they are expensive to construct.
BRIEF DESCRIPTION OF THE INVENTION
[0005] Preferred embodiments of the present invention seek to overcome the above disadvantages of the prior art.
[0006] According to an aspect of the present invention, there is provided an apparatus for providing percussion action in a rotary power tool having a rotary output shaft, the apparatus comprising at least one moveable mass adapted to have a component of movement parallel to the axis of the rotary output shaft to cause impacts to be applied to a working member of the tool; and conversion means for intermittently converting rotary movement of the rotary output shaft into movement of at least one the moveable mass to cause the impacts to be applied to the working member.
[0007] By providing an apparatus in which rotary movement of a rotary output shaft is intermittently converted into linear movement of a moveable mass which then causes impacts to be applied to an working member such as a drill bit, this provides the advantage that the apparatus is less expensive to manufacture than an apparatus requiring direct axial excitation of a flying striker mass, while reducing wear of moving parts compared with the prior art apparatus using ratchet plates. The invention also has the advantage that because the conversion means intermittently converts rotary movement of the output shaft into movement of at least one moveable mass, under certain circumstances it is possible to arrange the frequency of the percussive impulse applied to the working member of the tool to be substantially independent of the rotational frequency of the output shaft. This is highly advantageous in the field of power tools, since a power tool such as a drill will have an optimum rotational frequency range within which its percussive action operates most efficiently, but the rotational frequency of the drill will reduce when the drill bit encounters resistance. As the rotational frequency of the drill changes, it is difficult to maintain the percussion action within its optimum frequency range if the percussion frequency is dependent upon the rotational frequency of the output shaft. By making the percussion and rotational frequencies substantially independent of each other, this problem can be overcome.
[0008] The conversion means is preferably adapted to convert said rotary movement of the rotary output shaft into movement of at least one said moveable mass in a direction substantially parallel to the axis of rotation of the rotary output shaft. The conversion means may be adapted to intermittently convert rotary motion of said rotary output shaft into movement of at least one said moveable mass such that times when said conversion means converts said rotary movement of the rotary output shaft into movement of at least one said moveable mass alternate with times when impacts are applied to the working member. This provides the advantage of reducing the extent to which the percussion action transfers impulses to the motor of the tool, which could otherwise cause damage to the tool.
[0009] The apparatus may further comprise at least one impact member adapted to be impacted by at least one said moveable mass to cause impacts to be applied to the working member, wherein at least one of the mutually impacting surfaces of at least one said impact member and the corresponding movable mass are so shaped that energy associated with said mutual impacts is not dissipated substantially by air damping. This provides the advantage of minimising energy loss through rapid expulsion of air as said moveable mass applies a percussive impulse to the working member of the tool. At least one of said mutually impacting surfaces may be non-planar.
[0010] The conversion means may include at least one helical spring. The conversion means may further comprise restraining means for resisting expansion of the or each said helical spring in a radial direction. The restraining means may comprise at least one hoop, pin or strut mounted within at least one said spring.
[0011] The apparatus may further comprise clutch means having a first clutch member adapted to rotate with said rotary output shaft, and a second clutch member connected to said conversion means and adapted to intermittently engage said first clutch member and be rotated thereby to cause movement of at least one said moveable mass. The second clutch member may be adapted to disengage from said first clutch member when the or each said moveable mass applies an impact to said working member.
[0012] The second clutch member may include a substantially frustoconical outer surface adapted to frictionally engage a corresponding surface of said first clutch member. The cone angle of said substantially frustoconical outer surface is preferably not less than the friction angle between said substantially frustoconical surface and the corresponding surface of said first clutch member. This provides the advantage of minimising the risk of the second clutch member becoming wedged on the first clutch member.
[0013] The apparatus may further comprise rotation resisting means for causing relative rotation between said rotary output shaft and at least one said moveable mass. This provides the advantage of maximising the extent of actuation of said conversion means. The rotation resisting means may comprise means for resisting rotation of at least one said moveable mass relative to the housing of the tool. The rotation resisting means may be magnetic.
[0014] The apparatus may further comprise biasing means for biasing at least one said moveable mass in such a direction as to actuate said conversion means. The biasing means may include at least one spring. The biasing means may be magnetic.
[0015] According to another aspect of the present invention, there is provided a rotary power tool comprising a housing, drive means for causing rotation of a rotary output shaft, a rotary output shaft connected to said drive means, and an apparatus as defined above. The tool may further comprise de-actuating means for de-actuating said apparatus.
[0016] Limited axial movement of said rotary output shaft relative to the location at which at least one said moveable mass applies a percussive impulse to said working member may be possible. This provides the advantage of minimising transfer of said impulse to the drive means, which could otherwise cause damage to a drive means such as a motor.
[0017] The tool may further comprise at least one further shaft adapted to be rotated by means of, and move axially relative to, said rotary output shaft. At least one said further shaft may be splined and substantially co-axial with said rotary output shaft. At least one said further shaft may be radially separated from said rotary output shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Preferred embodiments of the invention will now be described, by way of example only and not in any limitative sense, with reference to the accompanying drawings, in which:
[0019] [0019]FIG. 1 is a side cross-sectional view of part of a first embodiment of the hammer drill of the present invention;
[0020] [0020]FIG. 2 is a perspective view of part of a second embodiment of a hammer drill according to the present invention;
[0021] [0021]FIG. 3 is a further perspective view of the apparatus of FIG. 2;
[0022] [0022]FIG. 4 is a side cross-sectional view of the apparatus of FIGS. 2 and 3;
[0023] [0023]FIG. 5 is a schematic side cross-sectional view of part of a third embodiment of a hammer drill of the present invention; and
[0024] [0024]FIG. 6 is an enlarged view of region A of the drill of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIG. 1, a hammer drill 1 includes a percussive hammer apparatus mounted to a working shaft 2 of the drill. The working shaft 2 is rotated at a generally steady rotational speed by means of a motor (not shown) via a gear reduction mechanism including an integral gear 3 on working shaft 2 . The working shaft 2 is mounted to a housing 4 of the drill by means of bearings 5 , 6 .
[0026] The apparatus 1 includes a first mass 7 connected via a helical spring 8 to a second mass 9 , the second mass 9 being larger than the first mass 7 . The first mass 7 and second mass 9 are free to slide and rotate relative to the working shaft 2 , but the second mass 9 is prevented from rotating relative to the housing 4 by means of a pair of parallel bars 10 .
[0027] The first mass 7 has a generally frustoconical outer surface 11 which mates with a corresponding frustoconical surface 12 on integral gear 3 such that when the frustoconical surfaces 11 , 12 are fully in contact with each other, the cone angle, which is around 15°, causes a relatively large frictional torque for a relatively small amount of axial force pushing the first mass 7 into contact with the integral gear 3 . The cone angle is not less than the friction angle tan −1 μ, where μ is the coefficient of friction between first mass 7 and integral gear 3 , as a result of which the first mass 7 does not become stuck in engagement with frustoconical surface 12 when the spring 8 exerts any traction force tending to pull the first mass 7 away from the integral gear 3 .
[0028] At the limiting value of this condition (i.e. when the cone angle is exactly equal to tan −1 μ) the net frictional torque between the integral gear 3 and the first mass 7 has a maximum value of RF S , where R is the mean radius of frustoconical surface 11 and F S is the compression force in the spring 8 .
T S =RF S
[0029] The characteristics of the helical spring 8 are such that it causes a coupling between twist and axial compression/extension deformation. For some limited range of deformation, the torque and compression force in the spring are generally linearly related to the axial compression deformation and twist deformation of the spring through three spring constants k FF , k FT , k TT as follows:
[ F S T S ] = [ k FF k FT k FT k TT ] [ δ α ]
[0030] In which F S and T S are the compression force and torque in the spring, and δ and α are the compression deformation and twist deformation of the spring respectively. Spring constants k FF , k TT , and k FT are the spring constants corresponding to compression, twist, and combined compression and twist respectively. The torque is defined such that positive T S corresponds to a torque tending to accelerate the second mass 9 in the same direction as the rotation of the working shaft 2 .
[0031] The general increment in stored energy ΔSE in the spring for a change in deformation Δδ, Δα is as follows:
Δ SE=F S. Δδ+T S. Δα=k FF δ.Δδ+k FT α.Δδ+k FT δ.Δα+k TT α.Δα
[0032] the total stored energy SE therefore being
SE= 1 / 2 k FF δ 2 +k FT δα+ 1 / 2 k TT α 2
[0033] this is positive for all values of δ and α if
(k FF k TT )−(k FT ) 2 ≧0
[0034] Provided that k FT is positive (i.e. the handedness of the helical spring is such that turning the end nearest the integral gear 3 in the direction of rotation of the working shaft 2 tends to elongate the spring 8 ) then the presence of any torque at the interface between the first mass 7 and integral gear 3 will tend to increase the axial force reacted at the contact between frustoconical surfaces 11 , 12 and therefore increase the maximum possible interface torque.
[0035] The characteristics of the spring of the apparatus of the present invention are therefore chosen such that the existence of any positive torque at the interface between frustoconical surfaces 11 , 12 rapidly leads to the elimination of any rotational slip. It follows that the spring characteristic should be such that any increase in T S. ΔT S , which takes place without extension of the spring should result in an increase in F S. ΔF S. greater than ΔT S /R. This condition is satisfied if k FF R is greater than k FT .
[0036] The rotation of the first mass 7 causes axial movement of the second mass 9 , which delivers percussive impulses to an impulse face 13 mounted on the working shaft 2 near to a chuck 14 to which a drill bit (not shown) is mounted. The second mass 9 has a recess 15 adjacent the working shaft 2 to minimise energy loss caused by rapid expulsion of air from between two parallel surfaces. The second mass 9 is biased by means of a pair of springs 16 towards the integral gear 3 .
[0037] The operation of the hammer drill 1 shown in FIG. 1 will now be described.
[0038] If the working shaft 2 is rotating at a steady rotational speed and the first mass 7 , second mass 9 and spring 8 are initially stationary and the first mass 7 is not in contact with the integral gear 3 , the small pre-load force of springs 16 urges the first mass 7 into contact with the integral gear 3 . At the moment of contact, a torque at the interface between frustoconical surfaces 11 , 12 rotates first mass 7 and increases the compressive force in helical spring 8 .
[0039] The increase in compressive force increases the frictional torque between integral gear 3 and first mass 7 , which rapidly causes the interface to lock so that the first mass 7 has the same angular velocity as the working shaft 2 . Because the second mass 9 is prevented by parallel bars 10 from rotating with the first mass 3 , the helical spring 8 then begins to acquire twist, as a result of which the axial compression force in the helical spring 8 increases significantly.
[0040] As a result, the second mass 9 is urged towards impulse face 13 while the spring has a compressive force. The compressive force of spring 8 then decreases, causing the first mass 7 to separate from integral gear 3 , and the second mass 9 then strikes impulse face 13 . The second mass 9 is then urged by springs 16 back towards integral gear 3 to bring first mass 7 into contact with the integral gear, and the process then repeats itself. After a small number of cycles, the system develops a steady state behaviour in which there is a regular impulse, and the frequency of this impulse is set largely by the mass of the second mass 9 and the characteristics of helical spring 8 . It is therefore found that this frequency is generally insensitive to the rotational speed of the working shaft 2 .
[0041] Referring now to FIGS. 2 to 4 , in which parts common to the embodiment of FIG. 1 are denoted by like reference numerals but increased by 100, a hammer drill 101 of a second embodiment of the invention has a first mass 107 connected to a second mass 109 by means of a helical spring 108 including three individual helices 120 , 121 , 122 which are connected together by means of a series of rings 123 . The spring 108 of the embodiment of FIGS. 2 to 4 has the advantage of minimising radial expansion of the spring 108 as it acquires twist, which may otherwise reduce the extent to which the spring 108 converts rotary movement of first mass 107 into axial movement of second mass 109 .
[0042] Referring to FIGS. 5 and 6, in which parts common to the embodiment of FIG. 1 are denoted by like reference numerals but increased by 200, a hammer drill 201 of a third embodiment of the invention has a working shaft 202 comprising a rear part 202 a fixed relative to integral gear 203 and motor (not shown), and a front part 202 b which is axially slidable to a limited extent relative to the rear part 202 a. As shown in greater detail in FIG. 6, which is an enlarged schematic view of region A in FIG. 5, the rear part 202 a and front part 202 b are connected to each other by means of a generally frustoconical projection 230 on rear part 202 a (shown in dotted lines in FIG. 6), which is received in a correspondingly shaped recess in the front part 202 b. The front and rear parts 202 a, 202 b are splined, i.e. provided with ridges and grooves 231 so that when the front part 202 b is in mating contact with the rear part 202 a, rotation of the rear part causes corresponding rotation of the front part.
[0043] In the third embodiment of FIGS. 5 and 6, when the second mass 209 strikes impulse face 213 , part of the impulse delivered to the housing (acting towards the right in FIG. 5) is transferred to the front part 202 b of working shaft 202 . This causes front part 202 b to move to a limited extent to the right in FIGS. 5 and 6, which minimises the extent to which the impulse is transmitted via rear part 202 a to the motor. This in turn minimises the extent to which the impulse transmitted to the tool housing is transferred via working shaft 202 to the motor, which could otherwise damage the motor.
[0044] It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only, and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims. For example, instead of providing a working shaft 202 which consists of two parts 202 a, 202 b which can move axially relative to each other, it is possible to minimise the extent to which the impulse delivered to the tool housing is transferred back to the working shaft 202 by rotating the drill bit by means of a further shaft parallel to the working shaft 202 , so that the working shaft does not need to be in direct engagement with the motor. Also, it is possible to provide means to selectively disengage the hammer action of the present invention, for example by providing means for permanently disengaging the first mass 7 from the integral gear 3 and/or clamping the second mass 9 to the impulse face 13 when not in hammer mode (i.e. when in conventional drilling mode). | An apparatus for providing percussion action in a rotary power tool having a rotary output shaft, the apparatus comprising at least one moveable mass adapted to have a component of movement parallel to the axis of the rotary output shaft to cause impacts to be applied to a working member of the tool; and conversion means for intermittently converting rotary movement of the rotary output shaft into movement of at least one the moveable mass to cause the impacts to be applied to the working member. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of pending PCT/US2008/000677 filed on Jan. 18, 2008.
TECHNICAL FIELD
[0002] The field of this invention relates to a riding apparatus for treating a floor surface with a power cord handling swing arm.
BACKGROUND OF THE DISCLOSURE
[0003] Concrete floors are common today in large, medium and small retail stores, manufacturing and production facilities, warehouses, automotive shops and service centers, shopping centers, sidewalks, garages, commercial buildings and residential basements. The strength of concrete provides the durability and rigidity required in these environments. However, the exterior surface of a newly poured concrete floor, once dry, is often rough, uneven, and provides a dull appearance. Furthermore, when left in this unfinished state, the concrete will inherently produce dust particles from the constant scuffing, whether it is from foot traffic or wheeled traffic that can build over time and become a nuisance to those who work and/or live in these environments. It is well known to first grind the concrete surface and then coat the surface with a sealant to smooth the concrete, to make it aesthetically pleasing to the eye, and to help reduce dust particles.
[0004] In the grinding process, commonly used grinding machines usually have a planetary or direct drive belt and gear drive systems containing a plurality of circular drive plates mounted to gears on a deck with removable abrasive pads attached to each drive plate. These grinding machines may also be referred to as grinding, honing, abrasive or abrading machines. They may also be referred to as polishing and cleaning machines. Hereinafter, the term “polishing and cleaning” is used in the generic sense and includes abrasion, scrubbing, sweeping, honing, grinding, sanding and/or abrading, cleaning and polishing. These types of machines can also be referred to as an apparatus for treating a floor surface. The term “treating a floor surface” as used herein can mean cleaning, abrading, sanding, scrubbing, sweeping, polishing, grinding or honing a floor surface. These polishing and cleaning machines may typically be electric walk along machines where an operator stands behind the machine and pushes it along at a certain pace such that the deck sufficiently grinds, abrades, hones, polishes and or cleans the floor surface. These walk along configurations can produce fatigue in the operator and the operator's position behind the machine prevents a clear view of the floor surface until the floor surface passes under the operator's feet well behind the deck. Thus if a spot on the floor is missed or not adequately prepared, the operator may need to back up a distance to redo the spot.
[0005] Riding polishing and cleaning machines are known but have had certain drawbacks. Firstly, some are large using standard tractor bodies powered by internal combustion gas, diesel or propane engines. The exhaust from such gasoline, diesel or propane engines makes it less desirable to use within an interior confined space. The use of internal combustion engines and hydraulic drive systems also introduces the significant probability that there may be leakage of oil, petroleum based or synthetic based lubricant or fluid onto a porous cured top layer of concrete or an even more porous substrate. Any leakage or spillage of oil, gasoline diesel fuel or grease onto the surface will be readily and permanently absorbed into the concrete and leave a permanent stain that will never yield a proper polished surface free of stains. Furthermore the oil, grease, or lubricant can contaminate the cutters or other grinding, and polishing pads or tools.
[0006] In addition, many of these machines are quite large and the operator has no view or a poor view of the floor after the deck passes over. Thus on-the-spot quality control for just prepared floor surface is extremely difficult.
[0007] Riding polishing and cleaning machines have had awkward configurations with either rear positioned seating or enclosed cab seating for the operator which blocks his view. Other machines have open high precarious seating which can make the operator feel vulnerable or unsafe in such a high open position from the floor.
[0008] Electric powered riding polishing and cleaning machines are also commercially utilized. While the wheels and vehicular controls are powered by on board rechargeable batteries, the proper high pressure, torque and speed power needed for the cleaning and abrasive deck is too demanding for present day battery technology so the electric power is provided through a power cord from a remote power supply. The power cord often intrudes in the way of the apparatus wheels and deck particularly when the ride on machine is heading in the direction back toward the power supply. A significant amount of time is spent by the operator manually getting off the vehicle to move the cord out of the way of the vehicle.
[0009] Another difficulty with the known riding polishing and cleaning machines is the difficulty in changing the grit pads or cutters when the grit pads or cutters become worn. Replacing the worn pads or cutters, or in some cases replacing the entire deck is both burdensome and time consuming to the user.
[0010] Another common problem is dust control. Often the vacuum system at the deck picks up only about 80 percent of the generated dust. The remaining dust must be picked up by a sweeping deck. Previous sweeping decks have been an integral part of the ride-on apparatus's chassis. As such when uneven flooring or an obstacle is encountered, the sweeping apparatus can be jammed or not provide the necessary ground clearance.
[0011] What is needed is a riding polishing and cleaning apparatus that allows an operator a relatively low seating position and have direct view of the floor surface behind the cleaning and abrasive deck. What is also needed is a riding polishing and cleaning apparatus that has a power cord handling system. What is also needed is a riding polishing and cleaning apparatus that has a sweeping deck that is vertically adjustable with respect to the apparatus chassis. What is also needed is a riding polishing and cleaning apparatus that has an easily liftable, tillable and disengageable polishing and cleaning deck.
SUMMARY OF THE DISCLOSURE
[0012] In accordance with one aspect of the invention, a riding apparatus for treating a floor surface has a main motorized vehicle with steering and drive wheels and a forwardly located seat for an operator and left and right foot rests for feet of the operator. A polishing and cleaning deck is mounted in front of the vehicle and is operably connected thereto to be moved thereby with a clearance formed between a front of the main motorized vehicle and a rear of the polishing and cleaning deck. The left and right foot rests are spaced apart to form a gap therebetween with the gap and the clearance aligned with the seat located for providing a line of sight for the operator through the gap and clearance to see the floor surface between the polishing and cleaning deck and the main motorized vehicle.
[0013] Preferably, the vehicle has a low profile rear body section positioned to have its upper surface located below the normal eye level of the operator when seated on the seat such that a full 360 degrees field of vision to the rear is directly available to an operator. The upper surface of the vehicle body is desirable sloped downwardly from a position immediately behind the seat to a rear end of the riding apparatus.
[0014] According to another aspect of the invention, an upper positioned swing arm is pivotably connected about a substantially vertical pivot axis point behind and above the operator seat and constructed to horizontally swing to the left and to the right of a rearwardly extending position down a center line of the main motorized vehicle. The swing arm has a length more than one-half the width of the vehicle such that the swing arm has sufficient length to extend the restrained section of the cord beyond a left and right side of the vehicle when swinging to its full left or right position. The power cord has a restrained section near a distal end of the swing arm and operably connected to the polishing and cleaning decks for transferring electric power to the deck. Preferably, the pivot is constructed to provide the swing arm to swing approximately 90 degrees to either side of the centered rearwardly extending position.
[0015] In one embodiment, the vehicle has two front wheels and a rear wheel. The rear wheel is steerable and operably connected to an electric motor for driving the vehicle. The electric motor is powered by an on-board battery source that is directly and continuously rechargeable via the main onboard power supply vehicles main power supply when powered on and during vehicle operation.
[0016] It is desirable that the polishing and cleaning deck is pivotably connected along a generally horizontal laterally extending axis to the vehicle through a front distal end of a raisable link arm such that the deck can be pivoted to a generally vertical position to expose the underside of the deck when the deck is in a raised position off of the floor surface. Preferably the link arm has a notch at a distal end and a closable latch for being movable between a closed position to retain the deck to be pivotably mounted to the link arm and an open position to allow the link arm to vertically move to disengage from the deck when in its lower floor engaging position.
[0017] According to another aspect of the invention, a riding apparatus for treating a floor surface has a sweeping deck mounted under the vehicle behind the polishing and cleaning deck through a linkage that provides relative vertical movement with respect to the vehicle. The sweeping deck comprises a motorized brush for sweeping a floor, a hopper for receiving dust from the brush and a castor wheel for providing a lower stop for the sweeping deck. Preferably, a vacuum system is operably connected to collect dust from both the polishing and cleaning deck and the hopper in the sweeping deck.
[0018] The linkage system includes a lifting actuator to raise the sweeping deck and when in a floor engaging position allows the sweeping deck to automatically lift, i.e. float upwardly, with respect to the vehicle body when encountering a raised floor surface or obstacle under the vehicle body wheels to prevent the sweep deck from jamming the roller brush.
[0019] In accordance with another aspect of the invention, a power cord handling system for a riding apparatus with a polishing and cleaning deck for treating a floor surface powered from a power cord includes an upper positioned swing arm pivotably connected to the riding apparatus about a substantially vertical pivot axis to horizontally swing the swing arm to the left and to the right of a rearwardly extending position when a torque is exerted thereon. The power cord has a restrained section near a distal end of the swing arm and operably connected for providing electric power to the polishing and cleaning deck. The swing arm has a length more than one-half the width of the vehicle such that the swing arm has sufficient length to extend beyond a left and right side of the riding apparatus when swinging to its full left or right position to position the restrained section of the power cord beyond the respective left and right side of the vehicle. A stop mechanism prevents the swing arm from further horizontal rotation beyond its full left and full right position. A remote power cord reel assembly allows the power cord to be unreeled therefrom when the riding apparatus is moving away from the reel assembly and constructed to substantially take up slack of the power cord when the riding apparatus is moving toward the reel assembly.
[0020] Preferably the reel assembly having a spring loaded rotatable reel and a weighted frame to stabilize against horizontal torque force exerted by the spring loaded reel.
[0021] In accordance with another aspect of the invention, an electric powered riding apparatus for treating a floor surface has a motorized vehicle and a power cord extendable from the apparatus to an electric source. A jointed swing arm has a proximate arm member pivotably connected about a vertical axis to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm section and has a retainer for mounting the power cord. The distal arm member is resiliently biased to extend straight out with respect to the proximate arm member.
[0022] The swing arm is dimensioned to extend the distal arm section beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to allow bending of the distal member with a side force above the predetermined amount.
[0023] Preferably, the swing arm is dimensioned to extend at least from its pivotable connection to the vehicle to a rear corner of the vehicle. The proximate arm member has a length no more than one-half the width of the vehicle such that the pivot vertical axis is always within the side extent of the vehicle.
[0024] In one embodiment, the spring member having sufficient force to maintain the distal arm member straight with respect to the proximate arm member against normal drag forces exerted by the power cord on the floor surface and able to resiliently bend upon the distal arm member abutting against a building support column. The proximate arm member and distal arm member have a mechanical stop therebetween which stops the bending of the distal arm member at approximately 90 degrees with respect to the proximate arm member. The distal arm member has a raised arm section that overlays the proximate arm member. The raised arm member is connected to the spring member. The spring member has an opposite end connected to the proximate arm member. The spring member is preferably in the form of a gas spring having a tubular cylinder member and rod extending from the tubular cylinder member. The distal end of the distal arm member may have at least one roller member pivotably attached about a vertically oriented pivot axis.
[0025] According to another aspect of the invention, a swing arm for managing a power cord to an electric vehicle has a proximate arm member with a pivotable connection about a vertical axis for connection to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm member and is resiliently biased to extend straight out with respect to the proximate arm member. The swing arm is dimensioned to extend the distal arm member beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to bending of the distal arm member upon exertion of a side force above the predetermined amount.
[0026] In accordance with another aspect of the invention, an electric vehicle has a power cord extendable from the vehicle to an electric source. A swing arm has a length extending a least one-half of the width of the vehicle to extend beyond a selected one of the left and right side of the vehicle when swung to a respective full left and right position from a rearwardly extending center position about a substantially vertical pivot axis point. The swing arm has a connection for retaining the power cord near a distal end of the swing arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Reference now is made to the accompanying drawings in which:
[0028] FIG. 1 is a top perspective view showing a riding apparatus for treating a floor surface according to one embodiment of the invention with a vehicle panel removed to expose the interior;
[0029] FIG. 2 is an enlarged fragmentary view with the deck shell removed illustrating the polishing and cleaning deck and its mounting frame shown in FIG. 1 ;
[0030] FIG. 3 is a top plan view of the riding apparatus shown in FIG. 1 with the deck shell and vehicle panels removed to show the interior components;
[0031] FIG. 4 is a fragmentary bottom perspective view of the polishing and cleaning deck illustrating the vacuum hose intakes;
[0032] FIG. 5 is a side elevational view of the riding apparatus illustrating a person's field of vision and the lifting and tilting of the front deck to expose the underside of the polishing and cleaning deck;
[0033] FIG. 6 is an enlarged side elevational view illustrating the polishing and cleaning deck's connecting linkage to the main vehicle body of the riding sander;
[0034] FIG. 7 is a fragmentary side elevational view of the floating sweeping deck under the main vehicle body;
[0035] FIG. 8 is an enlarged elevational view from the other side of the sweeping deck;
[0036] FIG. 9 is a fragmentary top plan view illustrating an optional edge grinder and polisher attached to the polishing and cleaning deck;
[0037] FIG. 10 is a side elevational view illustrating the power chord connection to a take up reel and power source;
[0038] FIG. 11 is an enlarged side elevational view of the power chord reel shown in FIG. 10 ;
[0039] FIG. 12 is a top plan view schematically illustrating the position and motion of the riding apparatus and the swing arm during typical back and forth use of the riding apparatus;
[0040] FIG. 13 is a schematic side elevational view of a riding apparatus with a second embodiment of a swing arm;
[0041] FIG. 14 is an enlarged top plan view of the swing arm shown in FIG. 13 ;
[0042] FIG. 15 is a side elevational view of the swing arm shown in FIG. 14 ;
[0043] FIG. 16 is a top plan view of the proximate arm member shown in FIG. 14 ;
[0044] FIG. 17 is a top plan view of the distal arm member shown in FIG. 14 ;
[0045] FIG. 18 is a top plan view showing the distal arm member being pivoted to a 90 degrees angle with respect to the proximate arm member;
[0046] FIG. 19 is a top plan view of a third embodiment of a swing arm having three rollers on the distal arm member;
[0047] FIG. 20 is a schematic top plan view of the riding apparatus shown in FIG. 13 moving in a forward direction;
[0048] FIG. 21 is a schematic top plan view of the riding apparatus shown in FIG. 20 moving in a rearward direction and angled to change its floor line;
[0049] FIG. 22 is a schematic top plan view of the riding apparatus shown in FIG. 21 after it has moved to its new floor line and moving in a reverse direction;
[0050] FIG. 23 is a view similar to FIG. 22 where the swing arm commences abutment with a building column and the distal arm member begins to pivot toward the front of the vehicle as the vehicle moves rearwardly; and
[0051] FIG. 24 is a view similar to FIG. 23 showing the swing arm distal arm member fully pivoted to a 90 degrees position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] Referring now to FIG. 1 , a riding apparatus 10 for treating floor surfaces has a battery operated main vehicle body 12 , a forwardly positioned polishing and cleaning deck 14 , a sweeping deck 16 , and a swing arm 18 for a power cord 20 .
[0053] The vehicle body 12 has a forward positioned operator seat 22 with controls 24 readily positioned for hand operation to control speed, direction and other needed vehicle and deck functions and foot controls 26 , for example a brake and transmission clutch. The seat 22 is positioned over the electric batteries storage container 27 . The electric batteries 31 stored in container 27 as shown in FIG. 3 can be conventional lead acid type or any state of the art battery that powers the vehicle motion. The seat 22 is also aligned above an axis 29 defined by the two front wheels 28 .
[0054] Two foot rests 30 are positioned apart to rest the operator's left and right feet. A gap 32 is formed between the two foot rests 30 . The gap 32 is aligned over the clearance 37 between the center section of the polishing and cleaning deck 14 and the main vehicle body 12 to provide a line of sight to the floor surface. Side vented windows 33 to the inside of the front wheels 28 also provide a line of sight to the floor surface behind the left and right side sections of the front deck 14 . The side vented windows 33 have a support grate 35 that can be used as a single step for an operator 62 to access seat 22 .
[0055] As shown more clearly in FIGS. 2 , 3 , and 4 , three cleaning and abrasive heads 36 that are operated by electric motors 38 are housed within shell 34 . The electric heads 38 are powered from a remote power source delivered through a power chord as described later. The heads 36 are mounted to a deck frame 40 . The deck frame has a horizontally disposed round bar 42 which engages an operable claw end 44 of two parallel arms 46 .
[0056] As shown in FIG. 5 , the arms 46 are operated and powered to move between a lower operating position and raised service position to lower the deck 14 onto the floor surface and also to raise the deck 14 . The arms 46 may be power operated for example by hydraulic cylinders 48 through a linkage 49 between the raised and lower positions as shown in FIG. 6 . In addition, the hydraulic cylinder 48 can provide extra force in the lower position to add some of the weight of the vehicle 12 onto the deck 14 when more downward force is needed during the more aggressive grinding and abrasive operation of the deck 14 . For example, the cylinders 48 can lift the front wheels 28 off of the floor to add the weight to the deck 14 . It is foreseen that hydraulic cylinder 48 can be replaced by other types of power mechanisms, such as electrically driven devices. This use of downward force from the main vehicle eliminates the need of external weight and its associated cumbersome carrying, storing and handling.
[0057] Furthermore the frame 40 can pivot within the claw end 44 to pivot to deck 14 to a service position shown in FIG. 5 to expose the disc pad under each head and access the underside of all the disc heads 36 . A removable handle 50 may engage a horizontal grip tube 51 so that an operator can manually pivot the deck 14 . One of several types of locking devices may be engaged to keep the deck 14 in this servicing position. It is noted that the use of the single lever 50 rotates the entire deck including all three heads 36 in one pivoting motion. The deck is raised sufficiently high to assure that the side heads 36 also clear the floor during this pivoting motion. Optionally, the round tube 42 may have a cam lever thereon to be operated by a hydraulic cylinder or linear actuator for power pivoting of the deck. A linear actuator when used can double as a lock due to its worm gear ratio inherently designed therein.
[0058] As shown in FIG. 6 , the deck 14 can be disengaged from the vehicle and arms 46 by opening of the claw end 44 , further lowering of the arms 46 to clear the claw end 44 from the round bar 42 and moving the vehicle 12 rearwardly to leave the deck 14 on the floor. Before the vehicle rearward movement, the flexible central vacuum hose 52 can be disconnected as well as any quick connect wiring plugs that provide the power to the electric motors 38 . Reversing the process, reattaches the claw end 44 with the bar 42 . The claw end 44 can be retained in the closed position by a standard lock mechanism for example a clevis pin and retaining hairpin style clip. Alternatively, the claw end 44 opening and closing can be automated and further expedited for example by use of a pneumatic cylinder, electric linear actuator or a remotely operated manual linkage. In this way, the vehicle 12 quickly and can easily switch decks 14 when desired i.e. when decks have different grit pads 70 thereon or switching from a grinding and/or polishing deck to a cleaning deck. In other words, a second deck 14 may be on the floor surface ready to be engaged with the main motorized vehicle 12 after the first deck 14 is disengaged.
[0059] The round bar 42 is positioned by locating it at or near the fore and aft center of gravity of the deck 14 . The round nature of the bar 42 also allows the deck 14 to pivot thereabout to automatically become horizontal. The front claw 44 provides sufficient clearance for the bar 42 to rotate therein when the claw is in the closed and locked position. As shown with the three heads 36 as positioned, the bar is behind the electric motor 38 of the center head and slightly in front of the electric motors 38 of the left and right heads 36 to achieve the center of gravity balance.
[0060] The hydraulically operated arms 46 are operated by hydraulic cylinder 48 through linkage 49 that pivots the arms 46 about a rear connection bar 68 which lifts the entire deck 14 including the round bar 42 , all the heads 36 , and frame 40 . Furthermore as shown, easy access to abrasive pads or cutters 70 may be further enhanced by pivoting of the deck about round bar 42 to place the operating underside 72 of the deck 14 in a forward direction. The easy accessibility allows for ease in changing the pads 70 when needed.
[0061] Referring to FIG. 4 , the central vacuum hose 52 is connected to a vacuum manifold 54 . Vacuum hoses 56 connect the central manifold 54 to two similar side manifolds 58 . The manifolds 54 and 58 connect to the respective heads 36 . The central vacuum hose 52 leads to the vacuum system to the rear of the operator as described later. The vacuum manifolds 52 and 58 are in communication with the interior of heads 36 through apertures 59 .
[0062] As shown in FIG. 5 , an operator 62 is seated in a forward position at the front end of the vehicle 12 and behind the deck 14 . The vehicle is constructed to provide a greatly enhanced view of the floor surface by operator 62 . Firstly, by being up front, the operator 62 has a much better angle to see the floor surface just before it goes under the deck as indicated at 59 . Secondly, the clearance 37 between the rear of the deck 14 and the front of the vehicle 12 and the gap 32 between the foot rests 30 allow for visual viewing of the floor surface after the deck passes over behind the center abrasive head 36 to the area 59 of the floor. Thirdly, the windows 33 allow the operator 62 a line of sight to each area 61 of the floor behind the other two side heads 36 inside of wheels 28 . This visibility just behind all three heads provide real time monitoring of the floor surface and any defects that are discovered can be immediately corrected. To aid in illuminating the floor, optional lights, such as lamps 65 and others (not shown) may be installed on and under the vehicle and aimed to these floor areas 55 , 59 and 61 .
[0063] In addition, the low profile of the body 12 well below the operator's head allows for rear visibility without the need of mirrors to facilitate good vision at the corners during turns and also during rearward motion when necessary. The low profile of the entire vehicle 12 provides for the seat 22 to be relatively close to the floor but still provide a commanding view fully about the vehicle. Furthermore, the low profile provides a security measure and a feeling of safety for the operator 62 as compared to high open cockpit positions found in the prior art. For example, it is feasible to obtain the seat cushion to be 35″ to 45″ high off of floor.
[0064] As shown in FIG. 5 , the vehicle has a single rear wheel assembly 80 that is both powered and steerable to maneuver the vehicle 12 . The use of joystick 82 on the front control panel 24 can be used to steer the rear wheel. Alternatively a conventional steering wheel can also be used. One suitable drive wheel is sold under the Metalrota trademark and can give 180 degree steering or turning capability i.e. 90 degrees in each direction.
[0065] Dust control is accomplished by several separate systems. The first vacuum system picks up dust inside the bowls of grinder heads 36 through the apertures 57 as shown in FIG. 4 and through hoses 54 and 52 which are operably connected to an inlet 63 of first stage centrifugal separator 64 shown in FIG. 3 which functions as a pre-cleaner that spins the heaviest solids into a disposable bag lined container 66 . The outlet of the centrifugal separator is drawn into a four stage vacuum motor 68 whose outlet 74 is connected to an envelope filter bag 76 which filters the remaining smaller particles before the air is expelled out through the filter media to the ambient atmosphere. The filter bag 76 has filter media therein which can be cleaned by a backflush system for reversing air flow in a forceful and pulsing fashion to unplug or clean the filter media. This can be accomplished for example by an electrically driven air pump pressurizing an accumulator tank. A dump valve electrically is coupled to a 5 or 6 position switching valve which can be plumbed to the individual bag type filter media. A timer is used to time the dump valve or a pressure switch is used to empty the accumulator tank.
[0066] A second dust controller includes a sweeping deck 16 suspended under the vehicle 12 . As shown more clearly in FIGS. 7 and 8 , the sweeping deck 16 includes a frame 84 that is suspended via cables 86 or parallel rods to the vehicle 12 . A hopper 88 is mounted under the frame and has an open side 89 facing a powered roller brush 90 . The hopper 88 is also connected to the vacuum system to evacuate the dust therein to the vacuum system as described above and maintain the hopper in a condition for receiving more dust from the roller brush. The size of the hopper can thus be significantly reduced to an amount correlated with higher CFM (Cubic Feet per Minute) rated vacuums. The roller brush 90 is powered by a motor 92 mounted to the broom arm 94 and belt driven thereby. The broom arm 94 is pivotably adjustable through a wear adjustment knob 96 to maintain proper contact of the brush to the floor as the bush wears and its diameter decreases as shown in phantom in FIG. 8 . The open side 89 may be closed by a door panel 91 when the apparatus is wet scrubbing to prevent wet slurry from entering the hopper 88 .
[0067] The entire sweeping deck can be lifted by an actuator 98 that is connected to the frame 84 through a non rigid cable 100 . The non rigid connection allows the rear caster 102 to act as a stop. The non rigid cable 100 prevents the actuator from overloading the casters or the deck would fail to be in the proper position to the floor. In addition should a collision object be encountered by the sweeping deck, the non rigid link 100 allows the entire sweep deck to float over the collision object and thereby minimize damage. Alternatively, the non rigid cable 100 may be replaced by a rigid linkage that is connected via a vertical oriented slot that allows relative vertical movement between the linkage and either the actuator or the sweeping deck 16 to accomplish the same effect. Furthermore, the sweeping deck 16 if damaged can be easily removed from the existing machined for ease of service without disabling the remainder of the vehicle 12 . A replacement sweeping deck can be easily substituted for a damaged one if necessary.
[0068] Dust wipers (e.g. elastomeric squeegees or brushes) 105 are mounted in front of each front wheel 28 to direct dust inwardly to the inside track of the front wheels 28 . Thus the wheels 28 track through less dust and the dust is directed toward the sweeping deck and roller brush 90 . The wipers may be mounted approximately 45 degrees away from the line of travel to redirect the dust inwardly.
[0069] A rear seal assembly 104 includes a recirculation flap 106 and a rear flap 108 both mounted to a hook frame 110 . The rear seal assembly 104 can then be suspended behind the sweeping deck and engaged onto a hanger hook 112 on the sub frame 84 which temporarily holds the rear seal assembly 104 in place until two retaining bolts or pins (not shown) are installed which secure the rear seal assembly 104 in its engaged position. The subassembly 104 can thus be easily removed and installed and the removed assembly 104 can be worked on away from the vehicle 12 in a convenient location rather than under the vehicle.
[0070] An optional edge grinder as shown in FIG. 9 can further increase the efficiency of the riding sander. The edge grinder attachment 114 is spring loaded through torsion spring 116 off of the deck 14 to be 100 percent retracted upon impact along a wall 118 . Upon contact with the wall 118 , the edge grinder retracts the necessary amount up to 100 percent retraction. The torsion spring allows retraction and recovery to its normal extended position without the need for the operator to stop production to reset anything.
[0071] The vehicle 12 also stores a clean water tank 120 and a recovery tank 122 at the rear end thereof as illustrated in FIG. 3 . The clean water tank may either dispense water, a water cleaning solution mix or a densifier solution used during the grinding process. The solution uses gravity through a distribution bar mounted under the sweeping deck frame. The hopper entrance may be blocked and the sweeping brush becomes a rotary paint brush spreading the applied solution.
[0072] During a sequential grinding pass, the secondary vacuum applied to the hopper is turned off and an independent vacuum attached to the recovery tank is actuated picking up the slurry accumulated at the rear seal 108 .
[0073] In addition an optional small separate pump can deliver water or water mist into or ahead of the grinding heads 36 to enhance the cutting action and extend the life of the cutters 72 . This water delivery system also allows the section of wet grinding. A rear squeegee 111 gathers up any remaining slurry and an appropriate positioned vacuum picks up the gathered slurry. This squeegee 111 eliminates the need for a separate wet grinding machine.
[0074] A power cord handling system is shown in FIGS. 1 , and 10 - 12 . The power cord is used to deliver power to the electric motors 38 of the heads 36 as well as for recharging the electric batteries 31 used to power the motor to drive the vehicle 12 . The power cord 20 extends from a swing arm 18 . The swing arm 18 is pivotably mounted from an upper central tower or arc 124 . The swing arm normally extends rearwardly as shown in FIG. 10 when the vehicle is driven away from the power source 126 and a reel assembly 128 as shown in FIG. 10 . As the vehicle is driven away, the reel rotates as the chord is unrolled therefrom. The reel assembly 128 as shown in FIG. 11 has a take up reel 130 pivotably mounted on a frame 132 that is weighted by weight base 134 that may have about 175 pounds of weight. The reel is spring loaded to be able to take up approximately 150 feet of power cord that contains four #6 flexible wires inside and abrasion resistant sheath of approximately ⅞″ diameter. The weight is used to stabilize the reel assembly 128 against take up force of the spring against the full 150 feet of cord that produces about a 175 pound horizontal pull without sliding or tipping over. The reel assembly has a feed-in cord 136 from a power source such as an outdoor generator.
[0075] As shown in FIG. 12 , as the vehicle 12 moves away from the reel assembly, the swing arm extends rearwardly. As the vehicle 12 turns from the initial direction away from the reel, the swing arm is free to pivot to the side of the vehicle 12 to continue to point toward the reel. The swing arm is allowed to pivot up to approximately 90 degrees to either side as shown when the vehicle 12 is turned moving in a transverse direction. A stop member 136 on top of the arc 124 limits the motion to the 90 degrees such that when the vehicle returns in a direction toward the reel, the swing arm remains at the full left or right position. Furthermore, the reel automatically takes up slack cord as the vehicle 12 moves in a direction toward the reel and allows power cord to be released as the vehicle moves away from the reel. The swing arm 18 has a dimension sufficiently great to extend beyond the left or right side of the vehicle 12 when it is in the full left or right position. In this manner, the power cord is retained off to the side of the vehicle 12 when the vehicle goes in a direction toward the reel. The positioning of the power cord automatically away from the front of the vehicle 12 provides the continuous operation of the vehicle 12 without the need for an operator to stop operating and manually move the power cord off to the side.
[0076] The swing arm may be fitted with a sensor so that if the arm sensor sends a torque above a predetermined amount between the two stops 136 , a warning indicator such as a light or an alarm may be sounded to alert the operator that there is an undesirable condition with the reel, power cord or arm. The sensor may also if desired, be coupled to a deactuation device that safely interrupts the power to the main vehicle until the situation causing the excessive torque is eliminated.
[0077] The reel assembly 128 may also have a wiper 140 positioned to engage and wipe clean the power cord 20 as it is pulled from and reeled back into the reel assembly 128 . This wiper 140 also further reduces the spread of free dust created by the deck 14 .
[0078] Another method for covering floor surfaces is by using shorter runs and instead of making a u-turn which takes time, the operator merely backs up the riding apparatus and slightly turns to a new lane i.e. new floor line. He then moves forward again and back again in a zigzag fashion. When such a zig-zag motion of the ride-on apparatus is done, a modified swing arm as illustrated in FIGS. 13-24 is desired. This swing arm 218 retains the power cord 220 via a hook 238 . There is no usage of the reel 128 in this set up.
[0079] As shown in FIGS. 13 and 20 when the riding apparatus is travelling in a forward direction and away from the from its cord source, the swing arm 218 is usually pulled to the center and rear of the main vehicle body 12 by the drag resistance of the cord 220 . This places the swing arm 218 within the side confines of the vehicle body 12 as clearly shown in FIG. 20 .
[0080] The swing arm 218 has a proximate arm member 222 that is pivotally connected at end 228 to the riding apparatus 10 through a vertical axis. As shown in FIGS. 14-18 , the swing arm 218 also has a distal arm member 224 that is pivotally connected to the proximate arm member through pivotal connection 230 through both arm members 222 and 224 . This pivot connection 230 is also about the vertical axis. The distal arm member has hook 238 mounted at its distal end and a roller 226 also rotatably connected near the distal end for rolling around vertically oriented pivot axis 227 . While the embodiment shown in FIG. 14 shows a single roller, other embodiments may have a plurality of rollers such as the embodiment shown in FIG. 19 that illustrates three rollers. The distal arm has a raised section 240 to provide clearance over the proximate arm 222 . A resilient spring for example in the form of a gas spring member 232 or coil (not shown) is connected to the distal arm at pivot point 234 and to the proximate arm at pivot point 236 . The gas spring 232 normally provides resilient bias to the distal arm member 224 straight on it with respect to the proximate arm member 222 . The spring member 232 provides sufficient resistance to maintain the distal arm member straight against any side forces exerted by dragging of up to 200 feet of power cord along a concrete surface either in the forward direction as shown in FIG. 20 or in as the vehicle 12 moves in the reverse direction as shown in FIG. 22 .
[0081] When a side torque of above a predetermined amount is exerted on the distal arm member 224 , the distal arm can then pivot i.e. yield to the side exerted torque. Such a large side torque may be presented by a building column which may hit the distal arm as the riding apparatus passes. The distal arm member 224 may bend to a position up to a 90 degree as illustrated in FIG. 18 with respect to proximate arm member 222 . A mechanical stop 242 between the two arm members 222 and 224 prevents the distal arm member 224 from flexing more than 90 degrees as shown in FIG. 18 . In this position, the gas spring 232 is almost at its full extension with its inner piston rod 238 extending out therefrom. The gas spring 232 in this position provides for a retraction force so that when the side torque is released, the rod 238 retracts again and pulls the distal arm section 224 back to its straight position as illustrated in FIG. 14 . The connection pivot point 234 of the gas spring is a significant distance form the pivot point 230 of the distal arm member 224 to the proximate arm member 222 to provide for a mechanical advantage of the gas spring and to allow a full 90 degrees of movement of the two arm members 222 and 224 before mechanical contact between the two arm members create a mechanical stop. The geometry also allows the rotation of the distal arm member 224 to go in either direction for a total of 180 degrees of motion with respect to the proximate arm member 222 .
[0082] The zig-zag motion of the riding apparatus 10 and the side bending of the swing arm can be better illustrated with reference to FIGS. 20 to 24 as the vehicle encounters a building support column 250 . When the operator ends the forward run and starts to reverse and turns the vehicle to change lanes and do an overlapping run as shown in FIG. 21 , the drag of the cord 220 riding apparatus 10 then swings the arm 218 sideways. The length of the swing arm 218 is dimensioned to clear either rear corner 240 of the vehicle main body 12 . The operator then straightens out the vehicle still travelling in the reverse direction as shown in FIG. 22 . In this condition, the swing arm 218 extends sideways and protrudes significantly outside the side confines of the vehicle 12 .
[0083] Furthermore, the proximate arm member 222 is dimensioned to be wholly within the side confines of the vehicle 12 . The pivot axis 234 is also within the confines of the vehicle 12 at about a midpoint of the sing arm 218 . The side to side overlap action of the vehicle back and forth runs may vary but it is always less than the width of the vehicle width. It is possible that the overlap allows the sideways extending swing arm 218 , particularly the distal arm member 224 to be within reach of a building support column 250 as shown in FIG. 23 . While the operator is concentrating on making a straight rearward pass as he looks back over his shoulder while steering, he may not pay attention to the reach and position of the swing arm 218 .
[0084] If and when the distal arm member encounters an obstacle, for example a building support column 250 as shown in FIG. 23 , it will yield. The gas spring force is low enough to allow such yielding of the distal arm member when it encounters fixed objects such as building columns. The arm can bend up to 90 degrees to be completely within the confines of the vehicle width as shown in FIG. 24 to allow the vehicle to back up past the building column. Once the building column is cleared, the distal arm member will resiliently pivot back to its extended position as shown in FIG. 97 .
[0085] The roller 226 is preferably a rubber style wheel to further minimize any damage that might occur from contact with walls and columns. Furthermore, the rubber wheels are advantageous when the apparatus 10 is near a room corner and the operator needs to reverse to back up out of the corner. The wheels 226 rolls down the wall preventing the arm from grabbing and digging into the wall, particularly if the wall is made from soft material, for example dry wall. The embodiment shown in FIG. 19 illustrating three rollers 226 even further reduces the impact of collision between the column and the arm since most of the impact will be with the rollers 226 that will tend to roll as opposed to only the distal arm what would otherwise drag against the wall or column.
[0086] Variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims. | A swing arm for managing a power cord to an electric vehicle has a proximate arm member with a pivotable connection about a vertical axis for connection to the vehicle in proximity to a longitudinal center line of the vehicle. A distal arm member is pivotably connected about a pivot vertical axis to the proximate arm member and resiliently biased to extend straight out with respect to the proximate arm member. The swing arm is dimensioned to extend the distal arm member beyond a side of the vehicle when the swing arm extends laterally with respect to the vehicle. A spring member is connected to the distal arm member for resiliently biasing the distal arm member to extend straight out with respect to the proximate arm member against a side force below a predetermined amount and yieldable to bending of the distal arm member upon exertion of a side force above the predetermined amount. | 1 |
[0001] This application claims the benefit of European Patent Application EP13382103 filed 21 Mar. 2013.
[0002] The present disclosure relates to fixed constructions and more specifically to methods and arrangements for controlling the tension of tensioning cables in precompressed tower sections.
BACKGROUND ART
[0003] Most existing concrete towers, are pre-compressed (or “pre-stressed”) to account for extreme loads, such as winds that may affect the integrity of their structure. Typically these towers have a reinforced concrete column fitted with tensioning cables, such as steel cables. Towers for wind turbines may be steel, concrete or hybrid towers. Hybrid towers may have a lower concrete section and an upper steel section.
[0004] FIG. 1 shows a typical wind turbine tower. A concrete tower section has been indicated. FIG. 2 is a cross-section of the tower section of FIG. 1 with a typical arrangement of tensioning cables. The tensioning cables exert a compression on the tower section to to avoid or reduce the possibilities of the concrete section being submitted to tension under the influence of a load, such as a wind load. As the cables must account for extreme events, such as ripples of high wind, the towers are precompressed to withstand loads caused by these extreme events and the cables are accordingly tensioned.
[0005] FIG. 3 shows the negative and positive stress distribution in the base of a tower under a wind load. The point suffering the highest negative stress is point A in FIG. 3 . This is the windward point at the base of the tower. A tensioning cable at point A must be pre-tensioned to counteract the negative stress caused by wind load W. The tensioning cables may generally be equally pre-tensioned around the base as wind loads may be expected from all sides. As a consequence, when a windward tensioning cable counteracts a wind load, a leeward tensioning cable simply adds compression to the leeward point (point B in FIG. 3 ) that is already under compression by the wind load. This means that the tower has to be dimensioned to withstand compression that is at least double the compression exerted by the tensioning cables. Consequently, the cross-section of the tower is calculated accordingly. Therefore, large amounts of concrete are required to account for this additional compression. This has a direct impact on the cost of construction of a tower.
SUMMARY OF THE INVENTION
[0006] There is a need for a new tower and a new tensioning method that at least partially resolves some of the above mentioned problems. It is an object of the present invention to fulfill such a need.
[0007] In a first aspect of the invention a tower is disclosed that may comprise a tower section, a pair of flanges, a plurality of tensioning cables and at least one tensioner. The tower section may have a wall surrounding an inner space. The pair of flanges may extend from the wall and may be arranged around an upper and a lower part of the tower section. Each flange may be arranged with a plurality of cable support elements. The plurality of tensioning cables may extend along the tower section. Each tensioning cable may be attached at one end to a cable support element arranged with the upper flange and at the other end to a cable support element arranged with the lower flange. The at least one tensioner may be arranged between two of the plurality of tensioning cables.
[0008] The term “flange” in this respect may be used to denote a tower portion where cables are attached or embedded. Such tower portion may or may not be connecting the tower section with the foundation or with another tower section.
[0009] The cable support elements may form part of the flange or may be attached to the flange. An example of a cable support element is a cable terminator. However, any type of element that may support the cable with the flange may be used.
[0010] The at least one tensioner may pull the two cables towards each other, thus increasing the tension exerted by each cable. As the tension increases, so does the compression of the respective area of the tower.
[0011] In some embodiments, each cable may be coupled to one tensioner. For an even number 2*n of cables, n tensioners are required so that the tension of each pair of cables can be individually set.
[0012] In some embodiments, the at least one tensioner may be arranged half-way along the length of each pair of tensioning cables. This arrangement distributes the stress induced to the tensioning cables more evenly between the upper cable support element and the lower cable support element.
[0013] In some embodiments, each tensioning cable may be coupled to more than one tensioner. By coupling each tensioning cable to more than one tensioner, the same tension may be achieved with smaller or less potent tensioners.
[0014] In some embodiments, the tensioning cables may be arranged in consecutive pairs and the cables of each pair may be coupled to the same tensioners. The resulting tension is then a product of the sum of pulling forces from the plurality of tensors arranged between each pair of tensioning cables. This arrangement may be beneficial if the space between two consecutive cables is limited.
[0015] In some embodiments each tensioning cable may be coupled to a first tensioner and to a second tensioner. The first tensioner may be arranged between the tensioning cable and a first neighboring tensioning cable. The second tensioner may be arranged between the tensioning cable and a second neighboring tensioning cable. This arrangement allows a more uniform distribution of tensions between consecutive cables, as the tension of each cable is related to the tension of both neighboring cables.
[0016] In some embodiments, the tower may further comprise a controller, coupled to each tensioner, for detecting a load and instructing each tensioner to pull the tensioning cables. The controller may be connected to sensors for detecting a load, such as a wind load caused by a wind ripple. Detecting a load may comprise detecting force and direction of the load. Detecting the direction of the load may determine the principal tensioner, or a principal group of tensioners that needs to be actuated. Detecting the force of the load may determine the pulling force of the principal tensioner or group. A principal tensioner may be defined as the tensioner at the point of the most negative stress due to the detected load. For example, if the load is a bending load caused by a wind ripple, the principal tensioner shall be defined as the tensioner closer to the windward part of the tower section where the most tension in the tower would be expected due to the wind ripple. By contrast, the hindmost tensioner shall be defined as the tensioner closer to the leeward part of the tower section, where the least tension is expected and the most compression will take place due to the wind.
[0017] In some embodiments each tensioner may comprise a first cable grip, for gripping the first cable of each pair of cables, a second cable grip for gripping the second cable of each pair of cables, and a tensioning module, attached to said first and second cable grips, for setting the tension of each tensioning cable by pulling the cable grips towards each other. The cable grips may be in the form of sleeves or jackets each firmly surrounding a portion of its respective tensioning cable. One skilled in the art may appreciate that any suitable type of grip for tensioning cables may be used. The grip shall surround the tensioning cable in such a way that it would not slip along the tensioning cable during or after a pulling action by the tensioning module. The tensioning modules may be pistons. However, any type of actuator that can exert a pulling force may be used as a tensioning module without departing from the scope of the invention.
[0018] When the tower is a wind turbine tower, then the expected load is a wind load. However, the arrangement of the tensioners may also account for the loads caused by the rotation of the blades or by the rotation of the nacelle.
[0019] In another aspect of the invention, a method of setting the tension of tensioning cables in a tower is disclosed. The method may comprise the steps of detecting a load, calculating a desired tension of a pair of consecutive cables for counteracting the load, calculating a pulling force between the consecutive cables for setting the desired tension, and pulling the consecutive cables until the tension is the desired one. The first step may be undertaken by sensors arranged around the tower or even external to the tower. The second and third steps may be undertaken by a controller. The controller may be part of the tower or may be external to the tower. The fourth step may be undertaken by a tensioner. The cables may be pretensioned with a safety tension corresponding to a safety precompression of the tower. This pretensioning may be provided by cable support elements or by tensioners. In the latter case, a minimum pulling force may be applied to the cables by the tensioners to provide the required minimum pretensioning. Finally, when the tower is a wind turbine tower, the load may be a bending load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Particular embodiments of the present invention will be described in the following by way of non-limiting examples, with reference to the appended drawings, in which:
[0021] FIG. 1 shows a wind turbine tower.
[0022] FIG. 2 is a cross-section of a tower section with a typical arrangement of tensioning cables.
[0023] FIG. 3 is an illustration of the positive and negative stresses around the base of a tower under a wind load.
[0024] FIG. 4 shows a tensioning cable arrangement according to an embodiment in a relaxed state.
[0025] FIG. 4A shows the tensioning cable arrangement of FIG. 4 in an excited state.
[0026] FIG. 5 shows a tensioning cable arrangement according to another embodiment in a relaxed state.
[0027] FIG. 5A shows the tensioning cable arrangement of FIG. 5 in an excited state.
[0028] FIG. 6 shows a tensioning cable arrangement according to yet another embodiment in a relaxed state.
[0029] FIG. 6A shows the tensioning cable arrangement of FIG. 6 in an excited state.
[0030] FIG. 7 is a comparative tension diagram.
[0031] FIG. 8 is a comparative compression diagram.
[0032] FIG. 9 is a flow diagram of a method according to an embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
[0033] FIG. 4 shows a tensioning cable arrangement according to an embodiment in a relaxed state. A portion of a concrete tower section 5 may include a portion of an upper flange 15 and of a lower flange 15 ′. A plurality of tensioning cables 10 A, 10 B, 10 C, 10 D may be arranged in parallel in the portion of the tower section 5 . Each tensioning cable extends along the tower section 5 .
[0034] Each tensioning cable 10 A- 10 D may be attached at one end to a cable support element 20 A- 20 D of the upper flange 15 and at the other end to a cable support element 20 A′- 20 D′ of the lower flange 15 ′. A first tensioner 30 AB is arranged between cables 10 A and 10 B. A second tensioner 30 CD is arranged between cables 10 C and 10 D. Each of the tensioners 30 AB, 30 CD comprises a tensioning module 32 AB, 32 CD and a pair of grips ( 35 A, 35 B) and ( 35 C, 35 D). During the relaxed state of FIG. 4 , the tensioners 30 AB and 30 CD do not pull cables 10 A- 10 D and the tension the cables exert to tower section 5 is a minimum safety tension. The grips may be in the form of sleeves or jacket, elastically gripping the cables so that they may not slip when the cables are in the relaxed state. Alternatively, the tensioners may exert a limited safety tension during the relaxed state so that the tower is under compression.
[0035] FIG. 4A shows the tensioning cable arrangement of FIG. 4 in an excited state. When a load is detected, the tensioners 30 AB and 30 CD may be instructed to pull the cables 10 A- 10 D so that the tension in the tower section 5 is increased. As shown in FIG. 4A , the tensioning module 32 AB is contracted and the distance between grips 35 A, 35 B is reduced. As a consequence the cables 10 A, 10 B are pulled closer and the compression they exert on the tower section 5 increases. Accordingly, the tensioning module 32 CD is contracted and the distance between grips 35 C, 35 D is reduced. As a consequence the cables 100 , 10 D are pulled closer and the compression they exert on the tower section 5 increases.
[0036] One skilled in the art may appreciate that a relatively small horizontal pulling force of the tensioners may translate in a high vertical tensioning force at the cables. The arrangement of FIG. 4A shows that the pairs 10 A, 10 B and 10 C, 10 D are equally pulled. One skilled in the art may appreciate that this would typically be the case if the windward point was in the middle between cables 10 B and 10 C, indicated with dashed line A-A′. In other cases, the tension required from each pair may be individually adapted and as a consequence, the distance between the cables of each pair would not be the same.
[0037] Furthermore, the distribution of tensioning between pairs of cables may be at the discretion of the tower operator. Therefore, in some cases a higher tension may be desired by a principal tensioner and a lower tension by neighboring tensioners for a certain load, while in other cases a more distributed tensioning between a principal and neighboring tensioners may be desirable.
[0038] FIG. 5 shows a tensioning cable arrangement according to another embodiment in a relaxed state. In this embodiment two tensioners are arranged between tensioning cables belonging to a pair. A first tensioner 130 AB and a second tensioner 130 AB′ are arranged between cables 110 A and 110 B. A third tensioner 130 CD and a fourth tensioner 130 CD′ are arranged between cables 110 C and 110 D. Each of the tensioners 130 AB, 130 AB′, 130 CD, 130 CD′, may comprise a tensioning module 132 AB, 132 AB′, 132 CD, 132 CD′, respectively, and a pair of grips ( 135 A, 135 B), ( 135 A′, 135 B′), ( 135 C, 135 D) and ( 135 C′, 135 D′), respectively. During the relaxed state of FIG. 4 , the tensioners do not pull cables 110 A- 110 D and the tension the cables exert to tower section 105 is a minimum safety tension.
[0039] FIG. 5A shows the tensioning cable arrangement of FIG. 5 in an excited state. When a load is detected, the tensioners 130 AB, 130 AB′, 130 CD, 130 CD′ are instructed to pull the cables 110 A- 110 D so that the tension in the tower section 105 is increased. As shown in FIG. 5A , the tensioning modules 132 AB, 132 AB′ are contracted and the distance between grips 135 A, 135 B and 135 A′, 135 B′ is reduced. As a consequence the cables 110 A, 110 B are pulled closer and the compression they exert on the tower section 105 increases. Accordingly, the tensioning modules 132 CD, 132 CD′ are contracted and the distance between grips 135 C, 135 D and 135 C′, 135 D′ is reduced. As a consequence the cables 110 C, 110 D are pulled closer and the compression they exert on the tower section 105 increases. The arrangement of FIG. 5A shows again that the pairs 110 A, 110 B and 110 C, 110 D are equally pulled. Similarly to FIG. 4A , this would ideally be the case if the windward point was in the middle between cables 110 B and 110 C, indicated with dashed line A-A′. In other cases, the tension required from each pair may be different and as a consequence, the distance between the cables of each pair would not be the same.
[0040] Comparing the embodiments of FIG. 4A and FIG. 5A , it may be seen that the contraction of the tensioning modules is the same. However, in FIG. 5A the cables are under higher tension as the angle 59 of each cable to the flange is higher than the corresponding angle 49 of FIG. 4A . As a consequence, with the arrangement of FIGS. 5 and 5A , and using the same type of tensioners, it is possible to have the same tension with smaller pulling force at each tensioner, compared to the arrangement of FIGS. 4 and 4A . Accordingly, it is possible to have a higher tension with the same pulling force. Therefore, the arrangement of FIG. 5 , 5 A allows the use of smaller or less potent tensioners for achieving the same tension as the one achieved with the arrangement of FIG. 4 , 4 A.
[0041] FIG. 6 shows a tensioning cable arrangement according to yet another embodiment in a relaxed state. In this embodiment each tensioning cable is coupled to a first tensioner and to a second tensioner. The tensioner 230 AB is arranged between tensioning cables 210 A, 210 B. The tensioner 230 BC is arranged between tensioning cables 210 B, 210 C. The tensioner 230 CD is arranged between tensioning cables 210 C, 210 D. Further tensioners are partially shown arranged between tensioning cable 210 A and another cable (not shown) and between tensioning cable 210 D and another tensioning cable (not shown). During the relaxed state of FIG. 6 , the tensioners do not pull cables 210 A- 210 D and the tension the cables exert to tower section 205 is a minimum safety tension.
[0042] FIG. 6A shows the tensioning cable arrangement of FIG. 6 in an excited state. When the tensioning module 232 AB is contracted the distance between the respective grips 235 A, 235 B is reduced. As a consequence the cables 210 A, 210 B are pulled closer along the line formed by grips 235 A, 235 B and the compression they exert on the tower section 205 increases. Accordingly, when the tensioning module 232 BC is contracted the distance between grips 235 B, 235 C is reduced. As a consequence the cables 210 B, 210 C are pulled closer along the line formed by grips 235 B, 235 C and the compression they exert on the tower section 205 further increases. Finally, when the tensioning module 232 CD is contracted the distance between grips 235 C, 235 D is reduced. As a consequence the cables 210 C, 210 D are pulled closer along the line formed by grips 235 C, 235 D and the compression they exert to the tower section 205 increases even further. In FIG. 6A , the contraction of tensioning module 232 BC is shown higher than the contraction of tensioning modules 232 AB, 232 CD which is shown equal among the two. This would be the case if the windward point was in the center between the cables 210 B and 210 C, indicated with dashed line A-A′.
[0043] The arrangement of FIGS. 6 , and 6 A allows for a more uniform and fine-tuned distribution of tension between the cables, as the tension of each cable may be set by two tensioners, each allowed to exert a different pulling force.
[0044] FIG. 7 is a comparative tension diagram. It illustrates that in examples of the present invention, less tension is required during a relaxed state of a tower, while the appropriate tension is exerted when a load is present. The X axis of the diagram represents the distance from a point of the tower to the most windward point of the tower.
[0045] The Y axis represents the tension value. Conventionally, the tensioning cables would exert the tension shown with the dashed line L 1 . That is, conventionally, all the cables always exert the same tension to the tower as the tension is not controllable and must remain maximum at all times to account for winds in all directions.
[0046] In contrast, according to the various examples disclosed herein, in a relaxed state, only a minimum safety tension Ts is required, as depicted with line L 2 .
[0047] Lines L 1 and L 2 have a tension difference equal to “A” as shown in FIG. 7 . During the relaxed state, the tensioners are not pulling any cables. When a load is detected, some of the tensioners around the tower are activated. Those tensioners closer to the windward point exert a higher pulling force leading to a higher tension in the respective cables. Those closer to the leeward point do not exert any pulling force or exert a lower pulling force leading to a lower tension. This is represented by the inclined line L 3 .
[0048] Although the line L 3 is shown straight, this is only for illustration purposes. The shape of line L 3 may actually vary and be crooked or stepped, based on the number of cables in the tower and their arrangement within the tower, and the tension exerted to each cable or pair of cables by the corresponding tensioners. In general, the starting point may always be higher than the ending point, as illustrated by line L 3 , i.e. the tension of the cables and the compression they exert on the tower may be higher at the windward side of the tower than at the leeward part. The area R shown in FIG. 7 represents the area of allowable range of cable tension.
[0049] FIG. 8 is a comparative compression diagram under load. Again, the X axis of the diagram represents the distance from a point of the tower to the most windward point of the tower. The Y axis represents the compression value. The compression of the tower is equal to the sum of cable tension plus compression due to a load.
[0050] Closer to the windward point, the compression due to the load is negative, i.e. the tower portion is submitted to tension due to the wind load. In a typical tower without tensioners between cables, the compression is equal to Cs (safety compression). The safety compression which is the sum of the tension
[0051] T in the cables and the tension due to the wind load-Cw. The tension T in the cables directly determines the compression in the tower section. At the windward point, as a result of the load, the compression of the tower section is reduced to a minimum safety compression.
[0052] The tension T of the cables at the windward point must always be above an anticipated maximum-Cw so that a concrete tower section is always under compression.
[0053] In a tower in accordance with examples of the present invention, under a certain load W, the total compression is again equal to Cs at the windward point, as the cable tension is lowered from the minimum safety tension Ts to the value Tw (then tension corresponding to a design wind load). Tw may be equal to the value T used in towers without tensioners so that a minimum safety compression Cs remains the same at the windward point.
[0054] However, at the leeward point, in a typical tower without tensioners between cables, the compression is equal to Cmax, which is the sum of the tension T of the cables (leading to a compression of equal amount in the concrete tower section) plus compression C L . C L is the amount of compression at the leeward point due to the load W. In a tower with tensioners according to examples of the present invention, the value of tension T of the cables remains equal to the safety tension Ts at the leeward point (no tensioners are activated). The total compression is then, at the leeward point, equal to C L plus Ts.
[0055] In some implementations, the safety tension Ts may even be reduced, possible even to zero, under a load W, if the minimum safety tension is provided by the tensioners and not by the cable support elements. The minimum compression Cs required for keeping the tower under compression is then provided by the positive stress C L under a load situation. As may be seen by FIG. 8 , the maximum compression is equal to Cmax-A. Therefore the maximum compression at a point around the tower may be reduced by at least a value A when using the tensioners disclosed. Consequently, towers with significantly less concrete may be constructed. Similarly, existing towers can be retrofitted to withstand higher loads than what they were constructed for, or to extend their lifetime by reducing loads.
[0056] FIG. 9 is a flow diagram of a method according to an embodiment. In a first step 910 , a load is detected by a sensor. In a next step 920 , a desired tension of a tensioning cable is calculated. The desired tension for each cable may be calculated according to the direction of the load and the intensity of the load. In a next step 930 , a pulling force of a tensioner is calculated so that the corresponding cable(s) can exert the desired tension. Finally, in step 940 , a pair of cables is pulled by a tensioner based on the calculated pulling force. Accordingly, all the required cables are pulled based on the respective pulling force calculated during the previous step for each cable or pair of cables.
[0057] The cables may be pretensioned by cable terminators in a relaxed stated, i.e. without a load present, to provide a minimum compression to the tower section. Alternatively, the cables may be pretensioned by tensioners arranged between the cables, pulling the cables to provide the minimum tension required for the minimum compression. In this case, under a load, the tensioners closer to the leeward point may be relaxed, as the minimum compression is provided by the load.
[0058] Although only a number of particular embodiments and examples of the invention have been disclosed herein, it will be understood by those skilled in the art that other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof are possible. Furthermore, the present invention covers all possible combinations of the particular embodiments described. Thus, the scope of the present invention should not be limited by particular embodiments, but should be determined only by a fair reading of the claims that follow. | Methods and arrangements for controlling the tension of tensioning cables in precompressed towers are disclosed. The towers may comprise a tower section ( 5 ), a pair of flanges ( 15, 15′ ), a plurality of tensioning cables ( 10 A- 10 D)and at least one tensioner ( 30 AB, 30 CD). The pair of flanges may be arranged around an upper and a lower part of the tower section. The at least one tensioner may be arranged between two of the plurality of tensioning cables ( 10 A- 10 D). The tensioner may pull the tensioning cables in response to a load signal to increase the tension. | 5 |
BACKGROUND OF THE INVENTION
The invention is directed to a tube furnace for the performance gas reactions, especially for the production of hydrocyanic acid according to the BMA process (hydrocyanic acid-methane-ammonia process), in which the individual structural parts in consideration of energy and industrial safety aspects are arranged in a special way to each other and besides each other. The previously known type furnaces for the performance gas reactions, especially at temperatures above 900° C., for example at temperatures between 1000° C. and 1500° C. consist of a series of parallel connected heating chambers which are mounted with freely suspended ceramic tubes or tube assemblies. Each of these chambers is heated separately. The flue gas discharge takes place via a separate branch channel which is joined via transition pieces with the individual chambers. The vertically arranged ceramic tubes, whose inside represents the actual reaction space, are supplied with the necessary heat for the reaction through the tube walls so that the heating chambers accordingly must be lined with a temperature resistant material. The heat is produced by gas or oil burners. The combustion air is heated recuperatively. The burners, of which 2 elements are needed per chamber, are arranged in the lower region of the chamber in order that the entire length of the reaction tubes as far as possible can be brought to the required reaction temperature. The heat of the departing flue gases can be used for preheating the air and/or for producing the steam.
It is possible with several furnaces, to connect every two furnaces to a common branch channel which then is arranged between these two furnaces and via a collection channel with the help of an induced draft blower to use the heat content of the flue gas in a waste-heat boiler for the production of steam.
The recuperators for the preheating of the combustion air are in each case arranged between two chambers and are heated simultaneously with the reaction tubes (German Pat. No. 1,041,476 and related Endter U.S. Pat. No. 2,987,382. The entire disclosure of Endter is hereby incorporated by reference and relied upon).
However, a disadvantage of great importance in this is that there are needed two burners per heating chamber so that when there are present a large number of heating chambers there must be manipulated and adjusted an even larger number of burners. This is not without problems since the combustion process and therewith the control of the reaction temperature is greatly influenced by the manner of travel of the burner. Among others, this is especially made difficult by the fact that freely suspended reaction tubes can only be incompletely sealed off compared to the lower furnace covering.
A further disadvantage of this known furnace is its quite large outer surface which leads to energy losses.
These disadvantages are avoided by the furnace of the invention. Also, through a different arrangement of the recuperators, there is produced a higher preheating of the combustion air and therewith a better cooling of the flue gases.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematically drawn cross section of the furnace through a twin heating chamber and the component parts;
FIG. 2 shows an alternative construction; and
FIG. 3 shows still another form of the furnace.
In the drawings like numerals refer to like parts.
SUMMARY OF THE INVENTION
The subject matter of the invention is a tube furnace for the performance of gas reactions, especially for the production of hydrocyanic acid according to the BMA process, in ceramic tube assemblies which are freely suspended within the furnace in heating chambers and whereby the furnace contains as essential parts, burner a flue gas-branch channel and recuperators which is characterized by the furnace being essentially of a masonry block or cube 1 walled construction with a metal construction on the outside, with at least two twin type furnaces arranged next to each other, the furnace containing, in the form of a structural unit, the ceramic tube assembly heating chambers 2 arranged with recuperator spaces 3 having recuperators 4 and joined to the middle of the furnace as well as a flue gas branch channel 5 aranged between the two recuperator spaces 3 and whereby each heating chamber 2 has a maximum of only one burner 9.
A favorable development of the process of the invention comprises the provision of flue gas conduits 7 between the heating chamber 2 and the recuperator spaces 3 having control members 6. The flue gas conduits preferably receive the flue gases of the heating chamber in the vicinity of the upper furnace cover and preferably introduce these gases from below into the recuperator spaces.
A further improvement is produced by so dimensioning and arranging the recuperator spaces 3 as well as the recuperator components that they provide for one or more adjacently arranged heating chambers 2.
Finally it is additionally advantageous to form the furnace in such manner that there are arranged in the flue gas-branch channel one or more heat exchangers, one of which is indicated at 10, for the combustion air.
DETAILED DESCRIPTION
FIG. 1 is a schematically drawn cross section of the furnace through a twin chamber and the component parts. It should be recognized that under the twin type arrangement there is provided a Janus head type arrangment. In the drawing 1 indicates the building block or cube shaped formed entire furnace consisting of the brick lining with temperature resistant, fire proof material and a jacket, for example of sheet metal; 2 indicates the heating chambers, 3 a recuperator space with the recuperator component 4, 5 the flue gas branch channel, 7 the flue gas conduits and 6 the control members for the flue gas conduits, which controls are known per se, 8 represents the ceramic reaction tubes and 9 the burner. This type of twin unit is able to be arranged in any number in series in succession. For one manner of mounting the tubes, see the aforementioned Endter U.S. Pat. No. 2,987,382.
A further development of the form of the furnace of the invention is shown in FIG. 2. The reference numerals have the same meaning as in FIG. 1.
Finally, there is shown in FIG. 3 a development of the furnace of the invention in which as well as in FIG. 2, the flue gas conduits 7 are omitted and the burners 9 are arranged in the upper part of the heating chamber 2, so that the heating of the tube assembly is carried out in counterflow manner. The fule gases of the heating chamber 2 in this case are drawn off in the vicinity of the lower bottom plate and the recuperator spaces supplied from below. The reference numerals in FIG. 3 have the same meaning as in FIG. 1.
It is also possible within the invention to provide 2 or more heating chambers with only one burner.
Through the special conduit of the flue gas there is attained that a further utilization of its heat content only takes place when the true reaction process has already taken place.
The recuperators even can be exchanged for these during the operation of the adjacent chambers without disadvantage. Through this arrangement it is possible to mount the chamber with new tubes and for this time to throttle or even completely cut off the passage of the air through the recuperator and burner. This is made possible through the arrangement of the control members at the flue gas entrance-into the flue gas-branch channel.
The flue gas-branch channel 5 is arranged between the recuperator spaces as a continuous channel. It merely needs an upper and lower cover.
The customary manner of construction of for example, 2 piece chamber furnaces including the necessary flue gas-transition pieces and including the necessary branch channel has a reflecting surface of about 200 m 2 . The furnace of the invention on the contrary only has a surface of 100 m 2 whereby in the region of the branch channel substantially lower temperatures occur.
Besides through the invention the volume of the furnace hours is reduced. In the customary construction of for example, 16 furnaces there is needed a furnace hours having about 21,000 m 3 of converted space, according to the invention about 12,500 m 3 .
Besides the resulting savings in energy there are also substantially lower construction costs.
The flue gas-branch channel in which the flue gases of the heating chambers are collected is arranged between the heating chambers through which there results a considerable saving of space as well as a small reflecting surface. The two walls of the channels in each case are formed from the recuperator chambers so that there is only needed one lower and upper cover.
Through this arrangement there are eliminated the earlier required transition pieces between each heating chamber and the branch channel.
The air additionally can be preheated in this flue gas-branch channel before it is supplied to the recuperator or recuperators, with the help of the heat exchangers flue gas/air installed there.
The thus arranged branch channel for example, has on the upper and lower cover a surface of only about 12 m 2 while in comparison the branch channel of the known furnace inclusive of the transition piece has about 60 m 2 of reflecting surface.
The entire disclosure of German priority application No. P 3134851.3 is hereby incorporated by reference. | There is described a furnace for the performance of gas reactions in a ceramic assembly of tubes in which the heating chambers (2), the recuperators (4) and the flue gas-branch channel (5) are arranged in a compact, energy saving type of construction. The furnace is especially suited for the production of hydrocyanic acid according to the BMA process (hydrocyanic acid-methane-ammonia process). | 1 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application serial No. 60/678,309, filed May 6, 2005 and entitled “Portable Ballistic Shelter System”, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to shelters, and more particularly to portable armor provided in connection with portable shelters such as tents and soft-sided shelters, so as to provide shelters capable of withstanding various types of ammunition and fragmentation and thereby protect the occupants within.
BACKGROUND OF THE INVENTION
[0003] Temporary shelters such as tents can be provided with one or more layers of material forming the outer boundaries or walls of the structure. Such layers are generally penetrable by common ammunition and fragmentation or shrapnel. While such weaknesses are of little concern to a recreational camper, they become of grave concern to those engaged in activities within tents that are positioned in military zones and other hostile areas. Such tent or shelter deployments must necessarily be close to the hostile activities in order to provide individuals such as troops with proper medical attention, decontamination facilities, and the like; however, the standard shelter wall structure provides little to no protection to the shelter occupants.
SUMMARY OF THE INVENTION
[0004] The present invention provides a portable, lightweight ballistic panel as part of a shelter capable of withstanding penetration by ammunition and fragmentation, so that the occupants of the shelter remain safe and unharmed. In one embodiment of the invention, wall segments or panels of ballistic material are provided so as to hang from an interior or exterior frame member of the shelter. In another embodiment, the present invention provides a frame independent of the shelter frame to which the panels can be secured. The panels can be provided such that they fold up into portable and manageable units.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a top right perspective view of a sample shelter structure in which the present invention can be deployed, with one end wall broken away.
[0006] FIG. 2 is a top right perspective view of the shelter of FIG. 1 , with portions of the roof cut away to show interior features.
[0007] FIG. 3 is a right front perspective view of a series of adjoining tent structures in which the present invention can be deployed.
[0008] FIG. 4 shows a right side view of a portion of a wall structure in accordance with the present invention.
[0009] FIG. 5 shows a front view of an interior wall as outfitted in accordance with one embodiment of the present invention.
[0010] FIG. 6 shows a front view of an interior wall as outfitted in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] As shown in FIGS. 1 and 2 , temporary shelters 12 such as tents can be provided with one or more layers of material forming the outer boundaries or walls 14 of the structure. In some cases, material also is provided to form a floor 16 covering the otherwise exposed ground within the tent or structure. Doors 15 and windows 17 are frequently provided as well. In some shelter systems, an outer layer or cover fabric 18 is employed along with an inner layer or liner fabric 20 to provide substantial protection from the elements as well as different physical invasive species (e.g., insects, chemical or biological weapons, etc.). These fabrics are portable and may be joined together in series to form a longer structure or complex, as shown at 30 in FIG. 3 . Further, some shelters are provided with external or internal stabilizing frames 22 to facilitate the shelter build-out and strengthen the shelter frame.
[0012] FIG. 4 is a right side view of a portion of a wall structure in accordance with the present invention. As shown in FIG. 4 , a wall 14 and window 17 are provided along with internal framework 22 . A ballistic panel 25 can be suspended from the framework 22 such as by a hook member 26 secured to the framework and looped through an opening in the panel. The opening can be reinforced by a grommet 27 , for example. In one embodiment of the invention, the hook members 26 can be slidably mounted to the framework so as to enable a customized fitting of the ballistic paneling. For example, if a portion of a shelter were barricaded behind a military vehicle or other large object, there may be no need for ballistic paneling for that portion, as any ammunition, fragmentation or other would-be penetrating element would need to first go through the vehicle before it reached the tent. In such examples, ballistic paneling may only be required for the remaining portion of the shelter not protected by the outside object (e.g., vehicle), in which case the hook members can be moved along the framework and positioned such that the paneling secured to the hook members appropriately covers the unprotected areas of the shelter. As further shown in FIG. 4 , it will be appreciated that lighting 28 and other necessary internal objects can be positioned within the tent inside of the wall structure provided in accordance with the present invention to safely allow lighting or other functions within the tent, while not being exposed to projectiles. The hook members can optionally be clasp members, such as C-shaped metal clasps biased in the closed position and having a hinged portion which allows a user to open the otherwise closed clasp to receive a loop, grommet or eyelet, for example. In one embodiment of the invention, peg members are integrally formed with the frame or tent wall for receiving the loop, grommet or eyelet.
[0013] In one embodiment, a secondary frame separate and apart from the primary frame can be erected inside of the primary frame to provide a surface for mounting the panels or wall members. The secondary frame can be dimensioned so as to extend to the edges of the interior of the shelter generally defined by the wall members and somewhat defined by the primary frame where applicable.
[0014] FIG. 5 shows a front view of the interior wall of a shelter as provided in accordance with one embodiment of the present invention. As shown therein, one or more wall blankets or panels 25 are positioned and secured in place along the wall member 14 of the shelter 12 in accordance with one aspect of the present invention. Each panel can be rigid or non-rigid and can be formed using soft or hard armor material to withstand bullets, small arms fire, personnel ammunitions, fragmentation from explosions, or other known forms of penetrating and potentially lethal objects (hereinafter “projectiles”). In one embodiment, the panel includes an outer shell of heavy-duty nylon which can contain a ballistic insert packet made of plies of appropriate ballistic material, woven or non-woven. The insert packet in this embodiment can be any ultra high molecular weight polyethylene based fiber having an appropriately high strength to weight ratio and an appropriately low specific gravity so as to meet threat level standards. Spectra™ and Dyneema™ materials may be employed in one embodiment, as well as aramid materials such as Kevlar™ and Twaron™, for example. The insert packet can also be made of a para-aramid fiber in a woven or non woven form that possesses high tensile strength, cut and flame resistance and high chemical resistance. It will be appreciated that the outer shell can be provided of various types of materials depending upon the particular deployment requirements (e.g., waterproof, fire retardant, etc.).
[0015] As shown in FIG. 5 , the arrangement of panels can also accommodate entry and exit components of the existing tent or structure. Thus, for example, if there is a door 15 in a doorway or entryway provided as part of the existing shelter, the panels can be arranged such that two adjacent panels overlie one another at or around the entry way, as shown by arrow 35 . In such embodiment, a person desiring to enter or leave the tent can pull back or push away one of the panels and slip through the entry way. Each panel member can have the specific dimension of approximately 88 inches by approximately 110 inches, although the precise dimensions will depend upon the shelter type and the implementation involved in the deployment. In this way, the shelter of the present invention can be utilized as if the ballistics were not in the shelter. While any windows 17 will be covered in the preferred embodiment of the invention, the windows can still be opened if necessary to allow ventilation.
[0016] As further shown in FIG. 5 , wall panel 14 can be provided with attachment means such as grommets or eyelets 27 integrally formed into the panel such that the grommets can be placed over and around hooks 26 or similar items provided on a tent frame or external frame so as to depend downwardly and outwardly therefrom. The tent frame (whether as part of the existing tent or as provided separately) can be provided with a cable secured thereto for receiving the hook members. In one embodiment of the present invention, the hooks are held stationary by the cable member. In another embodiment, the hooks are slidable back and forth along a horizontal cable secured to the frame in such a way that the hooks can be easily moved to the location most accessible to the panel grommets.
[0017] Alternatively, the wall panel members can be secured to the shelter or shelter frame using attachment means such as a hook and loop connector, a zipper or a snap member, for example. In the embodiment incorporating a zipper, a first zipper edge or taper can be provided on the wall panel member and a second zipper edge or taper can be provided on the shelter wall or frame. Because of the non-rigid nature of the wall panel, once it is secured to the tent frame, it is collapsible along the provided wall of the tent or shelter, in the sense that the panel rests alongside the wall and does not extend obtrusively therefrom, as shown in FIG. 4 , for example.
[0018] In one embodiment of the invention, the panel can be provided with side attachment elements for securing to a separate panel in side-by-side format such that little or no space exists between the respective sides of the panels. Such arrangement can be through attachment mechanisms similar to that described for securing a panel to a structure frame as noted above. In one embodiment of the present invention, panels are placed and secured side by side with an overlap of, for example, four to six inches. In one embodiment, adjacent panels are integrally formed as a single unit. In another embodiment, the adjacent panels are integrally formed with a permanent hinge type member or are sewn or otherwise attached so as to allow either the front faces or the back faces of the panels to be mated upon hinging to assist in ease of transport, as well as breakdown and setup of the wall structure. The overlap formation can limit the ability of a projectile penetrating the seam of the two panels.
[0019] The present invention can also accommodate comers within tents or structures. A corner element may be configured to adhere or otherwise attach to the wall panel elements so as to protect any comers that may not otherwise be sealed using the panels described above. Such a corner member may be smaller in width, but of the same length so as to provide a full length barrier to any projectile that might otherwise be capable of penetrating a corner where two adjacent panels are not sufficiently overlapping. The corner member can also be provided with attachment means such as those described above for securely mating with appropriate receiving means of the tent or structure frame. In one embodiment, the side wall non-rigid panel can be bent and attached to the end panel to create sufficient overlap and protection.
[0020] FIG. 6 shows a front view of the interior wall of a shelter as provided in accordance with another embodiment of the present invention. As shown in FIG. 6 , a securing pole member 44 made of metal, plastic or other suitable material can be secured to a top portion of the panel members 25 such as by straps or other suitable means on the exterior of the panels, or by folding over a top portion of the panel member and stitching a seam substantially horizontally along the panel member so as to form an opening through which the pole member can be threaded. The pole member 44 can act as an anchoring point for securing straps, cords or other drawstring-type members 41 which can be used to raise and lower the panel members up and down the wall 14 . The straps 41 can be nylon or other suitable material and can be secured at one end to a top shelter frame member 23 and at the other end to the pole member 44 . In one embodiment of the present invention, the straps 41 are secured at a first end by hook and loop-type fasteners (or similar fasteners as described) to the pole member 44 of a corresponding panel 25 , and then positioned around an upper, substantially horizontal frame member 23 with the other end of the strap being secured to the pole member 44 or the panel member 25 itself using hook and loop-type fasteners or similar fasteners. In this way, one end of the strap members 41 can be disconnected from the pole or panel member so that the user can pull the strap member and thereby the panel member can be moved further up or down the shelter wall. As such, the present invention allows for adjusting the height of the ballistic panel member(s) on the wall.
[0021] In the embodiment shown in FIG. 6 , an overlap panel member 42 is provided in between two panel members 25 around a door opening 15 , and the overlap panel member 42 is not provided with a pole member or straps secured thereto. Rather, overlap panel member can be secured to the panel members 25 by sewing, hook and loop fastener or similar fastening means. In one embodiment of the present invention, overlap panel member is sewn to a first panel member, and then connected via hook and loop fastener to a second panel member adjacent the first panel member. In this way, the hook and loop-type fastener can be easily detached while the sewn connection of the overlap panel to the first panel member restricts the detachability. Thus, the overlap panel member can possibly pivot around the sewn seam as a door would pivot, thereby allowing a user easier entry and exit through a door 15 in the structure.
[0022] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A portable, lightweight ballistic panel integrated with a shelter is capable of withstanding penetration by ammunition and fragmentation, so that the occupants of the shelter remain safe and unharmed. In one embodiment of the invention, wall segments or panels of ballistic material are provided so as to hang from an interior or exterior frame member of the shelter. In another embodiment, the present invention provides a frame independent of the shelter frame to which the panels can be secured. The panels can be provided such that they fold up into portable and manageable units. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of provisional application No. 60/508,340, filed Oct. 3, 2003.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0002] The invention relates to a process that allows the production of a natural surfactant chemical, that has not previously been extracted from its natural source, and also to uses for the chemical in the formulation of cleaning products.
[0003] It is well known that some species of sea-weed, particularly those classified as “brown kelp” develop a coating on the surface of the fronds which gives the frond a slippery, soapy feel. However, there are no records of the chemical entities that constitute the surface being identified or extracted from the surface of the plant fronds.
[0004] Conventional processes used in the extraction of chemical compounds from sea-weed frequently make use of high temperatures and high pHs. These process conditions are detrimental to the stability of some chemical compounds produced by the sea-weed and in particular to a highly effective surfactant chemical with which certain species of seaweeds coat their fronds.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a process for producing natural surfactants and compositions based on the natural surfactants that overcome the above-mentioned disadvantages of the prior art methods and compositions of this general type, which extracts and stabilizes a surfactant in a cost effective manner.
[0006] With the foregoing and other objects in view there is provided, in accordance with the invention, a process for extracting a natural surfactant. The process includes providing a quantity of water, adding in a quantity of seaweed to the water resulting in a process medium, adding an enzyme solution to the process medium, and extracting the natural surfactant from the seaweed.
[0007] An alternative to adding the enzyme is to create the enzyme by fermentation using naturally existing bacteria and the addition of cellulose, a carbohydrate or a sugar.
[0008] In accordance with an added mode of the invention, there are the steps of adding sodium chloride or other salt to the water for adjusting ionic strength; and setting an elevated water temperature to be between 12° C. and 60° C. Preferably the seaweed is kelp fronds from brown kelp and the kelp fronds are added to the water by a ratio range of 5:1 to 50:1 by weight. The pH of the process medium is adjusted to be between 4.0 and 8.5 on a daily basis. This can be done by introducing any acid, citric acid being an example, or any base, potassium hydroxide being an example, to the process medium.
[0009] Ideally the enzyme solution is hemicellulases, polysaccharidases, cellulases, pectinase, or alkaline proteinases. Between 5 and 20 grams of the enzyme solution is added for every 100 kg of process medium.
[0010] During the process the amount of dissolved solids in the process medium is measured preferably using a refractometer or a commercially available solids analysis device using heat or radiation. Other analytical methods can also used to measure the surfactant content. For example, an oven could be used to evaporate the liquid from the process medium and a scale is used to measure the weight of the remaining solids.
[0011] The process medium is ideally stirred continuously or at least two times a day for resuspending the kelp fronds. The process medium can be stirred by introducing a stream of compressed air, nitrogen or other gases into the bottom of a process tank for keeping the kelp fronds in suspension. Alternatively or additionally, the process medium is manually stirred or stirred with an automated mechanical device.
[0012] The process is terminated when a measured dissolved solids or surfactant content of the process medium becomes stable for 24 hours. The process medium is filtered using a sieve, cloth, or net of a mesh size sufficient to retain and separate the kelp fronds from a remaining process medium resulting in a separated process medium. Preferably the separated process medium is then passed through an ultrafiltration system.
[0013] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0014] Although the invention is described herein as embodied in a process for producing natural surfactants and compositions based on natural surfactants, it is nevertheless not intended to be limited to the details described, since 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.
[0015] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The process according to the invention enables a surfactant chemical to be released from the surface of sea-weed (kelp) fronds without its subsequent destruction. The process also prevents chemical deterioration of the surfactant after its extraction.
[0017] Preferably the kelp fronds are freshly cut and not allowed to dry as this causes deterioration of the surfactant chemical extracted from the kelp. Alternatively, the kelp may be air dried at the point of harvesting, or dried mechanically before being used in the process. Naturally, any form of kelp can be used but process efficiencies deteriorate with the less ideal conditions.
[0018] Ideally, whole kelp fronds are used in the process but, alternatively, cut, segmented, shredded, powdered or freeze-dried material may be used.
[0019] For the purposes and uses to which the kelp derived surfactant is to be used, it is essential that the process used to cause the release of the surfactant does not involve conditions that cause deterioration of the surfactant chemical. Such conditions may be described as, but are not confined to: high or low levels of pH, for example below a pH of 4 or above a pH of 12.5; or the application of heat above a temperature of 60° C.
[0020] It is also essential that the process conditions do not cause any damage to the kelp fronds that will cause the release of undesirable contaminants from the interstices of the fronds or from intracellular chemicals. Such conditions may be defined as, but are not confined to: pH levels below 4.5 or above pH 10.0; temperatures of above 60° C.; or severe agitation by any form, such as stirrer paddles or pumps, that may cause damage or bruising of the plant fronds.
[0021] Also, to prevent osmotic damage it is preferable that the process is carried out in conditions of salinity that is approximate to those of the water from which the kelp was harvested.
[0022] It is also essential that an agent, such as an enzyme, such as, but not confined to: hemicellulases; polysaccharidases; cellulases; pectinase; or alkaline proteinases; which are derived from a plant or microbial source, be present either through addition or creation by fermentation using naturally existing bacteria and the addition of cellulose, a carbohydrate or a sugar, to facilitate the release of the surfactant chemical. Without such a release agent the yield from the process becomes very low and concentration to a useable concentration is uneconomical.
[0023] In the general process, the kelp fronds are suspended in cold water to a concentration of between, but not confined to 2 kg to 20 kg of kelp per 100 kg of water, the salinity of which has been previously adjusted to be close to that of sea water by the addition of a salt such as sodium chloride. The pH of the process medium is then adjusted between a pH range, but not confined to a pH of 6.0 to 8.0.
[0024] The invention will now be described in the form of process examples.
EXAMPLE 1
A First Process Embodiment
[0025] a). The salinity of an appropriate quantity of cold water, the temperature of which is maintained at a minimum of 12° C. and a maximum of 17° C. is adjusted by the addition of 35 grams/liter of a salt, for example but not limited to, sodium chloride.
[0026] b). The kelp fronds are added in a ratio of 10 kg of kelp to 100 kg of cold water.
[0027] c). The pH of the process mixture is then adjusted to between a minimum pH of 6.5 and a maximum of pH 8.5 either by the introduction of a solution of an acid such as citric acid (if the pH is too high) or by the introduction of a solution of a base such as potassium hydroxide (if the pH is too low). During the pH adjustment process the process medium is gently stirred, manually, by a paddle.
[0028] d). An enzyme solution containing the enzyme hemicellulase is added in the proportion of between 5 grams and 20 grams of the enzyme protein to 100 kg of process medium.
[0029] e). A measurement is made of the amount of dissolved solids in the water, using a refractometer or other suitable measuring system.
[0030] f). The process medium is stirred gently two to three times daily so as to re-suspend the kelp fronds.
[0031] g). The pH is adjusted, on a daily basis, to maintain a pH of between a minimum of 6.5 and a maximum of 8.5.
[0032] h). The process is terminated when the measured dissolved solids content of the process medium becomes stable for 24 hours. Normally the process will take between 3 and 5 days.
[0033] i). The process is stopped by filtering the process medium through a sieve, cloth, or net of a mesh size sufficient to retain and separate the kelp fronds from the remainder of the process medium.
[0034] j). Preferably, to obtain a useable concentration of the desired natural surfactant, the separated process medium is passed through an ultrafiltration system until the measured dissolved solids content reaches 10%.
[0035] k). The concentrated process medium is stabilized by adjusting the pH of the medium to between a minimum of pH 6.0 and a maximum of pH 8.0 by the addition of a solution of acid such as citric acid and the addition of a preservative such as potassium sorbate. The pH range chosen is that at which the natural surfactant is stable for a minimum of 2 years when kept at a temperature between 15° C. and 40° C.
EXAMPLE 2
A Second Process Embodiment
[0036] a). The salinity of an appropriate quantity of cold water, the temperature of which is maintained at a minimum of 12° C. and a maximum of 17° C., is adjusted by the addition of 35 grams/liter of a salt such as sodium chloride.
[0037] b). The kelp fronds are then added in a ratio of 10 kg of kelp fronds to 100 kg of cold water.
[0038] c). The pH of the process mixture is then adjusted to between a minimum pH of 6.5 and a maximum pH of 8.5 either by the introduction of a solution of an acid such as citric acid (if the pH is too high) or by the introduction of a solution of a base such as potassium hydroxide (if the pH is too low). During the pH adjustment process, the process medium is gently stirred, manually, by a paddle.
[0039] d). An enzyme solution containing the enzyme cellulose, which must have a low activity, is added in the proportion of between 5 grams and 20 grams of the enzyme protein to 100 kg of process medium.
[0040] e). A measurement of the amount of dissolved solids, using a refractometer or other suitable measuring system.
[0041] f). The process medium is stirred gently by the introduction of a stream of nitrogen into the bottom of the process tank so that the kelp fronds are kept in suspension.
[0042] g). The pH is adjusted on a daily basis to maintain a pH of between 7.5 and 8.0.
[0043] h). The process is terminated when the measured dissolved solids content of the process medium reaches at least 3% or becomes stable for 24 hours, whichever is the first. Normally, the process will take between 3 and 5 days.
[0044] i). The process is stopped by filtering the process medium through a sieve, cloth, or net of a mesh size sufficient to retain and separate the kelp fronds from the remainder of the process medium.
[0045] j). Preferably, to obtain a useable concentration of the desired natural surfactant, the separated process medium is passed through an ultrafiltration system until the measured dissolved solids content reaches 10%.
[0046] k). The concentrated process medium is stabilized by adjusting the pH of the medium to between a minimum of pH 6.0 and a maximum of pH 8.0 by the addition of a solution of an acid such as citric acid and the addition of potassium sorbate to a concentration of 0.1%. The pH range chosen is that at which the natural surfactant is stable for a minimum of 2 years when kept at a temperature of between 15° C. and 40° C.
EXAMPLE 3
A Third Process Embodiment
[0047] a). The salinity of an appropriate quantity of cold water, the temperature of which is maintained at a minimum of 12° C. and a maximum of 17° C., is adjusted by the addition of 35 grams/liter of a salt such as sodium chloride.
[0048] b). The kelp fronds are then added in a ratio of 10 kg of kelp fronds to 100 kg of cold water.
[0049] c). Heat in an appropriate form is applied to the tank jacket to raise the temperature of the process medium to 25° C.
[0050] d). The pH of the process mixture is then adjusted to between a pH of 7.5 and pH 8.0 either by the introduction of a solution of an acid such as citric acid (if the pH is too high) or by the introduction of a solution of a base such as potassium hydroxide (if the pH is too low). During the pH adjustment process the process medium is gently stirred, manually, by a paddle.
[0051] e). An enzyme solution containing the enzyme papain is added in the proportion of between 5 grams and 20 grams of the enzyme protein to 100 kg of process medium.
[0052] f). A measurement of the amount of dissolved solids, using a refractometer or other suitable measuring system.
[0053] g). The process medium is stirred gently by the introduction of a stream of nitrogen into the bottom of the process tank so that the kelp fronds are kept in suspension.
[0054] h). The pH is adjusted on a daily basis to maintain a pH of between 7.5 and 8.0.
[0055] i). The process is terminated when the measured dissolved solids content of the process medium reaches at least 2% or becomes stable for 24 hours, whichever is the first. Normally, this process will take between 3 and 5 days.
[0056] j). The process is stopped by filtering the process medium through a sieve, cloth, or net of a mesh size sufficient to retain and separate the kelp fronds from the remainder of the process medium.
[0057] k). Preferably, to obtain a useable concentration of the desired surfactant, the separated process medium is passed through an ultrafiltration system until the measured dissolved solids content reaches 10%.
[0058] l). The concentrated process medium is stabilized by adjusting the pH of the medium to between a minimum of pH 6.0 and a maximum of pH 8.0 by the addition of a solution of an acid such as citric acid and the addition of potassium sorbate to a concentration of 0.1%. The pH range chosen is that at which the natural surfactant is stable for a minimum of 2 years when kept at a temperature of between 15° C. and 40° C.
[0059] It is noted that any acid or base may be used for controlling the pH values and the acids and bases mentioned are only exemplary.
[0060] The invention now turns to using the surfactant (kelp extract), in various cleaning based products.
Product 1 - All Purpose Cleaner and Degreaser Typical composition Range Raw Materials % by weight % by weight Water 79.5 60.0-95.0 di-basic salt 3.0 1.0-10.0 (e.g. sodium carbonate) Non-ionic & Amphoteric 15.0 3.0-30.0 Surfactants Kelp Extract 2.5 0.5-10.0 Preservative q.s. q.s. (e.g. Potassium Sorbate) Total 100.0 100.00 q.s. = quantity sufficient.
Instructions:
[0062] a). Add the di-basic salt to the water and mix until dissolved.
[0063] b). Add the remaining ingredients in the order given.
Product 2 - Carpet Extraction Cleaner Typical composition Range Raw Material % by weight % by weight Water 89.0 60.0-95.0 Buffering Salt 2.0 0.5-10.0 (e.g. Sodium Carbonate) Builder 4.5 1.0-15.0 (e.g. Sodium Tripolyphosphate) Non-Ionic Surfactant 1.5 0.0-6.0 Kelp Extract 1.0 0.5-3.0 Fatty Acid esters 2.0 0.0-7.0 (e.g. Estasol) Total 100.0 100.0
Instructions:
[0065] a). Add the buffering salt and builder to the water and mix until dissolved.
[0066] b). Add the remaining ingredients in the order given.
Product 3 - High Performance Cleaner Typical composition Range Raw Material % by weight % by weight Water 81.1 40.0-95.0 Buffering Salt 1.5 0.25-7.0 (e.g. Sodium Carbonate) Non-Ionic & 10.0 1.5-30.0 Amphoteric Surfactants Kelp Extract 2.5 0.25-6.0 Triethanolamine 0.5 0.0-5.0 Builder 0.2 0.0-10.0 Fatty Acid Esters 1.5 0.0-10.0 (e.g. Estasol) Short Chain Esters 2.0 0.0-10.0 Plant Terpenes 0.7 0.0-10.0 (e.g. Dipentene) Total 100.0 100.0
Instructions:
[0068] a). Add the buffering salt to the water and mix until dissolved.
[0069] b). Add the remaining ingredients in the order given. | A process for extracting a natural surfactant includes the steps of providing a quantity of water, adding in a quantity of seaweed to the water resulting in a process medium, adding an enzyme solution to the process medium, and extracting the natural surfactant from the seaweed. The natural surfactant or kelp extract is then used in the formulation of many cleaning solutions. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a printing apparatus and, in particular, to a printing apparatus which is arranged to print an image on a discrete label or a continuous supply of tape. The invention also relates to a supply of labels and to a supply of image receiving tape.
[0003] 2. Related Technology
[0004] Printers are known which are arranged to print an image on a continuous supply of tape or on discrete labels held on a continuous backing layer.
[0005] It has been proposed to place markings on the back of the continuous backing medium or the backing layer of a continuous tape. For example, in EP 575 772 a thermal printer is disclosed on which an image is printed on discrete labels. Markings to identify the characteristics of the label can be provided either on the label itself or on the backing sheet. The markings are read by the thermal printer and are used to determine whether an image should be printed directly on the label by the thermal printer or whether an ink ribbon is required to print an image thereon.
[0006] U.S. Pat. No. 4,531,851 describes a printer which prints an image on a plurality of discrete labels carrying the backing web. Each label on the backing web has a marking which is used to control the timing of a printing. In other words, the signal resulting from the detection of the marks on each label is used to control when the printer is activated so that the image falls within the label boundaries.
[0007] EP 934 168 (Esselte N.V.) discloses a tape printing apparatus where markings are provided on the back of the tape. These markings are used for example to indicate the characteristics of the tape such as colour, tape width, whether or not an ink ribbon is required etc. In this document, the speed of the tape is determined from the markings and this in turn is used to control the speed of a motor to hold the speed constant. The information is also used to control the strobing of the print head in response to the speed.
[0008] JP 2000-318249 discloses a printer for an automatic cash delivery machine having a compensation unit which corrects a print start position by comparing actual and set mark detection times.
SUMMARY OF THE INVENTION
[0009] According to a first aspect, the invention provides a printer for printing an image on an image receiving material provided on a backing material, said backing material having regularly spaced markings provided on the back thereof, said printer comprising means for detecting said markings and means for determining at least one of a spacing between two markings and a width of a marking, comparing the determined marking width and/or spacing with a respective reference value and for causing printing to be stopped if at least one of the determined spacing and/or width differs from the respective reference value by more than a predetermined amount.
[0010] According to a second aspect, the invention provides an image receiving material provided on a backing material with regularly spaced markings provided on the back of the backing material for use in a printer comprising means for detecting said markings, means for determining at least one of a spacing between two markings and a width of a marking, comparing the determined marking width and/or spacing with a respective reference value and for causing printing to be stopped if at least one of the determined spacing and/or width differs from the respective reference value by more than a predetermined amount.
[0011] According to a third aspect, the invention provides a printer system for printing an image on an image receiving material provided on a backing material, said backing material having regularly spaced markings provided on the back thereof, said printer system comprising means for detecting said markings and means for determining at least one of a spacing between two markings and a width of a marking, comparing the determined marking width and/or spacing with a respective reference value and for causing printing to be stopped if at least one of the determined spacing and/or width differs from the respective reference value by more than a predetermined amount.
[0012] According to one embodiment, the invention provides a printer for printing an image on a image receiving material provided on a backing material, said backing material having regularly spaced markings provided on the back thereof, said printer comprising means for detecting said markings and means for sending information relating to said detected marking to a computer for processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a better understanding of the invention and as to how the same may be carried into effect, reference will now be made by way of example only to the accompanying drawings in which:
[0014] FIG. 1 shows two die cut labels on a backing material embodying the invention;
[0015] FIG. 2 shows a schematic view of a printer embodying the invention;
[0016] FIG. 3 shows a flow chart illustrating the method of the invention; and
[0017] FIG. 4 shows the output of a phototransistor of the arrangement of FIG. 2 .
DETAILED DESCRIPTION
[0018] Reference will first be made to FIG. 1 which shows two labels 4 on a backing material 2 defining a label supply 10 . The labels 4 are discrete labels i.e. die cut labels. The labels 4 are adhered to the backing material 2 . The backing material 2 has a release coating on the side to which the labels are adhered in order to allow the labels to be easily removed from the backing material once a label has been printed. Markings 6 are provided on the side of the backing material 2 opposite to that on which the labels 4 are provided. For schematic purposes, FIG. 1 shows the labels and markings apparently on the same side as the backing tape. This might occur in embodiments where the markings are invisible to the naked eye. However, in preferred embodiments of the invention, the markings are on the other side of the backing material 2 to the labels.
[0019] The markings each have the same width A and the same separation distance C. The height of the markings is indicated by B and the distance between the edge of the backing material and the start of a marking, as measured across the width of the backing material is D. By way of example only, A may be 3 mm, B may be 8 mm, C maybe 8 mm and D may be 11.5 mm. However, these measurements are given by way of example only and the size of the measurements may vary.
[0020] The markings may extend continuously along the length of the backing material or may be provided in clusters at regular intervals. For example, N markings equally spaced apart from one another may constitute a set of markings. There may be M sets of N markings with the sets of markings being separated by a distance which is greater than the separation of the markings within a set.
[0021] The size of the markings and/or the distance therebetween may be altered to reflect different label sizes and/or materials.
[0022] Reference is now made to FIG. 2 which shows a schematic view of a printer embodying the invention.
[0023] The label supply 10 is provided on a supply reel 12 . In alternative embodiments of the invention, the label supply may be provided in a cassette. In other embodiments of the invention, the label supply is provided as a fan-fold stack.
[0024] The supply reel 12 is mounted on a spindle 14 about which the supply reel can rotate.
[0025] A print head 18 is provided for printing on the die cut labels 4 . The print head 18 is controlled in accordance with data provided from a CPU (Central Processing Unit) 30 or any other suitable processing element or print head driver.
[0026] The image printed on the tape may be input by the user via a keyboard 36 . The keyboard 36 is connected to the CPU 30 . The CPU processes the input data from the keyboard and puts it into a format suitable for controlling the print head 18 .
[0027] The print head 18 acts against a platen 20 . In this embodiment, the platen 20 is rotatably driven by a motor 16 . The print head and/or the platen may be movable apart from one another to allow the easy insertion of the material between the platen and the printer head. During printing, the platen 20 and print head 18 will be urged one against the other. When the print head 18 and platen 20 are in the printing configuration, rotation of the platen 20 will cause image receiving material to be pulled from the supply roll 12 .
[0028] The motor 16 may be controlled in embodiments of the invention by the CPU 30 via an input line 32 .
[0029] Embodiments of the invention are provided with a sensor arrangement 25 . The sensor arrangement 25 comprises a light source 24 which may be a light emitting diode and a light detector 22 which may be in the form of a phototransistor. The phototransistor 22 is arranged to detect light emitted by the light source 24 which is reflected from the rear surface of the image receiving medium i.e. the surface on which the markings are provided. In embodiments of the invention the markings are darker than the background of the image receiving tape. Thus, more light is reflected from the regions between the markings to the photo transistor than when the light from the light emitting diode 24 impinges a marking.
[0030] In some embodiments of the invention a grating may be provided between the light emitting diode and photo transistor on the one hand and the backing material on the other hand. The grating is there to improve the quality of the wave form provided by the photo transistor 22 . The width of the slit of the grating is selected to have a width generally corresponding to the width of a single line. The provision of the grating can improve the contrast between the light regions and the dark regions. This in turn may provide sharper peaks and troughs in the wave form provided by the photo transistor.
[0031] The output of the photo transistor 22 is input via a line 26 to the CPU. The CPU 30 may control the light emitting diode 24 via line 28 .
[0032] The apparatus also comprises a display 40 which is controlled by the output of the CPU 30 via a line 42 . In particular, the output of the CPU 30 is input to a display driver 38 which controls the information displayed on the display 40 .
[0033] Reference will now be made to FIG. 3 which shows a flow chart illustrating the steps of the invention in conjunction with FIG. 4 which shows the output of the photo transistor 22 . In particular, FIG. 4 shows the wave form produced with intensity on the y axis and time on the x axis. As can be seen, there are regular troughs 50 with a low intensity. These correspond to the detection of the dark areas. These are separated by peaks 52 which are representative of the light areas. In practice, the wave form may be more sinusoidal. This may be processed or analysed to give the same results obtainable from the waveform of FIG. 3 using for example threshold values.
[0034] Reference is now made to FIG. 3 which shows a flow chart of a method embodying the invention.
[0035] In step S 1 , the CPU receives the signal from the photo transistor 26 .
[0036] In step S 2 , the CPU 30 analysis the received signal, in particular, the CPU is arranged to determine distance A, that is the width of the line. This is done by measuring the time for which a given trough is detected. It is assumed that the platen is rotating at a given speed x. Multiplication of the assumed speed of the platen by the time will give the distance A.
[0037] In step S 3 , the distance C is determined. This is determined in a similar manner to the distance A but instead the length of time for which a given peak exists is multiplied by the assumed speed to give the distance C.
[0038] In step S 4 , the measured values for A and C are compared to reference values indicating the actual values for those components, if the platen is rotating at speed x.
[0039] In step S 5 , it is determined whether the difference between the measured value of A and the actual value of A is in a predefined tolerance range. It is also determined whether the difference between the measured value for C and the actual value of C is also within a defined tolerance range. If the values are within the defined tolerance range, then the printing operation continues as normal. If it is determined that the values of C and/or A measured fall outside a defined tolerance range, then the printing is halted. An error message is optionally generated and this may be displayed on the display. The tolerance range may for example be plus or minus 20% of the actual values. To avoid anomalous results, printing is only stopped if the values of A and/or C are outside the defined tolerance range for Y consecutive marks and intervals. For example Y may be in the region of 3 . However, this is again a matter of design choice which takes into account the size of the markings, the sensitivity of the detection equipment and the like.
[0040] If the measurement is outside the defined tolerance range, this means that the speed which has been assumed for the speed on which the tape moves past the print head is not correct. This may for example be due to a label supply jam, motor malfunction, end of the supply or the like.
[0041] In the preferred embodiment of the invention, dark markings against a light back ground are used. In alternative embodiments light markings against a dark background can be used. Highly reflective markings can be used. Markings which are not visible may be used such as for example magnetic markings.
[0042] In one embodiment of the invention, a stand alone tape printer may be used. The stand alone printer would have the elements shown in FIG. 2 . In another embodiment of the invention a printer embodying the invention may be connected to a PC. In such a printer the display, display driver and keyboard functions would be provided by the P.C. At least part of the CPU function may be provided by a CPU of the PC.
[0043] The detection of the markings would take place in the printer. The processing of the results of the detection may take place in either a CPU of the printer or a CPU of the PC or a combination of a processing capability in the printer and the PC.
[0044] The printer may be connected to the PC via a cable or wireless connection.
[0045] Reference is made to reference values in this specification. It should be appreciated that a plurality of reference values may be used to define a range and if a value falls outside the range, printing is stopped.
[0046] Where the labels are die cut labels a registration mark or a hole may be provided on or through the backing layer at a location between the two labels. The mark or hole may comprise two or more marks or hole extending along a line parallel to the width of the backing layer. This hole or mark is detected using the arrangement shown and/or an additionally arrangement. Thus the printer is able to identify the beginning of a label and control the printing accordingly. | A printer for printing an image on an image receiving material provided on a backing material, the backing material having regularly spaced markings provided on the back thereof, said printer including a detector for detecting said markings, and a device for determining at least one of a spacing between two markings and a width of a marking, comparing the determined marking width and/or spacing with a respective reference value and for causing printing to be stopped if at least one of the determined spacing and/or width differs from the respective reference value by more than a predetermined amount. | 1 |
RELATED APPLICATION
This application claims the benefit under Title 35§ 119(e) of U.S. Provisional Application No. 60/234,121, filed Sep. 21, 2000.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,636,505 describes N-(substituted phenyl)-3-alkyl-, aryl- and heteroarylsulfonyl-2-hydroxy-2-alkyl- and haloalkylpropanamide compounds, methods for their preparation, and their utility in the treatment of malignant or benign prostatic disease or of androgen dependent disease conditions such as acne, hirsutism or seborrhoea. Bicalutamide, (±)-N-[4-cyano-3-(trifluoromethyl)phenyl]-3-[(4-fluorophenyl)sulfonyl]-2-hydroxy-2-methylpropanamide, is a particularly preferred specie of the above compounds. Bicalutamide is an effective, well-tolerated and convenient non-steroidal antiandrogen for use in the treatment of advanced prostate cancer. Preclinical and clinical studies have also indicated its potential as monotherapy, with quality of life advantages compared with castration (Schellhammer, Exp. Opin. Invest. Drugs, 8, p. 849 (1999)).
Bicalutamide has been prepared by reacting 3-trifluoromethyl-4-cyanoanaline with methacryloyl chloride followed by epoxidation of the resultant N-(3-trifluoromethyl-4-cyanophenyl)methacrylamide and subsequent epoxide ring opening with thiol and sulfone formation (U.S. Pat. No. 4,636,505; Tucker et al., J. Med. Chem., 31, p. 954 (1988)). Although that process is relatively straight forward, chromatographic separations required in the process makes it undesirable for use on a commercial scale. In addition, that process requires the use of relatively expensive starting materials.
Accordingly, what is needed in the art is a process for the preparation of N-(substituted phenyl)-3-alkyl-, aryl- and heteroarylsulfonyl-2-hydroxy-2-alkyl- and haloalkylpropanamide compounds which does not require the use of chromatographic separations and uses less expensive starting materials.
It is, therefore, an object of the present invention to provide an improved process for the preparation of N-(substituted phenyl)-3-alkyl-, aryl- and heteroarylsulfonyl-2-hydroxy-2-alkyl- and haloalkylpropanamide compounds which does not require the use of chromatographic separations and uses relatively less expensive starting materials compared to the art processes.
This and other objects and features of the present invention are described hereinbelow in more detail.
SUMMARY OF THE INVENTION
The present invention provides an improved process for the preparation of an N-(substituted phenyl)-3-alkyl-, aryl- or heteroarylsulfonyl-2-hydroxy-2-alkyl- or haloalkylpropanamide of formula I
wherein
Y is cyano, nitro, perfluoroalkyl, alkylcarbonyl, alkoxycarbonyl or alkylsulfonyl;
R is perfluoroalkyl, cyano, nitro, alkylcarbonyl, alkoxycarbonyl, alkyl or alkoxy;
R 1 is alkyl or haloalkyl; and
R 2 is alkyl, aryl or heteroaryl,
which process comprises:
(a) reacting a substituted benzene of formula II (II)
wherein Y and R are as described above, X is F, Cl, Br, I or —OSO 2 R 3 , and R 3 is alkyl or aryl with an α,β,-unsaturated propanamide of formula III
wherein R 1 is as described above in the presence of a first base to form an N-(substituted phenyl)-α,β-unsaturated propanamide of formula IV
(b) reacting the formula IV propanamide with an epoxidizing agent to form an epoxide of formula V
(c) reacting the formula V epoxide with a thiol of formula VI
R 2 SH (VI)
wherein R 2 is as described above in the presence of a second base to form a sulfide of formula VII
(d) reacting the formula VII sulfide with an oxidizing agent.
The present invention also relates to improved processes for the preparation of N-(substituted phenyl)-α,β-unsaturated propanamides of formula IV, epoxides of formula V, and sulfides of formula VII.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention preferably comprises reacting a substituted benzene of formula II with an α,β-unsaturated propanamide of formula III in the presence of a first base and an aprotic solvent, preferably in a temperature range from about −40° C. to 155° C., to form an N-(substituted phenyl)-α,β-unsaturated propanamide of formula IV; reacting the formula IV propanamide with an epoxidizing agent in the presence of an aprotic solvent, preferably in a temperature range from about −78° C. to 155° C., to form an epoxide of formula V; reacting the formula V epoxide with a thiol of formula VI in the presence of a second base and an aprotic solvent, preferably in a temperature range from about −78° C. to 155° C., to form a sulfide of formula VII; and reacting the formula VII sulfide with an oxidizing agent in the presence of an aprotic solvent, preferably in a temperature range from about −78° C. to 155° C.
Aprotic solvents suitable for use in this invention include, but are not limited to, halogenated hydrocarbons such as dichloromethane, carbon tetrachloride, chloroform, 1,2-dichloroethane, and the like; hydrocarbons such as hexane, heptane, and the like; aromatic hydrocarbons such as benzene, toluene, a xylene, mesitylene, and the like; halogenated aromatic hydrocarbons such as fluorobenzene, chlorobenzene, bromobenzene, a dihalobenzene, and the like; an ether such as diethyl ether, methyl t-butyl ether, tetrahydrofuran, and the like; an ester such as ethyl acetate, and the like; and an amide such as N,N-dimethylformamide, and the like; and mixtures thereof. In a preferred embodiment of the present invention, step (a) is conducted in the presence of an amide, preferably N,N-dimethylformamide; step (b) is conducted in the presence of a halogenated hydrocarbon, preferably dichloromethane; step (c) is conducted in the presence of an ether, preferably tetrahydrofuran; and step (d) is conducted in the presence of a halogenated hydrocarbon, preferably dichloromethane.
First and second bases useful in the processes of this invention include, but are not limited to, alkali metal hydrides such as sodium hydride, potassium hydride, and lithium hydride; alkali metal alkoxides such as sodium methoxide, potassium methoxide, sodium ethoxide, potassium ethoxide, sodium t-butoxide, potassium t-butoxide, and the like; alkali metal amides such as sodium amide, and the like; and alkyllithiums such as butyllithium, and the like. Preferred first and second bases include sodium hydride, potassium t-butoxide, sodium amide, and butyllithium with sodium hydride being more preferred.
Epoxidizing agents suitable for use in the present invention include conventional epoxidizing agents known in the art. Conventional epoxidizing agents particularly useful in the processes of this invention include, but are not limited to, peracids such as peracetic acid, trifluoroperacetic acid, 3-chloroperbenzoic acid, and the like; and dioxiranes such as dimethyldioxirane, methyltrifluoromethyldioxirane, and the like. Preferred epoxidizing agents include peracids with trifluoroperacetic acid being more preferred.
Oxidizing agents suitable for use in the oxidation of the formula VII sulfides of this invention include conventional oxidizing agents known in the art. Conventional oxidizing agents particularly useful for the oxidation of the formula VII sulfide of the present invention include, but are not limited to, peracids such as peracetic acid, trifluoroperacetic acid, 3-chloroperbenzoic acid, and the like; dioxiranes such as dimethyldioxirane, methyltrifluoromethyldioxirane, and the like; hydrogen peroxide; sodium periodate; N-methylmorpholine N-oxide; and oxone. Preferred oxidizing agents include peracids with trifluoroperacetic acid being more preferred.
The peracids utilized in the epoxidation and oxidation steps of the present invention may be conveniently prepared in situ from hydrogen peroxide and the corresponding acid anhydride. For example, trifluoroperacetic acid is preferably formed in situ from hydrogen peroxide and trifluoroacetic anhydride.
In a preferred process of the present invention, R 3 is trifluoromethyl. In another preferred process of this invention, X is F, Cl, Br or I, more preferably F.
Preferred formula I compounds produced by the process of the present invention are those wherein
Y is cyano, nitro or trifluoromethyl;
R is trifluoromethyl, cyano, nitro, methoxy or methyl;
R 1 is methyl or trifluoromethyl; and
R 2 is alkyl,
phenyl optionally substituted with one fluoro, chloro, cyano, nitro, methoxy or methylthio substituent, or
thienyl, imidazolyl, thiazolyl, benzothiazolyl, thiadiazolyl, pyridyl or pyrimidinyl each optionally substituted with one chloro, bromo or methyl substituent.
More preferred formula I compounds prepared by the process of this invention are those wherein
Y is cyano or nitro;
R is trifluoromethyl;
R 1 is methyl; and
R 2 is C 1 -C 4 alkyl, phenyl, p-fluorophenyl, thiazol-2-yl, 4-methylthiazol-2-yl, 5-methyl-1,3,4-thiadiazol-2-yl or 2-pyridyl.
The process of the present invention is particularly useful for the preparation of bicalutamide.
Optical isomers of the formula I compounds may be obtained by conducting the step (b) epoxidation under asymmetric conditions to give chiral compounds. For example, the formula IV propanamide may be epoxidized with a chiral dioxirane to give a chiral epoxide.
Listed below are definitions of various terms used herein. These definitions apply to the terms as they are used throughout the specification (unless they are otherwise limited in specific instances) either individually or as part of a larger group.
It should be noted that any heteroatom with unsatisfied valences is assumed to have the hydrogen atoms necessary to satisfy the valences.
The term “alkyl” or “alk” refers to a monovalent alkane (hydrocarbon) derived radical containing from 1 to 12 carbon atoms unless otherwise defined. An alkyl group is an optionally substituted straight, branched or cyclic saturated hydrocarbon group. When substituted, alkyl groups may be substituted with up to four substituent groups, R 4 as defined, at any available point of attachment. When the alkyl group is said to be substituted with an alkyl group, this is used interchangeably with “branched alkyl group”. Exemplary unsubstituted such groups include methyl, ethyl, propyl, isopropyl, n-butyl, t-butyl, isobutyl, pentyl, hexyl, isohexyl, heptyl, 4,4-dimethylpentyl, octyl, 2,2,4-trimethylpentyl, nonyl, decyl, undecyl, dodecyl, and the like. Exemplary substituents may include, but are not limited to, one or more of the following groups: halo (such as F, Cl, Br or I), haloalkyl (such as CCl 3 or CF 3 ), alkoxy, alkylthio, hydroxy, carboxy (—COOH), alkoxycarbonyl, alkylcarbonyloxy, amino (—NH 2 ), carbamoyl, urea, amidinyl or thiol (—SH).
The terms “alkoxy” or “alkylthio”, as used herein, denote an alkyl group as described above bonded through an oxygen linkage (—O—) or a sulfur linkage (—S—), respectively.
Sulfonyl denotes groups bonded by —SO 2 -linkages.
The term “alkoxycarbonyl”, as used herein, denotes an alkoxy group bonded through a carbonyl group.
The term “alkylcarbonyl” refers to an alkyl group bonded through a carbonyl group.
The term “aryl” refers to monocyclic or bicyclic aromatic rings, e.g., phenyl, substituted phenyl and the like, as well as groups which are fused, e.g., napthyl, phenanthrenyl and the like. An aryl group thus contains at least one ring having at least 6 atoms, with up to five such rings being present, containing up to 22 atoms therein, with alternating (resonating) double bonds between adjacent carbon atoms or suitable heteroatoms. Aryl groups may optionally be substituted with one or more groups including, but not limited to, halogen, alkyl, alkoxy, hydroxy, carboxy, carbamoyl, alkoxycarbonyl, nitro, trifluoromethyl, amino, cyano, alkyl S(O) t (t=0, 1 or 2) or thiol.
The term “heteroaryl” refers to a monocyclic aromatic hydrocarbon group having 5 or 6 ring atoms, or a bicyclic aromatic group having 8 to 10 atoms, containing at least one heteroatom, O, S, or N, in which a carbon or nitrogen atom is the point of attachment, and in which one or two additional carbon atoms is optionally replaced by a heteroatom selected from O or S, and in which 1 to 3 additional carbon atoms are optionally replaced by nitrogen heteroatoms, said heteroaryl group being optionally substituted as described herein. Exemplary heteroaryl groups include the following: thienyl, furyl, pyrrolyl, pyridyl, imidazolyl, thiadiazolyl, thiazolyl, oxazolyl, triazolyl, pyrazolyl, isoxazolyl, isothiazolyl, pyrazinyl, tetrazolyl, pyridazinyl, pyrimidinyl, triazinylazepinyl, indolyl, isoindolyl, quinolinyl, isoquinolinyl, benzothiazolyl, benzoxazolyl, benzimidazolyl, benzoxadiazolyl and benzofurazanyl. Exemplary substituents include one or more of the following: halogen, alkyl, alkoxy, hydroxy, carboxy, carbamoyl, alkoxycarbonyl, trifluoromethyl, nitro, cyano, amino, alkylS(O) t (t=0, 1 or 2) or thiol.
The term “halogen” or “halo” refers to chlorine, bromine, fluorine or iodine.
The term “perfluoroalkyl” refers to a C n F 2 n+1 group wherein n is an integer of 1 to 6.
Starting compounds of formulas II and III are known to those skilled in the art. Those starting compounds may be prepared by procedures known in the art or are commercially available.
In order to facilitate a further understanding of the invention, the following examples are presented primarily for the purpose of illustrating more specific details thereof. The scope of the invention should not be deemed limited by the examples, but encompasses the entire subject matter defined in the claims.
EXAMPLE 1
Preparation of N-[4-Cyano-3-(trifluoromethyl)phenyl]methacrylamide
To a solution of methacrylamide (153.00 g, 1797.88 mmol) in 800 mL of N,N-dimethylformamide was added 4-cyano-3-(trifluoromethyl)phenyl fluoride (200 g, 1057.58 mmol) at room temperature. The solution was cooled in a methanol/dry ice bath to −20° C. To this cooled solution was added sodium hydride (102 g, 2696.84 mmol), portion-wise, while keeping the reaction mixture temperature below 70° C. The reaction mixture was allowed to cool to room temperature and stirred for 4 hours under nitrogen atmosphere. Water (915 mL) was added followed by 18% HCl (250 mL) and hexane (970 mL). The resultant slurry was allowed to stir overnight. The solid was filtered, washed sequentially with water (3×150 mL) and hexane (100 mL), and dried at 60° C. to give the title product as an off white solid (260 g, 97%).
1 H NMR (CDCl 3 ) δ 7.87 (d, J=1.9 Hz, 111), 7.80 (dd, J=1.9, 8.5 Hz, 1H), 7.69 (bs, 1H), 7.62 (d, J=8.5 Hz, 1H), 5.69 (s, 1H), 5.44 (t, J=1.5 Hz, 1H), 1.90 (s, 3H).
EXAMPLE 2
Preparation of N-[4-Cyano-3-(trifluoromethyl)phenyl]methacrylamide epoxide
Preparation 1
To a stirred solution of N-[4-cyano-3-(trifluoromethyl)phenyl]meth-acrylamide (250 g, 983.4 mmol) in dichloromethane (1.2 L) was added 30% hydrogen peroxide (170 mL, 5900.6 mmol). The solution was cooled in a methanol/dry ice bath to −60° C. Trifluoroacetic anhydride (791.76 mL, 5605.6 mmol) was added slowly while keeping the reaction mixture temperature between −15 to 0° C. After the addition was complete, the reaction mixture was stirred at room temperature for 45 minutes under a nitrogen atmosphere, transferred to a separation funnel and diluted with water (1 L). The organic layer was collected, and the aqueous layer was extracted with dichloromethane (3×200 mL). The organic layers were combined, washed sequentially with saturated sodium bisulfite (1 L) and water (1 L), dried over sodium sulfate, and distilled. The residue was diluted with ethyl acetate (160 mL) and tert-butyl methyl ether (1.6 L). The resultant slurry was stirred overnight, filtered and dried at 60° C. to give the title product as a white solid (180 g, 68%). 1 H NMR (CDCl 3 ) δ 8.54 (s, 1H), 8.16 (d, J=1.9 Hz, 1H), 8.05 (dd, J=1.9, 8.5 Hz, 1H), 7.95 (d, J=8.5 Hz, 1H), 3.16 (s, 2H), 1.83 (s, 3H).
Preparation 2
To a stirred solution of N-[4-cyano-3-trifluoromethyl)phenyl]methacrylamide (1.8 g, 7.08 mmol), and dichloromethane (10 mL) was added hydrogen peroxide (1.22 mL, 42.5 mmol). The flask was then put in a water bath at room temperature. Trifluoroacetic anhydride (5 mL, 35.40 mmol) was added slowly. The reaction mixture was stirred and checked by HPLC. After 1 h and 40 minutes, the reaction mixture was transferred to a separation funnel using dichloromethane (35 mL). The organic layer was then washed with distilled water (15 mL), saturated aqueous sodium bisulfite (4×15 mL), saturated sodium bicarbonate (3×15 mL), brine (15 mL), dried over magnesium sulfate, filtered, concentrated and dried to give the title compound as a yellowish solid (1.94 g, 98.6% yield).
EXAMPLE 3
Preparation of N-[4-Cyano-3-(trifluoromethyl)phenyl]-3-[(4-fluorophenyl)thio]-2-hydroxy-2-methylpropanamide
To a 0° C. mixture of sodium hydride (19.3 g, 804.8 mmol) in tetrahydrofuran (333 mL) was added a solution of 4-fluorobenzenethiol (81.8 mL, 767.92 mmol) in tetrahydrofuran (248 mL) while maintaining the temperature below 25° C. during the addition. After the addition was complete, the mixture was stirred for five minutes, and a solution of N-[4-cyano-3-(trifluoromethyl)phenyl]methacryalmide epoxide (166 g, 614.3 mmol) in tetrahydrofuran (830 mL) was added slowly. The reaction mixture was stirred at room temperature for two hours, and the solvent was distilled off. The residue was diluted with ethyl acetate (885 mL), transferred to a separation funnel and washed sequentially with brine (220 mL) and water (440 mL). The organic layer was dried with magnesium sulfate, filtered, and concentrated to give the title product as a clear oil which solidified on standing (244.74 g, 100%). 1 H NMR (CDCl 3 ) δ 9.05 (s, 1H), 7.88 (m, 2H), 7.69 (m, 2H), 7.30 (m, 2H), 6.78 (d, J=1.3 Hz, 1H), 3.77 (br, 1H), 3.63 (d, J=14.0 Hz, 1H), 3.03 (d, J=14.0 Hz, 1H), 1.46 (s, 3H).
EXAMPLE 4
Preparation of N-[4-Cyano-3-(trifluoromethyl)phenyl]-3-[4-fluorophenyl)sulfonyl]-2-hydroxy-2-methylpropanamide (bicalutamide)
To a solution of N-[4-cyano-3-(trifluoromethyl)phenyl]-3-[(4-fluorophenyl)thio]-2-hydroxy-2-methylpropanamide (244.74 g, 614.3 mmol) in dichloromethane (1.5 L) was added 30% hydrogen peroxide (141.6 mL, 4914.7 mmol). The mixture was cooled to −55° C. Trifluoroacetic anhydride (520.6 mL, 3686.0 mmol) was added slowly while keeping the reaction mixture temperature between −15 to 0° C. After the addition was complete, the reaction mixture was stirred at room temperature for 16 hours, and diluted with ice cold water (500 mL) and brine (500 mL). The resultant slurry was stirred for 20 minutes, filtered, washed with tert-butyl methyl ether, and dried to give the title product as a white solid (255.2 g, 97%).
1 H NMR (DMSO-d 6 ) δ 10.40 (s, 1H), 8.44 (s, 1H), 8.22 (d, J=8.6 Hz, 1H), 8.10 (d, J=8.6 Hz, 1H), 7.93 (m, 2H), 7.38 (t, J=8.4 Hz, 2H), 6.42 (s, 1H), 3.95 (d, J=14.7 Hz, 1H), 3.72 (d, J=14.7 Hz, 1H), 1.40 (s, 3H). | The present invention provides an improved process for the preparation of N-(substituted phenyl)-3-alkyl-, aryl- and heteroarylsulfonyl-2-hydroxy-2-alkyl- and haloalkylpropanamide compounds of formula I that exhibit antiandrogenic activity and are useful in the treatment of malignant or benign prostatic disease or of androgen dependent disease conditions such as acne, hirsutism or seborrhea. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to novel compounds capable of modulating, regulating and/or inhibiting tyrosine kinase signal transduction. The present invention is also directed to methods of regulating, modulating or inhibiting tyrosine kinases, whether of the receptor or non-receptor class, for the prevention and/or treatment of disorders related to unregulated tyrosine kinase signal transduction, including cell growth, metabolic, and blood vessel proliferative disorders.
DESCRIPTION OF THE RELATED ART
[0002] Protein tyrosine kinases (PTKs) comprise a large and diverse class of proteins having enzymatic activity. The PTKs play an important role in the control of cell growth and differentiation.
[0003] For example, receptor tyrosine kinase mediated signal transduction is initiated by extracellular interaction with a specific growth factor (ligand), followed by receptor dimerization, transient stimulation of the intrinsic protein tyrosine kinase activity and phosphorylation. Binding sites are thereby created for intracellular signal transduction molecules and lead to the formation of complexes with a spectrum of cytoplasmic signaling molecules that facilitate the appropriate cellular response (e.g., cell division, metabolic homeostasis, and responses to the extracellular microenvironment).
[0004] With respect to receptor tyrosine kinases, it has been shown also that tyrosine phosphorylation sites function as high-affinity binding sites for SH2 (src homology) domains of signaling molecules. Several intracellular substrate proteins that associate with receptor tyrosine kinases (RTKs) have been identified. They may be divided into two principal groups: (1) substrates which have a catalytic domain; and (2) substrates which lack such domain but serve as adapters and associate with catalytically active molecules. The specificity of the interactions between receptors or proteins and SH2 domains of their substrates is determined by the amino acid residues immediately surrounding the phosphorylated tyrosine residue. Differences in the binding affinities between SH2 domains and the amino acid sequences surrounding the phosphotyrosine residues on particular receptors are consistent with the observed differences in their substrate phosphorylation profiles. These observations suggest that the function of each receptor tyrosine kinase is determined not only by its pattern of expression and ligand availability but also by the array of downstream signal transduction pathways that are activated by a particular receptor. Thus, phosphorylation provides an important regulatory step which determines the selectivity of signaling pathways recruited by specific growth factor receptors, as well as differentiation factor receptors.
[0005] Aberrant expression or mutations in the PTKs have been shown to lead to either uncontrolled cell proliferation (e.g. malignant tumor growth) or to defects in key developmental processes. Consequently, the biomedical community has expended significant resources to discover the specific biological role of members of the PTK family, their function in differentiation processes, their involvement in tumorigenesis and in other diseases, the biochemical mechanisms underlying their signal transduction pathways activated upon ligand stimulation and the development of novel drugs.
[0006] Tyrosine kinases can be of the receptor-type (having extracellular, transmembrane and intracellular domains) or the non-receptor type (being wholly intracellular).
[0007] The receptor-type tyrosine kinases (RTKs) comprise a large family of transmembrane receptors with diverse biological activities. The intrinsic function of RTKs is activated upon ligand binding, which results in phosphorylation of the receptor and multiple cellular substrates, and subsequently in a variety of cellular responses. The non-receptor tyrosine kinases represent a collection of cellular enzymes which lack extracellular and transmembrane sequences. A more detailed discussion of receptor and non-receptor tyrosine kinases is provided in Cowan-Jacob Cell Mol. Life Sci., 2996, 63, 2608-2625
[0008] There are a number of examples where RTK kinases, have been found to be involved in cellular signaling pathways leading to pathological conditions, including exudative age-related macular degeneration (Ni et al. Opthalmologica 2009 223 401-410; Chappelow et al. Drugs 2008 68 1029-1036), diabetic retinopathy (Zhang et al., Int. J. Biochem. Cell Biol. 2009 41 2368-2371), cancer (Aora et al. J. Path. Exp. Ther. 2006, 315, 971), psoriasis (Heidenreich et al Drug News Perspective 2008 21 97-105), rosacea (Smith, J. R., V. B. Lanier, et al. Br J Ophthalmol 2007, 91(2): 226-229) and hyper immune response. In ophthalmic diseases such as exudative age-related macular degeneration and diabetic retinopathy aberrant activation of VEGF receptors can lead to abnormal blood vessel growth. The importance of VEGFR signaling in the exudative age-related macular degeneration disease process is evident by the clinical success of multiple anti-VEGF targeting agents including Lucentis®, Avastin®, and EYLEA™ (Barakat et al., Expert Opin. Investig. Drugs 2009, 18, 637). Recently it has been suggested that inhibition of multiple RTK signaling pathways may provide a greater therapeutic effect than targeting a single RTK signaling pathway. For example in neovascular ocular disorders such as exudative age-related macular degeneration and diabetic retinopathy the inhibition of both VEGFR and PDGFR may provide a greater therapeutic effect by causing regression of existing neovascular blood vessels present in the disease (Adamis et al., Am. J. Pathol. 2006 168 2036-2053). In cancer inhibition of multiple RTK signaling pathways has been suggested to have a greater effect than inhibiting a single RTK pathway (DePinho et al., Science 2007 318 287-290; Bergers et al. J. Clin Invest. 2003 111 1287-1295).
[0009] The identification of effective small compounds which specifically inhibit signal transduction by modulating the activity of receptor and non-receptor tyrosine kinases to regulate and modulate abnormal or inappropriate cell proliferation is therefore desirable and one object of this invention.
SUMMARY OF THE INVENTION
[0010] The present invention relates to organic molecules capable of modulating, regulating and/or inhibiting tyrosine kinase signal transduction by blocking the VEGF and/or PDGF receptors. Such compounds are useful for the treatment of diseases related to unregulated tyrosine kinase signal transduction, including vascular proliferative disorders such as diabetic retinopathy, age-related macular degeneration and retinopathy of prematurity.
[0011] In one aspect, the invention provides a compound represented by Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
[0000]
[0000] wherein:
R 1 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen, NR 9 R 10 , C(O)NR 9 R 10 , (CR 11 R 12 ) p NR 9 R 10 , (CR 11 R 12 ) p C(O)OR 13 , (CR 11 R 12 ) p OR 13 , NR 9 C(O)(CR 11 R 12 ) p NR 9 R 10 , NR 9 C(O)(CR 11 R 12 ) p C(O)OR 13 , NR 9 C(O)(CR 11 R 12 ) p OR 13 , C(O)(CR 11 R 12 ) p NR 9 R 10 , C(O)(CR 11 R 12 ) p C(O)OR 13 , C(O)(CR 11 R 12 ) p COR 13 , C(O)NR 9 (CR 11 R 12 ) p NR 9 R 10 , C(O)NR 9 (CR 11 R 12 ) p C(O)OR 13 , C(O)NR 9 (CR 11 R 12 ) p COR 13 , NR 9 C(O)NR 10 (CR 11 R 12 ) p NR 9 R 10 , NR 9 C(O)NR 10 (CR 11 R 12 ) p C(O)OR 13 or NR 9 C(O)NR 10 (CR 11 R 12 ) p OR 13 ;
R 2 is hydrogen or NH 2 ;
R 3 is represented by one of the formulae below
[0000]
[0000] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is CR 8 or N;
[0012] n is 1 or 2;
m is 1 or 2;
p is 0, 1, 2, 3, 4, 5 or 6;
t is 0, 1, 2, 3, 4, 5 or 6;
u is 1, 2, 3, 4, 5 or 6;
R 4 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 5 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 6 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 7 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 8 is hydrogen, halogen, trifluoromethyl, substituted or unsubstituted C 1-12 alkyl, (CR 20 R 21 ) t NR 18 R 19 , (CR 20 R 21 ) t C(O)OR 22 , (CR 20 R 21 ) t OR 22 , O(CR 20 R 21 ) u NR 18 R 19 , O(CR 20 R 21 ) t C(O)OR 22 , O(CR 20 R 21 ) u OR 22 , NR 18 (CR 20 R 21 ) u NR 18 R 19 , NR 18 (CR 20 R 21 ) t C(O)OR 22 , NR 18 (CR 20 R 21 ) u OR 22 , C(O)(CR 20 R 21 ) t NR 18 R 19 , C(O)(CR 20 R 21 ) t C(O)OR 22 , C(O)(CR 20 R 21 ) t COR 22 , NR 18 C(O)(CR 20 R 21 ) t NR 18 R 19 , NR 18 C(O)(CR 20 R 21 ) t C(O)OR 22 , R 18 C(O)(CR 20 R 21 ) t OR 22 , C(O)NR 18 (CR 20 R 21 ) u NR 18 R 19 , C(O)NR 18 (CR 20 R 21 ) t C(O)OR 22 , C(O)NR 18 (CR 20 R 21 ) t COR 22 , NR 18 C(O)NR 19 (CR 20 R 21 ) u NR 18 R 19 , NR 18 C(O)NR 19 (CR 20 R 21 ) t C(O)OR 22 or NR 18 C(O)NR 19 (CR 20 R 21 ) u OR 22 ;
R 9 is hydrogen, substituted or unsubstituted C 1-12 alkyl, substituted or unsubstituted aryl, or together with the N and R 10 can form a substituted or unsubstituted heterocyclic ring;
R 10 is hydrogen, substituted or unsubstituted C 1-12 alkyl or together with the N and R 9 can form a substituted or unsubstituted heterocyclic ring;
R 11 is hydrogen, substituted or unsubstituted C 1-12 alkyl halogen, trifluoromethyl, or hydroxyl;
R 12 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen, trifluoromethyl or hydroxyl;
R 13 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 14 is substituted or unsubstituted C 1-12 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 15 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen or trifluoromethyl;
R 16 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen or trifluoromethyl;
R 17 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen or trifluoromethyl;
R 18 is hydrogen, substituted or unsubstituted C 1-12 alkyl, aryl or together with the N and R 19 can form a substituted or unsubstituted heterocyclic ring;
R 19 is hydrogen or substituted or unsubstituted C 1-12 alkyl or together with the N and R 18 can form a substituted or unsubstituted heterocyclic ring;
R 20 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen, trifluoromethyl or hydroxyl;
R 21 is hydrogen, substituted or unsubstituted C 1-12 alkyl, halogen, trifluoromethyl or hydroxyl;
R 22 is hydrogen or substituted or unsubstituted C 1-12 alkyl; and
with the proviso that m and n cannot be 2 in same time.
[0013] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
[0000]
R 3 is
[0014] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0015] n is 2;
m is 1;
p is 0, 1, 2, 3, 4, 5 or 6;
R 4 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 5 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 6 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 7 is hydrogen or substituted or unsubstituted C 1-12 alkyl;
R 9 is hydrogen, substituted or unsubstituted C 1-12 alkyl, substituted or unsubstituted aryl, or together with the N and R 10 can form a substituted or unsubstituted heterocyclic ring;
R 10 is hydrogen, substituted or unsubstituted C 1-12 alkyl or together with the N and R 9 can form a substituted or unsubstituted heterocyclic ring;
R 14 is hydrogen, substituted or unsubstituted C 1-12 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is hydrogen or substituted or unsubstituted C 1-12 alkyl.
[0016] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
[0000]
R 3 is
[0017] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0018] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen;
R 14 is hydrogen;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is hydrogen.
[0019] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
[0000]
R 3 is
[0020] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0021] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen;
R 14 is substituted or unsubstituted C 1-12 alkyl;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is hydrogen.
[0022] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
R 3 is
[0023]
[0000] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0024] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen;
R 14 is hydrogen;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is C 1-12 alkyl.
[0025] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
R 3 is
[0026]
[0000] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0027] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is substituted or unsubstituted C 1-12 alkyl;
R 10 is hydrogen;
R 14 is substituted or unsubstituted C 1-12 alkyl;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is substituted or unsubstituted C 1-12 alkyl.
[0028] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
R 3 is
[0029]
[0000] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0030] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is hydrogen;
R 10 is C 1-12 alkyl;
R 14 is substituted or unsubstituted heterocycle I;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is substituted or unsubstituted C 1-12 alkyl.
[0031] In another aspect, the invention provides a compound represented by Formula I
[0000] wherein:
R 1 is NR 9 R 10 ;
R 2 is hydrogen;
R 3 is
[0032]
[0000] Z 1 is (CR 4 R 5 ) n ;
Z 2 is (CR 6 R 7 ) m ;
Y is N;
[0033] n is 2;
m is 1;
R 4 is hydrogen;
R 5 is hydrogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 9 is substituted or unsubstituted C 1-12 alkyl;
R 10 is hydrogen;
R 14 is substituted or unsubstituted aryl;
R 15 is hydrogen;
R 16 is hydrogen;
R 17 is substituted or unsubstituted C 1-12 alkyl.
[0034] The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 12 carbon atoms. One methylene (—CH 2 —) group, of the alkyl group can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkyl groups can have one or more chiral centers. Alkyl groups can be independently substituted by halogen atoms, hydroxyl groups, cycloalkyl groups, amino groups, heterocyclic groups, aryl groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamide groups, ester groups, ketone groups.
[0035] The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be independently substituted by halogen atoms, sulfonyl C 1-8 alkyl groups, sulfoxide C 1-8 alkyl groups, sulfonamide groups, nitro groups, cyano groups, —OC 1-8 alkyl groups, —SC 1-8 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amide groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
[0036] The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cycloalkyl having at least one double bond. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be independently substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amide groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
[0037] The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
[0038] The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. One methylene (—CH 2 —) group, of the alkenyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by alkyl groups, as defined above or by halogen atoms.
[0039] The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond. One methylene (—CH 2 —) group, of the alkynyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkynyl groups can be substituted by alkyl groups, as defined above, or by halogen atoms.
[0040] The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or unsaturated, containing at least one heteroatom selected form oxygen, nitrogen, sulfur, or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S and N heteroatoms can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, amide groups, ketone groups, alkylamino groups, amino groups, aryl groups, ester groups, ketone groups, carboxylic acid groups, C 3-8 cycloalkyl groups or hydroxyl groups.
[0041] The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms, by removal of one hydrogen atom. Aryl can be substituted by halogen atoms, sulfonyl C 1-6 alkyl groups, sulfoxide C 1-6 alkyl groups, sulfonamide groups, carboxcyclic acid groups, C 1-6 alkyl carboxylates (ester) groups, amide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, aldehydes, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups. Aryls can be monocyclic or polycyclic.
[0042] The term “hydroxyl” as used herein, represents a group of formula “—OH”.
[0043] The term “carbonyl” as used herein, represents a group of formula “—C(O)—”.
[0044] The term “ketone” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —C(O)R x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
[0045] The term “ester” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —C(O)OR x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
[0046] The term “amine” as used herein, represents a group of formula “—NR x R y ”, wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
[0047] The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
[0048] The term “sulfonyl” as used herein, represents a group of formula “—SO 2 − ”.
[0049] The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
[0050] The term “sulfonate” as used herein, represents a group of the formula “—S(O) 2 —O—”.
[0051] The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
[0052] The term “nitro” as used herein, represents a group of formula “—NO 2 ”.
[0053] The term “cyano” as used herein, represents a group of formula “—CN”.
[0054] The term “amide” as used herein, represents a group of formula “—C(O)NR x R y ,” or “NR x R y C(O)—” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
[0055] The term “sulfonamide” as used herein, represents a group of formula “—S(O) 2 NR x R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
[0056] The term “sulfoxide” as used herein, represents a group of formula “—S(O)—”.
[0057] The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
[0058] The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
[0059] The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
[0060] The formula “H”, as used herein, represents a hydrogen atom.
[0061] The formula “O”, as used herein, represents an oxygen atom.
[0062] The formula “N”, as used herein, represents a nitrogen atom.
[0063] The formula “S”, as used herein, represents a sulfur atom.
[0000] Other defined terms are used throughout this specification:
“Ac” refers to acetyl
“Et” refers to ethyl
“iPr” refers to i-propyl
“Me” refers to methyl
“MeOH” refers to methanol
“PDGF” refers to platelet derived growth factor
“Ph” refers to phenyl
“PTKs” refers to protein tyrosine kinase
“RTKs” refers to receptor tyrosine kinase
“rt” refers to room temperature
“tBu” refers to t-butyl.
“THF” refers to tetrahydrofuran
“VEGF” refers to vascular endothelial growth factor
“VEGFR” refers to vascular endothelial growth factor receptor
Some compounds of the invention are:
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-(tert-butyl)phenyl)pyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-tert-butylphenyl)-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-methoxyphenyl)-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[4-(2-methoxyethyl)phenyl]-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(3-thienyl)pyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(1-methyl-1H-pyrazol-3-yl)-1,6-dihydropyridin-2(3H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(m-tolyl)-1,6-dihydropyridin-2(3H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(4-methylphenyl)pyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(2-methylphenyl)pyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(3-tert-butylphenyl)-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[4-(dimethylamino)phenyl]-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[3-(dimethylamino)phenyl]-4-methylpyridin-2(1H)-one; tert-butyl {4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}carbamate; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-1,3-dimethyl-1H-pyrazole-5-carboxamide; tert-butyl {4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}carbamate; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-1,3-dimethyl-1H-pyrazole-5-carboxamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-2-methylbenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-chlorobenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-chloro-4-fluorobenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(methylthio)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-chloro-3-(trifluoromethyl)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(trifluoromethyl)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-bromobenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methoxybenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methylthiophene-2-carboxamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methylbenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-methylbenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3,4-dimethylbenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-chloro-4-methoxybenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-2-fluoro-5-(trifluoromethyl)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-2-fluoro-5-methylbenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-5-tert-butylisoxazole-3-carboxamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-methoxy-3-(trifluoromethyl)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(methylsulfinyl)benzamide; 3-[({4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}amino)carbonyl]benzoic acid; 3-{4-[({4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}amino)carbonyl]phenyl}propanoic acid; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-[(4-methylpiperazin-1-yl)methyl]-3-(trifluoromethyl)benzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-4-fluorobenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3,4-dimethoxybenzamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-2-furamide; N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-5-methyl-2-furamide; 4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]-N-[(3-methyl-2-furyl)methyl]benzamide; 1-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(2-methylphenyl)urea; 1-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(3-methyl-2-furyl)urea; 3-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]-N-(3-methyl-2-furyl)benzamide; 4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]-N-(3-methyl-2-furyl)benzamide; 1-{3-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-(3-methyl-2-furyl)urea; 4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]-N-(2-methylphenyl)benzamide; 4-[({[6-(4-methyl-1-{4-[(3-methyl-2-furoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]amino}carbonyl)amino]butanoic acid; 2-methyl-N-(4-{4-methyl-3-[2-({[(3-morpholin-4-ylpropyl)amino]carbonyl}amino)-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-2-oxopyridin-1(2H)-yl}phenyl)benzamide; 2-hydroxyethyl[6-(4-methyl-1-{4-[(2-methylbenzoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]carbamate; 4-({[(6-{4-methyl-1-[4-({[(3-methyl-2-furyl)methyl]amino}carbonyl)phenyl]-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)amino]carbonyl}amino)butanoic acid; 4-[({[6-(4-methyl-1-{4-[(2-methylbenzoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]amino}carbonyl)amino]butanoic acid; 2-hydroxyethyl[6-(4-methyl-1-{4-[(3-methyl-2-furoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]carbamate; 3-methyl-N-(4-{4-methyl-3-[2-({[(3-morpholin-4-ylpropyl)amino]carbonyl}amino)-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-2-oxopyridin-1(2H)-yl}phenyl)-2-furamide; 1-(6-{1-[3-(dimethylamino)phenyl]-4-methyl-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)-3-(3-morpholin-4-ylpropyl)urea; 2-hydroxyethyl (6-{1-[3-(dimethylamino)phenyl]-4-methyl-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)carbamate; 4-({[(6-{1-[3-(dimethylamino)phenyl]-4-methyl-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)amino]carbonyl}amino)butanoic acid; 3-(4-{[6-(4-methyl-1-{4-[(2-methylbenzoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]amino}phenyl)propanoic acid; N-{4-[3-(2-anilino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-2-methylbenzamide; 3-{4-[(6-{4-methyl-1-[4-({[(3-methyl-2-furyl)methyl]amino}carbonyl)phenyl]-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)amino]phenyl}propanoic acid; 4-{3-[2-({4-[2-(4-hydroxypiperidin-1-yl)ethyl]phenyl}amino)-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-4-methyl-2-oxopyridin-1(2H)-yl}-N-[(3-methyl-2-furyl)methyl]benzamide; 4-[3-(2-anilino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]-N-[(3-methyl-2-furyl)methyl]benzamide; 3-(4-{[6-(4-methyl-1-{4-[(3-methyl-2-furoyl)amino]phenyl}-2-oxo-1,2-dihydropyridin-3-yl)-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl]amino}phenyl)propanoic acid; N-(4-{3-[2-{[4-(13-hydroxy-5,8,11-trioxa-2-azatridec-1-yl)phenyl]amino}-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-4-methyl-2-oxopyridin-1(2H)-yl}phenyl)-3-methyl-2-furamide; N-(4-{3-[2-({4-[2-(4-hydroxypiperidin-1-yl)ethyl]phenyl}amino)-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-4-methyl-2-oxopyridin-1(2H)-yl}phenyl)-3-methyl-2-furamide; N-{4-[3-{2-[(4-{4-[2-(2-hydroxyethoxy)ethyl]piperazin-1-yl}phenyl)amino]-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl}-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide; N-{4-[3-(2-anilino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide; 3-{4-[(6-{1-[3-(dimethylamino)phenyl]-4-methyl-2-oxo-1,2-dihydropyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-yl)amino]phenyl}propanoic acid; 1-[3-(dimethylamino)phenyl]-3-[2-({4-[2-(4-hydroxypiperidin-1-yl)ethyl]phenyl}amino)-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl]-4-methylpyridin-2(1H)-one; 3-(2-anilino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[3-(dimethylamino)phenyl]-4-methylpyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)pyridin-2(1H)-one; 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one.
[0142] Compounds of formula I are useful as protein kinase inhibitors. As such, compounds of formula I will be useful for treating diseases related to protein kinase signal transduction, for example, cancer, blood vessel proliferative disorders, fibrotic disorders, and neurodegenerative diseases. In particular, the compounds of the present invention are useful for treatment of mesangial cell proliferative disorders and metabolic diseases, lung carcinomas, breast carcinomas, Non Hodgkin's lymphomas, ovarian carcinoma, pancreatic cancer, malignant pleural mesothelioma, melanoma, arthritis, restenosis, hepatic cirrhosis, atherosclerosis, psoriasis, rosacea, diabetic mellitus, wound healing, inflammation and neurodegenerative diseases and preferably ophthalmic diseases, i.e. diabetic retinopathy, retinopathy of prematurity, macular edema, retinal vein occlusion, exudative or neovascular age-related macular degeneration, high-risk eyes (i.e. fellow eyes have neovascular age-related macular degeneration) with dry age-related macular degeneration, neovascular disease associated with retinal vein occlusion, neovascular disease (including choroidal neovascularization) associated with the following: pathologic myopia, pseudoxanthoma elasticum, optic nerve drusen, traumatic choroidal rupture, atrophic macular degeneration, geographic atrophy, central serous retinopathy, cystoid macular edema, diabetic retinopathy, proliferative diabetic retinopathy, diabetic macular edema, rubeosis iridis, retinopathy of prematurity, Central and branch retinal vein occlusions, inflammatory/infectious retinal, neovascularization/edema, corneal neovascularization, hyperemia related to an actively inflamed pterygia, recurrent pterygia following excisional surgery, post-excision, progressive pterygia approaching the visual axis, prophylactic therapy to prevent recurrent pterygia, of post-excision, progressive pterygia approaching the visual axis, chronic low grade hyperemia associated with pterygia, neovascular glaucoma, iris neovascularization, idiopathic etiologies, presumed ocular histoplasmosis syndrome, retinopathy of prematurity, chronic allergic conjunctivitis, ocular rosacea, blepharoconjunctivitis, recurrent episcleritis, keratoconjunctivitis sicca, ocular graft vs host disease, etc.
[0143] Some compounds of Formula I and some of their intermediates may have at least one asymmetric center in their structure. This asymmetric center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Applied Chem. (1976), 45, 11-13.
[0144] The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
[0145] The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic acid, hydroxyacetic acid, propanoic acid, lactic acid, pyruvic acid, malonic acid, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric acid, methylsulfonic acid, ethanesulfonic acid, benzenesulfonic acid, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta-Zürich, 2002, 329-345).
[0146] The base addition salt form of a compound of Formula I that occurs in its acid form can be obtained by treating the acid with an appropriate base such as an inorganic base, for example, sodium hydroxide, magnesium hydroxide, potassium hydroxide, calcium hydroxide, ammonia and the like; or an organic base such as for example, L-Arginine, ethanolamine, betaine, benzathine, morpholine and the like. (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta-Zürich, 2002, 329-345).
[0147] Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
[0148] With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
[0149] Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
[0150] The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
[0151] The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
[0152] In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0153] Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
[0154] Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
[0155] In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
[0156] The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
[0157] Pharmaceutical compositions containing invention compounds may be in a form suitable for topical use, for example, as oily suspensions, as solutions or suspensions in aqueous liquids or nonaqueous liquids, or as oil-in-water or water-in-oil liquid emulsions. Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable salt thereof, as an active ingredient with conventional ophthalmically acceptable pharmaceutical excipients and by preparation of unit dosage suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 2.0% (w/v) in liquid formulations.
[0158] For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 4.5 and 8.0 with an appropriate buffer system, a neutral pH being preferred but not essential. The formulations may also contain conventional pharmaceutically acceptable preservatives, stabilizers and surfactants. Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose cyclodextrin and purified water.
[0159] Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
[0160] Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
[0161] In a similar manner an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
[0162] Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place of or in conjunction with it.
[0163] The ingredients are usually used in the following amounts:
[0000]
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
0-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.8
antioxidant
as needed
surfactant
as needed
purified water
to make 100%
[0164] The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
[0165] The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution. One package may contain one or more unit doses. Especially preservative-free solutions are often formulated in non-resealable containers containing up to about ten, preferably up to about five units doses, where a typical unit dose is from one to about 8 drops, preferably one to about 3 drops. The volume of one drop usually is about 20-35 μl.
[0166] The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
[0167] The compounds of the invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
[0168] Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
[0169] The present invention is further directed to pharmaceutical compositions comprising a pharmaceutically effective amount of one or more of the above-described compounds and a pharmaceutically acceptable carrier or excipient, wherein said compositions are effective for treating the above diseases and conditions; especially ophthalmic diseases and conditions. Such a composition is believed to modulate signal transduction by a tyrosine kinase, either by inhibition of catalytic activity, affinity to ATP or ability to interact with a substrate.
[0170] More particularly, the compositions of the present invention may be included in methods for treating diseases comprising proliferation, fibrotic or metabolic disorders, for example cancer, fibrosis, psoriasis, rosacea, atherosclerosis, arthritis, and other disorders related to abnormal vasculogenesis and/or angiogenesis, such as exudative age related macular degeneration and diabetic retinopathy.
[0171] The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. Synthetic Scheme 1 set forth below, illustrates how the compounds according to the invention can be made.
[0000]
[0172] At this stage, those skilled in the art will appreciate that many additional compounds that fall under the scope of the invention may be prepared by performing various common chemical reactions. Details of certain specific chemical transformations are provided in the examples.
[0173] Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I.
[0174] The present invention is not to be limited in scope by the exemplified embodiments which are intended as illustrations of single aspects of the invention only. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description.
DETAILED DESCRIPTION OF THE INVENTION
[0175] The present invention relates to a method of regulating, modulating or inhibiting tyrosine kinases, whether of the receptor or non-receptor class, for the prevention and/or treatment of disorders related to unregulated tyrosine kinase signal transduction, including cell growth, metabolic, and blood vessel proliferative disorders, which comprises administering a pharmaceutical composition comprising a therapeutically effective amount of at least one kinase inhibitor as described herein.
[0176] In another aspect, the invention provides the use of at least one kinase inhibitor for the manufacture of a medicament for the treatment of a disease or a condition mediated by tyrosine kinases in a mammal.
[0177] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
[0178] It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
[0179] The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of hydrogen 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
[0180] The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
[0181] As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
[0182] Compound names were generated with ACDLabs version 12.5. Some of the intermediate and reagent names used in the examples were generated with software such as Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1.
[0183] In general, characterization of the compounds is performed according to the following methods; NMR spectra are recorded on 300 or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal.
[0184] All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
[0185] Usually the compounds of the invention were purified by medium pressure liquid chromatography, unless noted otherwise.
[0186] In particular the compounds of the present invention are selected from the compounds of Table 1, below, wherein: R 15 is hydrogen, R 16 is hydrogen, Z 1 is (CR 4 R 5 ) n , Z 2 is (CR 6 R 7 ) m , Y is N, R 2 is hydrogen, R 4 is hydrogen, R 5 is hydrogen, R 6 is hydrogen, R 7 is hydrogen, n is 2, m is 1, R 3 is formula II.
[0000]
TABLE 1
Ex.
R 1
R 17
R 14
Compound Name
2
NH 2
H
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(4- (tert-butyl)phenyl)pyridin- 2(1H)-one
4
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(4- tert-butylphenyl)-4- methylpyridin-2(1H)-one
5
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(4- methoxyphenyl)-4- methylpyridin-2(1H)-one
6
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-[4- (2-methoxyethyl)phenyl]-4- methylpyridin-2(1H)-one
7
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-1-(3-thienyl)pyridin- 2(1H)-one
8
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-1-(1-methyl-1H- pyrazol-3-yl)-1,6- dihydropyridin-2(3H)-one
9
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-1-(m-tolyl)-1,6- dihydropyridin-2(3H)-one
10
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-1-(4- methylphenyl)pyridin- 2(1H)-one
11
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-1-(2- methylphenyl)pyridin- 2(1H)-one
12
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(3- tert-butylphenyl)-4- methylpyridin-2(1H)-one
13
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-[4- (dimethylamino)phenyl]-4- methylpyridin-2(1H)-one
14
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-[3- (dimethylamino)phenyl]-4- methylpyridin-2(1H)-one
15
NH 2
CH 3
tert-butyl {4-[3-(2-amino- 7,8-dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}carbamate
16
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(4- aminophenyl)-4- methylpyridin-2(1H)-one
17
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-methyl-2- furamide
18
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-1,3-dimethyl- 1H-pyrazole-5- carboxamide
19
NH 2
CH 3
tert-butyl {4-[3-(2-amino- 7,8-dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}carbamate
20
NH 2
CH 3
3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-1-(4- aminophenyl)-4- methylpyridin-2(1H)-one
21
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-methyl-2- furamide
22
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-1,3-dimethyl- 1H-pyrazole-5- carboxamide
23
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-2- methylbenzamide
24
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4- chlorobenzamide
25
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-chloro-4- fluorobenzamide
26
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- (methylthio)benzamide
27
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4-chloro-3- (trifluoromethyl)benzamide
28
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- (trifluoromethyl)benzamide
29
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}benzamide
30
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- bromobenzamide
31
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- methoxybenzamide
32
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- methylthiophene-2- carboxamide
33
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- methylbenzamide
34
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4- methylbenzamide
35
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3,4- dimethylbenzamide
36
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-chloro-4- methoxybenzamide
37
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-2-fluoro-5- (trifluoromethyl)benzamide
38
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-2-fluoro-5- methylbenzamide
39
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-5-tert- butylisoxazole-3- carboxamide
40
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4-methoxy-3- (trifluoromethyl)benzamide
41
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3- (methylsulfinyl)benzamide
42
NH 2
CH 3
3-[({4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}amino)carbonyl] benzoic acid
43
NH 2
CH 3
3-{4-[({4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}amino)carbonyl] phenyl}propanoic acid
44
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4-[(4- methylpiperazin-1- yl)methyl]-3- (trifluoromethyl)benzamide
45
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-4- fluorobenzamide
46
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3,4- dimethoxybenzamide
47
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-2-furamide
48
NH 2
CH 3
N-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-5-methyl-2- furamide
49
NH 2
CH 3
4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]-N-[(3-methyl-2- furyl)methyl]benzamide
50
NH 2
CH 3
1-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-(2- methylphenyl)urea
51
NH 2
CH 3
1-{4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-(3-methyl-2- furyl)urea
52
NH 2
CH 3
3-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]-N-(3-methyl-2- furyl)benzamide
53
NH 2
CH 3
4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]-N-(3-methyl-2- furyl)benzamide
54
NH 2
CH 3
1-{3-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-(3-methyl-2- furyl)urea
55
NH 2
CH 3
4-[3-(2-amino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]-N-(2- methylphenyl)benzamide
56
CH 3
4-[({[6-(4-methyl-1-{4-[(3- methyl-2- furoyl)amino]phenyl}-2- oxo-1,2-dihydropyridin-3- yl)-5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl]amino}carbonyl)amino] butanoic acid
57
CH 3
2-methyl-N-(4-{4-methyl-3- [2-({[(3-morpholin-4- ylpropyl)amino]carbonyl} amino)-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-2- oxopyridin-1(2H)- yl}phenyl)benzamide
58
CH 3
2-hydroxyethyl [6-(4- methyl-1-{4-[(2- methylbenzoyl)amino] phenyl}-2-oxo-1,2- dihydropyridin-3-yl)- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2-yl]carbamate
59
CH 3
4-({[(6-{4-methyl-1-[4-({[(3- methyl-2- furyl)methyl]amino}carbonyl) phenyl]-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl)amino]carbonyl}amino) butanoic acid
60
CH 3
4-[({[6-(4-methyl-1-{4-[(2- methylbenzoyl)amino] phenyl}-2-oxo-1,2- dihydropyridin-3-yl)- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl]amino}carbonyl)amino] butanoic acid
61
CH 3
2-hydroxyethyl [6-(4- methyl-1-{4-[(3-methyl-2- furoyl)amino]phenyl}-2- oxo-1,2-dihydropyridin-3- yl)-5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2-yl]carbamate
62
CH 3
3-methyl-N-(4-{4-methyl-3- [2-({[(3-morpholin-4- ylpropyl)amino]carbonyl} amino)-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-2- oxopyridin-1(2H)- yl}phenyl)-2-furamide
63
CH 3
1-(6-{1-[3- (dimethylamino)phenyl]-4- methyl-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2-yl)-3-(3- morpholin-4-ylpropyl)urea
64
CH 3
2-hydroxyethyl (6-{1-[3- (dimethylamino)phenyl]-4- methyl-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2-yl)carbamate
65
CH 3
4-({[(6-{1-[3- (dimethylamino)phenyl]-4- methyl-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl)amino]carbonyl}amino)b
66
CH 3
3-(4-{[6-(4-methyl-1-{4-[(2- methylbenzoyl)amino] phenyl}-2-oxo-1,2- dihydropyridin-3-yl)- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl]amino}phenyl)propanoic acid
67
CH 3
N-{4-[3-(2-anilino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-2- methylbenzamide
68
CH 3
3-{4-[(6-{4-methyl-1-[4- ({[(3-methyl-2- furyl)methyl]amino}carbon yl)phenyl]-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl)amino]phenyl}propanoic acid
69
CH 3
4-{3-[2-({4-[2-(4- hydroxypiperidin-1- yl)ethyl]phenyl}amino)-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-4- methyl-2-oxopyridin-1(2H)- yl}-N-[(3-methyl-2- furyl)methyl]benzamide
70
CH 3
4-[3-(2-anilino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]-N-[(3-methyl-2- furyl)methyl]benzamide
71
CH 3
3-(4-{[6-(4-methyl-1-{4-[(3- methyl-2- furoyl)amino]phenyl}-2- oxo-1,2-dihydropyridin-3- yl)-5.6.7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl]amino}phenyl)propanoic acid
72
CH 3
N-(4-{3-[2-{[4-(13-hydroxy- 5,8,11-trioxa-2-azatridec- 1-yl)phenyl]amino}-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-4- methyl-2-oxopyridin-1(2H)- yl}phenyl)-3-methyl-2- furamide
73
CH 3
N-(4-{3-[2-({4-[2-(4- hydroxypiperidin-1- yl)ethyl]phenyl}amino)-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-4- methyl-2-oxopyridin-1(2H)- yl}phenyl)-3-methyl-2- furamide
74
CH 3
N-{4-[3-{2-[(4-{4-[2-(2- hydroxyethoxy)ethyl] piperazin-1-yl}phenyl)amino]- 7,8-dihydropyrido[4,3- d]pyrimidin-6(5H)-yl}-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-methyl-2- furamide
75
CH 3
N-{4-[3-(2-anilino-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl)-4- methyl-2-oxopyridin-1(2H)- yl]phenyl}-3-methyl-2- furamide
76
CH 3
3-{4-[(6-{1-[3- (dimethylamino)phenyl]-4- methyl-2-oxo-1,2- dihydropyridin-3-yl}- 5,6,7,8- tetrahydropyrido[4,3- d]pyrimidin-2- yl)amino]phenyl}propanoic acid
77
CH 3
1-[3-(dimethyl amino) phenyl]-3-[2-({4-[2-(4- hydroxypiperidin-1- yl)ethyl]phenyl}amino)-7,8- dihydropyrido[4,3- d]pyrimidin-6(5H)-yl]-4- methylpyridin-2(1H)-one
78
CH 3
3-(2-anilino-7,8-dihydro- pyrido[4,3-d]pyrimidin- 6(5H)-yl)-1-[3-(dimethyl amino)phenyl]-4- methylpyridin-2(1H)-one
[0187] The invention is further illustrated by the following non-limiting examples.
[0188] Compounds of Table 1 were prepared as follows:
Preparation 1
[0189]
3-bromo-2-(4-methoxybenzyloxy)pyridine
[0190] 3-bromo-2-(4-methoxybenzyloxy)pyridine was prepared by the procedure described in J. Med. Chem., 2008, 51, 3065. A pressure vessel was charged with anhydrous THF (25 ml) and sodium hydride (1.44 g, 36.18 mmol, 60% dispersion). To this stirred mixture was added portionwise a solution of 4-methoxybenzyl alcohol (5.0 g, 36.18 mmol) in anhydrous THF (15 ml). After addition was complete, the mixture was stirred at room temperature for 30 minutes and a solution of 3-bromo-2-chloropyridine (4.64 g, 24.08 mmol) in anhydrous THF (15 ml) was added. The vessel was sealed and the reaction mixture was heated at 75° C. for 6 hours. Upon cooling to room temperature, the reaction mixture was partitioned between ethyl acetate and water. The separated organic layer was washed with water, sat'd NaCl (aq.) , dried over MgSO 4 , filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 4:1 hexanes:EtOAc) gave the title compound as a clear oil (6.51 g, 92%).
Preparation 2
[0191]
2′-(4-Methoxybenzyloxy)-3,4,5,6-tetrahydro-2H-[1,3′]bipyridinyl-4-ol
[0192] A mixture of 3-bromo-2-(4-methoxybenzyloxy)pyridine (7.25 g, 24.65 mmol), 4-hydroxypiperidine (3.74 g, 36.97 mmol), tris(dibenzylideneacetone)dipalladium (451 mg, 0.493 mmol), racemic-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl (614 mg, 0.986 mmol), and sodium-t-butoxide (3.32 g, 34.51 mmol) in anhydrous toluene (90 ml) was heated at 85° C. under nitrogen for 22 hours. The reaction mixture was diluted with ethyl acetate, washed with sat'd NaCl (aq.) , dried (MgSO 4 ), filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 1:1 hexanes:EtOAc to 3:7 hexanes:EtOAc) gave the title compound as a brown, viscous oil (4.45 g, 57%).
Preparation 3
[0193]
2′-(4-Methoxybenzyloxy)-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one
[0194] A stirred solution of Dess-Martin periodinane (9.19 g, 21.67 mmol) in dichloromethane (95 ml) at room temperature was treated with a solution of 2′-(4-Methoxybenzyloxy)-3,4,5,6-tetrahydro-2H-[1,3′]bipyridinyl-4-ol (5.68 g, 18.06 mmol) in dichloromethane (60 ml) and the reaction mixture was stirred at room temperature (a mild exotherm was observed). After 1 hour, the reaction mixture was washed with sat'd Na 2 S 2 O 3(aq.) , sat'd NaHCO 3(aq.) , sat'd NaCl (aq.) , dried over MgSO 4 , filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 7:3 hexanes:EtOAc to 3:2 hexanes:EtOAc) gave the title compound as a yellow, viscous oil (4.01 g, 71%).
Preparation 4
[0195]
3-Dimethylaminomethylene-2′-(4-methoxybenzyloxy)-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one
[0196] A solution of 2′-(4-methoxybenzyloxy)-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one (962 mg, 3.08 mmol) in N,N-dimethylformamide-dimethylacetal (7.0 ml, 52.28 mmol) was heated at 75° C. for 21 hours. The solvent was removed in vacuo and the residue was eluted through a flash column (silica gel 60, 230-400 mesh, 8% methanol in EtOAc) to give the title compound as an orange, viscous oil (628 mg, 56%).
Preparation 5
[0197]
6-{2-[(4-methoxybenzyl)oxy]pyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-amine
[0198] A solution of 3-dimethylaminomethylene-2′-(4-methoxybenzyloxy)-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one (673 mg, 1.83 mmol) in ethanol (100 ml) was treated with guanidine carbonate (1.32 g, 7.33 mmol), followed by addition of sodium acetate trihydrate (1.99 g, 14.64 mmol) and the reaction mixture was refluxed for 21 hours. The solvent was removed in vacuo and the residue was partitioned between water and ethyl acetate. The separated organic layer was dried (MgSO 4 ), filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 6% methanol in EtOAc) gave the title compound as a light yellow, amorphous solid (477 mg, 72%).
Example 1
[0199]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)pyridin-2(1H)-one
[0200] A solution of 6-{2-[(4-methoxybenzyl)oxy]pyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-amine (1.77 g, 4.87 mmol) in dichloromethane (70 ml) was treated with trifluoroacetic acid (2.68 ml, 36.04 mmol) at room temperature. After stirring for 30 minutes, the solvent and excess acid was removed in vacuo and the residue was treated with ethyl acetate. Washing with sat'd NaHCO 3(aq.) gave a yellow, amorphous precipitate. The solid was collected, washed with water, EtOAc, MeOH and dried (774 mg, 65%). The product was suspended in a 2:1 (v/v) mixture of water:MeOH (125 ml) and heated to boiling with vigorous stirring for 1.5 hours. The undissolved solid remaining was collected by filtration while the mixture was still hot and washed with water, MeOH, and dried to give the title compound (478 mg, 40%).
Example 2
[0201]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-(tert-butyl)phenyl)pyridin-2(1H)-one)
[0202] A mixture of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)pyridin-2(1H)-one (52 mg, 0.20 mmol), 1-tert-butyl-4-iodobenzene (0.071 mL, 0.40 mmol), N,N′-dimethylethylenediamine (0.022 mL, 0.20 mmol), potassium phosphate tribasic (170 mg, 0.80 mmol), copper (I) iodide (15 mg, 0.080 mmol) in 1.0 mL NMP was heated at 80° C. for 6 hours. The reaction mixture was partitioned between EtOAc and aqueous NaHCO 3 solution, the EtOAc layer washed with H 2 O, brine, dried with anhydrous Na 2 SO 4 and rotary evaporated. The resulting oil was chromatographed eluting with CHCl 3 , then CHCl 3 /EtOAc (1:1), and then 5% MeOH in CHCl 3 /EtOAc (1:1). The solid obtained was then triturated with an EtOAc/hexane mixture to give a pale greenish-beige solid (46 mg, 61%). 1 H NMR (DMSO) δ: 8.03 (s, 1H), 7.48-7.54 (m, 2H), 7.28-7.33 (m, 2H), 7.27 (dd, J=6.7, 1.8 Hz, 1H), 6.87 (dd, J=7.3, 1.8 Hz, 1H), 6.37 (s, 2H), 6.27 (t, J=7.0 Hz, 1H), 4.07 (s, 2H), 3.46 (t, J=6.0 Hz, 2H), 2.69 (t, J=5.9 Hz, 2H), 1.33 (s, 9H).
Preparation 7
[0203]
3-Bromo-2-(4-methoxybenzyloxy)-4-methylpyridine
[0204] 3-bromo-2-(4-methoxybenzyloxy)-4-methylpyridine was prepared by the procedure described in J. Med. Chem., 2008, 51, 3065. A pressure vessel was charged with anhydrous THF (25 ml) and sodium hydride (1.44 g, 36.18 mmol, 60% dispersion). To this stirred mixture was added portionwise a solution of 4-methoxybenzyl alcohol (5.0 g, 36.18 mmol) in anhydrous THF (15 ml). After addition was complete, the mixture was stirred at room temperature for 30 minutes and a solution of 3-bromo-2-chloro-4-picoline (4.97 g, 24.08 mmol) in anhydrous THF (15 ml) was added. The vessel was sealed and the reaction mixture was heated at 75° C. for 6 hours. Upon cooling to room temperature, the reaction mixture was partitioned between ethyl acetate and water. The separated organic layer was washed with water, sat'd NaCl (aq.) , dried over MgSO 4 , filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 4:1 hexanes:EtOAc) gave the title compound as a clear oil which crystallized on standing (6.71 g, 90%).
Preparation 8
[0205]
2′-(4-Methoxybenzyloxy)-4′-methyl-3,4,5,6-tetrahydro-2H-[1,3′]bipyridinyl-4-ol
[0206] A mixture of 3-bromo-2-(4-methoxybenzyloxy)-4-methylpyridine (6.40 g, 20.77 mmol), 4-hydroxypiperidine (3.15 g, 31.15 mmol), tris(dibenzylideneacetone)dipalladium (761 mg, 0.831 mmol), racemic-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl (1.03 g, 1.66 mmol), and sodium-t-butoxide (2.79 g, 29.08 mmol) in anhydrous toluene (200 ml) was heated at reflux under nitrogen for 22 hours. Upon cooling to room temperature, the reaction mixture was filtered through celite and the filtrate was diluted with ethyl acetate, washed with sat'd NaCl (aq.) , dried (MgSO 4 ), filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 1:1 hexanes:EtOAc) gave the title compound as a black, viscous oil (4.76 g, 70%).
Preparation 9
[0207]
2′-(4-Methoxybenzyloxy)-4′-methyl-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one
[0208] A stirred solution of Dess-Martin periodinane (11.61 g, 27.37 mmol) in dichloromethane (122 ml) at room temperature was treated with a solution of 2′-(4-Methoxybenzyloxy)-4′-methyl-3,4,5,6-tetrahydro-2H-[1,3′]bipyridinyl-4-ol (7.49 g, 22.81 mmol) in dichloromethane (81 ml) and the reaction mixture was stirred at room temperature. After 1 hour, the reaction mixture was washed with sat'd Na 2 S 2 O 3(aq.) , sat'd NaHCO 3(aq.) , and sat'd NaCl (aq.) , dried over MgSO 4 , filtered, and concentrated. Elution through a flash column (silica gel 60, 230-400 mesh, 3:2 hexanes:EtOAc) gave the title compound as an off-white, crystalline solid (6.40 g, 86%).
Preparation 10
[0209]
3-Dimethylaminomethylene-2′-(4-methoxybenzyloxy)-4′-methyl-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one
[0210] A mixture of 2′-(4-Methoxybenzyloxy)-4′-methyl-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one (6.40 g, 19.61 mmol) in N,N-dimethylformamide-dimethylacetal (44.63 ml, 333.37 mmol) from a freshly opened bottle was heated at 100° C. for 48 hours. The solvent was removed in vacuo and the residue was eluted through a flash column (silica gel 60, 230-400 mesh, EtOAc to 8% methanol in EtOAc) to give title compound as an orange, viscous oil which slowly solidified on standing (5.21 g, 70%).
Preparation 11
[0211]
6-{2-[(4-methoxybenzyl)oxy]-4-methylpyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-amine
[0212] A solution of 3-dimethylaminomethylene-2′-(4-methoxybenzyloxy)-4′-methyl-2,3,5,6-tetrahydro[1,3′]bipyridinyl-4-one (5.21 g, 13.66 mmol) in methanol (340 ml) was treated with guanidine carbonate (9.84 g, 54.63 mmol), followed by addition of sodium acetate trihydrate (14.87 g, 109.28 mmol) and the reaction mixture was refluxed for 3 hours. The solvent was removed in vacuo and the residue was partitioned between water and dichloromethane. The separated organic layer was dried (MgSO 4 ), filtered, and concentrated to a red oil. The oil was taken up in a minimal volume of EtOAc and allowed to stand overnight at room temperature. The resulting yellow, crystalline solid was collected, washed with EtOAc, and dried to give the title compound (1.91 g). The mother liquor was concentrated and the residue was eluted through a flash column (silica gel 60, 230-400 mesh, EtOAc) to obtain an additional lot of the title compound (1.05 g) The total amount 2.96 g, 57%). HPLC analysis showed the compound has a purity of 98%.
Example 3
[0213]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one
[0214] A solution of 6-{2-[(4-methoxybenzyl)oxy]-4-methylpyridin-3-yl}-5,6,7,8-tetrahydropyrido[4,3-d]pyrimidin-2-amine (3.92 g, 10.39 mmol) in dichloromethane (150 ml) was treated with trifluoroacetic acid (5.71 ml, 76.89 mmol) at room temperature. After stirring for 30 minutes, the solvent and excess acid was removed in vacuo and the residue was treated with ethyl acetate. Washing with sat'd NaHCO 3(aq.) gave a yellow, amorphous precipitate. The solid was collected, washed with water, EtOAc, and dried in vacuo at 50° C. to give (1.65 g, 62%). HPLC analysis showed the compound has a purity of 97%.
Example 4
[0215]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-tert-butylphenyl)-4-methylpyridin-2(1H)-one
[0216] A mixture of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one, 1-tert-butyl-4-iodobenzene (0.071 mL, 0.40 mmol), N,N′-dimethylethylenediamine (0.022 mL, 0.20 mmol), potassium phosphate tribasic (170 mg, 0.80 mmol), copper (I) iodide (15 mg, 0.080 mmol) in 1.0 mL NMP was heated at 70° C. for 17 hours. The reaction mixture was partitioned between EtOAc and aqueous NaHCO 3 solution, the EtOAc layer washed with H 2 O, brine, dried with anhydrous Na 2 SO 4 and rotary evaporated. The resulting oil was chromatographed eluting with CHCl 3 , then CHCl 3 /EtOAc (1:1), and then gradient 3% to 6% MeOH in CHCl 3 /EtOAc (1:1). The solid obtained was then precipitated from an EtOAc/hexane mixture to give a pale yellow solid (44 mg, 57%). 1 H NMR (DMSO) δ: 7.94 (s, 1H), 7.48-7.53 (m, 2H), 7.43 (d, J=6.7 Hz, 1H), 7.27-7.33 (m, 2H), 6.30 (s, 2H), 6.19 (d, J=7.0 Hz, 1H), 3.98 (br. s, 2H), 3.31 (br. s, 2H), 2.68 (t, J=5.3 Hz, 2H), 2.19 (s, 3H), 1.32 (s, 9H)
Example 5
[0217]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-methoxyphenyl)-4-methylpyridin-2(1H)-one
[0218] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (25 mg, 0.097 mmol), 4-methoxy-iodobenzene (23 mg, 97 mmol) N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (5 mg, 22 mmol), and potassium phosphate (41 mg, 0.194 mmol) in 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (19 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was purified using the ISCO flash chromatography system using a 0-100% EtOAc gradient/100-0% Hexane gradient mixture. Following concentration of the appropriate fractions the crude solid collected was further purified by recrystallization using an Et 2 O/Hexane solvent mixture to give the title compound as an off white solid (13 mg, 37%). 1 H NMR (DMSO) δ: 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.61 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.28 (s, 2H), 6.37 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.72 (s, 3H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.18 (s, 3H).
Example 6
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[4-(2-methoxyethyl)phenyl]-4-methylpyridin-2(1H)-one
[0219]
[0220] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (26 mg, 0.099 mmol), N1,N2-dimethylethane-1,2-diamine (6 mg, 0.051 mmol), copper iodide (4 mg, 0.020 mmol), and potassium phosphate (41 mg, 0.194 mmol) in 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (12 h) at 70° C., the reaction was cooled to room temperature and was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a 0-100% EtOAc gradient/100-0% Hexane gradient mixture. The appropriate fractions were concentrated and then the crude product was further purified by recrystallization using an Et 2 O/Hexane solvent mixture, to give the title compound as an off white solid (12 mg, 32%). 1 H NMR (DMSO) δ 7.92 (s, 1H), 7.54-7.65 (m, 2H), 7.51 (d, J=6.7 Hz, 1H), 7.26-7.35 (m, 2H), 6.29 (s, 2H), 6.27 (d, J=7.0 Hz, 1H), 4.02 (br. S, H), 3.81 (m, 5H), 3.30 (s, 2H), 2.55 (t, J=5.3 Hz, 2H), 2.09 (t, J=3.4 Hz, 2H).
Example 7
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(3-thienyl)pyridin-2(1H)-one
[0221]
[0222] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (26 mg, 0.097 mmol), 3-iodothiophene (23 mg, 0.102 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (4 mg, 0.020 mmol), and potassium phosphate (41 mg, 0.194 mmol) in 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (16 h) at 70° C., the reaction was complete and therefore allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was then purified over silica using a 0-100% EtOAc gradient/100-0% Hexane gradient mixture after which, the appropriate fractions were concentrated to afford a solid. This solid was further purified by recrystallization using an Et 2 O/Hexane solvent mixture to give the title compound (11 mg, 35%). 1 H NMR (DMSO) δ: 7.98 (s, 1H), 7.92 (s, 1H), 7.84 (d, J=6.2, 1H), 7.22 (d, J=6.2, 1H), 6.28 (m, 1H), 6.17 (d, J=7.0 Hz, 2H), 3.98 (br. S, 2H), 3.33 (s, 2H), 2.56 (t, j=5.3 Hz, 2H), 2.17 (s, 3H)
Example 8
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(1-methyl-1H-pyrazol-3-yl)-1,6-dihydropyridin-2(3H)-one
[0223]
[0224] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (27 mg, 0.100 mmol), 3-iodo-1-methyl-1H-pyrazole (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (4 mg, 0.020 mmol), and potassium phosphate (43 mg, 0.197 mmol) 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted 3X's with EtOAc (3×5 mL) and 2X's with NaHCO 3 (3×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a 0-100% EtOAc/100-0% Hexane gradient mixture. A second column was done on the impure product using a gradient of MeOH/CHCl 3 after which, the appropriate fractions were concentrated, to afford a yellow solid (17 mg, 52%). 1 H NMR (DMSO) δ: 8.01 (s, 1H), 7.79 (d, J=6.0, 1H), 6.34 (d, J=6.0, 1H), 6.24 (m, 1H), 6.15 (d, J=7.0 Hz, 2H), 4.00 (br. S, 2H), 3.22 (s, 2H), 2.64 (t, j=5.3 Hz, 2H), 2.20 (s, 3H)
Example 9
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(m-tolyl)-1,6-dihydropyridin-2(3H)-one
[0225]
[0226] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (24 mg, 0.096 mmol), 1-iodo-3-methylbenzene (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (5 mg, 0.022 mmol), and potassium phosphate (44 mg, 0.199 mmol) in 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a CHCl 3 /EtOAc gradient. Upon reaching a 1:1 mixture of EtOAc and CHCl 3 , 3% MeOH was added and increased to 6% MeOH which, after concentrating the appropriate fractions, afforded the title compound as a pale yellow solid (16 mg, 47%). 1 H NMR (DMSO) δ: 7.99 (s, 1H), 7.80 (d, J=6.0, 1H), 6.56 (d, J=6.0, 1H), 6.28 (m, 1H), 6.20 (d, J=7.0 Hz, 2H), 3.99 (br. S, 2H), 3.31 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.15 (s, 3H).
Example 10
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(4-methylphenyl)pyridin-2(1H)-one
[0227]
[0228] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (25 mg, 0.097 mmol), 1-iodo-4-methylbenzene (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), Copper Iodide (5 mg, 0.024 mmol), and Potassium Phosphate (41 mg, 0.194 mmol) 2 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and then concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a CHCl 3 /EtOAc gradient. Upon reaching a 1:1 mixture of EtOAc and CHCl 3 , 3% MeOH was added and increased to 6% MeOH which, after concentrating the appropriate fractions afforded the title compound as a tan solid (13 mg, 38%). 1 H NMR (DMSO) δ: 7.90 (s, 1H), 7.50-7.59 (m, 2H), 7.44 (d, J=6.7 Hz, 1H), 7.25-7.32 (m, 2H), 6.19 (s, 2H), 6.08 (d, J=7.0 Hz, 1H), 3.89 (br. S, H), 3.29 (s, 2H), 2.64 (t, j=5.3 Hz, 2H), 2.13 (s, 3H), 1.99 (s, 3H).
Example 11
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-1-(2-methylphenyl)pyridin-2(1H)-one
[0229]
[0230] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (0.025 g, 0.097 mmol), 1-iodo-2-methylbenzene (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (6 mg, 0.049 mmol), copper iodide (5 mg, 0.020 mmol), and potassium phosphate (41 mg, 0.194 mmol) in 0.5 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a CHCl 3 /EtOAc gradient. Upon reaching a 1:1 mixture of EtOAc and CHCl 3 , 3% MeOH was added and increased up to 6% MeOH. After concentrating the appropriate fractions, a white solid was collected as the pure product (8 mg, 24%). 1 H NMR (DMSO) δ: 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.46 (m, 1H), 7.28-7.35 (m, 2H), 6.28 (s, 2H), 6.17 (m, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.21 (s, 3H), 2.07 (s, 3H).
Example 12
[0231]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(3-tert-butylphenyl)-4-methylpyridin-2(1H)-one
[0232] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (0.025 g, 0.097 mmol), 1-iodo-3-tertbutyl benzene (0.20 g, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (0.005 g, 0.049 mmol), Copper Iodide (0.004 g, 0.020 mmol), and Potassium Phosphate (0.041 g, 0.194 mmol) in 0.5 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with 3X's with EtOAc (˜5 mL) and 2X's with NaHCO 3 (˜10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using an 0-100% EtOAc gradient/100-0% Hexane gradient mixture. After concentrating the appropriate fractions, the pure product was collected as an off white solid (5 mg, 19%). 1 H NMR (DMSO) δ: 7.94 (s, 1H), 7.46-7.55 (m, 2H), 7.47 (m, 1H), 7.28-7.36 (m, 2H), 6.32 (s, 2H), 6.21 (m, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.25 (s, 3H), 2.09 (s, 9H).
Example 13
[0233]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[4-(dimethylamino)phenyl]-4-methylpyridin-2(1H)-one
[0234] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (25 mg, 0.097 mmol), 4-iodo-N,N-dimethylaniline (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (5 mg, 0.020 mmol), and potassium phosphate (40 mg, 0.191 mmol) in 0.5 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (15 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using an 0-100% gradient EtOAc/100-0% gradient Hexane. Following concentration of the appropriate fractions in vacuo the product was further purified by recrystallization using a Et 2 O/Hexane solvent mixture to give the title compound as a light grey solid (15 mg, 39%). 1 H NMR (DMSO) δ: 7.90 (s, 1H), 7.46-7.53 (m, 2H), 7.43 (d, J=6.7 Hz, 1H), 7.22-7.30 (m, 2H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 3.02 (s, 6H) 2.65 (t, j=5.3 Hz, 2H), 2.17 (s, 3H).
Example 14
[0235]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-[3-(dimethylamino)phenyl]-4-methylpyridin-2(1H)-one
[0236] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (25 mg, 0.097 mmol), 3-iodo-N,N-dimethylaniline (20 mg, 0.097 mmol), N1,N2-dimethylethane-1,2-diamine (5 mg, 0.049 mmol), copper iodide (5 mg, 0.020 mmol), and potassium phosphate (44 mg, 0.206 mmol) in 0.5 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (13 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using a 0-100% EtOAc gradient/100-0% Hexane gradient. The fractions containing the product were concentrated in vacuo and then further purified by recrystallization using an Et 2 O/Hexane solvent mixture to give the title compound (13 mg, 37%). 1 H NMR (DMSO) δ: 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.46 (m, 1H), 7.28-7.35 (m, 2H), 6.28 (s, 2H), 6.17 (m, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 3.00 (s, 6H), 2.66 (t, j=5.3 Hz, 2H), 2.18 (s, 3H).
Example 15
[0237]
tert-butyl {4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}carbamate
[0238] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (250 mg, 0.97 mmol), tert-butyl(4-iodophenyl)carbamate (200 mg, 0.97 mmol), N1,N2-dimethylethane-1,2-diamine (50 mg, 0.49 mmol), copper iodide (40 mg, 0.20 mmol), and potassium phosphate (410 mg, 1.94 mmol) in 2.0 mL of N-methylpyrrolidone was heated to 70° C. After allowing the reaction to stir overnight (17 h) at 70° C., the reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3×5 mL) and 2X's with NaHCO 3 (2×10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 , filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using an 0-100% EtOAc/100-0% Hexane gradient mixture. Following concentration of the appropriate fractions the title compound was collected as an off white solid (150 mg, 33%). 1 H NMR (DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.41 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.18 (s, 3H), 1.39 (s, 9H).
Example 16
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one
[0239]
[0240] Tert-butyl (4-(5-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-6-oxo-5,6-dihydropyridin-1(2H)-yl)phenyl)carbamate (150 mg, 0.334 mmol) was dissolved into a 1:1 mixture of MeOH/THF (˜10 mL) and treated with CF 3 COOH drop wise and the reaction was allowed to stir for 4 h. One the reaction was completed, the residual CF 3 COOH was neutralized with NaHCO 3 (aq). The reaction was then extracted with EtOAc (3×10 mL) and brine (˜10 mL). The combined organic layers were dried over anhydrous Na 2 SO 4 , filtered and then concentrated in vacuo. The crude organic oil was then purified via column chromatography (MeOH/CHCl 3 gradient). Concentration of the appropriate fractions provided the title compound (102 mg, 88%). 1 H NMR (DMSO) δ: 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.41 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.18 (s, 3H).
Example 17
[0241]
N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide
[0242] A solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one (25 mg, 0.075 mmol) in 2 mL of THF under N 2 (g) containing 3 mL of NEt 3 was treated with 3-methylfuran-2-carbonyl chloride (13 mg, 0.090 mmol). The reaction mixture was heated to 40° C. and allowed to stir for 3 h. The reaction was cooled and then extracted with EtOAc (3ט10 mL) and water (˜10 mL). The combined organic layers were then washed with ˜20 mL of NaHCO 3 (aq). The organic layers were then dried over anhydrous Na 2 SO 4 , filtered and then concentrated in vacuo. The crude mixture was purified over silica (EtOAc/Hexanes gradient). Following concentration of the appropriate fractions the title compound was collected as a grey solid (25 mg, 76%). 1 H NMR (DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.81 (d, J=5.6 Hz, 1H), 7.45-7.52 (m, 2H), 7.41 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.65 (d, J=5.6 Hz, 1H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.35 (s, 3H), 2.18 (s, 3H).
Example 18
[0243]
N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-1,3-dimethyl-1H-pyrazole-5-carboxamide
[0244] A solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one (26 mg, 0.078 mmol) in THF (3 mL) and NEt 3 (3 mL) was treated with 1,3-dimethyl-1H-pyrazole-5-carbonyl chloride (16 mg, 0.105 mmol). The reaction was heated to 40° C. and allowed to stir for 5 h. The reaction was cooled and then extracted with EtOAc (3ט10 mL) and water (˜10 mL). The combined organic layers were then washed with ˜20 mL of NaHCO 3 (aq). The organic layers were then dried over anhydrous Na 2 SO 4 , filtered and then concentrated in vacuo. The crude mixture was purified over silica (EtOAc/Hexanes gradient). Following concentration of the appropriate fractions the title compound was collected as a grey solid (25 mg, 76%). 1 H NMR(DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.81 (d, J=5.6 Hz, 1H), 7.45-7.52 (m, 2H), 7.41 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.65 (d, J=5.6 Hz, 1H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.35 (s, 3H), 2.18 (s, 3H).
Example 19
[0245]
tert-butyl {4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}carbamate
[0246] A degassed solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methylpyridin-2(1H)-one (250 mg, 0.97 mmol), tert-butyl(4-iodophenyl)carbamate (200 mg, 0.97 mmol), N1,N2-dimethylethane-1,2-diamine (50 mg, 0.49 mmol), copper iodide (40 mg, 0.20 mmol), and potassium phosphate (410 mg, 1.94 mmol) in 2 mL of N-methylpyrrolidone was heated to 70° C. and stirred overnight (17 h). The reaction was complete and allowed to cool to room temperature. The reaction was extracted with EtOAc (3ט5 mL) and with NaHCO3 (2ט10 mL). The crude organic layers were combined, dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was then purified using the ISCO flash chromatography system using an 0-100% EtOAc/100-0% Hexane gradient mixture. Following concentration of the appropriate fractions the desired product was collected as an off white solid (115 mg, 27%). 1 H NMR (DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.45-7.52 (m, 2H), 7.41 (d, J=6.7 Hz, 1H), 7.24-7.31 (m, 2H), 6.28 (s, 2H), 6.17 (d, J=7.0 Hz, 1H), 3.96 (br. S, H), 3.29 (s, 2H), 2.66 (t, j=5.3 Hz, 2H), 2.18 (s, 3H), 1.39 (s, 9H)
Example 20
[0247]
3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one
[0248] A solution of tert-butyl (4-(5-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-6-oxo-5,6-dihydropyridin-1(2H)-yl)phenyl)carbamate (112 mg, 0.334 mmol) in a 1:1 mixture of MeOH/THF (˜10 mL) was treated dropwise with CF3COOH and the reaction was allowed to stir for 4 h. One the reaction was completed, the residual CF 3 COOH was neutralized with NaHCO3 (aq). The reaction was then extracted with EtOAc (3ט10 mL) and brine (˜10 mL). The combined organic layers were dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude organic oil was then purified via column chromatography (MeOH/CHCl3 gradient). Following concentration of the appropriate fractions the title compound was isolated (112 mg, 88%). 1 H NMR (DMSO) δ: 7.91 (s, 1H), 7.80 (m, 1H), 7.41-7.52 (m, 2H), 7.41 (m, 1H), 7.26-7.32 (m, 2H), 6.65 (m, 1H), 6.23 (s, 2H), 6.14 (m, 1H), 4.00 (br. s, H), 3.24 (s, 2H), 2.67 (t, J=5.3 Hz, 2H), 2.34 (s, 3H), 2.22 (s, 3H).
Example 21
[0249]
N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-3-methyl-2-furamide
[0250] A solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one (25 mg, 0.075 mmol) was dissolved in THF (2 mL) and NEt 3 (3 mL) and then treated with 3-methylfuran-2-carbonyl chloride (13 mg, 0.090 mmol). The reaction was heated to 40° C. and allowed to stir for 3 h. The reaction was cooled and then extracted with EtOAc (3ט10 mL) and water (˜10 mL). The combined organic layers were then washed with ˜20 mL of NaHCO 3 (aq). The organic layers were then dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was purified over silica (EtOAc/Hexanes gradient). Following concentration of the appropriate fractions the title compound was isolated as a grey solid (25 mg, 76%). 1 H NMR (DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.80 (m, 1H), 7.42-7.52 (m, 2H), 7.41 (m, 1H), 7.24-7.32 (m, 2H), 6.66 (m, 1H), 6.28 (s, 2H), 6.14 (m, 1H), 4.01 (br. s, H), 3.24 (s, 2H), 2.67 (t, J=5.3 Hz, 2H), 2.35 (s, 3H), 2.20 (s, 3H).
Example 22
[0251]
N-{4-[3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-4-methyl-2-oxopyridin-1(2H)-yl]phenyl}-1,3-dimethyl-1H-pyrazole-5-carboxamide
[0252] A solution of 3-(2-amino-7,8-dihydropyrido[4,3-d]pyrimidin-6(5H)-yl)-1-(4-aminophenyl)-4-methylpyridin-2(1H)-one (26 mg, 0.078 mmol) in 3 mL of THF (3 mL) and NEt 3 (3 mL) was treated with 1,3-dimethyl-1H-pyrazole-5-carbonyl chloride (16 mg, 0.105 mmol). The reaction was heated to 40° C. and allowed to stir for 5 h. The reaction was cooled and then extracted with EtOAc (3ט10 mL) and water (˜10 mL). The combined organic layers were then washed with ˜20 mL of NaHCO 3 (aq). The organic layers were then dried over anhydrous Na 2 SO 4 (s), filtered and the concentrated in vacuo. The crude mixture was purified over silica (EtOAc/Hexanes gradient). Following concentration of the appropriate fractions the title compound was isolated as a grey solid (25 mg, 76%). 1 H NMR (DMSO) δ: 9.52 (s, 1H), 7.92 (s, 1H), 7.78 (m, 1H), 7.45-7.52 (m, 2H), 7.44 (m, 1H), 7.24-7.32 (m, 2H), 6.65 (m, 1H), 6.28 (s, 2H), 6.17 (m, 1H), 3.96 (br. s, H), 3.29 (s, 2H), 2.66 (t, J=5.3 Hz, 2H), 2.35 (s, 3H), 2.18 (s, 3H). VEGFR2 kinase potency of select analogs was determined by the following assay:
VEGFR2 Kinase Assay:
[0253] Biochemical KDR kinase assays were performed in 96 well microtiter plates that were coated overnight with 75 μg/well of poly-Glu-Tyr (4:1) in 10 mM Phosphate Buffered Saline (PBS), pH 7.4. The coated plates were washed with 2 mls per well PBS+0.05% Tween-20 (PBS-T), blocked by incubation with PBS containing 1% BSA, then washed with 2 mls per well PBS-T prior to starting the reaction. Reactions were carried out in 100 μL reaction volumes containing 2.7 μM ATP in kinase buffer (50 mM Hepes buffer pH 7.4, 20 mM MgCl 2 , 0.1 mM MnCl 2 and 0.2 mM Na 3 VO 4 ). Test compounds were reconstituted in 100% DMSO and added to the reaction to give a final DMSO concentration of 5%. Reactions were initiated by the addition 20 ul per well of kinase buffer containing 200-300 ng purified cytoplasmic domain KDR protein (BPS Bioscience, San Diego, Calif.). Following a 15 minute incubation at 30° C., the reactions were washed 2 mls per well PBS-T. 100 μl of a monoclonal anti-phosphotyrosine antibody-peroxidase conjugate diluted 1:10,000 in PBS-T was added to the wells for 30 minutes. Following a 2 mls per well wash with PBS-Tween-20, 100 μl of O-Phenylenediamine Dihydrochloride in phosphate-citrate buffer, containing urea hydrogen peroxide, was added to the wells for 7-10 minutes as a colorimetric substrate for the peroxidase. The reaction was terminated by the addition of 100 μl of 2.5N H 2 SO 4 to each well and read using a microplate ELISA reader set at 492 nm. IC 50 values for compound inhibition were calculated directly from graphs of optical density (arbitrary units) versus compound concentration following subtraction of blank values.
PDGFRβ Kinase Assay
[0254] Biochemical PDGFRβ kinase assays were performed in 96 well microtiter plates that were coated overnight with 75 μg of poly-Glu-Tyr (4:1) in 10 mM Phosphate Buffered Saline (PBS), pH 7.4. The coated plates were washed with 2 mls per well PBS+0.05% Tween-20 (PBS-T), blocked by incubation with PBS containing 1% BSA, then washed with 2 mls per well PBS-T prior to starting the reaction. Reactions were carried out in 100 μL reaction volumes containing 36 μM ATP in kinase buffer (50 mM Hepes buffer pH 7.4, 20 mM MgCl 2 , 0.1 mM MnCl 2 and 0.2 mM Na 3 VO 4 ). Test compounds were reconstituted in 100% DMSO and added to the reaction to give a final DMSO concentration of 5%. Reactions were initiated by the addition 20 ul per well of kinase buffer containing 200-300 ng purified cytoplasmic domain PDGFR-b protein (Millipore). Following a 60 minute incubation at 30° C., the reactions were washed 2 mls per well PBS-T. 100 μl of a monoclonal anti-phosphotyrosine antibody-peroxidase conjugate diluted 1:10,000 in PBS-T was added to the wells for 30 minutes. Following a 2 mls per well wash with PBS-Tween-20, 100 μl of O-Phenylenediamine Dihydrochloride in phosphate-citrate buffer, containing urea hydrogen peroxide, was added to the wells for 7-10 minutes as a colorimetric substrate for the peroxidase. The reaction was terminated by the addition of 100 μl of 2.5N H 2 SO 4 to each well and read using a microplate ELISA reader set at 492 nm. IC 50 values for compound inhibition were calculated directly from graphs of optical density (arbitrary units) versus compound concentration following subtraction of blank values.
[0000]
TABLE 2
In vitro VEGFR2 and PDGFR data
VEGFR2
PDGFR
Example
Kinase
Kinase
Number
Structure
IC 50 nM
IC 50 nM
2
286
655
3
>10000
3887
4
86
381
14
327
>1000
17
29
33
[0255] The fibrotic disorder is selected from the group consisting of hepatic cirrhosis and atherosclerosis.
[0256] The mesangial cell proliferative disorder is selected from the group consisting of glomerulonephritis, diabetic nephropathy, malignant nephrosclerosis, thrombotic microangiopathy syndromes, transplant rejection and glomerulopathies.
[0257] The metabolic disease is selected from the group consisting of psoriasis, diabetes mellitus, wound healing, inflammation and neurodegenerative diseases.
[0258] The blood vessel proliferative disorder is selected from the group consisting of diabetic retinopathy, exudative age-related macular degeneration, retinopathy of prematurity, pterigium, rosacea, arthritis and restenosis. | The present invention relates to organic molecules capable of modulating tyrosine kinase signal transduction in order to regulate, modulate and/or inhibit abnormal cell proliferation. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multi-function lance for use in a vacuum degassing chamber. The invention also relates to a technique for continuously performing, by using such a lance either intermittently or continuously, the multiple operations of preheating a vacuum degassing apparatus (generally comprising a vacuum degassing chamber, an evacuation means, a ladle, etc.) for vacuum refining, composition control and the like, of a molten steel; elevating the temperature of molten steel maintained inside the apparatus; blowing gaseous oxygen for decarburization and refining the molten steel, and blowing a powdered desulfurizing agent or the like for composition control of the molten steel.
2. Description of The Related Art
Recently, the molten steel output from a conversion furnace or an electric furnace is often subjected to further refining (denoted as secondary refining) in order to produce a high quality steel. For such secondary refining, a prevailing method comprises blowing oxygen onto the molten steel maintained inside the vacuum degassing apparatus (which is often referred to hereinafter as “a degassing chamber”) to perform decarburization. However, in such decarburization refining, the temperature of the molten steel can be lowered too greatly when the chamber is insufficiently preheated, or smooth operation can be disrupted due to the adhesion of a large quantity of raw metal to the inner wall of the degassing chamber.
Consequently, various countermeasures have been studied and implemented, such as preheating the degassing chamber itself, elevating the temperature of the molten steel, etc. Recently, in JP-A-Hei6-73431 (the term “JP-A” as used herein signifies “an unexamined published Japanese patent application”) there was proposed a vacuum degassing apparatus known as a so-called “complex lance 1 ” as shown in present FIG. 4, comprising an oxygen blowing portion having a throat portion 15 provided in its axial core, a downwardly extending portion 16 connected to the lower side thereof, and a gaseous fuel supply hole 17 opening into the downwardly extending portion 16 . This vacuum degassing apparatus is intended to achieve greatly favorable effects of blowing oxygen to the molten steel, heating the molten steel by burning gaseous fuel with oxygen, and preventing raw metal from adhering to the degassing chamber, etc., by using only one complex lance 1 .
However, according to the structure of the complex lance disclosed in JP-A-Hei6-73431, a gaseous fuel is simply blown out from the nozzle portion and mixed with oxygen. Consequently, the calorific value provided thereby was found insufficient as a practical matter to preheat the inside of the degassing chamber. Furthermore, because the structure is extremely simple, the following problems were expected to occur in practice:
(1) The structure is effective only when spontaneous ignition occurs upon mixing the oxygen and gaseous fuel, and the temperature therefore cannot be raised once the temperature inside the degassing chamber has been lowered. Moreover, the reliability is very poor.
(2) Even in case spontaneous ignition occurs, if for any reason the burning gas becomes extinguished during the operation, there remains a danger of causing an explosion due to the fuel gas filling inside the chamber.
(3) Thus, from the viewpoint of safety, the necessary preheating operation of the degassing chamber takes such a long time that productivity is decreased.
SUMMARY OF THE INVENTION
The present invention seeks to overcome the above-described problems by providing a multi-function lance for a vacuum degassing apparatus, that is capable of not only performing a preheating operation in a safer manner and in a shorter amount of time, but also blowing oxygen, elevating the temperature of molten steel, heating the vacuum degassing apparatus itself, and refining and controlling the composition of the molten steel by feeding powdered desulfurizing agents and the like, all using the same lance.
In order to achieve this object, the present inventors conducted extensive studies, and as a result developed a multi-function lance for use in a vacuum degassing chamber comprising a water-cooled cylindrical top-blown oxygen lance being equipped with a path for gaseous oxygen, and a nozzle provided at the downstream end of the oxygen path and used for blowing oxygen onto a molten metal; a water-cooled jacket surrounding the outer periphery of the top-blown oxygen lance; one or a plurality of a set of paths for a fluid fuel and a gas for burning the fuel, being positioned in the multi-function lance; and a combustion burners provided at the downstream end of said paths.
In accordance with another aspect of the present invention, there is provided a multi-function lance for vacuum degassing chamber as above, wherein at least one of said burners is equipped with an internally provided ignition plug.
According to still another aspect of the present invention, there is provided a multi-function lance for a vacuum degassing chamber as above, wherein an aperture having a transparent plate is provided axially centrally of the top-blown oxygen lance, and a sensor is provided that detects the flame via the aperture.
According to a further aspect of the present invention, here is provided a multi-function lance for a vacuum egassing chamber wherein a lance for blowing a powder is provided in parallel with the burner as shown in FIG. 5, or, instead of the burners, one or a plurality of lances for blowing a powder, are provided between said top-blown oxygen lance and the water-cooling jacket as shown in FIG. 6 .
The present invention also provides a method for using a multi-function lance in a vacuum degassing chamber, comprising actuating a combustion burner disposed in a vacuum degassing chamber comprising a top-blown oxygen lance equipped with a gaseous oxygen path formed with a nozzle provided at the downstream end of said oxygen path used for blowing oxygen onto a molten metal; a water-cooled jacket surrounding the outer periphery of the top-blown oxygen lance; one or a plurality of a set of paths for a fluid fuel and a gas for burning the fuel, being defined between the top-blown oxygen lance and the water-cooled outer jacket; a combustion burners provided at the downstream end of said paths; and a sensor provided as such that it detects the flame via an aperture provided in a transparent plate at the axial center of the top-blown oxygen lance; and supplying a small amount of oxygen to the inside of a top-blown oxygen lance connected to said aperture so as to elevate the temperature of the portion of the flame which is being detected by said sensor.
The invention also includes a method for using a multi-function lance in a vacuum degassing chamber, comprising operating a combustion burner associated with a vacuum degassing chamber that comprises a water-cooled cylindrical top-blown oxygen lance equipped with a gaseous oxygen path formed with a nozzle provided at the downstream end of said oxygen path used for blowing oxygen onto a molten metal; a water-cooled jacket surrounding the outer periphery of said top-blown oxygen lance; one or a plurality of a set of paths for a fluid fuel and a gas for burning the fuel, being positioned in the multi-function lance; and a combustion burners provided at the downstream end of said paths; wherein a powder is supplied to the inside of the top-blown oxygen lance to blow the powder onto the molten metal in the vacuum degassing chamber from the lance.
Thus, the multi-function lance of the present invention prevents the fluid fuel from being extinguished during operation, and enables heating a degassing chamber and blowing of oxygen in a safer and far more stable manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 ( a ) is an axial sectional view of an embodiment of the multi-function lance according to the present invention;
FIG. 1 ( b ) is a plan view of the FIG. 1 ( a ) embodiment;
FIG. 2 shows a preheating stage of a degassing tank using the multi-function lance according to the present invention;
FIG. 3 shows a decarburizing refining stage of a molten steel using the multi-function lance according to the present invention;
FIG. 4 shows a vertical cross section view of a prior art complex lance;
FIG. 5 ( a ) is an axial sectional view, along line A—A of FIG. 5 ( b ), of a multi-function lance according to another embodiment of the present invention, provided with a lance specifically used for blowing a powder in parallel with the burner, and a section plate 29 for establishing a defined path for circulation of cooling water;
FIG. 5 ( b ) is a plan view of the FIG. 5 ( a ) embodiment;
FIG. 6 ( a ) is an axial sectional view of a multi-function lance according to yet another embodiment of the present invention, provided with a lance specifically used for blowing a powder in the place of the burner;
FIG. 6 ( b ) is a plan view of the FIG. 6 ( a ) embodiment; and
FIG. 7 shows a stage of blowing powder onto molten steel in case powder is supplied to an upward oxygen blowing lance.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A fuller explanation of the present invention will now be given with reference to the accompanying drawings, which illustrate preferred but non-limiting examples of the present device and method. In the drawings, the following list associates the depicted reference numerals with the associated component:
1 Multi-function lance
2 Nozzle
3 Path for gaseous oxygen
4 Inflammable transparent plate
4 ′ Aperture
5 Sensor
6 Combustion burner
7 Path for fluid fuel
8 Path for a combustion gas (e.g., air)
9 Ignition plug
10 Vacuum degassing chamber (degassing chamber)
11 Slag pot
12 Ladle
13 Molten steel
14 Alloy hopper
15 Throat portion
16 Downwardly extending portion
17 Fuel gas supplying portion
18 Water-cooled cylindrical top-blown oxygen lance
19 Water-cooling jacket
20 Inner tube
21 Outer tube
22 Fluid fuel
23 Combustion gas (e.g., oxygen)
25 Gaseous oxygen
26 Cooling water
27 Melt
28 Powder
29 Section plate for cooling water
30 Powder compression feeding tank
31 Gaseous nitrogen
32 Compression-feeding powder
An embodiment according to the present invention is described below with reference to drawings for a case comprising four burners.
Referring to FIG. 1 ( a ) and FIG. 1 ( b ), a multi-function lance 1 for a vacuum degassing apparatus according to the present invention is based on water-cooled cylindrical top-blown oxygen lance 18 having a path for gaseous oxygen 3 and a nozzle 2 , which supply oxygen to be blown against the molten steel. The top-blown oxygen lance 18 is further surrounded by a water-cooling jacket 19 and a section plate for cooling water 29 is positioned in the multi-function lance, namely in water-cooling jacket 19 . A plurality of pipes are provided between the water-cooling outer jacket 19 and the top-blown oxygen lance 18 to provide paths 7 for a fluid fuel 22 and paths 8 for a combustion gas (e.g., oxygen) 23 . The downstream end of the pipes include built-in combustion burners 6 (referred simply hereinafter as “burners 6 ”). The burners 6 are generally provided in a double-tube structure, such that a fluid fuel (e.g., LPG) 22 flows through the inner tube 20 and a combustion gas 23 for the fuel flows through the outer tube 21 . An important aspect of the present invention is that an ignition plug 9 (at the downstream end of the inner tube 20 ) is attached to at least one of the plurality of burners 6 , so that a spark is generated to ignite the gas mixture comprising the fluid fuel 22 and the combustion gas 23 . In this manner, extinguishing during the operation of the burner 6 can be prevented from occurring.
In the present invention, to further increase the function of preventing extinguishing, a non-flammable transparent plate 4 made of quartz glass or the like is attached to the upstream end (i.e., the side opposite to the nozzle on the concentric axis) of the cylinder used as the path for gaseous oxygen 3 , so that the interior may be observed therethrough, and a sensor 5 (e.g., an ultraviolet detector) is provided for detecting the flame. If no flame is detected by the sensor 5 , the supply of the fluid fuel 22 and the combustion gas 23 to the burner 6 is halted, and a signal is sent to purge with an inert gas such as N 2 . Furthermore, a small amount of auxiliary oxygen for aiding combustion is simultaneously supplied to nozzle 2 together with the supply of the fluid fuel 22 so as to maintain the high temperature by stabilizing the flame in the vicinity of the nozzle 2 at a predetermined temperature. In this manner, false alarms from the sensor 5 are prevented.
The method for using the multi-function lance 1 according to the present invention in a vacuum degassing chamber 10 is described below. The inner and outer pipes (i.e., the paths 7 and 8 for the fluid fuel and the combustion gas, respectively) of the burner 6 are first purged with an inert gas such as gaseous N 2 for a predetermined duration of time, and, after supplying a fluid fuel 22 and a combustion gas 23 to the burner equipped with an ignition plug, the fuel is ignited by generating a spark. After confirming the ignition of the fuel by using the detection sensor 5 for the flame, or after the passage of a predetermined duration of time, the fluid fuel 22 and the combustion gas 23 are supplied to the other burner 6 to start combustion. After a passage of a predetermined duration of time, the combustion flame is monitored with the sensor 5 . If the flame is detected, the supply of the fluid fuel and the like is continued, but if the flame is not detected, the flame is extinguished and the inside of the burner 6 is purged with an inert gas such as gaseous N 2 . Simultaneously with the supply of the fluid fuel 22 to the burner 6 , a small amount of oxygen is supplied to the nozzle 2 to maintain the monitored flame at a high temperature, thereby preventing the malfunction of the sensor 5 from occurring. As a matter of course, if combustion failure occurs, the auxiliary oxygen gas for aiding combustion is stopped at the time the extinction is detected, and gaseous N 2 is supplied instead.
On the other hand, when aluminum is added to the molten steel 13 inside the vacuum degassing chamber 10 to elevate the temperature, or in case refining such as decarburization and the like is conducted, gaseous oxygen is blown from the nozzle 2 to accelerate the oxidation reaction. In such a case, no heating by the burner 6 of the (vacuum) degassing chamber 10 or the molten steel 13 is performed. Instead, a predetermined amount of inert gas such as gaseous N 2 is supplied to the burner to avoid clogging of the front end of the burner due to splashes and the like.
In case of performing composition control such as desulfurization by adding a powdered desulfurizing agent, etc., to the molten steel 13 inside the vacuum degassing chamber 10 , the powder is blown from an oxygen lance or a specifically provided lance. If a specific lance is used, the heating of the degassing chamber 10 using the burner 6 and the blowing of oxygen from the nozzle 2 is halted, and, instead, an inert gas such as gaseous N 2 (nitrogen) is supplied to the nozzle 2 and burner 6 in a predetermined quantity to avoid clogging of the front end of each lance due to splashes and the like.
EXAMPLE 1
A multi-function lance 1 according to the present invention was applied to a vacuum degassing apparatus 10 of a RH type. Since a large quantity of raw metal was first found to be adhered to the inner wall surfaces of the degassing chamber 10 used in vacuum refining, the raw metal was removed while operation was suspended, and, at the same time, the degassing chamber 10 was preheated for the next operation. After placing a vessel 11 (denoted as “a slag pot”) for receiving the melt 27 (e.g., raw metal, slag, etc.) at the lower side of the degassing chamber 10 as shown in FIG. 2, a multi-function lance 1 according to the present invention was inserted from the upper side of the degassing chamber 10 and positioned. Then, in accordance with the heating method of the degassing chamber 10 as described above, the burner 6 of the multi-function lance 1 was used to preheat the degassing chamber 10 . The vacuum degassing tank 10 is a RH type vacuum degassing tank capable of processing 180 tons of molten steel, and the preheating of the chamber was conducted for 5 hours in total by using gaseous propane as the fluid fuel, which was supplied at a flow rate of 60 Nm3/hr for 4 hours and at 134 Nm3/hr for one hour. During this process the temperature of the inner wall of the chamber was raised from 1045° C. to 1400° C. As a result, the removal of the raw metal and the preheating were smoothly achieved without suffering any extinction. The time necessary for the preheating was only about 70% of the time necessary in case of using a conventional lance 1 as shown in FIG. 4 .
Then, by using the preheated vacuum degassing chamber 10 , the decarburization smelting of a molten steel 13 was carried out. The molten steel 13 was fed into the ladle 12 , and the lower portion of the degassing chamber 10 was immersed therein. Thus, smelting was conducted by circulating the molten steel 13 under vacuum between the ladle 12 and the degassing chamber 10 . In this case, as shown in FIG. 3, the multi-function lance 1 according to the present invention was inserted from the upper side of the degassing chamber 10 and positioned, such that gaseous oxygen 25 was blown under predetermined conditions to the molten steel 13 via the nozzle 2 . The concentration of carbon (C) incorporated in the molten steel in the ladle ( 12 ) immediately after output from the conversion furnace was 496 ppm. Thus, by using the lance according to the present invention in an RH type vacuum degassing chamber ( 10 ), the molten steel was subjected to oxygen lancing refining under vacuum at an oxygen flow rate of 20 Nm3/min for a predetermined duration of time. After 23 minutes, the carbon concentration of the molten steel was found to be decreased to the region of super-low carbon content of 20 ppm. As a result, it was found that the decarburization of the molten steel 13 was conducted smoothly in a manner comparable to a case using a conventional lance 1 of FIG. 4 .
EXAMPLE 2
Referring to FIG. 7, an example of blowing a desulfurizing agent based on CaO using a multi-function lance according to the present invention is described below.
The powder was lanced under conditions as follows:
Amount of desulfurizing agent blown—6.7 kg/ton of molten steel
blowing rate—100 to 126 kg/min
blowing duration—15 to 18 minutes
Flow rate of carrier gas—3.0 Nm3/min
As a result, the content of sulfur was reduced to 15 ppm or less.
As described above, a safer preheating, decarburization refinig, or desulfurization operation, or any combination of these operations, can all be achieved using the same lance according to the invention, and in a shorter time.
While the invention has been described in detail by making reference to specific examples, it should be understood that various changes and modifications can be made without departing from the scope and the spirit of the present invention. | A multi-function lance for insertion into a vacuum degassing chamber, includes a top-blown oxygen lance provided as a path for gaseous oxygen. A nozzle is provided at a downstream end of the oxygen path used for blowing oxygen onto a molten metal. A water-cooled jacket surrounds the outer periphery of the top-blown oxygen lance. At least a set of paths for a fluid fuel and a gas for burning the fuel is positioned in a multi-function lance, namely in the water-cooled jacket, and a combustion burner is provided at a downstream end of the path. By using the multi-function lance according to the present invention, not only a safer and shorter preheating operation is enabled, but also oxygen lancing, temperature elevation of molten steel, and heating of the vacuum degassing apparatus itself are smoothly realized. | 5 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/444,921 filed Feb. 4, 2003, the complete disclosure of which is hereby expressly incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The subject invention relates to windshield wiper assemblies and, in particular, the structural frame, which embodies the drive and pivot mechanism for windshield wiper systems.
SUMMARY OF THE INVENTION
[0003] Windshield wiper systems commonly include a structural mechanism, which is mounted to the vehicle, which includes a bracket for mounting an electric motor for driving the windshield wiper system, pivot mounts for pivotally mounting pivot pins for the wiper blade rotation, and a linkage mechanism between the motor and the pivot pins, which drive the blades. Several different systems are available.
[0004] One such system includes stamped and formed elongate brackets having mounting feet for mounting to the vehicle, and a pivot mechanism having a bushing or bearing positioned along the length of the bracket, where the wipers should be mounted. A pivot pin will be positioned in the bearing and will be connected to the linkage, which causes the pivotal movement of the wiper blades.
[0005] Another assembly is known, which includes a tubular member having mounted at its ends cast or forged pivot mechanisms, whereby the end is substantially cylindrical in cross-section and can be placed in the tubular end and crimped thereto. Each of the castings includes a mounting area for receiving the pivot pin to which the windshield wipers can be connected. Such a device is shown in U.S. Pat. No. 5,536,1 00.
[0006] There are several drawbacks to the design mentioned in U.S. Pat. No. 5,536,100. First, for each different configuration, a different cast member is required, and in fact, a different cast member is required for opposite ends of the same assembly. Also, in the event that four pivot pins are located in the same assembly, then two of the interior pivot pins require a “T-configuration,” such that two ends of the cast pivot pin housing are crimped to the tubes. This means that the device can only be placed at ends of the tube. Naturally, the tube could be cut in several locations, and several couplings crimped, however this requires accuracy in location and at the same time damages the structural integrity of the tubular member itself.
[0007] It should be also be appreciated that many different configurations of the wiper blade mechanisms are necessary, given the various sizes and configurations of vehicles, particularly trucks, and in fact in some instances, different configurations of the assemblies are required for different options within the exact same vehicle. It should also be appreciated that in some instances, two pivot pins are positioned along the length of the tubular member, and in some cases, four pivot pins are mounted, depending upon the geometry of the wiping pattern, and the size of the windshield to which the assembly applies.
[0008] Thus, given the nature of the assembly configuration, the number of wiper blades involved, and the mounting of the assembly, it should be readily apparent that numerous cast pivot pin housings will be required to accommodate the variety of assemblies. Thus, the object of the invention is to improve upon the various assemblies mentioned above.
[0009] The objects have been accomplished by providing a windshield wiper assembly, comprising at least one elongate tubular frame member, and a plurality of pivot pin housing members. Each housing member has a flange portion having an open surface for mounting to an exterior surface of the tubular frame member and a pin mounting portion. Retaining means retain the pivot pin housings to the tubular frame member.
[0010] Preferably, the open surface is arcuate in cross section to substantially conform to the outside diameter of the elongate tubular frame member The open surface includes elongate ribs, having an edge for gripping the outer surface of the elongate tubular frame member. The flange portion is generally rectangular in configuration, where the arcuate open surface is configured on an elongate surface of the rectangular shape. The pin mounting portion is configured transversely to the elongate surface of the rectangular shape.
[0011] The retaining means is defined by a clamp assembly having at least one clip portion, which surrounds the elongate tubular frame member and the pivot pin housing member, retaining them together. The clamp assembly is comprised of two clip portions, which flank the pin mounting portion, and which circumscribe the combination of the elongate tubular frame member and the pivot pin housing member. The pivot pin housing member, on a face opposite the arcuate open surface, has indentations, and the two clip portions have free ends which are crimped into the indentations. The windshield wiper assembly further comprises piercing pins extending through the flange portion and extends into the elongate tubular frame member. The elongate tubular frame member includes mounting members to mount the assembly. The mounting members are defined by a portion of the elongate tubular member, flattened and formed with an aperture therethrough.
[0012] In another form of the invention, a method of forming an automotive wiper assembly, comprises the steps of providing a tubular structural component, providing the tubular structural component with the desired configuration, providing a pivot pin mounting housing having an open mounting face, applying the pivot pin mounting housing to the exterior surface of the tubular structural component, and retaining the pivot pin mounting housing to the tubular structural component.
[0013] The retaining step is provided by clamping the pivot pin mounting housing to the tubular structural component. The clamping is provided by wire clips being formed around the exterior of the tube and around the pivot pin mounting housing. The method further comprises the step of forming apertures in the outside face which is opposite the mounting face, and the free ends of the wire clips are crimped into the apertures. The tubular component is provided with a cylindrical cross-section. The method further comprises the step of driving pins through the pivot pin housing, and radially into the tube, to prevent rotation of the pivot pin housing.
[0014] Preferably, the tubular component is bent to define the desired configuration. The pivot pin housings are applied to the tubular component distant from the ends of the tube. The free ends of the tube are flattened into mounting flanges and mounting apertures are provided through the flanges.
[0015] The invention will now be described with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a perspective view of the wiper assembly poised relative to a windshield with which it would operate;
[0017] [0017]FIG. 2 is an enlarged view of the linkage mechanism;
[0018] [0018]FIG. 3 is an enlargement of the inset shown in FIG. 1, showing a pivot pin mechanism in perspective view;
[0019] [0019]FIG. 4 is a top plan view of the pivot mechanism of FIG. 3;
[0020] [0020]FIG. 5 is a side plan view of the pivot mechanism of FIG. 4;
[0021] [0021]FIG. 6 is a cross-section view through lines 6 - 6 of FIG. 4; and
[0022] [0022]FIG. 7 is a cross-section view through lines 7 - 7 of FIG. 4;
DETAILED DESCRIPTION OF THE INVENTION
[0023] With reference first to FIG. 1, a linkage mechanism is shown at 2 , poised relative to a windshield 4 , with which it will cooperate. It should be understood that the linkage 2 would be mounted adjacent to the windshield in a manner well known in the automotive field. With reference to FIGS. 1 and 2, the linkage mechanism is generally comprised of a tubular structural component 6 extending from end to end, with a first pivot mechanism 8 positioned at one end, and a second pivot mechanism 10 positioned at the opposite end. A motor 12 is mounted to the tubular component 6 , having a drive connection to linkage 14 , which in turn drives linkage 16 , through yoke 18 . It should be appreciated that motor 12 is configured to cause a reciprocity motion to linkage 14 . With respect now to FIGS. 2 and 3, yoke 18 is shown driving pin 20 (FIG. 3), whereas linkage 16 drives a lever 22 which in turn drives pin 24 (FIG. 2).
[0024] With reference now to FIG. 2, the various components mentioned above will be described in greater detail. As shown, tubular component 6 is shown having a generally cylindrical cross-section and having a plurality of bends. It should be appreciated that the tubular component could be a stainless steel tube, which can be easily bent, yet which is structurally rigid, and weatherproof. It should also be appreciated that any configuration could be defined, where the various bends are positioned as required to position the wiper blades relative to the windshield, or where the tubular component 6 is required to not interfere with another unrelated component. However, this tubular component will be discussed below, only by way of example to the many ways the tubular component could be manufactured and configured.
[0025] With respect to FIG. 2, the tubular component first has flattened end portions 30 , 32 having apertures therethrough for mounting purposes. Each end of the tubular component 6 includes a bend 34 , 36 , which tends to space the assembly away from the windshield to place the wipers in proper position. The tubular component then includes straight sections 38 , 40 to which the first and second pivot mechanisms 8 , 10 are mounted. The tubular component then includes a generally right angled bend, defined by tubular sections 44 , 46 , which help provide a position where motor 12 can be mounted, yet position motor 12 and linkage 14 in position with yoke 18 . Transition section 50 -merely connects the sections 40 and 46 together. It should also be appreciated that other various brackets can be provided, such as auxiliary mounting brackets 54 , 56 , and motor mounting bracket 58 .
[0026] With respect again to FIG. 2, motor 12 is shown connected to linkage 14 in a known manner, where pin 60 connects motor 12 to linkage 14 . At the opposite end, a fastener assembly 62 is provided connecting linkages 14 and 16 to yoke 18 . Yoke 18 includes a sleeve portion 64 to receive fastener assembly 62 , and a lever portion 66 connected to drive pin 20 , as best shown in FIG. 3. It should be appreciated that lever 66 could be connected to pin 20 in any known manner; lever 66 and pin 20 could be integrally cast or forged, they would be welded or press-fit, or they could be splined together. However, their connection is immaterial other than to say that the rotation of lever arm 66 causes a like rotation of pin 20 . Likewise, linkage 16 is attached to lever 22 , and lever 22 and pin 24 are attached in a manner similar to lever 66 , 20 , such that translation of linkage 16 causes a rotation of lever arm 22 and rotation of pin 24 .
[0027] With reference now to FIGS. 3-7, the pivot mechanisms 8 , 10 will be described in greater detail. It should be appreciated that these mechanisms are identical and thus only one need be explained in detail. What differs is only their location and the pivot pin, which is mounted therethrough.
[0028] As shown first in FIG. 3, the pivot mechanism 8 includes a cast housing portion 70 , which is retained to the tubular component 6 by way of retaining clips or clamps 72 , and prevented from rotating by piercing pins 74 (FIG. 6). As shown best in FIGS. 3, 4 and 5 , housing 70 includes a flange portion 76 and a pin mounting portion 78 . The flange portion 76 is generally rectangular in configuration and includes a top face 80 having recesses 82 and apertures 84 . The bearing section 86 extends transversely to the length of the housing 70 , and includes a bearing sleeve or bushing 88 press fit within the bearing section 86 . The face opposite the top face 80 is a confronting face 90 (FIG. 6) having a generally semi-cylindrical configuration. The face has longitudinally extending ridges 92 , which form gripping edges which “bite” into the tubular section 6 (FIG. 7). The housing 70 further includes a sleeve section 96 to receive a pantograph post 98 .
[0029] Finally, clips 72 and pins 74 will be described in greater detail. The clamps are formed from heavy wire and are formed around the housing 70 , with ends 100 crimped into recesses 82 . This retains the housing 70 to the tubular component 6 . Pins 74 may now be driven down into aperture 84 , and through tubular component 6 , as best shown in FIG. 6. This prevents (along with ridges 92 ) the twisting of the housings 70 relative to the tubular component 6 . With all of the components as described above, the assembly of the unit will now be described.
[0030] As mentioned above, the tubular component will be formed as required for the application. It should be appreciated that various and multiple configurations are possible, and that the tubular components can be formed in a typical fashion with a tube bender. Thereafter the motor 12 is mounted to its bracket 58 , whereupon linkage 14 can be positioned to motor 12 by way of fastener 60 . The linkage 14 can also be fastened at its opposite end to yoke 18 , whereupon pivot member 10 can be located along the length of tube sections 40 , and held temporarily. Link 16 is fixed at both ends, at one end by fastener member 62 , and at the opposite end by a fastener to lever 22 . This allows the pivot member 8 to be located along its corresponding section of tube 38 . Once the pivot members 8 , 10 are in their appropriate locations, then the clamp sections 72 can be applied as described above, with the ends 100 crimped into apertures 82 . The pins 74 are then driven into the tubes 6 , to the position shown in FIG. 6. The assembly can then be applied as a unit, and installed into an automotive application.
[0031] It should be appreciated that the above-described assembly has numerous advantages. Firstly, the overall assembly is more rigid, as the tubular component never needs to be severed. As mentioned above, where units are plugged into the ends of tubes, the tubes would be cut in several places, then the pivot members are clinched to the tube ends. Secondly, as the identical unit can be positioned in place, then lower inventory is required for such units, and the cost of producing them also drops. Finally, the overall cost is reduced as the assembly process is simplified. | A windshield wiper structural assembly and a method of forming the same is disclosed. The structural member is generally comprised of an elongate tubular component, which is bent to the desired configuration. The pivot mechanisms ( 8, 10 ) are designed for application to the exterior surface of the tubular component, whereupon they are clamped to the tubular component where they are retained. The clamping is done by wire clips which are crimped around the pivot mechanisms ( 8, 10 ). Pins can also be driven through the housings and the tubular component to prevent rotation of the housings. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates in general to wellbore completion and hydrocarbon production and, in particular, to a novel method of completing and producing long lateral wellbores.
BACKGROUND OF THE INVENTION
[0002] When a well is drilled, production casing is set so that the well can be properly cemented and the production zone(s) do not have fluid communication with other geological strata. The production zone is logged and then the production casing is perforated so that oil and/or gas can be drained from the production zone into the production casing of the well. Traditionally, hydrocarbon wells were drilled vertically down to and through one or more hydrocarbon production zone(s). As shown in FIG. 1 , a vertical wellbore 10 having a production casing 12 passes through a hydrocarbon production zone 14 . A plurality of perforations (not shown) formed in the production casing 12 using methods well known in the art permit hydrocarbons 16 to flow into the production casing 12 . The casing perforations also permit the production zone 14 to be treated to stimulate production by creating a plurality of fractures 18 in the production zone 12 using, for example, hydraulic fracturing techniques that are well known in the art. A production tubing 20 is used to deliver the hydrocarbons 16 to the surface. A packer 22 seals the annulus between the production tubing 20 and the production casing 12 .
[0003] Vertical wellbores have now been substantially abandoned in favor of more productive lateral wellbores that provide more exposure to the production zone. Although the first recorded true lateral well was drilled near Texon, Tex. in 1929, new technology developed over the last decade has permitted lateral drilling techniques to rapidly evolve. Hydrocarbon wells are now drilled vertically to a point above the production zone and then curved so that the wellbore enters the production zone at an angle and continues laterally within the production zone for more in-zone exposure to the hydrocarbon bearing formation. Some production zones are up to 300 feet (91.5 meters) thick, or more, and with lateral drilling techniques casing can be run up to 8,000 ft. (2.44 kilometers) into the production zone, thus providing significantly more area for hydrocarbons to drain into the production casing.
[0004] FIG. 2 is a schematic cross-sectional diagram of an exemplary prior art hydrocarbon well 30 with a lateral wellbore. Well know features such as the conductor and surface casing are not shown. A vertical section 32 of the hydrocarbon well 30 is drilled down into proximity of a production zone 14 , cased and cemented in a manner well known in the art. In many areas, the vertical section of the well may be 10,000 feet (3.05 kilometers) in length. In some areas the vertical section may exceed 10,000 feet (3.05 kilometers) in length. A curved section 34 of the hydrocarbon well 30 is then drilled into the production zone 14 . Once it is established that the curved section 34 is in the production zone 14 , a lateral wellbore 36 is drilled in a desired direction in as straight a path as possible within the production zone 14 . Recent innovations in work strings for completing lateral wellbores described in applicant's co-pending U.S. patent application Ser. No. 14/735,846 filed Jun. 10, 2015, the specification of which is incorporated herein by reference, permit lateral wellbores of at least 12,000 feet (3.66 kilometers) to be successfully completed. After the lateral wellbore 36 is drilled, a production casing 38 is run into the lateral wellbore 36 . The production casing 38 is generally “cemented in” before it is perforated for production. In any event, sections of the production casing 38 are perforated and stimulated using methods known in the art until an entire length of the production casing 38 has been perforated and the surrounding production zone 14 has been stimulated. A production tubing 42 is then run into the well and a packer 44 is set to seal the annulus. In a very long lateral bore, stimulation of the production 14 surrounding the lateral well bore 36 is a major undertaking and now costs more than drilling, casing and cementing the bore. Once stimulation and flow-back of stimulation fluids are completed, production of hydrocarbons from the wellbore 30 begins. In a shale basin such as found in the Bakken play, production is generally commercially viable for about 2 years, and may be extended by reworking the well using methods known in the art.
[0005] While the lateral wellbore method has been commercially successful, the potential for innovative production strategies has yet to be realized.
[0006] There therefore exists a need for a novel method of completing and producing long lateral wellbores.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the invention to provide a novel method of completing and producing long lateral wellbores.
[0008] The invention therefore provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: preparing a first production section of the long lateral wellbore for production, the first production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the first production section until production from the first production section is uneconomic; setting a plug to plug off the first production section of the long lateral wellbore; preparing a next production section of the long lateral wellbore for production, the next production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the next production section until production from the next production section is uneconomic; if hydrocarbons have not been produced from the entire long lateral wellbore, plugging off the next production section of the long lateral wellbore; and repeating the steps of preparing a next production section and producing from the next production section until an entire length of the long lateral wellbore has been prepared for production and produced until production from the long lateral wellbore is uneconomic.
[0009] The invention further provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: preparing a first production section of the long lateral wellbore for production, the first production section having a length of less than a total length of the long lateral wellbore; producing hydrocarbons from the first production section until production from the first production section is uneconomic; pulling production equipment from the long lateral wellbore; setting a plug to plug off the first production section of the long lateral wellbore; preparing a next production section of the long lateral wellbore for production, the next production section having a length of less than a total length of the long lateral wellbore; running the production equipment back into the long lateral wellbore; producing hydrocarbons from the next production section until production from the next production section is uneconomic; pulling the production equipment from the long lateral wellbore; pulling the plug from the long lateral wellbore; running the production equipment back into the long lateral wellbore until a packer is in an unperforated region between the first and next production sections of the long lateral wellbore; setting the packer in the unperforated region; installing a tubing at a wellhead of the long lateral well bore; pumping enhanced oil recovery flood fluid through the tubing into an annulus of a production casing of the long lateral wellbore, and hence down the annulus and through perforations in the production casing of the next production section; and producing hydrocarbons through a production tubing associated with the packer until the production of hydrocarbons is uneconomic.
[0010] The invention yet further provides a method of producing hydrocarbons from a cased and cemented long lateral wellbore, comprising: drilling a plurality of long lateral wellbores from a single well pad; preparing a first production section of each of the long lateral wellbores for production, the first sections having a length of less than a total length of the respective long lateral wellbores; producing hydrocarbons from the first production sections of the respective long lateral wellbores until production from the respective first production sections becomes uneconomic; setting a plug to plug off the first production section of each of the respective long lateral wellbores; preparing a next production section of the respective long lateral wellbores for production, the respective next sections having a length of less than a total length of the respective long lateral wellbores; producing hydrocarbons from the respective next production sections until production from the respective next production sections becomes uneconomic; if hydrocarbons have not been produced from an entire length of the respective long lateral wellbores, plugging off the next production section of the respective long lateral wellbores; and repeating the steps of preparing a next production section and producing from the next production section until an entire length of the respective long lateral wellbores have been prepared for production and produced until production from the respective long lateral wellbores becomes uneconomic.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, in which:
[0012] FIG. 1 is a schematic cross-sectional diagram of an exemplary prior art vertical hydrocarbon well;
[0013] FIG. 2 is a schematic cross-sectional diagram of an exemplary prior art lateral hydrocarbon well;
[0014] FIG. 3 is a schematic-cross sectional diagram of a lateral hydrocarbon well with a first section completed for production using the method in accordance with the invention;
[0015] FIG. 4 is a schematic-cross sectional diagram of the lateral hydrocarbon well shown in FIG. 3 with a second section completed using the method in accordance with the invention;
[0016] FIG. 5 is a schematic cross-sectional diagram of a portion of a lateral wellbore completed using a method in accordance with the invention.
[0017] FIG. 6 is a schematic cross-sectional diagram of the lateral hydrocarbon well shown in FIG. 4 configured for enhanced oil recovery using the method in accordance with the invention;
[0018] FIG. 7 is a schematic cross-sectional diagram of the lateral hydrocarbon well shown in FIG. 4 configured in another way for enhanced oil recovery using the method in accordance with the invention;
[0019] FIG. 8 is a schematic cross-sectional diagram of a detail of a lateral hydrocarbon well configured for enhanced oil recovery in accordance with the invention; and
[0020] FIG. 9 is a schematic diagram of lateral hydrocarbon wells drilled using methods in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The invention provides a method of completing lateral wellbores that leverages the potential of long lateral wellbores enabled by current lateral boring and completion equipment and techniques. Lateral wellbores in excess of 12,000 linear feet (3.66 kilometers) may now be drilled and completed. In accordance with the invention, such wellbores are completed in two or more production sections, and hydrocarbon is produced from each production section until production from that production section is exhausted or no longer commercially viable. In accordance with a further aspect of the invention, 2 or more lateral wellbores are drilled from the same drill pad and each wellbore is produced in production sections until all the wellbores in each pad have been produced. In accordance with a yet a further aspect of the invention, perforation and stimulation of each production section is carefully planned to permit the respective production sections to be re-stimulated if desired. In accordance with yet a further aspect of the invention, enhanced oil recovery (EOR) is practiced within a lateral wellbore by pumping EOR flood fluids down a work string into a first production section and producing hydrocarbons up the annulus of the production casing from a second production section, or pumping EOR flood fluids down the annulus of the production casing into the second production section and producing hydrocarbons up the work string from the first production section.
[0022] FIG. 3 is a schematic-cross sectional diagram of a lateral hydrocarbon well 100 having a production casing 101 , with a first production section 102 completed for production using the method in accordance with the invention. Modern drilling techniques permit very long lateral wellbores to be drilled and completed. This permits hydrocarbon deposits under natural bodies of water such as rivers 104 and/or cities 106 to be exploited without inconvenience or disturbance to surface features. In accordance with the method, after the long lateral wellbore is drilled, cased and cemented, only the first production section 102 at the farthest reach of the production casing 101 is perforated and stimulated for production. A length the first production section 102 is a matter of design choice and may depend on any one or more of a number of factors including; a production potential of the production zone 14 ; current or projected price for hydrocarbon products to be produced from the production section; current investment funds available for production stimulation treatments; availability of stimulation service providers; desired lifetime of the entire well; etc. In general each production section 102 has a recommended length of 2,000′-4,000′ (600-1,200 meters), or at most less than the entire length of the lateral wellbore of the hydrocarbon well 100 . Keeping production section 102 at a length of 4,000′ (1,200 meters) or less permits service providers to achieve a more focused stimulation treatment, which results in better production per linear foot of wellbore. Each production section 102 may also have a different length, as described below in more detail. An operator may decide to have 3 production sections in a 12,000 ft. lateral wellbore. The furthest production section out from the vertical wellbore may be 3,000′ in length. The second production section may be 4,000′ in length, and the last section would therefore be about 5,000′ in length.
[0023] After the first production section 102 of production casing 101 has been prepared for production using production casing perforation and formation stimulation techniques well known in the art, flow-back of stimulation fluids is performed in accordance with methods that are also known in the art. After flow-back, production from the hydrocarbon well 100 may commence. Depending on the production formation 14 , hydrocarbon may be initially produced up the production casing 101 . After production up the production casing 101 is not viable, a production tubing 108 is then run into the well. A packer 110 is set to seal the annulus around the production tubing 108 and production from the hydrocarbon well 100 continues or commences. A pump assisted lift may be required to produce hydrocarbons from the production section 102 , as understood by those skilled in the art. Production from the production section 102 continues until production from that production section is no longer commercially viable.
[0024] FIG. 4 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 3 with a second production section 112 of the production casing 101 completed using the method in accordance with the invention. Once production from production section 102 is no longer viable, the production tubing 108 and packer 110 are pulled from the well and a re-stimulation of section 102 may be performed to prolong production. Alternatively, a plug 114 is set in the unperforated interval “u” of the production casing 101 , where the packer 110 had been set. Perforating equipment (not shown) is then run into the production casing 101 and the production second section 112 is perforated and stimulated until an entire length of the second section 112 of the production casing 101 is prepared for production. A length of the unperforated section “u” left between the sections 102 and 112 is preferably at least one production casing joint (40′-12.2 m) in length and may be up to two casing joints in length. A length of the new production section 112 may be determined using production information collected during production from production section 102 . Consequently, new production section 112 may be longer, shorter, or the same length as production section 102 depending on production targets and any other factor relevant to operation of the hydrocarbon well 100 . An operator may also consider changing the stimulation treatment or service provider when stimulating the second production section 112 to determine the efficacy of a different treatment/service provider because production yields from the production sections 102 and 112 provide a direct comparison of stimulation efficacy since production from each section is from the same wellbore in the same production zone. Once stimulation and flow-back of stimulation fluids are completed, the production tubing 108 and the packer 110 are then run back into the wellbore and the packer 110 is reset. Production from the second production section 112 then commences and continues until the production from production section 112 is no longer economically viable, at which time the production section 112 may be plugged off, and the process of preparing another production section may be repeated until the entire lateral wellbore has been produced. Alternatively, enhanced oil recovery (EOR) may be performed, as described below with reference to FIGS. 6-8 , or re-stimulation of production sections 102 and 112 , or production section 112 alone, may be performed as described below with reference to FIG. 5 .
[0025] FIG. 5 is a schematic cross-sectional diagram of a portion of one of the lateral wellbores 100 with a production casing 101 in the production zone 14 completed using a method in accordance with a further aspect of the invention. In accordance with the invention, initial perforation and stimulation of each production section 102 , 112 (see FIG. 4 ) of the lateral wellbore 100 is carefully planned with consideration to the potential of re-stimulation the respective production sections 102 , 112 at a later date when a second stimulation procedure may be used to extend a life of the production section(s) 102 , 112 . Since re-stimulation must be done down a work string, which limits the flow rate of stimulation fluids, careful consideration must be given to the length of perforations that can be re-stimulated taking into account the distance of the production section 102 , 112 from the wellhead, the diameter of the production casing 101 , which determines a diameter of the work string that may be used, pressure loss in the work string, etc. Consequently, unperforated intervals “uu” are left between perforated runs 140 where fractures 150 are created by stimulation fluids. The unperforated intervals “uu” are long enough to ensure that stimulation fluids are unlikely to migrate down a backside of the production casing 101 during the re-stimulation procedure as this could have detrimental effects that would require expensive remediation.
[0026] FIG. 6 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 4 configured for enhanced oil recovery (EOR) using the method in accordance with the invention. After section 112 has been produced, or substantially produced, EOR may be considered to extract remaining hydrocarbon from the production zone 14 in production sections 102 , 112 . In accordance with one aspect of the invention EOR may be performed by removing the production tubing 108 and the packer 110 shown in FIG. 4 . The plug 114 is also removed (see FIG. 4 ). A work string 200 and packer 202 are then run into the well 100 until the packer 202 can be set in the unperforated interval “u” between production sections 102 and 112 where the plug 114 had been set. In one embodiment the work string 200 is the work string described in applicant's above-referenced U.S. patent application Ser. No. 14/735,846, though if the run through the lateral bore is not too long coil tubing or jointed tubing such as Hydril® PH6® may be used as the work string 200 . Once the packer 102 is set, an EOR flood fluid 210 such as, for example, carbon dioxide (CO 2 ), liquid nitrogen (LN 2 ), compressed natural gas (CNG), water (H 2 O), or brine is pumped from the surface down the work string 200 . The pressurized flood fluid enters the production zone 14 through the perforations in the production casing 101 of production section 102 . As the pressurized EOR flood fluid enters the production formation 14 , remaining hydrocarbon 220 is urged along a path of least resistance through the perforations in section 112 and up the annulus of the production casing 101 to the surface where it is produced through a production tubing 230 installed at the wellhead 240 . Using this method, EOR fluids are pumped into section 102 until the EOR flood fluid flows up the annulus of the production casing 101 to the wellhead 240 .
[0027] FIG. 7 is a schematic-cross sectional diagram of the lateral hydrocarbon well 100 shown in FIG. 4 configured in another way for EOR using the method in accordance with the invention. In this configuration, the production tubing 108 and the packer 110 are left in the well and EOR flood fluid 210 is pumped down the annulus through tubing 232 installed at the wellhead 240 . Since the production casing 101 is unperforated above production section 112 , the EOR flood fluid 210 is forced through the perforations in production section 112 into the production zone 14 . Hydrocarbons 220 in the production zone 14 are urged by the EOR flood fluid 210 along the path of least resistance through the perforations in production section 102 , where they enter the production casing 101 . The hydrocarbons 220 are contained by the packer 106 and are forced up the production tubing 108 to the surface. Generally after an initial production period, there is no longer enough downhole pressure to force hydrocarbons 220 to the surface whether under normal production conditions or under EOR. Consequently, a pump is required to move the hydrocarbons 220 to the surface, an example of which is explained below in more detail with reference to FIG. 8 .
[0028] FIG. 8 is a schematic cross-sectional diagram of a more detailed example of a lateral hydrocarbon well 100 configured for EOR in accordance with the invention. FIG. 8 is not drawn to scale. As shown in FIG. 8 , a lateral wellbore 100 with four production sections 102 , 112 , 133 and 144 . Each of the production sections 102 , 112 , 133 and 144 are separated by an unperforated region “u”. Each unperforated region “u” being at least one casing joint in length, as described above with reference to FIG. 3 . In this example, all four production sections 102 , 112 , 133 and 144 have been perforated, stimulated and produced. The production tubing 108 and packer 106 are then pushed down the production casing 101 past production section 144 and the packer 106 is set in the unperforated region “u” between production sections 144 and 133 . As explained above with reference to FIG. 7 , EOR flood 210 fluid is then pumped down the annulus from the wellhead 240 (see FIG. 7 ). The EOR flood fluid 210 is forced through perforations in the production section 144 and into the production zone 14 . Hydrocarbons remaining in the production zone 14 are urged along a path of least resistance through the perforations in production sections 133 , 112 and 102 and into the production casing 101 . The hydrocarbons 220 are lifted to the surface through the production tubing 108 by a plunger pump 260 . A sucker rod string 250 drives the plunger pump 260 , which is connected to the end of the production tubing 108 . The plunger pump 260 lifts the hydrocarbons 220 to the surface in a manner well known in the art. The sucker rod string is reciprocated by a balanced beam pump jack, commonly referred to as a “nodding donkey”, (not shown) in a manner well known in the art.
[0029] FIG. 9 is a schematic diagram of lateral hydrocarbon wells drilled using methods in accordance with a further aspect of the invention. In accordance with this aspect of the invention hydrocarbon wells are concentrated on well pads 300 a - c , which are located in convenient and unobtrusive locations, such as public road allowances off main rural roads, or the like, to minimize environmental impact while maximizing year round access. Each pad accommodates at least 2 hydrocarbon wells. In this example, each well pad 300 accommodates 4 lateral wells 301 , though the number of wells 301 on a well pad 300 is a matter of design choice dependent on at least: location, formation boundaries, lease holder rights and investment funds. Each of the wells 301 on each well pad 300 may be drilled in succession or at different times. Each well 301 has a lateral wellbore 302 that is drilled as long as possible given the limitations of: lease holder rights, production zone boundaries, and lateral wellbore completion equipment and technology. Lateral wellbores 302 cross paths but do not directly intersect, to provide a “network” of drainage within the production zone. Since current completion technology permits the completion of very long lateral wellbores 300 , they may be used to extract hydrocarbons underlying surface features such as a lake or reservoir 320 ; a river 330 ; a city, town or village 340 ; farm land 350 ; forest or recreational land 360 ; wet land (not shown) or the like. The network of drainage provided by the lateral wellbores is also suitable for EOR, since once produced some of the lateral wellbores 102 can be used as EOR flood fluid wellbores while others are used as EOR production bores.
[0030] The methods in accordance with the invention also permit an operator to close in a well when oil prices make production uneconomical. Once a currently producing section is depleted, it can be plugged and the well closed in until prices recover. Since the cased wellbore above the plug is not perforated, the well can be brought back online without any difficulty when oil prices recover to economic production levels.
[0031] The invention has been described with specific reference to wellbores in excess of 8,000′. However, the invention is equally applicable to lateral wellbores that are less than 8,000′ long. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims. | Long lateral wellbores are prepared for the production of hydrocarbons by preparing only a portion of the wellbore for production at a time, starting at a remote end of the long lateral wellbore. The prepared production section is produced until production becomes uneconomic before a further production section is prepared and produced. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This is a Continuation of Ser. No. 11/248,429 filed Oct. 13, 2005, which is a Continuation of Ser. No. 10/982,818, filed on Nov. 8, 2004, now issued U.S. Pat. No. 7,032,996 which is a Continuation of Ser. No. 10/040,472 filed on Jan. 9, 2002, now issued U.S. Pat. No. 6,942,334 the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
The following invention relates to a hand-held computing device, of the type commonly referred to as a personal digital assistant, with an internal printer. More particularly, though not exclusively, the invention relates to a personal digital assistant having a pagewidth drop-on-demand printhead and a source of print media located in the personal digital assistant.
A personal digital assistant, such as the type commonly known under the trade mark Palm Pilot, is typically a hand-held portable electronic device having a fold down display screen and a control panel. The display screen is typically of a touch screen type that reacts to touches made by a user controlling a pixel pen. Alternatively user inputs are provided to the digital assistant through a keypad or in-built curser ball.
Personal digital assistants provide a user with the convenience to be able to store diaries, address books, meeting schedules etc in a compact, transportable form as well as to be able to instantly add new entries such as meeting notes, new addresses etc.
Much of the benefit of such portable prior art personal digital assistants is lost however if a print-out of any stored information is required. To print information, prior art digital assistants must be connected to a print device compatible with the digital assistant which requires additional cabling to be carried thus reducing the portability of the digital assistant. Alternatively the digital storage medium that stores the images within the digital assistant must be transferred to another computer having compatible software for reading the storage medium and which is connected to a printer. Each of the above alternatives can only be implemented if these other computing devices are readily at hand. The prior art personal digital assistants are thus yet to reach their maximum potential as a functional medium for storing and transporting information. With the advent of mobile communications technologies potentially allowing electronic commerce to be conducted through one's digital assistant, it is becoming essential that digital assistants have more suitable print capabilities for printing hard copies of the information stored in the digital assistant.
However, presently, printer technology has not been suitable for incorporating into personal digital assistants without a significant compromise in the size and portability of such devices.
OBJECTS OF THE INVENTION
It is an object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages.
It is another object of the present invention to provide a personal digital assistant having an in-built printer.
It is a further object of the invention to provide a personal digital assistant having an in-built printer without significantly increasing the size over prior art digital assistants.
It is a further object of the present invention to provide a personal digital assistant from which stored information can be printed without connecting the digital assistant to additional computing or printing devices.
DISCLOSURE OF THE INVENTION
There is disclosed herein a hand held personal digital assistant including information storage means, display means, in-built printer means, control means allowing a user to selectively retrieve and display information from said storage means on said display means and to print said information using said printer means and means allowing a user to enter and store new information in said information storage means.
Preferably the personal digital assistant includes a body section connected to said display means through a hinge joint, said body section housing said information storage means and said control means, wherein at least a portion of said printer means is disposed in said hinge joint.
Preferably the printer means includes a supply of print media located within said personal digital assistant.
Preferably said supply of print media is located substantially within said hinge.
Preferably a printhead of the printer is a monolithic pagewidth printhead.
Preferably the printhead is an ink jet printhead.
Preferably the body or hinge includes a releasable cover portion through which a portion of the printer including the print media and/or an ink cartridge can be removed.
Accordingly, the present invention provides a hand held personal digital assistant comprising an information storage device; a display; a printer comprising a pagewidth printhead wherein said printhead is an inkjet printhead; and a user interface allowing a user to selectively retrieve and display information from said storage device on said display; print said information using said printer; and enter and store new information in said information storage device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example with reference to the accompanying diagrammatic drawings in which:
FIG. 1 shows a three dimensional view of a print engine, including components in accordance with the invention;
FIG. 2 shows a three dimensional, exploded view of the print engine;
FIG. 3 shows a three dimensional view of the print engine with a removable print cartridge used with the print engine removed;
FIG. 4 shows a three dimensional, rear view of the print engine with the print cartridge shown in dotted lines;
FIG. 5 shows a three dimensional, sectional view of the print engine;
FIG. 6 shows a three dimensional, exploded view of a printhead sub-assembly of the print engine;
FIG. 7 shows a partly cutaway view of the printhead sub-assembly;
FIG. 8 shows a sectional end view of the printhead sub-assembly with a capping mechanism in a capping position;
FIG. 9 shows the printhead sub-assembly with the capping mechanism in its uncapped position;
FIG. 10 shows an exploded, three dimensional view of an air supply arrangement of the print engine;
FIG. 11 shows a personal digital assistant having a built in printer;
FIG. 12 shows the internal components of a personal digital assistant having a built in printer;
FIG. 13 shows a personal digital assistant with a releasable cover portion; and
FIG. 14 is a schematic block diagram of components incorporated into a personal digital assistant having a built-in printer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 to 10 of the accompanying drawings, reference numeral 500 generally designates a print engine, in accordance with the invention. The print engine 500 includes a print engine assembly 502 on which a print roll cartridge 504 is removably mountable. The print cartridge 504 is described in greater detail in U.S. Pat. Nos. 6,238,044 and 6,425,661, the contents of that disclosure being specifically incorporated herein by reference.
The print engine assembly 502 comprises a first sub-assembly 506 and a second, printhead sub-assembly 508 .
The sub-assembly 506 includes a chassis 510 . The chassis 510 comprises a first molding 512 in which ink supply channels 514 are molded. The ink supply channels 514 supply inks from the print cartridge 504 to a printhead 516 ( FIGS. 5 to 7 ) of the printhead sub-assembly 508 . The printhead 516 prints in four colors or three colors plus ink which is visible in the infra-red light spectrum only (hereinafter referred to as ‘infra-red ink’). Accordingly, four ink supply channels 514 are defined in the molding 512 together with an air supply channel 518 . The air supply channel 518 supplies air to the printhead 516 to inhibit the build up of foreign particles on a nozzle guard of the printhead 516 .
The chassis 510 further includes a cover molding 520 . The cover molding 520 supports a pump 522 thereon. The pump 522 is a suction pump, which draws air through an air filter in the print cartridge 504 via an air inlet pin 524 and an air inlet opening 526 . Air is expelled through an outlet opening 528 into the air supply channel 518 of the chassis 510 .
The chassis 510 further supports a first drive motor in the form of a stepper motor 530 . The stepper motor 530 drives the pump 522 via a first gear train 532 . The stepper motor 530 is also connected to a drive roller 534 ( FIG. 5 ) of a roller assembly 536 of the print cartridge 504 via a second gear train 538 . The gear train 538 engages an engageable element 540 ( FIG. 2 ) carried at an end of the drive roller 534 . The stepper motor 530 thus controls the feed of print media 542 to the printhead 516 of the sub-assembly 508 to enable an image to be printed on the print media 542 as it passes beneath the printhead 516 . It also to be noted that, as the stepper motor 530 is only operated to advance the print media 542 , the pump 522 is only operational to blow air over the printhead 516 when printing takes place on the print media 542 .
The molding 512 of the chassis 510 also supports a plurality of ink supply conduits in the form of pins 544 which are in communication with the ink supply channels 514 . The ink supply pins 544 are received through an elastomeric collar assembly 546 of the print cartridge 504 for drawing ink from ink chambers or reservoirs 548 ( FIG. 5 ) in the print cartridge 504 to be supplied to the printhead 516 .
A second motor 550 , which is a DC motor, is supported on the cover molding 520 of the chassis 510 via clips 552 . The motor 550 is provided to drive a separating means in the form of a cutter arm assembly 554 to part a piece of the print media 542 , after an image has been printed thereon, from a remainder of the print media. The motor 550 carries a beveled gear 556 on an output shaft thereof. The beveled gear 556 meshes with a beveled gear 558 carried on a worm gear 560 of the cutter assembly 554 . The worm gear 560 is rotatably supported via bearings 562 in a chassis base plate 564 of the printhead sub-assembly 508 .
The cutter assembly 554 includes a cutter wheel 566 , which is supported on a resiliently flexible arm 568 on a mounting block 570 . The worm gear 560 passes through the mounting block 570 such that, when the worm gear 560 is rotated, the mounting block 570 and the cutter wheel 566 traverse the chassis base plate 564 . The mounting block 570 bears against a lip 572 of the base plate 564 to inhibit rotation of the mounting block 570 relative to the worm gear 560 . Further, to effect cutting of the print media 542 , the cutter wheel 566 bears against an upper housing or cap portion 574 of the printhead sub-assembly 508 . This cap portion 574 is a metal portion. Hence, as the cutter wheel 566 traverses the capped portion 574 , a scissors-like cutting action is imparted to the print media to separate that part of the print media 542 on which the image has been printed.
The sub-assembly 506 includes an ejector mechanism 576 . The ejector mechanism 576 is carried on the chassis 510 and has a collar 578 having clips 580 , which clip and affix the ejector mechanism 576 to the chassis 510 . The collar 578 supports an insert 582 of an elastomeric material therein. The elastomeric insert 582 defines a plurality of openings 584 . The openings 584 close off inlet openings of the pins 544 to inhibit the ingress of foreign particles into the pins 544 and, in so doing, into the channels 514 and the printhead 516 . In addition, the insert 584 defines a land or platform 586 which closes off an inlet opening of the air inlet pin 524 for the same purposes.
A coil spring 588 is arranged between the chassis 510 and the collar 578 to urge the collar 578 to a spaced position relative to the chassis 510 when the cartridge 504 is removed from the print engine 500 , as shown in greater detail in FIG. 3 of the drawings. The ejector mechanism 576 is shown in its retracted position in FIG. 4 of the drawings.
The printhead sub-assembly 508 includes, as described above, the base plate 564 . A capping mechanism 590 is supported displaceably on the base plate 564 to be displaceable towards and away from the printhead 516 . The capping mechanism 590 includes an elongate rib 592 arranged on a carrier 593 . The carrier is supported by a displacement mechanism 594 , which displaces the rib 592 into abutment with the printhead 516 when the printhead 516 is inoperative. Conversely, when the printhead 516 is operational, the displacement mechanism 594 is operable to retract the rib 592 out of abutment with the printhead 516 .
The printhead sub-assembly 508 includes a printhead support molding 596 on which the printhead 516 is mounted. The molding 596 , together with an insert 599 arranged in the molding 596 , defines a passage 598 through which the print media 542 passes when an image is to be printed thereon. A groove 700 is defined in the molding 596 through which the capping mechanism 590 projects when the capping mechanism 590 is in its capping position.
An ink feed arrangement 702 is supported by the insert 599 beneath the cap portion 574 . The ink feed arrangement 702 comprises a spine portion 704 and a casing 706 mounted on the spine portion 704 . The spine portion 704 and the casing 706 , between them, define ink feed galleries 708 which are in communication with the ink supply channels 514 in the chassis 510 for feeding ink via passages 710 ( FIG. 7 ) to the printhead 516 .
An air supply channel 711 ( FIG. 8 ) is defined in the spine portion 704 , alongside the printhead 516 .
Electrical signals are provided to the printhead 516 via a TAB film 712 which is held captive between the insert 599 and the ink feed arrangement 702 .
The molding 596 includes an angled wing portion 714 . A flexible printed circuit board (PCB) 716 is supported on and secured to the wing portion 714 . The flex PCB 716 makes electrical contact with the TAB film 712 by being urged into engagement with the TAB film 712 via a rib 718 of the insert 599 . The flex PCB 716 supports busbars 720 thereon. The busbars 720 provide power to the printhead 516 and to the other powered components of the print engine 500 . Further, a camera print engine control chip 721 is supported on the flex PCB 716 together with a QA chip (not shown) which authenticates that the cartridge 504 is compatible and compliant with the print engine 500 . For this purpose, the PCB 716 includes contacts 723 , which engage contacts 725 in the print cartridge 504 .
As illustrated more clearly in FIG. 7 of the drawings, the printhead itself includes a nozzle guard 722 arranged on a silicon wafer 724 . The ink is supplied to a nozzle array (not shown) of the printhead 516 via an ink supply member 726 . The ink supply member 726 communicates with outlets of the passages 710 of the ink feed arrangement 702 for feeding ink to the array of nozzles of the printhead 516 , on demand.
In FIG. 10 , the air supply path for supplying air to the printhead 516 is shown in greater detail. As illustrated, the pump 522 includes an impeller 728 closed off by an end cap 730 . The cover molding 520 of the chassis forms a receptacle 732 for the impeller 728 . The cover molding 520 has the air inlet opening 734 and the air outlet opening 736 . The air inlet opening 734 communicates with the pin 524 . The air outlet opening 736 feeds air to the air supply channel 518 which, in FIG. 10 , is shown as a solid black line. The air fed from the air supply channel 518 is blown into the printhead 516 to effect cleaning of the printhead. The air drawn in via the pump 522 is filtered by an air filter 738 , which is accommodated in the print cartridge 504 . The air filter 738 has a filter element 740 which may be paper based or made of some other suitable filtering media. The filter element 740 is housed in a canister, having a base 742 and a lid 744 . The lid 744 has an opening 746 defined therein. The opening 746 is closed off by a film 748 which is pierced by the pin 524 . The advantage of having the air filter 738 in the print cartridge 504 is that the air filter 738 is replaced when the print cartridge 504 is replaced.
It is an advantage of the invention that an air pump 522 is driven by the stepper motor 530 , which also controls feed of the print media to the printhead 516 . In so doing, fewer components are required for the print engine 500 rendering it more compact. In addition, as the same motor 530 is used for operating the air pump 522 and for feeding the print media 542 to the printhead 516 , fewer power consuming components are included in the print engine 500 rendering it more compact and cheaper to produce.
It is also to be noted that, in order to make the print engine 500 more compact, the size of the print engine assembly 502 is such that most of the components of the assembly 502 are received within a footprint of an end of the print cartridge 504 .
In FIG. 11 there is depicted a personal digital assistant having an internal printer. The digital assistant 901 includes a body section 902 housing the main circuitry of the digital assistant including a digital storage medium. A display screen 904 is pivotably connected to the body section 902 about a hinge joint 905 . The screen 904 pivots between a closed position ( FIG. 12 ) where the screen lies adjacent the body section 902 thus allowing safe transport, and an open position ( FIG. 11 ) where the screen 904 is visible to a user.
The body section 902 includes a control panel 906 on an upper surface thereof that includes all buttons required to operate the functions of the digital assistant including the functions of the printer. Using this control panel, a user can selectively view any stored information and make any new entries or amendments. The control panel also includes keys allowing the user to selectively print any of the stored information. A slot 910 in the front edge of the body is used for ejecting printed media 911 .
The display screen is of a known touch screen type allowing a user to control the digital assistant using a compatible pixel pen (not shown) through which the user selects items on a displayed menu. In addition the digital assistant may include known pattern recognition software that allows a user to enter information by writing on the screen whereafter the user's input is analysed and converted into text.
In FIG. 14 there is schematically depicted in block diagram form the key internal components of a personal digital assistant having an internal printer. The printer would typically utilize a monolithic printhead 814 which could be the same as described above with reference to FIGS. 1 to 10 , but could alternatively be another compact printhead capable of printing on suitably sized print media. Print data from the memory 909 of the digital assistant or a display screen dump 904 is fed to a print engine controller 813 which controls the printhead 814 .
A micro-controller 807 associated with the print engine controller controls a motor driver 809 which in turn drives a media transport device 810 . This might be the same as stepper motor 530 described earlier.
The micro-controller 807 also controls a motor driver 811 which in turn controls a guillotine motor 812 to sever a printed sheet from an in-built roll of print media after an image is printed. A sheet being driven by media transport device 810 is shown at 911 in FIG. 11 . The guillotine might be of the form of cutter wheel 566 described earlier.
When ready, printer control buttons on the control panel can be depressed to activate the print engine controller to print stored information either from memory or as a screen dump from the display screen. This would in turn activate the micro-controller 807 to activate the media transport 810 and guillotine 812 .
FIG. 12 shows an internal view of the personal digital assistant in its closed position. The printer engine 500 described previously is disposed within the body section 902 with the removable print media cartridge 504 being disposed in the hinge joint 905 linking the body section 902 with the display screen 904 . Printed media ejected from the print media passage 548 of the print engine travels substantially along the inner surface of the bottom panel of the body section 902 and exits the digital assistant at ejector slot 910 . Because the print roll 504 is disposed within the hinge joint 905 , the personal digital assistant of the present invention can be made substantially the same size as prior art digital assistants.
The body section 902 and hinge 905 include a releasable portion 912 pivotably connected through a hinge 913 and secured in a closed position by a catch 914 . Opening of this portion ( FIG. 13 ) allows the ink containing print roll cartridge 504 to be removed and replaced. Further details of a removable print roll cartridge are described in our co-pending application IN/PCT/2002/02045/CHE mentioned earlier.
While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. It will further be understood that any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates. | A personal digital assistant is provided which has a body housing a memory for storing personal digital assistant information, a printhead for printing the stored information, a bay extending along a first edge of the body for removably receiving a print media cartridge for supplying print media to the printhead, and control circuitry for controlling functions of the personal digital assistant, and a display pivotally mounted to the body at said first edge for displaying the stored information. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to personal lubricants, which are highly spreadable on latex rubber and human skin and which provide a lubricious warming effect upon contact with moisture.
BACKGROUND OF THE INVENTION
[0002] Lubricants have been employed for a number of applications, including lubrication of latex condoms and lubrication of skin. More recently, lubricants have been designed to take advantage of the heat that is generated when glycerin or propylene glycol is dissolved in water. Unfortunately, glycerin and propylene glycol do not spread readily on skin and other surfaces and irritate skin after prolonged use, since glycerin extracts water from the skin surface. The spreadability of such lubricants is further compromised by the addition of one or more insulating agents, such as honey, isopropyl myristate and/or isopropyl palmitate, which reportedly help to retain the heat of the lubricant (see, e.g., U.S. Pat. App. Pub. Nos. 2004/0138074, 2003/0232090, 2003/0211161 and 2003/0207772, and Int'l App. Pub. Nos. WO 03/092652, WO 03/092651 and WO 09/092650, discussed below).
[0003] U.S. Pat. No. 4,851,434 (the '434 patent) to Deckner discloses a non-greasy, non-irritating moisturizer, and compositions containing as the major moisturizing component the di-, tri- or polyglycol amide or glucamine reaction product with an a-hydroxy-substituted fatty acid, with the formula containing hydrogen or a lower alkyl, preservatives, thickeners, skin-soothing agents, such as allantoin and/or dl-panthenol, and water. The non-irritating moisturizer disclosed in the '434 patent does not produce a warming effect when it contacts body-generated moisture and does not spread spontaneously on latex and human skin.
[0004] U.S. Pat. No. 4,952,560 to Kigasawa et al. discloses an ointment base containing a water-soluble protein consisting of gelatin, casein and soybean protein and a monohydric alcohol with a carbon number of 2 to 4 and/or an oleginous substance and additionally containing a wetting agent selected from the group consisting of an alkylene glycol containing 2 to 6 carbon atoms, polyethylene glycol having an average molecular weight of about 200 to 800, glycerin, trimethylolpropane and sorbitol, in a range of 1 to 35 weight % based on the weight of the whole ointment. While the ointment base improves percutaneous absorption of drugs, it is too thick to function as a lubricant.
[0005] U.S. Pat. No. 5,441,723 to Simmons discloses a non-toxic hypocompatible biodegradable germicide. The non-toxic hypocompatible biodegradable germicide is effective against a wide range of pathogenic organisms and comprises 65-75 wt % of a monohydric alcohol selected from the group consisting of isopropyl, methyl, ethyl, n-propyl, n-butyl, tert-butyl, allyl, or mixtures thereof, and from about 4% to about 16% by weight of at least one polyhydric alcohol selected from the group consisting of propylene glycol, 1,3 propanediol, 1,2 butanediol, PEG 400, glycerol or 1,4 butanediol, or mixtures thereof in proportion by weight. The monohydric alcohol in the germicide provides the primary disinfecting or killing effect on the pathogenic organisms, while the polyhydric alcohol reduces the surface glaze formed by the monohydric alcohol and the surface tension formed by water or water-based body fluids, thereby enabling the disinfectant/antiseptic to kill pathogenic organisms and act equally effectively on a patient or inanimate surface without deleterious effects. The monohydric alcohol also lowers the flash point of the composition, soothes the skin, and slows the rate of evaporation. In this regard, the germicide is not a lubricant and does not include a warming constituent. The polyhydric alcohol, by reducing the rate of evaporation of the monohydric alcohol, essentially cools the surface by evaporative cooling.
[0006] U.S. Pat. No. 5,512,289 to Tseng et al. discloses a spermicidal anti-viral lubricant composition containing a water-soluble polymeric gel matrix comprising a hydroxyalkyl cellulose with 2 to 6 carbon atoms; an alkylphenoxypolyethoxyethanol spermicide; and a solubilizing moiety comprising a polyethoxylated non-ionic compound, such as polyethoxylated castor oil. The use of an alkylphenoxypolyethoxyethanol spermicide prevents collapse of the hydroxyalkyl cellulose gel. The addition of a solubilizer substantially prevents the collapse of the gel matrix and permits the gel matrix to maintain its properties in the composition. The spermicidal composition can be dispersed by use of a pharmaceutically acceptable vehicle, such as water, alcohols, e.g., ethanol, glycerin, propylene glycol, and mixtures thereof. A typical formulation of the spermicidal lubricant can include water 75.50 wt %, glycerin 17.00 wt %, hydroxyethyl cellulose 1.00 wt %, polyvinyl pyrrolidone 0.90 wt %, carboxymethyl cellulose 1.00 wt %, Nonoxynol-9 spermicide 2.00 wt %, polyethoxylated castor oil 2.00 wt %, methylparaben 0.20 wt %, sorbic acid 0.05 wt %, and citric acid 0.35 wt %. Since glycerin and glycol are already dissolved in water, the lubricant does not provide a warming effect.
[0007] U.S. Pat. No. 5,514,698 to Ahmad et al. discloses an antifungal vaginal cream composition. The composition has stable viscosity at human body temperature and comprises about 0.4 to 10.0% of an imidazole antifungal agent (of miconazole, econazole, terconazole, saperconazole, itraconazole, ketoconazole, and clotrimazole), about 1.0% to 5.0% of a fatty acid ester (isopropyl stearate, isopropyl myristate, isopropyl palmitate, and isopropyl laurate), about 1.0% to 25.0% of aliphatic alcohols (cetyl alcohol, stearyl alcohol and propylene glycol), about 2.0% to 5.0% of a surfactant (polysorbate 60 or polysorbate 80), about 0.02% to 0.20% of an antioxidant (butylated hydroxyanisole), a sufficient amount of inorganic base (NaOH or KOH) to adjust the pH range to a value of about 3.0 to 7.0, and water. This vaginal cream is not a lubricant and is expected to maintain its viscosity for prolonged time periods at body temperature. Even though propylene glycol is used in the composition, it is already mixed with water and, therefore, no warming effect takes place when the cream contacts body-generated moisture.
[0008] U.S. Pat. No. 5,649,825 to Ratkus discloses a dental root canal bacterialcidal lubricant, which allows the cleaning wires or files to move more freely when removing a nerve from a tooth. The composition reduces packing of tissue and dentin debris within the nerve cavity. This formulation is also resistive to decomposition during cold weather shipping, and includes cetyl alcohol, stearyl alcohol, sodium lauryl sulfate, stearic acid, propylene glycol, methyl paraben, propyl paraben, and butyl paraben in a purified water solution. The lubricant does not provide a warming effect.
[0009] U.S. Pat. No. 5,885,591 to Ahmad et al. discloses highly lubricious personal lubricant compositions containing one or more polyhydric alcohols, one or more water-soluble polymers derived from cellulose, water, and, optionally, preservatives and alkali metal or alkaline earth metal bases. These compositions can provide a vehicle for delivering medicaments for contraception and for the treatment and prevention of disease. The personal lubricant composition contains about 30% glycerin, about 5% propylene glycol, about 10% sorbitol, about 0.4% preservative, about 0.4% hydroxyethylcellulose, about 0.01% sodium hydroxide, and about 50% water. The composition has a lubricity of 33 to about 466. The personal lubricant composition attaches to mucous membranes and is not readily washed off. Since the composition already contains water, no heating or warming reaction occurs when the lubricant is applied to the body and the glycerin comes in contact with body-generated moisture.
[0010] U.S. Pat. No. 6,139,848 to Ahmad et al. discloses stable personal lubricant compositions containing at least one water-soluble polyhydric alcohol, a water-soluble polymer derived from cellulose, tocopherol or a tocopherol derivative, a nonionic water-soluble or dispersible emulsifier, and water. The lubricious, oily tocopherol or tocopherol derivative is present as an emulsion in the personal lubricant. The emulsifier preferably is a polyalkylene emulsifier chosen from the group consisting of polyoxyethylene (20) sorbitan monostearate, commonly known as Tween 60 or Polysorbate 60, and polyethylene glycol ether of isocetyl alcohol (commonly known as Isoceteth 20 or Arlasolve 200, which is available from ICI Americas, Inc., New Castle, Del.). The water-soluble polyhydric alcohol serves to increase the lubriciousness of the compositions. The water-soluble cellulose-derived polymer serves to impart the desired slipperiness and viscosity to the composition. Water is desired in sufficient quantity to be delivered as moisture to the mucous membranes and to provide consistency and viscosity to the composition. The nonionic surfactants emulsify tocopherol, tocopherol acetate or other tocopherol derivatives into a microemulsion in which the internal or oil phase is reduced to very small globules measuring 2 or less than 2 microns in size. Due to their immensely small size, the emulsion globules do not coalesce and serve to assist in maintaining the homogeneity of the emulsions and to preserve physical stability of the compositions. Since the polyhydric alcohol (glycerin) is already combined with water, no heating or warming reaction occurs when the lubricant is applied to the body.
[0011] U.S. Patent Application Publication No. 2001/0039380 to Larson et al. discloses in vivo biocompatible acoustic coupling media comprising polyethylene oxide (PEO), at least one of polyalkylene glycols and polyhydric alcohols, and the balance water. Since water is already added to polypropylene alcohol, the exothermic reaction of mixing has already occurred, and no additional warming occurs when the lubricant is used.
[0012] U.S. Patent Application Publication No. 2003/0207772 and International Patent Application Publication No. WO 03/092651 to Ahmad et al. (see also U.S. Pat. App. Pub. No. 2003/0211161 and Int'l Pat. App. Pub. No. WO 03/092652) disclose warming and nonirritating lubricating compositions containing polyhydric alcohols and an insulating agent. The polyhydric alcohol comprises glycerin, alkylene glycol, or a mixture thereof. The alkylene glycol is selected from the group consisting of propylene glycol, butylene glycol and hexalene glycol, whereas the polyethylene glycol is selected from the group consisting of polyethylene glycol 300 and polyethylene glycol 400. The insulating agent is selected from the group consisting of honey, isopropyl myristate and isopropyl palmitate. A warming action is created by the heat released during dissolution of the polyhydric alcohol in water, and the insulating agent retains the heat. The insulating agent is an essential part of the composition of the lubricant, and reduces the spreading capability of the warming lubricant.
[0013] U.S. Patent Application Publication No. 2003/0232090 and International Patent Application Publication No. WO 03/092650 to Ahmad et al. disclose warming and nonirritating lubricating compositions. Also disclosed are substantially anhydrous, warming, non-toxic and nonirritating lubricating compositions containing polyhydric alcohols, a gelling agent and, alternatively, a pH-adjusting agent for treating fungal and bacterial infections. The polyhydric alcohol comprises glycerin, alkylene glycol, polyethylene glycol, or a mixture thereof. The alkylene glycol is selected from the group consisting of propylene glycol, butylene glycol and hexalene glycol, whereas the polyethylene glycol is selected from the group consisting of polyethylene glycol 300 and polyethylene glycol 400. The insulating agent is selected from the group consisting of honey, isopropyl myristate and isopropyl palmitate. The use of insulating agents reduces the spreading capability of the warming lubricant.
[0014] U.S. Patent Application Publication No. 2004/0037911 to Letoumeau et al. discloses a genital lubricating composition. The composition comprises (i) fatty acids and/or homeopathic dilutions of plant extracts and (ii) a physiologically acceptable carrier. According to a preferred embodiment, the genital lubricant composition comprises about 0.05% to about 0.5% hemp seed oil and a physiologically acceptable carrier so that it forms a lotion, a cream or a gel. The composition is particularly useful for use as a vaginal moisturizer, or as a personal lubricant for use prior or during sexual intercourse. The fatty acids can be hemp oil, linoleic (CI8:2) acid or linolenic (C18:3) acid. The plant extracts include extracts from Caladium seguinum, Sepia officianalis, Lycopodium clavatum, and Onosmodium virginanium. The exact composition of the carrier is not disclosed. This lubricant does not have any polyhydric alcohol and does not produce a warming sensation.
[0015] U.S. Patent Application Publication No. 2004/0086575 to Smith discloses anti-viral compositions. The anti-viral compositions contain at least one zinc compound, at least one phenolic antioxidant (and optionally other ingredients), and a pharmaceutical carrier. The zinc compound is selected from the group consisting of zinc, zinc chloride, zinc acetate, zinc citrate, zinc sudoxicam, zinc sulfate, zinc nitrate, zinc carbonate, zinc tartrate, zinc maliate, zinc lactate, zinc aminoacetate, zinc aspartate, zinc glutamate, zinc propionate, zinc oleate, zinc benzoate, zinc gluconate, zinc butyrate, zinc formate, zinc glycerate, zinc glycolate, zinc oxide, zinc ethylenediamine tetraacetate, zinc pentosan polysulfate, zinc oxyacetate, and hydrates. The phenolic antioxidant comprises at least one compound represented by the formula:
[0016] wherein each R is independently an aliphatic hydrocarbon residue, with or without oxygen, comprising 1 to about 12 carbon atoms, x is from 1 to 3, y is from 0 to 3, z is from 1 to 3, and x+y+z is 6 or less. The pharmaceutical carrier comprises at least one of water, alcohol, fatty acids, fatty acid esters, and waxes. The composition does not function as a lubricant.
[0017] U.S. Patent Application Publication No. 2004/0138074 to Ahmad et al. discloses substantially anhydrous, warming, non-toxic and nonirritating lubricating compositions containing polyols and preferably an insulating agent. The substantially anhydrous lubricant composition comprises a polyol, which increases in temperature by at least about 5° C. upon exposure to moisture and which has a maximum Energy Release Index of at least about 11 mJ/mg. The polyhydric alcohol is selected from glycerin, alkylene glycol, polyethylene glycol, polypropylene glycol, PEGylated compounds, block copolymers comprising polyalkylene glycol, and their mixtures. The use of insulating agents, such as honey, isopropyl myristate and isopropyl palmitate, reduces the spreading capability of the warming lubricant.
[0018] European patent document EP 0636374 to Tseng discloses a spermicidal anti-viral lubricating composition containing an antiviral alkylphenoxypolyethoxyethanol spermicide, a water-soluble polymeric gel matrix, and a solubilizer, which permits the spermicide to be compatible with the gel matrix. Preferably, a polyethoxylated compound, such as polyethoxylated castor oil, is used. There is no warming agent present in the lubricant, since the water-soluble polymer functions as the lubricating agent.
[0019] Japanese patent document JP 2292212 to Hans Eke Rennaruto Bidesutoreemu discloses a sterilizable gel. This sterilizing gel comprises a carboxypolymethylene polymer (carboma) and 1-90% polyhydric alcohol for stabilization (e.g., ethylene glycol). The carboma can be sterilized by assistance of the polyhydric alcohol and avoids deterioration of the gel when the gel is sterilized by γ-radiation derived from cobalt 60. This is not a warming gel and polyhydric alcohol is only used to prevent discoloration during γ-radiation.
[0020] Japanese patent document JP 2003183115 to Saijo discloses a poikilothermal lubricant. The lubricant may contain ingredients that cause cooling or warming. The warming or cooling ingredient is a dispersant that is not water-soluble and is protected by a polymeric coating. It is unclear what is the nature of the warming agent and what is the mechanism of the warming action.
[0021] International Patent Application Publication No. WO 93/18740 to Dunbar discloses a shaving gel. The water-based, non-foaming, shaving gel comprises from 0.05 to 4.0% of a carboxypolymethylene, from 2.00 to 52.0% of a polyhydric alcohol, and, optionally, a silicone derivative, an antipruritic agent, preservative agents, a chelating agent, a neutralizing agent, a solubilizing agent, a UV light-absorbing agent, or a perfume. The preferred polyhydric alcohol is glycerin. The gel is applied directly to dry skin and hair prior to shaving with a razor blade and provides a close, comfortable and well-lubricated shave. The shaving gel does not provide a warming effect.
[0022] Notwithstanding the advances in the field of lubricants and more particularly in the field of warming lubricants and related articles, there remains a need in the art for a warming lubricant that provides effective elastohydrodynamic lubrication as evidenced by improved spreadability on skin, condoms and other surfaces with which it is brought in contact.
SUMMARY OF THE INVENTION
[0023] The present invention provides a spreadable warming lubricant that exhibits excellent spreadability and low surface tension and contact angle, thereby providing a well-wetted, uniform, thin layer during skin to skin contact and condom latex film to skin contact. The warming lubricant composition has sufficient viscosity to establish easily a thin film on either skin or condom latex film with a film thickness ranging from 0.01 to 0.1 mm. The spreadable warming lubricant composition is substantially anhydrous and comprises a mixture of glycerin with another polyhydric alcohol in the range of 40%-60% each and a non-ionic surfactant in the range of 0.1 to 3%. The polyhydric alcohol is preferably propylene glycol, and the non-ionic surfactant is preferably polysorbate 20, polysorbate 40, polysorbate 60 or polysorbate 80. The preferred spreadable warming composition comprises 49.75% glycerin, 49.75% propylene glycol, and 0.5% polyoxyethylene sorbitan monolaurate (polysorbate 20).
[0024] The spreadable warming lubricant releases heat when mixed with moisture, which can be skin-generated. The temperature rise is optimal when nearly equal volumes of the spreadable warming lubricant and moisture are mixed. An excess of either moisture or the warming lubricant reduces the temperature rise because the heat released has to heat a larger mass. Therefore, the quantity of the warming lubricant desirably is limited to the quantity of moisture available during use. Thus, when used with a latex condom, for example, the spreadable warming lubricant desirably coats the surface of the condom as a thin layer. When the interior and exterior of a latex condom is not coated with a lubricant, there is rubbing between skin and latex, which produces friction and irritation. The presence of a thin, well-spread layer of spreadable warming lubricant minimizes, if not eliminates, friction and irritation and assures uniform heat release, which, in turn, provides a comfortable warming sensation. The thin, well-wetted, warming lubricant layer that is in contact with (i) a condom latex surface and skin or (ii) skin and skin results in elastohydrodynamic lubrication that effectively reduces friction even when the contacting surfaces deform.
[0025] Incorporation of lubricant on a condom latex surface as a uniform coating in general is difficult to achieve. However, the present inventive spreadable warming lubricant wets latex with a small contact angle. Therefore, the addition of a small quantity of about 0.2-5 ml of spreadable warming lubricant to a condom package results in the migration of the warming lubricant over the internal and external surfaces of the condom. This migration process coats essentially the complete internal and external surfaces of the latex condom with a thin layer of warming lubricant within a period of approximately a week. Thus, the present inventive spreadable warming lubricant is advantageous in that it enables uniform coating of a lubricant on a condom. Accordingly, the present invention also provides a latex condom, onto which a spreadable warming lubricant has been applied in accordance with such a method.
[0026] When the spreadable warming lubricant is used as skin lubricant, the warming lubricant is applied to the skin in an amount that approximates the available skin moisture. Optionally, moisture can be added to the skin prior to the application of the spreadable warming lubricant. The reaction between moisture and the spreadable warming lubricant results in the release of heat, thereby creating a warming sensation. The spreadability of the warming lubricant is essential for this warming effect, since the quantity of moisture available on skin is generally small and the quantity of spreadable warming lubricant applied desirably is matched with this quantity of moisture so as to optimize the warming effect. In the absence of spreadability, the warming lubricant would be concentrated in the area of initial application to the skin and the desired effects of lubrication and warmth would not be optimized.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention provides an improved warming lubricant that provides and maintains a thin elastohydrodynamic lubricating film between skin and either skin or latex. The lubricant exhibits excellent spreadability due to sufficient viscosity, a low surface tension, and a low contact angle. The lubricant is substantially anhydrous, preferably containing less than about 5% water, more preferably containing less than about 3% water, and most preferably containing less than about 2% water, such as less than about 1% water. Having sufficient viscosity, a film thickness ranging from about 0.01 to 0.10 mm, such as about 0.05 to 0.10 mm, can be achieved on skin or latex rubber.
[0028] Accordingly, the present invention provides a spreadable warming lubricant comprising glycerin with another polyhydric alcohol and a non-ionic surfactant. Preferably, glycerin is present in an amount from about 40% to 60%, the polyhydric alcohol is present in an amount from about 40% to 60%, and the non-ionic surfactant is present in an amount from about 0.1% to 3%.
[0029] Any suitable polyhydric alcohol can be used. Preferably, the polyhydric alcohol is propylene glycol. Other polyhydric alcohols, such as butylene glycol, hexalene glycol, and polyethylene glycol, are known in the art.
[0030] The warming lubricant has constituents that release heat by exothermic heat of dissolution when mixed with moisture, such as skin-generated moisture. Since skin-generated moisture is generally small in quantity, the quantity of warming lubricant desirably is small in quantity to take advantage of the exothermic heat release to provide a warming effect. An excessive amount of the warming lubricant in the presence of a small amount of skin-generated moisture results in only a small temperature rise resulting in a minimal warming effect. The small quantity of spreadable warming lubricant can only be effective if it creates a stable elastohydrodynamic film over the skin or between skin and a latex article.
[0031] Polyhydric alcohols react with water to release heat by an exothermic dissolution reaction. This effect is well-known and documented in several chemistry textbooks including supplier literature of Dow Chemical Company (Midland, Mich.). Any of the polyhydric alcohols, including glycerin, propylene glycol, butylene glycol, hexalene glycol, and polyethylene glycol, exhibit this exothermic reaction. The spreadable warming lubricant has glycerin and a polyhydric alcohol, preferably propylene glycol, mixed in an appropriate ratio to ensure that the viscosity of the mixture provides sufficient lubricating properties. The higher the viscosity, the higher is the drag when the contacting surfaces are moved with respect to one another. In addition, higher viscosity compositions tend to form thick lubricating films, since gravitational forces are inadequate to form a thin film, whereas lower viscosity compositions run off easily, forming very thin lubricating films.
[0032] The viscosity of a glycerin—propylene glycol mixture as a function of composition is shown in Table 1 below. Propylene glycol viscosity is too low to be useful as a lubricant, while glycerin has too high a viscosity to produce evenly a thin lubricating film. Table 1 also documents the warming effect of the lubricant composition in three trials. Propylene glycol provides the largest warming effect, while glycerin produces the smallest warming effect.
TABLE 1 % Propylene Glycol 0 50 100 % Glycerin 99.7% 100 50 0 Test No. 1 2 3 1 2 3 1 2 3 T max (° C.) 35.7 35.8 35.8 37.2 37.5 37.6 38.5 38.1 38.5 T b (° C.) 23.8 23.8 24.1 24.1 24.0 24.0 23.8 24.0 24.1 ΔT sample = T max − T b (° C.) − Tsf 5.7 5.8 5.5 6.9 7.3 7.4 8.5 7.9 8.2 Avg warming, ΔT (° C.) 5.7 7.2 8.2 Viscosity (at 25° C.) ˜565.5 cps ˜140 cps ˜32 cps T b = room temperature of sample T max = highest temperature of sample upon mixing with equal amount of water at 37° C. Tsf = 6.2° C., inherent effect of mixing water at 37° C. with water at room temperature ΔT sample = increase in temperature of sample after mixing with equal amount of water at 37° C. cps = centipoises
[0033] The lubricant must wet the surfaces in question and must have a low contact angle. This requirement is even more important when the surfaces in contact are deformable and the adhesion of the film to the surface needs to be better, thus demanding even a smaller contact angle. If the contact angle is large, the lubricating fluid film disrupts creating islands, which are physically separated, and rubbing now occurs between skin and skin or between skin and latex, both of which are high friction coefficient couples providing skin irritation. Improved wetting of a glycerin-propylene glycol mixture is accomplished by addition of 0.1 to 3 percent of non-ionic surfactants.
[0034] Non-ionic surfactants, as the name implies, do not contain ionic constituents. They are “ionically” inert. A vast majority of all non-ionic detergents are condensation products or ethylene oxide with a hydrophobe. This group of detergents is enormous, and the permutations endless. They are the single largest group of all surfactants. Nonionic Surfactants: Organic Chemistry, Nico M. van Os, ed., Marcel Dekker (1998), specifically incorporated by reference herein, discusses a number of non-ionic surfactants, including polyoxyethylene alkylphenols, alcohols, esters of fatty acids, mercaptans, and alkylamines, nonionic surfactants containing an amide group, and polyol ester surfactants. Dow Chemical Co. markets a number of non-ionic surfactants under the trade name ‘DOWFAX’. These polyethylene glycol formulations provide superior softening, conditioning, and skin-smoothing characteristics, since polyglycols dissolve or are compatible and miscible in various organic liquids.
[0035] Polysorbate compositions are also non-ionic surfactants and are available as polysorbate-20, 40, 60; 65 and 80. They are polyoxyethylene sorbitan monoesters (PS) of the general formula:
[0036] wherein R is laureate, palmitate, stearate or oleate and each of w, x, y and z is independently 1 or 2; or each of w, x, y and z is independently less than or equal to 17 and the sum of w, x, y and z is 20. Polysorbate-20 is polyoxyethylenesorbitan monolaurate, CAS #9005-64-5, with a chemical composition of sorbitan mono-9-octadecenoate poly(oxy-1,1-ethanediyl). Polysorbate 40 is polyethylene glycol sorbitan monopalmitate, polyoxyethylene sorbitanmonopalmitate, CAS# 9005-66-7, Polysorbate 60 is polyethylene glycol sorbitan monostearate, polyoxyethylene sorbitanmonostearate, CAS #9005-67-8, and Polysorbate 80 is polyoxyethylenesorbitan monooleate, CAS# 9005-65-6.
[0037] Tables 2 A, B and C show the effect of the addition of polysorbate 20 to warming lubricant compositions containing propylene glycol and glycerin on drop diameter, when a fixed volume of liquid is applied to a substrate, including glass, latex condom film and skin, and the corresponding contact angle. This contact angle is determined by dropping a fixed volume of 25 μl of lubricant mixture using a microsyringe on a flat substrate of glass, condom latex film or skin, respectively, and measuring the diameter of the spread of the warming lubricant as a function of time. The contact angle is calculated using a well-known formula (Roberts et al., Surface Treatments to Reduce Friction—Rubber Chemistry and Technology, 63:722 (1990)) as shown below, wherein D is the diameter of the lubricant and V is the volume of the warming liquid:
TABLE 2 A D 3 V = 24 Sin 3 θ π ( 2 - 3 Cos θ + Cos 3 θ ) . Substrate: GLASS Average Base Diameter of Drop (mm) & Contact Angle (degrees) 50% 49.50% Propylene Propylene Propylene Glycol, 49.5% Glycol, Lapse Drop Glycol, glycerin, Glycerin, Propylene 0.5% time Vol. 50% glycerin 0.5% PS20 Glycerin 0.5% PS20 Glycol PS20 (mins) (μL) mm deg mm deg mm, deg mm, deg mm deg mm deg 1 25 7.0 39 8.0 27.4 6.0 56.4 6.5 41.5 7.0 39 8.0 27.4 10 25 7.0 39 9.5 16.8 6.0 56.4 8.0 27.4 8.0 27.4 10.0 14.4 60 25 7.5 32.7 10.5 12.5 7.0 39 10.0 14.4 8.0 27.4 11.5 9.5 135 25 7.5 32.7 12.0 8.4 7.5 32.7 — — 8.0 27.4 12.5 7.4 300 25 8.0 27.4 12.5 7.4 8.0 27.4 12.0 8.4 8.5 23.1 13.5 5.9
[0038]
TABLE 2B
Substrate: CONDOM LATEX FILM Average Base Diameter
of Drop (mm) & Contact Angle (degrees)
49.50%
50%
Propylene
Propylene
Glycol,
Propylene
Lapse
Drop
Glycol,
49.5% glycerin,
Glycerin,
Propylene
Glycol,
time
Vol.
50% glycerin
0.5% PS20
Glycerin
0.5% PS20
Glycol
0.5% PS20
(mins)
(μL)
mm
deg
mm
deg
mm
deg
mm
deg
mm
deg
mm
deg
1
25
5.0
78.9
6.0
56.4
5.0
78.9
6.0
56.4
6.0
56.4
7.0
39
10
25
5.0
78.9
7.0
39
5.0
78.9
6.0
56.4
6.0
56.4
7.0
39
60
25
5.0
78.9
9.0
19.6
5.5
67.5
8.5
23.1
6.0
56.4
8.0
27.4
135
25
6.0
56.4
9.0
19.6
6.5
41.5
9.0
19.6
7.0
39
9.0
19.6
300
25
6.0
56.4
9.0
19.6
7.0
39
10.0
14.4
7.5
32.7
9.5
16.8
[0039]
TABLE 2C
Substrate: SKIN ON ARM Average Base Diameter of Drop (mm) & Contact Angle (degrees)
49.75%
50%
Propylene
Propylene
Glycol,
Propylene
Lapse
Drop
Glycol,
49.75% glycerin,
Glycerin,
Propylene
Glycol,
time
Vol.
50% glycerin
0.5% PS20
Glycerin
0.5% PS20
Glycol
0.5% PS20
(mins)
(μL)
mm
deg
mm
deg
mm
deg
mm
deg
mm
deg
mm
deg
1
25
6.0
56.4
6.5
41.5
5.0
78.9
6.0
56.4
7.0
39
7.0
39
5
25
7.5
32.7
10.5
12.5
5.5
41.5
8.0
27.4
8.0
27.4
8.0
27.4
[0040] The contact angle measured by this spreading drop measurement compares well with the Kruss Contact Angle measurement as shown in Table 2D below. Skin tests could not be successfully conducted using the Kruss contact angle meter since the applied drop spreads too rapidly.
TABLE 2D Substrate CONDOM LATEX FILM Contact Angle (degrees) 49.75% Propylene Glycol, 50% Propylene Glycol, 49.75% glycerin, Lapsed time 50% glycerin 0.5% PS20 Glycerin (mins) (deg) (deg) (deg) 1 85.06 57.45 84.86 5 88.14 50.75 82.9 10 86.26 48.48 79.25
[0041] The surface tensions of the warming lubricants were measured and are shown below in Table 2E.
TABLE 2E Surface Tension (N/m) 49.75% Propylene Glycol Propylene 50% Propylene Glycol, 49.75% glycerin, Glycerin, Propylene Glycol, 50% glycerin 0.5% PS20 Glycerin 0.5% PS20 Glycol 0.5% PS20 (N/m) (N/m) (N/m) (N/m) (N/m) (N/m) 0.046 0.037 0.067 0.036 0.0385 0.03825
[0042] It is, therefore, very clear that adding 0.5% of polysorbate 20 increases the spread diameter of the lubricant, and decreases contact angle and surface tension in all cases. The combination of appropriate lubricant viscosity and lubricant spreading capability generates an effective warming lubricant as demonstrated by the warming lubricant composition having 49.75% propylene glycol, 49.75% glycerin, and 0.5% polysorbate 20.
[0043] Even though this specific composition is shown in Tables 2A-C, the propylene glycol can be in the range of 40% to 60%, glycerin can be in the range of 40 to 60%, and polysorbate 20 or other non-ionic surfactant can be in the range of 0.1 to 3%. The viscosity of glycerin propylene glycol is relatively stable in this compositional range, and polysorbate 20 and other non-ionic surfactants are effective in improving the contact angle.
[0044] The warming lubricant can be used as a skin lubricant wherein a small drop [VOLUME] of the warming lubricant is applied over skin and rubbed. Any skin-generated moisture quickly produces a warming effect as the warming lubricant combines with moisture. The warming lubricant is highly spreadable and produces a soothing effect.
[0045] The spreadable warming lubricant can be applied to a condom latex surface. Due to its enhanced spreading character, the warming lubricant spreads over the internal and external surface of the condom latex. The utility of a lubricated condom is related to distribution of the lubricating agent on the condom surface, since this lubrication is what prevents irritation. Any lubricant that does not spread well has bare spots, where latex condom surface rubs directly on skin and creates increased friction, stickiness and irritation. In order to quantify this effect, a small amount of spreadable warming lubricant was applied on the external surface of a condom, and the spreading of the warming lubricant was measured. The results are shown below in Table 2F.
TABLE 2F Migration Up Condom Shaft (weeks) Time 1 2 3 1 2 3 week weeks weeks week weeks weeks Propylene 0 0 0 50 50 50 glycol % Glycerin % 100 100 100 50 50 50 Migration up 5 4.5 5.7 13.3 18.5 18.5 condom shaft after 1, 2, 3 wks (cm)* Migration up 15 15.5 16.8 16.8 17.5 17 condom shaft with 0.5% Polysorbate 20 after 1, 2, 3 wks (cm)
[0046] The 50%-50% mixture of glycerin and propylene glycol had a higher migration distance up the condom shaft as compared to pure glycerin. When polysorbate 20 was added to the lubricant, both glycerin and the 50%-50% mixture of glycerin and propylene glycol showed improvement in the migration distance of the lubricant up the condom shaft, particularly within one week.
[0047] The mode of application of the spreadable warming lubricant in condoms includes dropping a measured quantity of warming lubricant consistent with the skin-generated moisture. Since the skin-generated moisture is generally in the range of 0.2 to 5 ml, the quantity of the warming lubricant desirably is less than 5 ml. This small quantity of the warming lubricant has to be spread all over the internal and external surface of the condom latex to provide effective lubrication and warming effect. During packaging of a condom, the measured quantity of lubricant is added, and the spreading effect is relied on to disperse the lubricant across the internal and external surfaces of the condom.
[0048] When the spreadable warming lubricant is used as skin lubricant, the lubricant is applied to the skin in an amount that approximates the available skin moisture. Optionally, moisture can be added to the skin prior to the application of the spreadable warming lubricant. The reaction between moisture and spreadable warming lubricant results in the release of heat, thereby creating a warming sensation. The spreadability of the warming lubricant is essential for this warming effect, since the quantity of moisture available on skin is generally small and the quantity of spreadable warming lubricant applied desirably is matched with this quantity of available moisture so as to optimize the warming effect. In the absence of spreadability, the warming lubricant would be concentrated in the area of initial application to the skin and the desired effects of lubrication and warmth would not be optimized. The combination of suitable viscosity, low surface tension and contact angle with respect to human skin results in spreading of the warming lubricant on the skin so as to provide an optimal, soothing warming effect.
[0049] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0050] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0051] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention. | A substantially anhydrous, spreadable warming lubricant composition comprising a mixture of glycerin, a polyhydric alcohol, and a non-ionic surfactant, the viscosity of the composition being less than that of glycerin but greater than that of the polyhydric alcohol, thereby promoting formation of a useful thin layer on a surface with which the composition is brought into contact, the surfactant improving wetting and spreadability of the composition on skin and latex, such that the composition can be applied to skin or a condom and provide an optimal warming effect upon contact with ambient moisture during use and such that the composition can be added to a condom package and, over the course of about a week, spread and coat nearly the entire internal and external surfaces of the condom. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a mounting bracket and, more particularly, to an adjustable bracket for mounting an automotive component.
[0003] 2. Description of Related Art
[0004] Traditionally, brackets have been used to attach automotive components to vehicles and to substantially restrain movement of such components. For example, an automotive component such as a radiator can be fixed in place with a bracket. To install the bracket, one portion of the bracket is attached to the vehicle and another portion of the bracket is attached to the automotive component. Attachment of the bracket to the vehicle is typically accomplished using standard fasteners (e.g., bolts, screws, rivets). Similarly, the bracket can be attached to the automotive component using a standard fastener such as a bolt and/or a special tool.
[0005] One disadvantage of a conventional bracket is that such a bracket typically has a preformed shape and is designed to be installed at a predetermined location in the vehicle. Accordingly, a conventional bracket can only be used to secure an automotive component having dimensions that correspond to the shape and predetermined placement of the bracket. As a result, the conventional bracket is unable to accommodate components of varying size or components that deviate from specified dimensional tolerances. Moreover, conventional brackets are attached to automotive components using standard fasteners and/or special tools, which increases the manufacturing cost and assembly time because extra parts must be purchased and utilized on the assembly line.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention relates to a bracket for securing a vehicle component. The bracket includes a stationary member configured to be attached to a vehicle and a movable member slideably mounted on the stationary member. The movable member is configured to move from a first position to a second position to thereby secure the vehicle component.
[0007] Another aspect of the present invention relates to a bracket. The bracket includes a support member for attachment to a vehicle body and a clamping member mounted on the support member. The clamping member is slideably adjustable so that the clamping member can be adjusted to secure vehicle components of various sizes.
[0008] Another aspect of the present invention relates to a method for securing a vehicle component in place. The method includes providing a bracket that includes a stationary member and a moveable member slideably mounted on the stationary member; attaching the stationary member to a vehicle body in the vicinity of a vehicle component; moving the moveable member toward the vehicle component; discontinuing moving the moveable member when it contacts the vehicle component; and either automatically during the movement or subsequent to the movement, engaging a latching mechanism to substantially restrain movement of the vehicle component.
[0009] Another aspect of the present invention relates to a vehicle. The vehicle includes a module containing at least a radiator and a bracket including a stationary member configured to be attached to a vehicle and a movable member slideably mounted on the stationary member. The movable member is configured to move from a first position to a second position to thereby secure the module in place.
[0010] Yet another aspect of the present invention relates to a method for installing an automotive component in a vehicle. The method includes providing a module containing at least a radiator; installing the module in the vehicle; providing a bracket that includes a stationary member and a moveable member slideably mounted on the stationary member; attaching the stationary member to the vehicle so that the moveable member is positioned above a top surface of the module; moving the moveable member toward the top surface of the module until the moveable member contacts the top surface of the module; and activating a latching mechanism, either during the movement or subsequent to the movement, to retain the moveable member in contact with the top surface of the module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the description, serve to explain principles of the invention.
[0012] FIG. 1 a is a perspective view of a first embodiment of a bracket according to the present invention.
[0013] FIG. 1 b is a perspective view of a second embodiment of a bracket according to the present invention.
[0014] FIG. 2 a is a perspective view of the bracket of FIG. 1 a in an uninstalled position.
[0015] FIG. 2 b is a perspective view of the bracket of FIG. 1 b in an uninstalled position.
[0016] FIG. 3 a is a perspective view of the bracket of FIG. 1 a in an installed position.
[0017] FIG. 3 b is a perspective view of the bracket of FIG. 1 b in an installed position.
[0018] FIG. 4 is a side elevation view of the bracket of FIG. 1 b.
[0019] FIG. 5 a is a top plan view of the bracket of FIG. 1 a.
[0020] FIG. 5 b is a top plan view of the bracket of FIG. 1 b.
[0021] FIGS. 6 a to 6 c are detailed drawings showing details of the brackets of FIGS. 1 a and 1 b.
[0022] FIGS. 7 a and 7 b are drawings showing details of the stationary member of the bracket of FIGS. 1 a and 1 b.
[0023] FIG. 8 a is a top view and FIG. 8 b is a perspective view showing details of the movable portion of the bracket of FIG. 1 a and FIG. 1 b.
[0024] FIG. 9 a is a perspective view and FIG. 9 b is a cross-sectional view showing an isolator member of the bracket of FIG. 1 a and FIG. 1 b.
[0025] FIG. 10 is an exploded view of the bracket shown in FIG. 1 b.
[0026] FIG. 11 is a front view of a preferred, optional locking member, and FIGS. 11 a and 11 b are cross-sectional views taken along the lines A-A and B-B, respectively.
[0027] FIG. 12 is a perspective view of an optional insert member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] Reference will now be made in detail to presently preferred embodiments of the invention, an example of each being illustrated in the accompanying drawings. An effort has been made to use the same reference numbers throughout the drawings to refer to the same or like parts.
[0029] FIGS. 1 a , 2 a , 3 a and 5 a show a first embodiment of a bracket 10 according to the present invention. FIGS. 1 b through 5 b show a second embodiment according to the invention. The bracket 10 is configured to secure an automotive (or vehicle) component 100 in position when the automotive component 100 is installed in a vehicle. As shown in FIGS. 1-3 , the bracket 10 includes a stationary member 20 , a moveable member 30 , and a latch mechanism 40 . The second embodiment, shown in FIG. 1 b , differs from the first embodiment mainly by virtue of employing a separate locking member 60 to selectively engage the latch mechanism.
[0030] The stationary (or support) member 20 supports the moveable member 30 and is configured to be attached to a vehicle structure such as a vehicle frame or body. As shown in FIGS. 1 and 2 , the stationary member 20 includes fastening members 22 a and 22 b for attaching the stationary member 20 to the vehicle structure. The fastening members 22 a and 22 b preferably include holes 22 c and 22 d , respectively, so that the fastening members 22 a and 22 b can be connected to the vehicle structure using standard fasteners such as bolts, screws, or rivets. Alternatively, the fastening members 22 a and 22 b can be attached to the structure by welding or bonding.
[0031] As shown in FIGS. 7 and 8 , the stationary member 20 includes a mounting interface 24 that is configured to engage a corresponding mounting interface 34 on the moveable member 30 so that the moveable member 30 is supported on the stationary member 20 . For example, the mounting interface 24 of the stationary member 20 may include a first guide rail 24 a and a second guide rail 24 b (shown in FIG. 7 ). Similarly, the mounting interface 34 of the moveable member 30 may include a first jaw 34 a and a second jaw 34 b (shown in FIG. 8 ). As shown in FIGS. 5 and 6 , the moveable member 30 is mounted on the stationary member 20 by inserting the guide rails 24 a , 24 b into the jaws 34 a , 34 b , respectively. In this manner, the stationary member 20 supports the moveable member 30 .
[0032] The moveable (or clamping) member 30 is mounted on the stationary member 20 so that a position of the moveable member 30 is adjustable relative to the stationary member 20 . For example, the moveable member may be adjustable between a first position (shown in FIG. 2 ) in which the moveable member 30 is not contacting the automotive component 100 (i.e., an uninstalled position) and a second position (shown in FIG. 3 ) in which a contact surface 38 of the moveable member 30 is contacting a top surface 110 of the automotive component 100 (i.e., an installed position). Preferably, the moveable member 30 is slideably mounted on the stationary member 20 so that the moveable member 30 can move from the first position toward the second position. For example, the jaws 34 a , 34 b may be slideable along a length of the guide rails 24 a , 24 b . As a result, a height of the moveable member 30 is adjustable so that the bracket 10 can secure automotive components of various sizes and dimensional tolerances.
[0033] The moveable member 30 is adapted to be actuated from the uninstalled position to the installed position in a simple manner that does not require the use of special tools. For example, the moveable member 30 may be moved from the uninstalled position to the installed position by applying a force to an upper surface 36 of the moveable member 30 so that the moveable member 30 moves toward the automotive component 100 . The force may be applied, for example, by a hand of a person or by a robot or a machine. The degree of force required to actuate the moveable member 30 will vary depending on the design of the bracket 10 and can be readily determined by one of skill in the art. In the case of the first embodiment of FIG. 1 a , the force is typically greater than in the case of the second embodiment of FIG. 1 b , as explained below.
[0034] The bracket 10 includes a latch mechanism 40 that may enable either one-way actuation of the moveable member 30 or two-way actuation of the moveable member 30 . Specifically, the latch mechanism 40 in the first embodiment is configured to allow only one-way movement of the moveable member 30 in a direction toward the automotive component 100 (i.e., in a direction toward the second or installed position) and to prevent movement of the moveable member 30 in a direction away from the automotive component 100 (i.e., in a direction toward the first or uninstalled position). In this case, the latch mechanism 40 is activated automatically as the moveable member 30 moves along the stationary member 20 toward the installed position. For example, the latch mechanism 40 may include an ratchet mechanism 42 that is designed to be automatically engaging. The ratchet mechanism 42 has teeth 42 a (shown in FIG. 7 ) disposed on the stationary member 20 and a projection 42 b (shown in FIG. 8 ) disposed on the moveable member 30 . Each tooth 42 a includes an inclined surface S 1 and a substantially straight surface S 2 . As shown in FIG. 8 , the inclined surfaces S 1 slope toward the installed position so that the projection 42 b slides over an inclined surface S 1 when sufficient force is applied to the upper surface 36 of the moveable member 30 . After traversing an inclined surface of a tooth 42 a or when application of the force is halted, the projection 42 b snaps into a space 42 c between adjacent teeth 42 a and is prevented from moving back toward the uninstalled position by a surface S 2 . In this manner, the latch mechanism 40 allows the moveable member 30 to proceed in only one direction and can retain the moveable member 30 in a particular position. Thus, in one preferred embodiment, the bracket 10 includes an automatic latch mechanism 40 that operates automatically for one-way actuation of the moveable member 30 without the use of additional parts such as fasteners or special tools.
[0035] In the alternative second embodiment, the bracket 10 includes a selectively engageable latch mechanism adapted to be manually locked or activated (e.g., by a person or robot) to secure the moveable member 30 in a desired position. In the second embodiment shown in FIG. 1 b , a separate locking member 60 is provided to selectively engage the latch mechanism 40 in its final latched condition when the moveable member 30 has reached its final position. In this embodiment, the projection 42 b is oriented such that is either does not contact or engage with the ratchet teeth 42 a , or so that it only lightly contacts teeth 42 a . In this way, the moveable member can be moved more easily and optionally can be moved in both directions during mounting of a part or component. Only when the moveable member 30 is positioned in its final location is the locking member 60 inserted and/or fully inserted into the moveable member, in order to bias the projection 42 b into (more) secure engagement with the teeth 42 a . Details of one preferred locking member 60 are shown in FIGS. 11 , 11 a and 11 b.
[0036] Of course, many other types of selectively engageable locking systems are conceivable. For example, other systems for selectively engaging the ratchet mechanism are conceivable. In another example, the selectively engageable locking mechanism could include at least one aperture disposed on the moveable member 30 and a plurality of corresponding apertures disposed on the stationary member 20 . The moveable member 30 could be moved along the stationary member 20 until the aperture on the moveable member 30 aligns with an aperture on the stationary member 20 that is at the desired position. The manual latch mechanism could be activated by inserting a pin through the aligned apertures so that the moveable member 30 is retained relative to the stationary member 20 . When a selectively engageable latch mechanism is employed, the moveable member 30 can be configured for one-way (i.e., one direction) or two-way (i.e., two direction) actuation.
[0037] The latch mechanism 40 may also include a release member for releasing or disengaging the latch mechanism 40 . When the latch mechanism 40 is actuated, the moveable member 30 is released and can be freely moved along the stationary member 20 in either direction (i.e., in a direction toward the installed position and in a direction toward the uninstalled position). As shown in FIG. 5 a , an optional release member 44 may be, for example, a lever configured to allow the projection 42 b to disengage from a space 42 c . In this manner, the bracket 10 can be readjusted after initial installment, e.g., to replace the mounted component. Alternatively, the bracket 10 may be configured for a single use so that readjustment of the bracket 10 is accomplished by breaking the bracket 10 to disengage the latch mechanism 40 and replacing the bracket 10 with a new bracket. In the case of the second embodiment, the locking member 60 can be removed in order to reposition the moveable member 30 .
[0038] The stationary member 20 and the moveable member 30 may be formed of any material suitable for use in a vehicle application. For example, the stationary member 20 and the moveable member 30 may be formed of a polymer, a composite, or a metal. Preferably, however, the stationary member 20 and the moveable member 30 are formed of a nylon plastic.
[0039] As shown, e.g., in FIGS. 1 and 4 , the moveable member 30 preferably includes an isolator member 38 a having a clamping surface 38 . When the moveable member 30 is retained in the installed position by the latch mechanism 40 , the clamping surface 38 preferably contacts a top surface 110 of the automotive component 100 with sufficient force to securely stabilize (or fix) the component 100 in position so that movement of the component 100 is substantially restrained. The degree of force required to stabilize the component 100 depends on the automotive application and can readily be determined by one of skill in the art. Preferably, the clamping surface 38 and the isolator member 38 a are formed of a polymer or rubber material. The material can also be selected so as to reduce the transmission of vibration through the isolator member 38 a , i.e., by having a degree of resilience.
[0040] The moveable member 30 of the bracket 10 may include an aperture 50 that permits access to a portion of the automotive component 100 when the bracket 10 is in the installed position. For example, the top surface 110 of the automotive component 100 may include a connection 150 (e.g., for attaching a hose such as a coolant hose). To permit access to the connection 150 when the bracket 10 is in the installed position, the stationary member 20 is connected to the vehicle structure so that an axis A-A of the aperture 50 of the moveable member 30 substantially aligns with an axis B-B of the connection 150 . Accordingly, when the moveable member 30 is moved into the installed position, the connection 150 is received in the aperture 50 (shown in FIG. 3 ) to enable access to the connection 150 .
[0041] In certain applications for the moveable member having an aperture 50 , it may also be desirable to include an optional insert that lines the aperture 50 . Such an insert is shown in exploded FIG. 10 and also in FIG. 12 . This insert is typically made of a more wear resistant material, such as a hard plastic, metal or composite material, since one reason to include such an insert is to prevent wear of the isolator member 38 a.
[0042] In operation, the bracket 10 may be utilized to secure and stabilize the automotive component 100 in a vehicle. For example, the automotive component 100 (e.g., a module containing at least a radiator) is installed in a vehicle. The stationary member 20 of the bracket 10 is attached to the vehicle so that the moveable member 30 is positioned above the top surface 110 of the automotive component 100 . A force is applied to the upper surface 36 of the moveable member 30 so that the moveable member 30 moves relative to the stationary member 20 toward the top surface 110 of the automotive component 100 . Application of the force is continued at least until the contact surface 38 of the moveable member 30 contacts the top surface 110 of the automotive component 100 . Preferably, application of the force is continued until the contact surface 38 is pressed against the top surface 110 of the component 100 with sufficient force to substantially restrain movement and/or stabilize the component 100 . The latch mechanism 40 is activated (automatically or selectively) to thereby retain the moveable member 30 in contact with the top surface 110 of the automotive component 100 .
[0043] In both the first and second embodiments, the two relatively moveable parts of the bracket can be initially connected to one another, e.g., by having the ratchet mechanism engaged in the first (or one of the initial few) tooth. This minimizes the number of separate parts to be handled during assembly or when supplying the assembly line. In the second embodiment, this initial connection can be either as a result of a partial or a complete insertion of the locking member 60 , and or by providing differently configured teeth near the beginning of the row of teeth. Obviously, the locking member can optionally be removed, if desired, during adjustment of the bracket, but this is not necessary.
[0044] Thus, according to embodiments of the present invention, an adjustable bracket for securing automotive components of varying size and/or dimensional tolerance is provided. The adjustable bracket improves vehicle manufacturability and reduces cost by decreasing the number of parts and the assembly time required to install and secure an automotive component. Although the automotive component 100 shown in FIGS. 2 and 3 is a module that includes a radiator, a condenser, and a fan (i.e., a condenser radiator fan module or CRFM), the present invention is not limited to such modules. Rather, the invention applies to any automotive component that needs to be stabilized and/or securely fixed in place in a vehicle. Such automotive components include, for example, radiators, condensers, batteries, filter housings, coolant overflow reservoirs, fuel tanks, and electronic control modules.
[0045] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only. | The invention relates to a mounting bracket ( 10 ), in particular for mounting a radiator ( 100 ). The bracket ( 10 ) comprises a stationary member ( 20 ) to be attached to the vehicle and a movable member ( 30 ) slideably mounted on the stationary member ( 20 ), preferably using guide rails ( 24 a, 24 b ). The movable member ( 30 ) is configured to move from a first position to a second position to thereby secure the radiator ( 100 ). A ratchet mechanism ( 42 ) including teeth ( 42 a ) on the stationary member ( 10 ) may be provided to lock the movable member ( 30 ). An independent claim is included directed to a method for securing a vehicle component. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] The present invention pertains to a consumer food product container having at least one removable premium that is integral with and separable from the receptacle. More particularly, this application is directed toward an erectable blank of material that may be prepared by producing a subsequently detachable area from the surface of the blank. The area is preferably printed using high color graphics and generally having a resolution greater than about 150 lines per inch. The remainder of the blank may be printed using lower resolution imaging and in one to two colors. The removable area may be used to create various remembrance articles, collection pieces, souvenir items and other pictorial and graphic illustrations that aid in retention of customers and promotion of various products and services.
BACKGROUND OF THE INVENTION
[0003] Printed products, such as pieces that are intended to be used in business communications, can be delivered in a wide variety of formats, constructions and configurations. Normally, one of the most significant limiting factors for a manufacturer being able to produce a particular construction or expand product capabilities is the equipment the manufacturer has on hand to generate such printed pieces.
[0004] There are a number of promotional and premium type consumer give away activities ranging from direct mail offerings to in store promotions to direct consumer package application. Many of these offerings provide some sort of nominal premium by which to engender a consumer to the particular product being offered. Some of these opportunities may require the individual to collect coupons, points and even submit a small remuneration in order to obtain the premium that is offered. Other applications provide for immediate gratification of the consumer at the point of sale location, however such applications also increase the possibility of theft and product damage, particularly if the premium has any real or perceived value to a passerby.
[0005] Consumer food packages, such as ready to eat (RTE) cereals are generally well known and are produced from a blank of paperboard material. Often such RTE packages are provided with premium cradles, portions integrated with the blank of material that are used to carry a toy, CD or other trinket designed to promote purchases of the product. In other instances, such RTE packages may have a toy or other premium deposited within the package itself to prevent the premium from being removed by anyone other than the purchaser of the product.
[0006] In other constructions, RTE packages have also been provided with posters, signs and the like that typically require the user to cut the item from the package, which may in turn destroy the package leaving the contents to spoil in the event the consumable food product contained within the receptacle have not been previously consumed.
[0007] Other consumer food product packages, particularly those that are provided in connection with take out or delivery food service applications have generally not benefited from such promotional opportunities. This may be due to one of several possible reasons, ranging from the type of material that is used in manufacturing the consumable food product to the cost associated with producing a product having a premium connected or otherwise associated with the food container.
[0008] In the former situation, corrugated cardboard is often used to construct pizza type boxes and other similar fast food types. The corrugated material cannot be processed through high resolution imaging equipment due to its thickness and thus some entrepreneurial individuals have begun adhering additional materials to the surface of the container in order to create some marketing and advertising activity.
[0009] In addition, as in the case of a pizza delivery box, the food contents more often than not will contact with the container causing spoiling of the container as grease or other food products or derivatives may contaminate the corrugated material, thus disincenting the supplier of such products from wanting to spend more money on the container.
[0010] Moreover, most fast food and convenience food containers, such as a pizza box, are normally obtained by consumers in a hurry largely due to societal trends that have limited the amount of time an individual or family may have in order to engage in meal time activity. In such a situation, the consumer simply cares more about the contents of the container rather than the package of the container itself. Most such containers are printed typically using one or two colors of ink at a relatively low image quality resolution. The printing generally may depict the name of the establishment, phone number and perhaps a less than accurate image of the food product contained in the package.
[0011] Convenience food providers have for many years attached advertising sheets externally to the food package container. Such sheets often provided coupons toward future purchases, announced special food product offers and limited time availability of certain specialty food products. While some of these sheets have been printed using high color graphics, the sheets are commonly overlooked by consumers as unneeded collateral material. In addition, such sheets may be difficult to remove as the adhesive permanently secures a portion of the sheet to the carton or alternatively, the adhesive is applied in a hap-hazard fashion making removal of the sheet difficult and often resulting in tearing of the sheet.
[0012] In addition to the foregoing drawbacks, many small to medium sized establishments that may offer delivery or take out type services to their clientele will often purchase generic food containers and receptacles from a food service company. This is largely due to the cost associated with obtaining a small production run of personalized food packages for these businesses as the volume of packages required is simply not large enough to obtain a quality product at a reasonable price.
[0013] Flexography is one exemplary conventional technology that is commonly used today for the printing of decorative items, because of the ability to print multiple colors. Flexographic technology is commonly used in the rendering of packaging, marketing communications and normally will utilize a series of plates and one or more stations, containing inks; to apply colored images to the web as the web traverses the press. Through improvements in ink qualities and other modifications and enhancements in the technology, the image quality in flexographic presses and resulting products has improved to about 150 lines per inch.
[0014] Typically, for a point of reference, screens that have rulings of about 60 to 100 lines per inch are normally used to make halftone printed images for newspapers. Screens with about 120 to 150 lines per inch are commonly used today to produce images for magazines and commercial printing. Such screens are regularly produced by electronic dot generation.
[0015] Electronic dot generation is normally performed by computers that use unique screening algorithms in cooperation with electronic scanners and image setters to produce halftone images that are to be subsequently used to render an image. The pixels of digitized images are first assembled into dots that are then used to form shapes, sizes, rulings, etc. which create the ultimate image produced on the substrate.
[0016] While such conventional technology such as flexography is desirable for use in such printing due to the economies that can be achieved when compared with other types of printing processes, such as lithography, there are a number of drawbacks in utilizing this process for certain applications. Initially, the quality is limited, despite improvements in the technology to about 150 lines per inch. This can make some complicated graphics appear “grainy”. Other images such as those that use flesh tones or deep or rich colors, may look faded or “washed out”. The effects of this level of image resolution can detract from the product appearance which may diminish the value of the technology and the products produced particularly for the prime label market. With increasing sophistication of consumers, as well as technology and expectations from each, such effects may be undesirable to potential end users.
[0017] Thus, there is a need for a corrugated consumer convenient food package for fast food and delivery applications that provides the outlet with an aesthetically pleasing package and which can be used in the promotion of products and services for small to medium sized business applications and one which will provide a removable premium that increases customer retention and repeat consumer businesses for such establishments.
BRIEF SUMMARY OF THE INVENTION
[0018] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0019] Surprisingly it has been found that there is a demand for convenience or fast food delivery packages having one or more removable premiums to distinguish a product offering from more generic packages that have customarily been used in connection with servicing the food delivery industry.
[0020] The present invention relates to a unique, convenient food delivery package that can be produced with a removable premium that is created through printing at a relatively high resolution, one greater than about 150 lines per inch. The removable premium is intended to be part of a collector series or to provide other memorabilia to drive customer retention and acquisition. The package is preferably constructed from a corrugated material and may be provided with protective material on one face that is opposite the face or surface used in connection with the premium.
[0021] In one exemplary embodiment of the presently described invention, a corrugated consumer convenient food package, is presented and includes a substantially planar blank constructed preferably from corrugated material. The blank has first and second panels with each blank having first and second longitudinally extending sides and first and second transversely extending edges. Each of the panels has first, second and third peripherally extending wings hingedly connected to each of the panels about the first and second longitudinally extending sides and the first transversely extending edge. The panels are joined to one another by a hinged spine connected to each of the panels along the second transversely extending edges.
[0022] Each of the panels has first and second faces directly opposed to one another with the second face of the first panel overlying the second face of the second panel when the blank is folded about the spine.
[0023] A central portion is provided in the first face of the first panel and is defined by a line of weakness that extends about a periphery of the central portion. The central portion is printed with graphics that has a resolution of greater than about 150 lines per inch. The graphics along with a portion of the package create at least a first removable premium that is used for consumer retention and the graphics do not include discounts or coupons.
[0024] The shape created by the line of weakness and defining the removable premium may be selected from any suitable configuration including geometric, animate, inanimate, and alpha and numeric characters.
[0025] A protective material may also be provided in connection with the construction of the present invention. The protective material is preferably used to prevent contamination of the carton or package by the food product, such as oil or grease that may be present with the particular food product. The protective material is selected from a group that includes coatings, such as wax and other barriers, synthetic films, metal foils, cellulosic based materials like wax paper or parchment paper and the like.
[0026] The carton or package may also be provided with a second removable premium which may for example be used on the second panel first face so that additional pieces may be provided in connection with a collection series or alternatively a wholly distinct collection series.
[0027] In a still further exemplary embodiment, a convenience food package having at least one removable premium is presented and includes a first substantially planar panel that has first and second longitudinally extending sides, first and second transversely extending edges and first and second faces. Each of the longitudinally extending sides has a hinged flap that extends outwardly from the sides and runs substantially along each of the longitudinally extending sides. The first panel has a hinged flap that extends outwardly from the first transversely extending side and runs substantially along the transversely extending edge.
[0028] A second substantially planar panel that has first and second longitudinally extending sides, first and second transversely extending edges and first and second faces. Each of the longitudinally extending sides has a hinged flap that extends outwardly from the sides and runs substantially along each of the longitudinally extending sides. The second panel has a hinged flap that extends outwardly from the first transversely extending side and runs substantially along the transversely extending edge.
[0029] A third planar panel is provided and is substantially smaller than each of the first and second panels. The third panel has first and second faces, first and second longitudinally extending sides and first and second transversely extending edges.
[0030] The first panel is connected to the third panel along the first transversely extending edge and the second panel is connected to the third panel along the second transversely extending edge.
[0031] At least one removable premium area is provided on the first face of the first panel. The removable premium area is defined by lines of weakness that extend completely about the removable premium area and create a periphery. The removable premium area is printed with graphics depicting a collectable image with a resolution of greater than 150 lines per inch.
[0032] In a yet still further exemplary embodiment of the present invention, a food delivery carton having a detachable printed premium is presented and includes a blank of substantially planar corrugated material. The blank has first and second substantially quadrate panels and each of the panels having first, second, third and four edges. The panels each have first and second faces and the panels are connected to one another along one of the edges of each panel.
[0033] A printed collection piece provided as part of a continuing collection series and is printed on the first panel first face and is surrounded by a line of weakness that defines a periphery of the collection piece. The collection piece is produced with a resolution of greater than about 150 lines per inch.
[0034] A protective material is disposed on the first panel second face and positioned so as to be substantially directly opposed to the collection piece on the first panel first face.
[0035] The removable premium that is provided in connection with the food delivery package will preferably consume more than fifty percent of the available printed area of the face or surface of the panel on which it is printed. It should however be understood that the collection piece may occupy all of the available printable space or a much smaller portion. In addition, the premium may include a single element or may have several elements, such as for example collectors cars provided in the area of the premium.
[0036] These and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:
[0038] FIG. 1 depicts a front view of the food convenience package of the present invention showing removable premiums;
[0039] FIG. 2 provides a rear view of the food convenience package of the present invention illustrating the protective material used in preventing contamination of the premium from the contents; and
[0040] FIG. 3 presents a front view of convenience food package that has been assembled or erected for delivery to a consumer in connection with an order or request for a particular food product.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present invention is now illustrated in greater detail by way of the following detailed description which represents the best presently known mode of carrying out the invention. However, it should be understood that this description is not to be used to limit the present invention, but rather, is provided for the purpose of illustrating the general features of the invention.
[0042] The term “food grade” sheet or material as used herein refers to sheets of material that may be used in direct contact with consumable food products such as parchment paper, aluminum foils, wax paper, wax coatings, synthetic films, metal foils and other materials.
[0043] Consumer or convenient food packages as used herein include delivery and take out packages, such as pizza delivery boxes, cartons and the like which are preferably constructed from corrugated materials and may be erected from a substantially planar blank of material to form a food container for consumer use.
[0044] The term “premium” as used herein includes a portion of the food package or carton this is printed with significantly higher resolution and image quality than any surrounding printing and is intended to be of such quality that a consumer would like to retain the item after removal from the panel or surface to which it is printed. The premium of the present invention is preferably part of a series that encourages collections of multiple premiums that are delivered in successive time periods or may be obtained in a random configuration in order to promote customer retention and acquisition. In addition, the premium may be provided with personalized indicia such as the name of the customer or particular specifics relating to the individual premium as well as static printing indicia such as the name of the establishment offering the premium.
[0045] The term “personalized information” refers to information that is printed or imaged onto a substrate or document which is generally variable or unique and which may change from document to document or segment to segment so as to create a customized message or communication for each recipient. Examples of personalized information may include names, addresses, descriptions, plans, coding, numbering, promotional text, etc. that may have been acquired from the intended recipient through surveys, questionnaires or answers given to various inquiries generated in response to a request for goods or services.
[0046] The term “static or fixed” information refers to printed or imaged information that generally does not change from document to document or segment to segment and may include a general description or body of information about particular products, services, places, etc. that may be of interest to the intended recipient and represents a standard message that the manufacturing or supplier wishes to convey to an end user or customer of the offering.
[0047] The shape created by the line of weakness and defining the removable premium may be selected from any suitable configuration including geometric, animate, inanimate, and alpha and numeric characters. For example, in connection with a racing promotion, the periphery created by the lines of weakness may include an outline of a stock car or other racing vehicle. Other shapes provided in connection with promotions may resemble animals, such as a promotion promoting the preservation of wildlife, or may be other inanimate objects such as famous castles of the world. The shape may also be generally quadrate, round, triangular or square so that pictures of scenery, people, events and the like may be created.
[0048] Examples of image generating or high quality printing devices that are suitable for use in practicing the invention include high resolution imaging devices such as Indigo®, available from Hewlett Packard of Palo Alto, Calif. or Karat available from KBA of Williston, Vt. Ideally, the present invention seeks to provide a segment or intermediate with a series of segments that has a quality of about 150 or more lines per inch and preferably more than 300 lines per inch, which is approximately equal to about 2500 to 3500 dots per inch (“DPI”) in order to create a high quality image that is intended to be aesthetically appealing to the consumer.
[0049] Reference is now directed to FIG. 1 of the present invention in which a convenience food delivery package is generally referenced by numeral 10 . The package is preferably constructed of a corrugated material but other materials are of course suitable for the practice of the present invention including paper board and other relatively thick cellulosic based board stock.
[0050] The package 10 has a first panel 8 that is substantially planar. The first panel 8 includes first and second longitudinally extending sides 12 and 14 and first and second transversely extending edges 16 and 18 . Each of the longitudinally extending sides 12 and 14 have flaps 20 and 22 extending peripherally outwardly from the sides and the first transversely extending edge 16 has a further flap 24 that extends peripherally outwardly from the edge. The flaps 20 , 22 and 24 are hingedly connected to each of the respective sides or edges by a score in the corrugated material that allows the flaps 20 , 22 and 24 to be folded upwardly or downwardly, depending on the construction being produced, about the periphery so as to form short walls when the blank is erected into the food package.
[0051] The first panel 8 also includes a central area 11 that is printed with a high resolution image, in this example a racing car. The central area 11 that will form the premium is surrounded by a line of weakness 13 that defines the periphery of the removable premium. As shown in FIG. 1 , the line of weakness 13 generally follows the contours of the shape of the printed premium. The premium in the central area 11 will preferably be printed with a resolution of greater than about 150 lines per inch and more preferably at about 300 lines per inch.
[0052] The panel 8 may also be printed with other indicia 15 which may show the origin of the carton or package 10 as well as other suitable or related graphics. Typically, this additional printing 15 will be provided in a much lower resolution and often in only a single color.
[0053] A spine or third panel 26 is connected to the first panel 8 . The panel 26 has first and second longitudinally extending sides 25 and 29 and first and second transversely extending edges 27 and 28 . The panel 26 is hingedly connected to the first panel 8 along a first transversely extending edge 27 . That is, due to a score in the material forming the blank 10 , the panel 26 can be folded upwardly or downwardly to form a back wall for the contents of the container. As can be seen from FIG. 1 , panel 26 is substantially smaller than either panel 8 or 30 and is roughly equivalent in size to the flaps surrounding the periphery of the blank.
[0054] The blank 10 is provided with a second panel 30 which includes first and second longitudinally extending sides 32 and 34 and first and second transversely extending edges 36 and 38 . Each of the longitudinally extending sides 32 and 34 have flaps 40 and 42 extending peripherally outwardly from the sides and the first transversely extending edge 36 has a further flap 44 that extends peripherally outwardly from the edge. The flaps 40 , 42 and 44 are hingedly connected to each of the respective sides or edges by a score in the corrugated material that allows the flaps 40 , 42 and 44 to be folded upwardly or downwardly, depending on the construction being produced, about the periphery so as to form short walls when the blank is erected into the food package.
[0055] The second panel 30 also includes a central area 31 that is printed with a high resolution image, in this example a substantially quadrate area depicting a castle. The central area 31 that will form the premium is surrounded by a line of weakness 33 that defines the periphery of the removable premium. As shown in FIG. 1 , the line of weakness 33 generally follows the contours of the shape of the printed premium, a geometric square. The premium in the central area 31 will preferably be printed with a resolution of greater than about 150 lines per inch and more preferably at about 300 lines per inch.
[0056] The panel 30 may also be printed with other indicia 35 which may be personalized indicia and 37 which may be static printing. The printing may be used to indicate the number of collectible pieces in a series. Typically, this additional printing 37 will be provided in a much lower resolution and often in only a single color.
[0057] Attention is now directed to FIG. 2 of the presently described invention which provides the reverse side of FIG. 1 of the blank 10 . The first panel second face 50 has been provided with a protective coating 52 which for convenience is shown as covering substantially all of the second face 50 . The protective coating 52 will preferably be a food grade material that is suitable for direct food contact. In addition, the material will also preferably be impervious to grease, oil, moisture and other potential contaminates that may spoil the premium that has been printed on the first face as described in connection with FIG. 1 . The area occupied by the premium, or the outline of the premium is shown in FIG. 2 and is represented by the lines of weakness 54 that extend all the way through the corrugated material that makes up the blank 10 .
[0058] The second panel second face 56 is also shown in FIG. 2 as having been provided with a protective material 58 again which covers substantially all of the interior of the face of the second face 56 . The area occupied by the premium that has been printed on the reverse side is represented by numeral 60 .
[0059] It should be understood that the protective material may only be applied to one face of one panel in the event only one premium is provided and the material may also only be provided in the area that the premium occupies on the reverse side. Quadrate areas of the protective coating have been drawn for convenience only. In the even that the protective material is coated onto the surfaces 50 and/or 56 , such as may be the case of a wax based coating, upon removal of the premium, which is accomplished by tearing, punching or cutting along the lines of weakness the consumer may simply wipe off any moisture, grease or oil that may have accumulated on the surface as the wax based coating will be impermeable to such substances so as to protect the image from being contaminated.
[0060] Alternatively, a sheet of metal foil, parchment paper, wax paper may either be adhered or placed over the face of the panels so as to protect the premium from contamination. In such instances, the sheet is then simply removed from the panel and discarded allowing the consumer to utilize the premium that has been provided.
[0061] FIG. 3 of the presently described embodiment shows a erected convenience food package and is referenced by numeral 70 . The first face of the first panel 72 is provided with a printed premium 74 , again using the race car example from FIG. 1 , and a line of weakness 76 extending about the periphery of the premium 74 to allow for removal of the premium from the carton 70 . The carton 70 , first face 72 may also be provided with indicia related to the premium offering designated by 78 and more generic or static indicia 80 relating to the type of product or showing origin of the food product. In addition, the carton 70 may be printed with personalized indicia directly on the surface 72 of the carton 70 which relates to the specifics of an order, such as a phone number and delivery address as shown in FIG. 3 .
[0062] Through use of the present invention one or more premiums may be printed and provided to aid in customer retention or acquisition. The premiums may be readily removed and accumulated by a consumer and the collection used and enjoyed by the consumer as opposed to simply discarding the entire convenience food package. The present invention, thus allows food delivery applications the opportunity to enhance the ordering experience and to potentially enhance the appearance of the product in front of the customer.
[0063] It will thus be seen according to the present invention a highly advantageous consumer convenient food package having at least one removable high quality printed premium has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, and that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.
[0064] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as it pertains to any apparatus, system, method or article not materially departing from but outside the literal scope of the invention as set out in the following claims. | A convenience fast food package is provided with at least one removable printed premium that is rendered through the use of high resolution imaging equipment on a central area or portion of the package. The premium is defined in one face of a panel of the package through the use of lines of weakness that allow the premium to be readily removed and utilized by a consumer. The food package of the present invention is produced in accordance with a customer retention and development program. | 1 |
FIELD OF THE INVENTION
The present invention generally relates to subsea multiphase pumping systems and related equipment, for instance, as employed in the petroleum industry. More particularly, the present invention relates to twin-screw and/or positive displacement pumps in the contents just mentioned.
BACKGROUND OF THE INVENTION
As generally known, a subsea multiphase pump, particularly as employed in marine-based oil fields, is typically configured for pumping a combination of petroleum, water, natural gas, and, at times, small particulates (such as sand). Typically, a “pump suction flow,” in the form of a fluid mixture of liquid, gas and solids, travels through the production flow line to the multiphase pump. The pump thus actually pumps a combination of pump suction flow along with any recirculated liquid from the pump discharge.
Twin-screw multiphase pumps have been demonstrated to work admirably in petroleum applications. However, such pumps require a minimum of liquid in the multiphase mixture to maintain a seal between the screw flanks and the screw tips and casing, which requires careful attention in the detailed systems design.
In multiphase service, when this liquid minimum is not present, the pump ceases to pump but still continues to rotate, thus defeating the purpose of the installation. In a subsea installation, the cost of the pumping system is high enough that the loss of production with no boost represents a substantial loss of revenue.
Additionally, when the pump ceases to produce flow against a pressurized discharge line, the liquid in the discharge tends to leak back into the pump. This heated liquid is continuously “regurgitated”, maintaining pump head but not generating any pump flow. The power used to compress gas, which also is regurgitated to the pump suction, will heat the liquid phase and the pump rotors. The heat will remain in the absence of a mass flow, and the pump can thus be damaged if it is not shut down.
In oil fields in particular, there is generally some uncertainty about the size of gas “slugs” that naturally occur in the flowing multiphase oil and gas mixture. Loss of liquid for short periods of time (e.g., fractions of a second) is sufficient to cause the pump to cease pumping even though it continues to run. The transport time for a fluid element, between entering the pump screw entrances and exiting the pump is typically 5-8 revolutions, or typically 0.16-0.27 second for a pump operating at 1800 rpm).
A “GLCC”, or Gas Liquid Cylindrical Cyclone, provides an arrangement for separating gas and liquid from a multiphase mixture. This technology utilizes a vessel with a tangential inlet to form a vortex. Separation of the multiphase fluid occurs due to centrifugal, gravitational and buoyancy forces. Known arrangements abound (see, e.g., U.S. Pat. No. 5,526,684 to Chevron). Typically, a GLCC will be interposed between a pump and an outlet line.
A common approach to ensuring continuous liquid flow, when this is not the norm in an oil field flow line, is to employ recirculation. In recirculation, liquid is separated in the discharge of the pump and some portion of it, e.g. ˜5% of the pump's full volumetric flow regardless of speed, is throttled back to the pump suction. This same liquid can be reseparated at the pump discharge, while the pump can continue to pump and compress an incoming single-phase gas slug indefinitely.
Any recirculation, of course, detracts from pump efficiency in that the liquid recirculated reduces the capacity of the pump, and volumetric efficiency is thus reduced. Additionally, work is required to pump the recirculated fluid back to the discharge pressure condition. In effect, the need for recirculation normally presents a requirement for more energy and a larger pump to do a particular job.
Gas that is entrained with the recirculation liquid is even worse for pump performance. The gas expands upon exiting the recirculation-throttling device, and as a result reduces the volume of suction flow by a factor corresponding to the pressure ratio times its volume at discharge pressure. In effect, 1 cu. ft of gas that is carried under with the liquid phase, and which is recirculated can become 5-6 cu. ft at suction conditions, depending on the pressure ratio across the pump. Additionally, compressive work has to be performed on this gas to recompress it to discharge conditions. Consequently, a need exists to provide good efficiency in limiting free gas (vs. gas in solution) from the liquid being recirculated.
However, several provisions typically need to be addressed. For one, recirculated liquid is typically heated by the compression of the gas during multiphase operation and therefore increases the pump suction temperature. In the event that the only incoming fluid is gas, then sufficient mass flow to remove the heat will not be present and the recirculated liquid will heat up. If liquid does not reach the pump, this heating process goes forward continuously until the pump is damaged or automatically shut down based on the discharge temperature.
Additionally, the discharge separation presents an efficiency in separating the liquid from the gas. For instance, in a GLCC, liquid that is entrained with the gas flow goes out of a GLCC at the recombination point and is lost out the discharge flow line; this is known as liquid carryover. A separator with good efficiency minimizes this loss of liquid. The larger the volume of liquid that can be retained in the recirculation vessel (or vessels attached to the recirculation vessel), the longer the system can stay in operation without running out of liquid or overheating.
Further, since the liquid phase carries the particulates (typically sand and rust), if sufficient velocity of the liquid is not maintained through the separator then these particulates tend to settle out of the liquid and accumulate. Once they have sufficiently accumulated, they can be recirculated in higher concentrations through the pump either as a result of transients (stop-starts) or of just having the natural accumulation collapse into the recirculation line. Typical topside systems have cleanout ports to keep this from happening, but this is undesirable for subsea systems where intervention is limited or difficult. Accordingly, subsea systems typically need to employ liquid velocities high enough to keep particulates in suspension during all times of normal operation.
In view of the foregoing, a compelling need has been recognized in connection with resolving the issues framed above with regard to pump recirculation.
From another standpoint, naturally occurring flow in a multiphase pipeline produces a variety of flow profiles, such as annular, wave and “slug” flow profiles. Slug flow, for its part, is represented by alternating volumes of gas and oil. For a given line size, gas volume, liquid density, liquid viscosity and pressure, these slugs tend to present a recurring pattern and accordingly form waves with a natural frequency and a shape for the liquid and gas phases. These waves exhibit a variability that can be characterized in frequency with a mean and standard deviation (although these properties are rarely known explicitly).
If the production pipeline or local pump connections experience abrupt changes in elevation, however, the wave variability can change adversely such that the liquid slugs will resemble a periodic square wave with little liquid in the leading and trailing edges of each slug. In this and other cases, slugs can thus end up presenting fluid to the pump as only a gas phase, or at least as a gas phase with a liquid content lower than the minimum required to provide a seal.
Consequently, if such gas-dominated slugs are long in duration (at least long enough for a slug to pass through the pump, or likely fractions of a second) then the pump will lose “prime”. Because the pumping systems at hand typically run continuously with slug periods in the 2-10 second range, a large population of slugs are normally generated in continuous operation. As a consequence, examples of the entire population of plus or minus 3-sigma slugs are experienced frequently (e.g., daily) and even examples 6-sigma slugs are experienced periodically (e.g., monthly).
As such, failure of the incoming flow to contain a minimum amount of liquid, e.g. ˜5% of the full flow rating of the pump, can result in a loss of prime and, thus, flow stagnation and heat-up issues within the pump as mentioned further above.
A conventional countermeasure involves the provision of temperature sensors and, in that connection, automatic pump shutdown protection. While this indeed proves to be an effective measure for protecting the pump, overall operability and efficiency still remain major issues, since unplanned pump shutdowns will clearly result in upsets to production and processing facilities. Restarting the pump, flow line, and other components, potentially can take several hours and require other resources such as gas lift and MEG (Mono-Ethylene Glycol) injection.
In view of the above problems, strides have indeed been made towards minimizing or eliminating the loss of prime events in twin-screw multiphase pump operation, albeit with less than optimal results. The use of liquid recirculation, as discussed further above, has proven to be effective, while presenting disadvantages. Another approach involves separating the liquid in the suction and metering it into the pump. If the capacity of such a separator is large enough, the pump can end up traversing long periods where the liquid in the incoming fluid satisfies the ˜5% threshold by combining liquid retained in the separator with the incoming fluid stream. In subsea applications however, larger tanks and separate metering pumps can be impractical to implement because of weight constraints and the desire to avoid complexity and increase reliability. A practical suction separator for subsea use can be designed to handle variations in the incoming slug flows, if the design scope is limited to the variation anticipated by the pump capacity and well yield. For situations where there is no correlation to pump capacity and well production, such as start-up or system upsets, the recirculation system has to be used.
Accordingly, in view of the foregoing, yet another compelling need has been recognized in connection with implementing a more efficient and cost-effective solution in connection with liquid slug management and distribution.
SUMMARY OF THE INVENTION
There is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a recirculation system for subsea multiphase pumps, in the context of a GLCC. Preferably included is a baffle plate or analogously functioning device in a recombination vessel of a GLCC.
Additionally, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, an arrangement for providing a continuous minimum liquid flow into pump suction via the use of a tangential inlet into a cylindrical “slug distributor” vessel. Preferably, the vessel further includes a perforated plate, breather tubes, a standpipe and metering holes at the bottom of the vessel to deliver liquid flow at a metered rate to the pump inlet.
In a particularly preferred embodiment of the present invention, a subsea multiphase pumping system will include salient aspects of both of the broadly defined implementations discussed just above (i.e., the recirculation arrangement and the slug distribution arrangement).
In summary, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a multiphase pumping system for subsea operation, the system comprising: a pump; a flow inlet for accepting incoming multiphase flow and directing incoming multiphase flow generally towards the pump; a flow outlet for directing outgoing multiphase flow generally away from the pump; a flow management apparatus in fluid communication with the pump and at least one of the flow inlet and the flow outlet; the flow management apparatus acting to ensure a minimum liquid content in multiphase flow entering the pump; the flow management apparatus comprising: a gas liquid cylindrical cyclone in communication with the flow outlet; a recirculation port disposed in the gas liquid cylindrical cyclone; and a recirculation line in communication with the recirculation port, the recirculation line acting to direct flow generally towards the pump.
Further, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a multiphase pumping system for subsea operation, the system comprising: a pump; a flow inlet for accepting incoming multiphase flow and directing incoming multiphase flow generally towards the pump; a flow outlet for directing outgoing multiphase flow generally away from the pump; a flow management apparatus in fluid communication with the pump and at least one of the flow inlet and the flow outlet; the flow management apparatus acting to ensure a minimum liquid content in multiphase flow entering the pump; the flow management apparatus comprising: a liquid slug distributor; the liquid slug distributor comprising an inlet and an outlet, the outlet being in communication with the pump; the liquid slug distributor acting to regulate gas slugs incoming from the inlet in a manner to ensure propagation, through the outlet, of a minimum liquid content in multiphase flow.
Additionally, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a gas liquid cylindrical cyclone for a multiphase pumping system for subsea operation, the gas liquid cylindrical cyclone comprising a recirculation port for communicating with a pump.
Moreover, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a liquid slug distributor for a multiphase pumping system for subsea operation, the liquid slug distributor comprising: an inlet; and an outlet for communicating with a pump; the liquid slug distributor acting to regulate gas slugs incoming from the inlet in a manner to ensure propagation, through the outlet, of a minimum liquid content in multiphase flow.
Furthermore, there is broadly contemplated herein, in accordance with at least one presently preferred embodiment of the present invention, a method of providing multiphase pumping in subsea operation, the method comprising: providing a pump; accepting incoming multiphase flow and directing incoming multiphase flow generally towards the pump; directing outgoing multiphase flow generally away from the pump; ensuring a minimum liquid content in multiphase flow entering the pump; the step of ensuring a minimum liquid content comprising: providing a gas liquid cylindrical cyclone; and recirculating at least a portion of liquid flow in the gas liquid cylindrical cyclone generally towards the pump.
The novel features which are considered characteristic of the present invention are set forth herebelow. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention and its presently preferred embodiments will be better understood by way of reference to the detailed disclosure herebelow and to the accompanying drawings, wherein:
FIG. 1 provides a schematic overview of a subsea multiphase pumping system;
FIG. 2 is a perspective view of several components of a production loop in a subsea multiphase pumping system;
FIG. 3A is a cut-way elevational view of a GLCC from FIG. 2 ;
FIG. 3C is a cross-sectional plan view of a tangential inlet from FIG. 3A ;
FIG. 3B is a side elevational view of a baffle in isolation;
FIGS. 4A and 4B , respectively, are cut-away plan and elevational views of a liquid slug distributor from FIG. 2 ;
FIG. 4C is another cut-away elevational view of the liquid slug distributor of FIG. 4B ; and
FIG. 4D is a close-up view of a perforated plate portion within dotted circle 4 D from FIG. 4B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As broadly employed herein, it should be understood and appreciated that the term “fluid” can refer to a liquid, a gas, a mixture or suspension thereof, or a mixture or suspension of liquid and/or gas with solid material such as particulates.
FIG. 1 broadly illustrates, in schematic form, a subsea multiphase pumping system in accordance with a presently preferred embodiment of the present invention. An inlet line (or well/manifold flow line) 102 leads to a production loop (to be described in more detail) while an outlet line (or production flow line) 104 leads out of this loop. Per convention, a bypass valve 106 may interconnect the inlet line 102 and the outlet line 104 . Further, an admission valve 108 may be provided where the inlet line leads into the production loop and an outlet valve 110 may be provided where the outlet line leads out of the production loop.
Inlet line 102 preferably leads into a combination twin-screw pump and slug distributor in accordance with an embodiment of the present invention. Slug distributor 112 , preferably positioned above pump 114 , will be discussed in greater detail herebelow. Per convention, suction pressure and temperature transmitters 116 / 118 , as well as discharge temperature and pressure transmitters, 120 / 122 may be provided as shown.
A connecting line 123 preferably leads from pump 114 to GLCC 126 via a check valve 124 and tangential inlet 125 . GLCC 126 , for its part (and in a manner better appreciated herebelow), includes a cyclonic column 128 and recombination column 130 per convention. These are interconnected at an upper region via gas connector 132 and a lower region via liquid connector 134 . A recombination port 136 is disposed at a vertically intermediate point of recombination colunm 130 , while towards a vertically lower portion there is preferably provided a recirculation port 138 . Recombination port 136 accepts recombined gas and liquid and feeds into outlet line 104 while recirculation port 138 feeds into a recirculation line 140 . Not shown within recombination column 130 is a baffle plate, which will be discussed in greater detail herebelow.
Recirculation line 140 , for its part, feeds generally back into slug distributor 112 after passing through a choke valve 142 and past suction pressure and temperature transmitter. An intercooler 139 may optionally be provided (see discussion further below).
Having provided a basic framework for understanding and appreciating various embodiments of the present invention, FIG. 2 shows, in perspective view, several components of a production loop. FIGS. 3A-4D , on the other hand, show various components of the production loop from FIG. 2 in somewhat greater detail. It should be understood and appreciated that FIGS. 2-4D merely provide an illustrative and non-restrictive example of a production loop and, to the extent that the components in FIGS. 2-4D appear, or are oriented or positioned, differently from components in FIG. 1 , those in FIG. 1 are merely shown in a highly stylized and schematic format for greater clarity. As such, components in FIG. 2-4D that are analogous to components in FIG. 1 bear reference numerals advanced by 100 .
The discussion now turns to a GLCC 226 and related recirculation components in accordance with a preferred embodiment of the present invention. It should be understood that such a recirculation arrangement could be employed of its own merit in a subsea pumping system, or may be combined with a liquid slug distributor to be discussed in more detail further below. FIGS. 2 and 3 A- 3 C may be referred to simultaneously in connection with the discussion presented below. As such, FIG. 3A is a cut-way elevational view of a GLCC from FIG. 2 , while FIG. 3B is a cross-sectional plan view of a tangential inlet from FIG. 3A , and FIG. 3C shows a baffle in isolation.
As shown, and as conventionally known, connecting line 223 leads to a tangential inlet 225 in the form of a sloping inlet pipe. The “tangential” aspect of this inlet is characterized by its approach at a tangent to vertical cyclonic column 228 . Thusly, the sloped inlet 225 begins a preseparation of the incoming fluid mixture into phases while at the point of tangential entry itself, a vortex is initiated within cyclonic column 228 . As can be appreciated, centrifugal force will then tend to urge gas out of the incoming liquid.
As the gas and liquid separate from each other by way of the vortex just mentioned, the former will be urged upwardly and the latter, downwardly, by virtue of their relative specific gravities. Then, per convention, they will proceed to recombination colunm 230 via connectors 232 (for gas) and 234 (for liquid). Each of these connectors may include a flow meter to aid in measurement of the respective flow rates or flow volumes of gas and liquid.
Accordingly, recombination column 230 affords the capability of recombining the gas and liquid for transport, particularly, out of recombination port 236 and into outlet line 204 . Known mathematical models typically take into account the piping between the cyclonic column 228 and the recombination port 236 , whereby it is generally desired that a pressure equilibrium be established between the tangential inlet 225 and the recombination point 236 . Normally, the liquid and gas connectors (or legs) 234 / 232 are typically made of the same diameter pipe, and differences in pressure losses through the liquid and gas connectors 234 / 232 are reconciled by appropriately choosing the height of the recombination port 236 .
In accordance with a preferred embodiment of the present invention, the recombination column 230 is used for liquid inventory storage and can be similar in size to, or greater in diameter than, the cyclonic column 228 . Whereas cyclonic column 228 is preferably sized (e.g., in diameter) to maximize the centrifugal forces in the fluid (albeit limited by erosion considerations), recombination column 230 is itself preferably sized to preserve the velocity of the liquid as it climbs up the column, so as to keep any and all particulates in suspension. This contrasts significantly with conventional GLCC's, where a cyclonic column is usually considerably greater in diameter than a recombination column (or than piping used in a recombination capacity).
Once the maximum vortex velocity is determined for a given capacity (again, erosion velocity limited) and the minimum flow rate in the vertical recombination column is selected (again, to keep particulates in suspension), it will be appreciated that the general storage capacity of GLCC 226 can also be tailored by the variable of the height of the columns 228 / 230 . Continuity requires that taller columns still have the same vertical velocity as shorter ones; however, the total pressure loss through the GLCC is increased with taller liquid columns.
Indicated at 238 is an integrated recirculation port, in accordance with a preferred embodiment of the present invention. Port 238 is preferably located at a very low point of recombination column 230 so as to maximize available inventory in both columns 228 / 230 for recirculation. When there is no net liquid coming into the pump system at large, the liquid in GLCC 226 will drop below the level of the recombination port 236 , eliminating the direct loss of liquid from the GLCC 226 . Only liquid leaving port 236 in a gas phase would then be lost to the system.
As a particularly advantageous refinement, and as can best be appreciated from FIG. 3A , a baffle plate 242 is preferably included in the recombination column 230 . The baffle plate 242 will essentially act to prevent entrained gas and particulates, that would be present in liquid entering from connector 234 , from going directly to the recirculation port 238 , thus preventing an inadvertent concentration of two constituents of the liquid phase that would be adverse for the pump (i.e., free entrained gas and particulates).
As such, it is to be recognized that recombination column 230 will preferably present a uniform distribution of gas and particulates across its diameter. In this connection, the baffle plate 242 will direct the particulates and gas with a vertical velocity before they are returned to the recirculation port 238 . Since particulates have negative buoyancy, they will be urged downwardly to the recirculation port 238 at the concentrations typically found in the recombination column 230 . On the other hand, any entrained gas will have net buoyancy and will continue to rise even from the portion of the liquid that is reversing direction to go to the recirculation port 238 .
Preferably, the baffle 242 will not welded be at the bottom and, as shown in FIG. 3C , has chamfers 242 a/b cut out on the lower corners. The chamfers 242 a/b assist in fitting the baffle into recombination column 230 and also let liquid flow into the recirculation line 240 when there is no net liquid coming into the system; thus, when the liquid level falls below the top of the baffle 242 it can still flow to the recirculation line 240 . At such times, gas carry under is not much of an issue given the low liquid velocities. When there is a lot of liquid flow and gas carry under is an issue, the liquid will tend to impinge on the baffle 242 and get diverted vertically upward, improving the separation of gas as described. Preferably, the baffle will be solid enough to divert the bulk of the flow but (via chamfers 242 a/b ) be “leaky” enough to avoid becoming a “dam” when there is only standing oil in the columns.
Though not essential, a heat exchanger or cooler could be included along the recirculation line between recirculation port 238 and any pump or slug distributor. This could be embodied, e.g., by a single coil, or pair of parallel coils, comprising relatively large diameter tubing; see, e.g., the intercooler 139 in FIG. 1 .
Most preferably, liquid traversing recirculation line 240 will encounter a fluid resistor of some type to reduce the discharge pressure to the level of the pump suction pressure it will be “meeting”, and preferably in a controlled manner. While such a resistor could be embodied by a laminar flow tube (which could double as a heat exchanger/intercooler) or a fixed resistor/orifice with a single stage or multiple orifices in series (e.g., made of tungsten carbide for erosion resistance, a variable resistor or choke valve may preferably be employed. A flow meter, indicated at 242 in FIG. 2 (in accordance with an embodiment where recirculation line 240 feeds into a slug distributor 212 ) can itself feed into a choke valve 246 as just described, wherefrom liquid flow then proceeds into distributor 212 . In another variant, any of the options just mentioned could be coupled with a fast-acting shutoff valve (or, in the context of a choke valve, some type of fast-closing feature). As shown, a discharge connection 241 may preferably be provided at an underside of flow meter 242 , to connect with a branch 266 of a discharge outlet 264 that extends from slug distributor 212 .
It should be appreciated that a flow meter 242 will allow for a precise setting of choke valve 246 . Additionally, the flow meter 242 would be able to detect any flow resistance change, to permit the choke valve ( 246 ) opening to be reset in compensation. Such resetting could be automatic (e.g. via feedback) or could be performed via manual controls (e.g. from a remote location). The particular arrangement chosen and employed can be governed by the parameters and context of the system at hand.
Though not shown, a fast-acting shut-off valve may also optionally be included in recirculation line 240 . This could provide a measure of insurance in the event of pump motor shutdown, to avert leakage of recirculation liquid into pump suction that could otherwise be employed in a pump restart. In other words, the shut-off valve (or optionally a fast choke with good shut-off characteristics) would trap liquid in the GLCC 226 for use with the next restart. (As such, GLCC 226 may preferably be located above the pump suction so that liquid will tend to feed via gravity to the pump suction for a restart.)
The disclosure now turns to a discussion of a liquid slug distributor 212 in accordance with a preferred embodiment of the present invention. It should be understood and appreciated that a liquid slug distributor as broadly contemplated herein may be employed of its own merit or could be combined with a GLCC recirculation arrangement such as that just discussed. FIGS. 2 and 4 A- 4 D may be referred to simultaneously in connection with the discussion presented below. As such, FIGS. 4A and 4B , respectively, are cut-away plan and elevational views of a liquid slug distributor from FIG. 2 . FIG. 4C is another cut-away elevational view of the liquid slug distributor of FIG. 4B . FIG. 4D is a close-up view of a perforated plate portion within dotted circle 4 D from FIG. 4B .
A liquid slug distributor 212 , as shown, may preferably be embodied by a closed cylindrical vessel with its own tangential inlet 213 , into which inlet line 202 leads. A “bowl” is essentially formed in the vessel via the installation of a standpipe 248 installed vertically in the center and extending through the bottom of the vessel; this may be thought of as a contained space ( 212 a ) defined about standpipe 248 , through and over which incoming liquid describes a vortex. An outlet pipe 250 is located at the base of the cylinder, larger in diameter than the standpipe, and will lead to a pump (e.g., twin-screw pump) 214 (not shown but schematically indicated via dotted lines). The standpipe 248 feeds into outlet pipe 250 .
Metering holes 252 of appropriate size penetrate the bottom of the bowl 212 a in a circle surrounding the standpipe 248 but enclosed by the outlet pipe 250 . (Here, six evenly distributed holes are provided.) This results in a recombination of the fluid flowing through the standpipe 248 with fluid passing through the metering holes 252 . Additionally, a perforated plate 254 is preferably installed just below the level of the tangential inlet 213 and (as best appreciated by FIG. 4D ) includes a plurality of throughholes or apertures 256 . Perforated plate 254 serves to provide support for the standpipe 248 and also constitutes a location where agglomerations of wax can captured and inhibited; preferably, the size of throughholes 256 is such that any wax that does progress therethrough will not be sufficient to plug the preferably larger metering holes 252 and instead will simply be broken up and easily pass through the system.
Breather tubes 258 , preferably three in number and distributed evenly about standpipe 248 as appreciated from FIG. 4A , extend through the perforated plate 254 and allow gas below the plate to pass to a higher space within the vessel where gas predominates and thence out via standpipe 248 . As such, the tubes 258 thus allow liquid passing through the perforated plate 254 to displace gas accumulated below the plate 254 as liquid flows out through the metering holes 252 and the liquid level in the bowl. The tubes 258 allow the flow characteristic of the perforated plate 254 to be known by permitting the entire flow area associated with perforated plated 254 to be reserved for liquid flow, while tubes 258 are essentially reserved for gas; since liquid enters in a vertex, it will not enter tubes 258 so that liquid and gas flow will remain almost entirely separate. A simple diaphragm or web 260 preferably physically interconnects the breathing tubes 258 with standpipe 248 at an upper region of all of these, whereby further support and stability is imparted to the entire internal assembly.
The liquid storage capacity of slug distributor 212 is governed by its diameter and height, reduced by the diameter and height of the standpipe. The depth of a vortex caused by the flow through the tangential inlet 213 also reduces the stored capacity in the bowl 212 a . The tangential velocity and centrifugal acceleration used to promote gas separation (and thus keep liquid in the bowl 212 a ) is determined by the flow rate, inlet pipe diameter and bowl diameter, while the tangential velocity of course needs to be limited by erosion concerns. The contributory forces causing liquid to flow through the metering holes 252 include the head of the liquid and the differential pressure generated by pressure accumulation caused by gas flow through the standpipe 248 . Note that the liquid flow is not constant; it is greatest at the end of a liquid slug and the start of a gas slug. At such an instant, the liquid level is the greatest and the pressure accumulation resulting from gas flow through the standpipe 248 provides a pressure gradient between the upper surface of the liquid and the outlet 250 .
It will be appreciated that the bowl size is a function of the period of the incoming slugs, the flow rate and the gas volume fraction. Thus, by way of an illustrative and non-restrictive practical example a flow rate of 500 m 3 /hr (2200 gpm) with a gas volume fraction of 80% and a period of 3 seconds with a standard deviation of 1 second presents more than enough liquid to satisfy a continuous 5% or 25 m 3 /hr (110 gpm) of liquid; the average liquid flow would be 100 m 3 /hr (440 gpm). Preferably, the bowl will be configured to hold enough liquid to sustain a gas slug that is 9 seconds in length (3+6*Sigma), which is about 16.5 gallons after accounting for the reduction caused by the vortex.
In general, since pumps as employed herein typically operate at a fixed flow and speed, even when the liquid portion of a slug enters the distributor 212 the gas flow exiting though the standpipe 248 is the same as during the gas portion of the slug because the entering liquid displaces gas out of the bowl 212 a and through the standpipe 248 . In the event that the bowl 212 a is filled, the metered flow is a function of the liquid level, the pressure accumulation due to gas flow and the flow coefficient of the metering holes. When the liquid level exceeds the height of the standpipe 248 , the pressure accumulation in the standpipe 248 is slightly higher due to the presence of liquid flow, which is compensated for by the change in elevation from the inlet to the outlet. Calculations for the peak differential pressure and static head for these conditions can easily be performed, as can the average flow rates for each condition.
By way of additional components, two auxiliary connections 262 and 264 may extend outwardly from outlet 250 as shown. A branch 266 of outlet 264 may extend upward to meet the connection 241 discussed previously.
Outlet 262 may be a connection for a combined pressure and temperature transmitter of a type used subsea, with outlet 262 may be the combination point for incoming fluid and the recirculated fluid, with outlet 264 being the connection point for fluid from the GLCC that is being recirculated.
It is to be appreciated that while the GLCC recirculation arrangement and liquid slug distributor may each singly be incorporated into a general subsea multiphase pumping system of their own accord, there is contemplated in accordance with a particularly preferred embodiment of the present invention a very advantageous combination of the two. Each, on its own, can help ensure that a minimum liquid flow threshold (e.g. ˜5% as already described) can be maintained. However, particular advantages are enjoyed when both arrangements are employed together.
On the one hand, the liquid slug distributor, on its own, may not be able to sustain operation if the loss of liquid exceeds a period equal to several standard deviations in the mean slug length. Additionally, it may not be able to provide sufficient flow assurance during start-up, at least until continuous periodic slug flow is achieved. On the other hand, the GLCC recirculation arrangement, on its own, may be able to support a loss of liquid of indefinite length (especially if a cooler or heat exchanger is employed) but reduces the volumetric efficiency of the process by consuming pump capacity while still requiring the power for full capacity at a given pump speed. The problem is aggravated by gas returning to the pump suction either as free gas or gas being liberated from solution when the liquid is restored to suction pressure. Typically the gas doubles the loss in pump capacity compared to the liquid required. The amount of gas returned is proportional to the amount of liquid being recirculated.
Accordingly, a combined system involving both arrangements is particularly well-geared towards optimizing pump operation. For its part, the GLCC recirculation arrangement system can provide continuous liquid flow in the face of long gas trains and even during startup where liquid sealing can permit the pump acting on gas in the production flow line to significantly lower the suction pressure of the flow line and consequently coax a well to start to flow. On the other hand, the liquid slug distributor vessel provides liquid flow assurance in steady-state conditions, making high rates of recirculation unnecessary. Instrumentation that may already be provided for pump operation and recirculation control and monitoring coupled with an appropriate operating strategy can achieve more optimal operation of the pump than possible with either system alone.
A general protocol for optimizing a composite liquid distribution/recirculation system, as broadly contemplated herein, can take the following form. For start-up and until steady state operation is achieved, recirculation can be provided at approximately 5% of pump total capacity. This quantity may be reduced for lower differential pressure during start-up; generally, the required recirculation rate will be a function of the screw outer diameter (in the twin-screw pump), the cube of the clearance and the square root of pump differential pressure. As a consequence, lower recirculation flow will be acceptable at lower differential pressures. Once steady state operation is achieved, the GVF (Gas Volume Fraction) being experienced by the pump, as well as the pump flow, can be estimated by the temperature rise across the pump and the pump speed and differential pressure; one will know in advance the specific heat of the liquid (water and petroleum) and the water cut (% of water in the liquid phase which increases as the well[s] age). In essence, as temperature rise increases (indicating high GVF), the higher the recirculation rate should be. For low temperature rise (indicating low GVF), the slug distributor alone would likely be sufficient, while for higher temperature rise more recirculation would be required.
In brief recapitulation, it will be appreciated that broadly embraced herein are systems and equipment that provide for good subsea installation and practice, by virtue of compactness, comparative low weight and freedom from intervention, as compared with topside installation. The issues of prime loss (though insufficient liquid) and pump overheating (because of fluid recirculation with a 100% gas inlet) become increasingly important as the pump boost pressure is increased in subsea contexts.
There are broadly contemplated herein, in accordance with at least one embodiment of the present invention, methods and arrangements providing continuous operation of a subsea multiphase pumping system, via boosting a multiphase petroleum stream via the use of a recirculation system. Also, the present invention, in accordance with at least one preferred embodiment, seeks to bring about distribution of unsteady liquid flow in a multiphase mixture into a more continuous minimum liquid flow. The distribution preferably occurs timewise, via averaging nearly square waves of liquid into a uniform flow.
In further recapitulation, it will be appreciated herein that the following, alone or in any combination, represent some examples of advantageous features associated with at least one presently preferred embodiment of the present invention: a recombination column may have an average diameter greater than or equal to an average diameter of a cyclonic column; a recombination column may have an average diameter sufficient for preserving liquid flow velocity to maintain particulates within liquid flow in suspension; and a baffle may extend across a major portion of a diametric dimension of a recombination column.
Without further analysis, the foregoing will so fully reveal the gist of the present invention and its embodiments that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute characteristics of the generic or specific aspects of the present invention and its embodiments.
If not otherwise stated herein, it may be assumed that all components and/or processes described heretofore may, if appropriate, be considered to be interchangeable with similar components and/or processes disclosed elsewhere in the specification, unless an express indication is made to the contrary.
If not otherwise stated herein, any and all patents, patent publications, articles and other printed publications discussed or mentioned herein are hereby incorporated by reference as if set forth in their entirety herein.
It should be appreciated that the apparatus and method of the present invention may be configured and conducted as appropriate for any context at hand. The embodiments described above are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | In subsea multiphase pumping systems, the use of a gas-liquid cylindrical cyclone (GLCC) as a separator to recirculate liquid from pump discharge to pump suction, especially during high gas inlet conditions from a multiphase petroleum stream. Further contemplated is protection of the pump from momentary high gas inlet conditions due to an incoming slug flow profile from a petroleum stream, via transforming a naturally varying multiphase petroleum stream into separated phases for measured distribution to the pump suction and ensuring a minimum liquid flow. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an agricultural tractor having a rear suspension and in particular a draft compensating rear suspension in which the suspension is designed to reduce or minimize the effect of draft loads on the tractor attitude by minimizing compression or extension of the rear suspension.
2. Description of the Related Art
An agricultural tractor is intended primarily for off-road usage and is designed primarily to supply power to agricultural implements. An agricultural tractor propels itself and provides a draft force in the direction of travel to enable an attached, soil engaging, implement to perform its intended function. Furthermore, an agricultural tractor may provide mechanical, hydraulic and/or electrical power to the implement. Agricultural tractors must be designed with sufficient normal force, i.e. a down force, acting on the drive wheels to produce the needed draft force. Agricultural tractors differ from cargo carrying vehicles, such as pickup trucks and semi-truck tractors, in that trucks are not designed to produce a continuous draft load. A truck only needs to produce a draft load during periods of acceleration and deceleration and relies on the weight of the cargo to produce the normal force on the drive wheels.
There is a continuous desire to increase the productivity of agricultural tractors. Productivity can be increased by tractor designs that maintain tire-soil contact force when traversing uneven terrain, both during field operations and during road transport. To maintain tire-soil contact force on an uneven terrain, it is necessary to provide a suspension system to allow the tires to follow the terrain. When a suspension is added to an agricultural tractor, between the chassis and the wheels, with the hitch on the suspended chassis, an undesirable interaction occurs between the suspension and draft load. The draft load reaction through the suspension tends to force the rear suspension into jounce, i.e. the suspension compresses, causing the wheels to move upward relative to the suspended chassis. As the suspension compresses, the pulled implement, such as a plow, runs deeper, increasing the draft load. The higher the draft load, the more the rear suspension compresses until it is fully compressed. Once fully compressed, the suspension no longer provides a benefit. If the suspension is only partially compressed, it will still reduce the amount of suspension travel available to maintain tire-soil contact force and to improve the tractor ride. Suspension compression also affects the clearance under the vehicle, the height of the drawbar and hitch above the ground plane, and the attitude of the tractor.
The interaction between the suspension and draft load can interfere with the proper operation of hitch controls. When the hitch control senses the need to reduce the depth of the implement in the ground, the suspension compresses, instead of raising the implement. The reverse is true if the hitch control senses the need to lower the implement.
One way to overcome the problem of suspension compression is to provide a system that compensates for the draft load by extending the suspension. This is accomplished by adding hydraulic fluid to the system to return the suspension to a center position, whereby suspension travel in each direction is still available. However, this significantly increases the spring rate of the suspension under a draft load, resulting in a harsher ride. Furthermore, adding and removing fluid to a circuit with an accumulator results in a large energy waste.
Another solution is to provide a rigid beam axle mounted to the chassis through the suspension and mount the hitch to the unsuspended beam axle. This avoids reacting of the draft load through the suspension. However, the implement will not receive the benefit of the suspension and will follow the motion of the axle.
Yet another alternative is to provide a means to lock out the suspension when performing draft work. This eliminates all benefits of the suspension.
All of the above solutions to the interaction of the suspension to the draft load reduce the effectiveness and benefit of the rear suspension.
SUMMARY OF THE INVENTION
The present invention relates to an agricultural tractor having a rear suspension with draft compensating geometry to control the compression of the rear suspension in response to a draft load. The draft load is applied to the chassis by a ground engaging implement. The tractive load and torque at the rear wheels are reacted through the side view instantaneous center of the rear suspension. The placement of the instantaneous center affects the chassis reaction to the wheel load and torque. Locating the suspension instantaneous center on a line of 100% draft-compensation will eliminate the motion of the suspension due to the draft load. If the instantaneous center is located below the 100% draft-compensation line, the suspension will compress under a draft load, whereas if the instantaneous center is located above the 100% draft-compensation line, the suspension will extend under a draft load. The distance between the instantaneous center and the 100% draft compensation line will determine the amount of compression or extension of the suspension. An expected response to the draft load is to compress the suspension. In a tractor without a suspension, the draft load typically compresses the rear tires. By properly locating the instantaneous center of the suspension, an opposing force is created to counteract, completely or partially, the suspension compression.
The draft compensating suspension geometry can be used to eliminate or reduce the amount of suspension travel used to react to the draft load. As a result, the suspension will have travel available to react to irregular terrain profiles, which provides the operator with better ride and control. It also permits the suspension to be less stiff to terrain inputs. A draft compensating suspension also reduces the interaction between the suspension and the hitch draft control system. A draft compensating geometry eliminates the need for complex control systems to control suspension height and vehicle attitude.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the agricultural tractor of the present invention having a draft compensation rear suspension.
FIG. 2 is a rear view of the left side of the rear suspension.
FIG. 3 is a perspective view of the left side rear suspension without the outboard final drive housing.
FIG. 4 is a side view of the left side chassis illustrating the connection of the control arms to the tractor frame.
FIG. 5 is a side view free body diagram of the dynamic loads acting on the tractor.
FIG. 6 is a side view schematic representing the suspension system.
FIGS. 7 and 8 are side schematics of tractors illustrating two different degrees of draft compensation.
DETAILED DESCRIPTION OF THE INVENTION
An agricultural tractor 10 according to the present invention is shown in FIG. 1 . The tractor 10 includes a frame 12 , front wheels and tires 14 , rear wheels and tires 16 and a cab 18 forming an operator station. A front hood 22 covers an engine 24 .
The frame 12 includes a pair of channel members 28 between which a transmission 26 is housed. Only one of the channels is shown in FIG. 1. A rear drive differential case 30 is attached to the rear ends 32 of the steel channels 28 and thus forms a part of the tractor frame structure. The term “frame structure” is used broadly to mean both separate frame elements such as the channels 28 and other structural members mounted thereto such as the differential case and transmission, etc. Some tractors may be designed without separate frame members and form a frame structure entirely of drive train components such as the engine, transmission, front and rear drive differential cases, etc. The differential case 30 houses a rear differential drive that is driven by the transmission 26 . The rear differential has left and right outputs 34 to drive the left and right rear wheels 16 .
A three-point hitch 36 is mounted to the rear of the differential case 30 . The three-point hitch includes a pair of lower draft links 38 and an upper link 40 . Lift links 42 are attached to the draft links 38 and extend upwardly therefrom. The lift arms and the rock shaft of a conventional three point hitch are not shown. In addition to the three-point hitch, a drawbar 44 extends rearwardly from the differential case 30 . A PTO housing 46 with a PTO shaft 48 is also mounted to the differential case 30 .
The rear wheels 16 are mounted to outboard planetary final drives 50 , only the left side final drive 50 is shown in FIG. 2 . The left and right sides of the rear axle and suspension are substantially identical. The final drive 50 is attached to the frame 12 by upper and lower suspension control arms 52 , 54 . The upper control arm 52 is generally V-shaped, having a front leg 56 and a rear leg 58 . The two legs are joined together at an outboard apex 60 that forms a ball joint 61 having a ball stud 62 that is coupled to the housing of the final drive 50 at the top of the housing. The inboard ends of the legs 56 , 58 are joined to the frame 12 by ball joints 64 and 66 respectively. The ball joints 64 , 66 include ball studs 68 and 70 , respectively, shown in FIG. 4 .
The lower control arm 54 is similar to the upper control arm 52 , having a front leg 72 and a rear leg 74 joined together at an outboard apex 76 . The apex 76 forms a ball joint 78 having a ball stud 79 for attachment to the final drive housing at the bottom of the housing. The legs 72 , 74 of the lower control arm are joined to the frame 12 by ball joints 90 , 92 having ball studs 94 , 96 . The ball joints at the inboard and outboard ends of the control arms 52 , 54 enable the outboard final drives 50 to move up and down relative to the frame 12 , as shown by the double arrow 98 in FIG. 2 . One or both of the ball joints at the inner end of each control arm can be replaced with pivot pins.
Vertical loads are transmitted between the differential case 30 and the outboard final drives 50 by front and rear hydraulic cylinders 100 , shown only schematically by a phantom line. The front hydraulic cylinder extends between front mounting brackets 102 on the frame 12 and a stud (not shown) on the front of the final drive housing. The rear hydraulic cylinder 100 extends between rear mounting brackets 104 on the differential case and a rear stud 106 on the final drive housing. The hydraulic cylinders 100 are part of a hydraulic circuit that includes a pressure accumulator in a known manner to provide the suspension system with a hydro-pneumatic spring system. Other spring devices can be used in place of the hydraulic cylinders such as metal springs, air bags, etc.
Since the final drive 50 is attached to the upper and lower control arms through ball joints, it is possible to rotate the final drive 50 about a generally upright axis passing through the ball joints 61 and 78 . To prevent this rotation, a fixed length link 108 extends between the differential case 30 and the outboard final drive housing 50 , rearward of the lower control arm 54 .
A drive shaft 110 shown schematically by a phantom line connects the left output 34 from the differential to the final drive 50 .
With reference to FIG. 4, the ball joints 64 , 66 that attach the upper control arm 52 to the frame 12 define an upper control arm pivot axis 84 . Likewise, the lower ball joints 90 , 92 define a lower control arm pivot axis 86 . The axes 84 , 86 converge toward one another, forward of the rear wheels 16 at the side view instantaneous center of the rear suspension. The location of the side view instantaneous center is a critical factor in designing the suspension geometry so that it provides the desired degree of draft compensation as described below.
The various loads on a tractor are shown in reference to the free body diagram in FIG. 5 . The forces shown in FIG. 5 are as follows:
D A Aerodynamic drag
R xf Rolling resistance of the front tires
R xr Rolling resistance of the rear tires
F xf Longitudinal force at the front tires (traction)
F xr Longitudinal force at the rear tires (traction)
W f Load on the front wheel
W r Load on the rear wheel
W Total Vehicle weight
a x Longitudinal acceleration
R dbx Longitudinal drawbar load
R dbz Vertical drawbar load
θ Angle of slope
Assuming the tractor does not accelerate in pitch, the load on the front axle can be found by summing moments about the point O r , with clockwise moments being positive: W f L + D A h a + Wa x h g + R dbx h db + R dbz d db + Wh sin θ - Wc cos θ = 0 1 )
Solving for the load on the front axle: W f = 1 L ( Wc cos θ - D A h a - Wa x h g - R dbx h db - Wh sin θ ) 2 )
The load on the rear axle can be found by summing moments about the point O f . D A h a + Wa x h g + R dbx h db + R dbz ( d db + L ) - W r L + Wh sin θ + Wb cos θ = 0 3 )
Solving for load on rear axle: W r = 1 L ( Wb cos θ + D A h a + R dbx h db + R dbz ( d db + L ) + Wh sin θ + Wa x h g ) 4 )
For static loads on a level ground, θ, D A , R dbx , R dbz and a x all equal zero, thus: W f = W fs = W c L 5 ) W r = W rs = W b L 6 )
For low speed accelerations on level ground θ and D A equal zero then: W f = W c L - R dbx h db L - R dbz d db L - Wa x g h L 7 ) W r = W b L + R dbx h db L + R dbz ( d db + L ) L + Wa x g h L 8 )
Since any suspension is equivalent to a trailing arm, the pitch control performance can be quantified by analyzing the free body diagram of the suspension shown in FIG. 6 . In FIG. 6, points A f and A r are the virtual pivot points of the front and rear suspensions on the vehicle body. Since the arm is rigidly attached to the axle (resisting axle wind up), it has the ability to transmit a vertical force to the sprung mass which can be designed to counteract draft loads that compress the rear suspension.
The sum of the moments about A f or A r must be zero when the system is in equilibrium. Note that the rear load is characterized as a static component, W rs , plus a dynamic component, ΔW r , rising from longitudinal load transfer. For simplicity, axle weights are neglected. Counter-clockwise torque's are positive.
Σ M Ar =W r d r −W rs d r −ΔW r d r −F xr ( e r −r r )=0 9)
Σ M Af =−W f d f +W fs d f +ΔW f d f −F xf ( e f −r f )=0 10)
Where:
W fs and W rs are the static loads on the front and rear axles and suspensions respectively.
ΔW f and ΔW r are the dynamic changes in front and rear suspension loads respectively.
r f and r r are the rolling radii of the front and rear tires respectively.
Solving equation 9 for ΔW r : Δ W r = W r - W rs - F xr ( e r - r r d r ) = k r δ r 11 )
Where:
k r is the rear suspension spring rate.
δ r is the rear suspension deflection (positive jounce).
Then substituting W b L
for W rs from equation 6 and W r = W b L + R dbx h db L + R dbz ( d db + L ) L + Wa x g h L Δ W r = R dbx h db L + R dbz ( d db + L ) L + Wa x g h L - F xr ( e r - r r d r ) 12 )
Since: F xr = ( 1 - ξ ) ( R dbx + Wa x g ) = ( 1 - ξ ) F x 13 )
Where:
ξ is the fraction of the total tractive force developed on the front tires.
F x is the total tractive force developed by the tractor.
Therefore: Δ W r = R dbx h db L + R dbz ( d db + L ) L + Wa x L h L - ( 1 - ξ ) F x ( e r - r r d r ) = k r δ r . 14 )
Solving equation 10 for ΔW f : Δ W f = W f - W fs + F xf ( e f - r f d f ) = k f δ f 15 )
Where:
k f equals the front suspension spring rate
δ f equals the front suspension deflection (positive jounce).
Substituting W fs = W c L
from equation 5 and W f = W c L - R dbx h db L - R dbz d db L - Wa x g h L
from equation 7, results in: Δ W f = - R dbx h db L - R dbz d db L - Wa x g h L + F xf ( e f - r f d f ) 16 )
Since: F xf = ξ F x = ξ ( R dbx + Wa x g ) 17 )
Where ξ is the fraction of the total tractive force developed on the front tires. Therefore: Δ W f = - R dbx h db L - R dbz d db L - Wa x g h L + ξ F x ( e f - r f d f ) = k f δ f 18 )
The pitch angle of the tractor, θ p , is simply the sum of the suspension deflection divided by the wheel base. θ p = δ r - δ f L 19 )
Substituting into equation 19, equations 14 and 18 for δ r and δ f results in: θ p = 1 L R dbx k r h db L + 1 L R dbz k r ( d db + L ) L + 1 L Wa x gk r h L - 1 L ( 1 - ξ ) F x k r ( e r - r r d r ) + 1 L R dbx k f h db L + 1 L R dbz k f d db L + 1 L Wa x gk f h L - 1 L ξ F x k f ( e f - r f d f ) 20 )
For field operations, quasi-steady state conditions exist, and a x =0. Then θ p becomes: θ p = 1 L R dbx k r h db L + 1 L R dbz k r ( d db + L ) L - 1 L ( 1 - ξ ) F x k r ( e r - r r d r ) + 1 L R dbx k f h db L + 1 L R dbz k f d db L - 1 L ξ F x k r ( e f - r f d f ) 21 )
Since F x =R dbx : θ p = 1 L R dbx k r h db L + 1 L R dbz k r ( d db + L ) L - 1 L ( 1 - ξ ) R dbx k r ( e r - r r d r ) + 1 L R dbx k f h db L + 1 L R dbz k f d db L - 1 L ξ R dbx k f ( e f - r f d f ) 22 )
Since the suspension reacts the torque of the outboard planetary final drive 50 of the tractor 10 , r r =r f =0. θ p becomes: θ p = 1 L R dbx k r h db L + 1 L R dbz k r ( d dbz + L ) L - 1 L ( 1 - ξ ) R dbx k r e r d r + 1 L R dbx k f h db L + 1 L R dbz k f d db L - 1 L ξ R dbx k f e f d f 23 )
Since:
R dbx =R dh cos β
R dbz =R db sin β
Where:
R db is the drawbar pull
β is the angle of the drawbar pull with respect to the vehicle horizontal axis.
For small angles of β, sin β0 and the cos β1. θ p = 1 L R db k r h db L - 1 L ( 1 - ξ ) R db k r e r d r + 1 L R db k f h db L - 1 L ξ R db k f e f d f 24 ) θ p = 1 L R db [ 1 k r h db L - 1 L ( 1 - ξ ) 1 k r e r d r + 1 k f h db L - ξ 1 k f e f d f ] 25 )
For the pitch angle to be zero, the term in brackets must equal zero. 0 = h db L - ( 1 - ξ ) e r d r + k r k f h db L - ξ k r k f e f d f 26 ) e r d r = 1 ( 1 - ξ ) [ h db L + k r k f h db L - ξ k r k f e f d f ] 27 )
The equation 27 defines a line 80 shown in FIG. 7 that extends from the center of the rear tire patch upward and forward. If the side view instantaneous center of the rear suspension, 82 , is located on this line, the suspension geometry will produce a 100% compensation of the draft forces, resulting in no rear suspension compression or extension when the tractor produces a draft force. As a result, the line 80 is referred to as the “100% draft compensation line”.
The side view instantaneous center of the rear suspension is the point of intersection 82 of the pivot axis 84 of the upper control arm and the pivot axis 86 of the lower control arm. In FIG. 7, the instantaneous center 82 is located above the line 80 . This is the lift zone where the draft force will produce an extension of the rear suspension. In FIG. 8, the instantaneous center 82 is located below the 100% draft compensation line and is in the compression zone. A draft force will result in compression of the rear suspension. The further the instantaneous center 82 is from the 100% draft compensation line, the greater the effect of the draft load on the suspension system.
The amount of draft compensation can be quantified by: e r d r actual e r d r 100 % draft compensation × 100 = % draft compensation 28 )
If the location of the instantaneous center produces, for example, 60% draft compensation, then 60% of the draft load is compensated by an opposing force that counteracts compression or extension of the suspension. The remaining 40% of the draft force will result in suspension compression and can be partially or totally reacted by the suspension load leveling system, depending on the leveling system design. Some compression is desired as it is the expected response of a tractor to a draft load, resulting from tire compression in non-suspended tractors. Load leveling will increase the suspension spring rate, but not nearly as much as would be required if the load leveling system reacted to the entire draft force. With a draft compensating suspension geometry, a less complex load leveling system is needed and requires less power to operate. Load leveling suspension systems are generally known.
The line 80 defined by the equation 27 above provides draft compensation for the horizontal component of the draft force. If the angle β (the draft force angle to horizontal) is a value other than zero, there will be both horizontal and vertical components to the draft force. Only the horizontal component is compensated for by the suspension geometry. As noted above, the compensation may be full or partial, depending on the location of the suspension instantaneous center relative to the line of 100% compensation. The vertical component of the draft force will act to compress or extend the rear suspension, depending on the direction of the vertical draft component. The effect of the vertical component on the tractor attitude may be reduced, or eliminated, by a load leveling system. Since the suspension instantaneous center is fixed on the tractor, the percentage of the total draft [compensation] that is compensated by the suspension geometry varies as a function of the angle β. The exact amount of draft compensation will vary depending on the particular implement and angle β of the draft force produced by the implement. Accordingly, the amount of draft compensation is usually expressed as a range.
If the suspension did not have a load leveling system, the suspension geometry could be designed with the instantaneous center above the line of 100% draft compensation to produce a suspension extension to counter a vertical draft component to control the vehicle attitude. This can be expressed as a draft compensation value that is greater than 100%.
The equation 27 above results from equation 22 where r r and r f =0 in the case of an outboard planetary final drive. For a tractor having an inboard final drive, equation 22 would resolve differently for the slope of the 100% draft compensation line since the dimensions r r and r f are the rolling radii of the tires.
The desired percentage of draft compensation produced by the suspension geometry will vary depending upon the tractor design, the total amount of tire motion available through the suspension system, the suspension spring rate and the load leveling system. Where greater suspension travel is available, a lower amount of draft compensation may be needed to still have sufficient suspension travel to traverse an uneven terrain. Where a relatively large amount of suspension travel is available, a suspension geometry providing 30% draft compensation may be adequate. The tractor 10 above has draft compensation between 40-60%. However, where the suspension travel is smaller, draft compensation between 60-80% may be required to insure adequate suspension travel remains for traversing a rough terrain.
The draft compensating suspension of the present invention on an agricultural tractor enables the implement hitch to be mounted on the suspended frame of the tractor and avoid the negative consequences of the draft load reacting through the suspension to either compress or extend the suspension. The suspension allows the implement to be suspended as well, providing greater control over the implement operation.
The invention should not be limited to the above-described embodiment, but should be limited solely by the claims that follow. | An agricultural tractor having a rear suspension with draft compensating geometry to control the compression or extension of the rear suspension in response to a draft load. The draft compensating suspension enables the tractor hitch to be mounted on the suspended frame or chassis of the tractor rather than mounting the hitch to a non-suspended beam axle or locking out the suspension during draft work. The draft load is applied to the chassis by a ground engaging implement. The tractive load and torque at the rear wheels are reacted through the side view instantaneous center of the rear suspension. The placement of the instantaneous center will determine the suspension reaction to the wheel load and torque. Locating the suspension instantaneous center on a line of 100% draft-compensation will eliminate the motion of the suspension due to the draft load. If the instantaneous center is located below the 100% draft-compensation line, the suspension will compress under a draft load. If the instantaneous center is located above the 100% draft-compensation line, the suspension will extend under a draft load. The distance between the instantaneous center and the 100% draft compensation line will determine the amount of compression or extension of the suspension. | 8 |
FIELD OF THE INVENTION
The invention relates to ironing devices. More particularly the inventions relates to the arrangement and constructive design of a handle of an ironing device.
BACKGROUND OF THE INVENTION
In the art several ironing devices have been proposed. The French Patent FR 602 293 proposes an ironing device with a pivotely connected handle, which, upon the application of an operating force thereon, opens a valve such that steam is being generated. After removal of the operating force, the valve shuts and the generation of steam is stopped.
A drawback of this ironing device is that the pivot of the handle of this device is positioned at the rear end of the handle, thus requiring the user to apply an unpractical, forwardly tilted force to the handle in order to release the steam.
A further drawback is that the ironing device in this document does not allow the control of other functions such as e.g. a spray function, a shot of steam function, dosing and/or metering functions in a practical way.
SUMMARY OF THE INVENTION
The object of the invention is to provide an ironing device that is overcoming or alleviating at least one of the drawbacks of ironing devices of the art while maintaining the advantages thereof. Further objects of the invention may be to improve the comfort of use of ironing devices while maintaining a robust, effective, economical and practical design.
At least one of these and/or other objects are reached by an ironing device comprising: a base; a handle moveable relative to the base; a resilient member biasing the handle in an upper position and allowing movement of the handle upon exertion of a force thereon by a user towards a lower position; a steam controller operatively connected to the handle such that the release of steam of the ironing device at least in part is intuitively controlled by the force exerted on the handle by the user; a console that is connected with the base and that is provided with at least one operating button; and at least one recess in the handle at least partly accommodating the console, the console and the handle being configured so that the at least one operating button is operable with the same hand that holds the handle.
By this arrangement, the user can intuitively control the amount of steam and/or the temperature of the ironing device while simultaneously he/she can control the additional features such as e.g. a steam pulse, a water spray pulse and/or other features.
Due to the recess within the handle, the console is allowed to remain fixed within the pivotable handle. The handle is allowed to move independently from the console, the buttons and/or displays while these remain embedded within the handle. Thus the operation of this ironing device becomes intuitive without losing the operational advantages of the additional buttons, controls and/or displays of the ironing device.
Accordingly, the user can operate the ironing device and control the intuitive emission of steam and the other buttons and controls with one and the same hand. The hand of the user can remain in the same position during the operating of any of the buttons and/or the controls.
Since the console with the buttons and/or controls remains installed on the base, the vulnerable parts can be firmly and simply mounted into the device. Thus a practical and easily operable ironing device is proposed, that remains robust and requires a relatively uncomplicated design and manufacture.
Another advantage is that, by this arrangement, the moving of the handle prevents unintentional interference with any control and/or any button, so that the unintentional pressing of any of these controls and/or buttons is avoided.
A further aspect of the invention is a method of ironing comprising the steps of: providing an ironing device as described above, exerting a force on the handle such that it moves relative to the base and intuitively controlling the amount of steam emitted by the ironing device by exerting more or less force to the handle.
Further embodiments can be found in the dependent claims. These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding, embodiments of the ironing device will be further elucidated by the following Figures, wherein:
FIG. 1 is a schematic side view of a first embodiment;
FIG. 2 is a schematic top view of a second embodiment;
FIG. 3 is a schematic top view of a third embodiment;
FIG. 4A is a schematic side view of a fourth embodiment in a first position;
FIG. 4B is a schematic side view of a fourth embodiment in a second position;
FIG. 5A-D is a set of graphs representing schematically several embodiments of a relation between the force exerted onto the handle and the amount of steam being emitted.
In the figures and the description the same or corresponding parts will have identical or similar reference signs. The embodiments shown should not be understood as limiting the invention in any way or form.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 depicts a side view of an ironing device 1 . The ironing device 1 comprises a base 2 and a handle 3 . Below the base 2 , and ironing sole 15 is arranged, which can be provided with steam and/or water holes 16 . Inside the base 2 or the handle 3 a reservoir 13 is arranged for water. Although in FIG. 1 the reservoir is arranged within the ironing device, alternatively the reservoir can be a separate or remote reservoir, for instance connected to the ironing device by means of a water or steam transporting line. During the use of the ironing device 1 , steam can be generated and released or emitted upon the cloth to be ironed through the holes 16 .
In FIG. 1 , the handle 3 is pivotely connected to the base 2 by means of a pivot 8 . The handle 3 is further provided with a cut out or recess 5 wherein a console 6 is placed. On the console 6 , operating buttons, controls 7 and/or displays may be arranged. The lower side the console 6 is mounted on the base 2 of the ironing device 1 .
The handle 3 may, for example be at its rear side 12 provided with a resilient element 9 . This resilient element 9 can for instance be a rubber bellow, a sleeve with e.g. a spring incorporated therein and/or made of other resilient material.
At the front end side of the handle 2 , for protection of the inner parts from water or steam entering, the handle 2 may be provided with a flexible protecting seal 10 . This flexible protecting seal 10 may be, for instance, a transparent rubber sleeve, which closes off the pivoting connection between the base 2 and the handle 3 , which can further also enclose the console 6 and the buttons and/or the controls 7 .
The handle 3 is connected to a controller 4 that can control the amount of steam being emitted. In order to control the amount of steam being emitted, the controller 4 may be connected to a valve 14 which can for instance open a connection between the reservoir 13 and the sole 15 . The control 4 may be of an electrical, mechanical and an electromechanical nature. The water can evaporate during its travel through the sole 15 and thus provide additional steam to the cloth to be ironed.
In case the handle 3 is pressed down further, the controller 4 can be adapted to open the valve 14 even more such that more steam is generated and emitted. Thus the user of the ironing device 1 may adjust the amount of steam being emitted and learn to intuitively operate the ironing device 1 .
The resilient element 9 can for instance provide an increasing counterforce when the handle 3 is forced down. Thus the relative motion in relation to the force applied to the handle 3 can be set. Also the relative opening of the steam valve 14 can be adapted such that a well designed relation between the force applied on the handle and the amount of steam being emitted can be precisely adjusted.
Examples of graphs representing different relations between the amount of force exerted on the handle 3 and the amount of steam being emitted can de found in FIGS. 5 a - d , which are described in more detail further below.
Since the flexible protecting seal 10 can be attached to the handle 3 as for instance a tight fitting transparent sleeve, the buttons 7 and/or the controls on the console 6 can be visible and can be operated. During a slight pivoting of the handle 3 relative to the base 2 , the flexible protecting seal 10 will flex and allow the handle 3 to be rotated without resistance. Thus the controls and/or the buttons 7 remain operable by the user, even by means of the very same hand the user is using to exert the force upon the handle 3 .
Thus an ironing device 1 is obtained that is provided with increased user convenience and a more adaptive steam supply.
In FIG. 2 , a top side view of a second embodiment of the invention is presented. In this embodiment the recess or the cut out 5 is provided as a central opening within the handle. The buttons and/or controls 7 are positioned on a console 6 that is—from a top side view—surrounded by the handle 3 . In this embodiment, the buttons, controls 7 and/or displays are thus a fixed island within the pivotable handle 3 . Other stationary elements within the fixed console 6 can be a water filling hole, a knob, a steam selector slide, a steam and/or water spraying nozzle, a lime build up protector and/or other functional parts of a conventional ironing device.
In an alternative embodiment as represented by FIG. 3 the buttons and/or controls 7 are distributed around a central part 3 a of the handle 3 , where these buttons and/or controls 7 are positioned upon a divided console 6 , which is arranged on each side of the handle 3 .
In both the embodiments shown in FIGS. 2 and 3 as well the embodiments shown in FIGS. 4A and 4B , the consoles 6 are base 2 mounted, whereas the handle 3 is pivotly connected to the base 2 and rotates relative to the base 2 as well as relative to the consoles 6 . In these embodiments the handle 3 can preferably rotate around a pivot that is arranged at the front side end 11 of the handle 3 .
The front side portion 11 of the handle 3 may be a separate portion attached to the handle 3 in a robust way. This front end portion 11 may be a flexible sealing member. It can for instance be a continuous structure in order to provide maximum rigidity, although constructions with openings reinforced for rigidity may also be considered. These reinforcements may be in the form of flanges, curved walls, ribs etc. which can be formed together with the front end portion or can alternatively be attached thereto.
In the embodiments shown in FIG. 4A the ironing device 1 is shown in a first position where the handle 3 is in its higher position relative to the base 2 . In dashed lines the lower position of the handle 3 is depicted. In FIG. 4B , the lower position of the handle 3 is depicted where the resilient member 9 is compressed. As can be seen in the FIGS. 4A and 4B , the console 6 together with the buttons and/or controls 7 do not move relative to the base 2 .
The downward motion of the handle 3 may be restricted or controlled by means of a stopper at the rear end 12 of the handle 3 . The rear end 12 could be provided with an effective stopping tolerance tool such as a resilient element 9 .
As the activation of the steam emission via the pivoting handle 3 should be intuitive, the movement of the handle 3 can be kept at a minimum such that it allows easy and low effort activation of the steam emission during ironing strokes. The pivoting movement of the handle 3 could therefore be less than 10 degrees or the translational movement of the rear end of the handle could be less than 15 mm.
Since the consoles 6 and the buttons and/or controls 7 are not moving or rotating in relation to the base 2 , all the connections and wiring can be fixedly and durably be connected. By the resilient element 9 and/or the flexible protecting seal 10 , the inner components can be protected from water and/or dust ingress. The front end 11 of the handle 3 , when arranged as a flexible portion could may prevent the material from cracks or fissures due to the hinging effects of the handle 3 .
Both the flexible seal 10 and the resilient element 9 provide protection of the internals of the ironing device and may be produced with in-mold techniques or may alternatively be fixed separately to the base 2 and/or the handle 3 . The resilient element 9 and the protective seal 10 can further provide additional esthetical functionality to the ironing device 1 .
In these embodiments, the intuitive handle can be constructed in such a way as to allow easy activation of the steam emission during ironing strokes. A front end pivoting or hinging handle turns out to be easily able to be activated and thus to emit steam. Because of the arrangement of the pivot at the front end side of the handle, a downward force application during a forward stroke happens naturally as the user pushes the iron forward. In the backward stroke, generally the user tends to iron over the same area as in the forward stroke, during which the user tends to apply less downward force. Due to the resilient nature of the resilient element, the handle is moved upwards, thus decreasing the amount of steam being emitted during the backward stroke. In this way with the ironing device according to these embodiments, during an ironing exercise less energy could be needed. Thus the operating costs may be reduced in a beneficial way.
In FIG. 5A-D schematic relations between the exerted force F and the amount of steam S are depicted. In these diagrams the abscissa represents the amount of force F that is exerted on the handle 3 and the ordinate represents amount of steam S being emitted. In FIG. 5A a linear relation between the amount of force and the amount of steam being emitted is given. For a user this means that twice as forceful using the ironing device means twice as much steam.
In FIG. 5B the amount of steam being emitted exponentially increases with the amount of force being applied. This means that a user has to apply a lot of force to obtain some steam whereas an additional amount of force will further extra proportionally increase the amount of steam being emitted.
In FIG. 5C the amount of steam being emitted when only a minor force is applied will be relatively high, whereas the incremental steam production will with considerable additional force only be limited.
In FIG. 5D even when no force is applied, some offset steam is emitted anyhow. In the FIGS. 5A to 5C only steam is emitted when at least some force is exerted upon the handle whereas in the embodiment of FIG. 5D a basic steam production is provided irrespective of the force being exerted.
While the invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited in any way or form to the disclosed embodiments. In any embodiment of the invention as described before numerous adaptations and modifications are possible. For instance the reservoir 13 is described to contain water. Other fluids or mixtures thereof can similarly be applied. Examples thereof might be starch or alcohol containing fluids and/or softeners containing fluids. The handle 3 is depicted to rotate from a pivot 8 arranged at the front side 11 of the handle. The pivot can also be a resilient element that flexes and thus allows a rotating motion of the handle. Alternatively the handle 3 may be shifted downwards a little by the first and second resilient element. In this alternative the handle can be pushed down in order to obtain the emission of steam.
In the description the console is described to comprise buttons, controls, displays, water filling holes, steam and/or water spraying nozzles, knobs, dials and other functions. The amount of functions is not limited to these described elements, other functions and elements can be incorporated within the console 6 as well. For example special component dosing such as softener components, stiffening components and/or other functionalities may similarly be integrated within the console.
Throughout this text and the claims, the term resilient, flexible and/or flexible material(s) is to be understood but not limited to special materials that are resilient in that they regain their original shape after deformation. Examples of flexible materials are rubber, like silicon rubber, natural rubber, butadiene rubber, different elastoplastic materials and the like. Also other synthetic or natural resilient materials can be used.
Other materials can have a similarly high elastic limit due to their specific shape. Springs of any kind and of any material can hold these very same resilient properties.
Throughout this text the wording front end or front end portion refers to the front end of the ironing device or the front end of the handle, being typically that end that is pointing in the same direction as the tip of the elongated triangular arrowhead shape of the sole 15 of the ironing device 1 . Typically, users grab the ironing device automatically such that the thumb of the user is positioned directing towards the front end side of the handle and the ironing device.
Throughout the text the term intuitive and or intuitively refers to a skill of a user that he or she automatically develops during the use of the device. The relation between the amount of steam being emitted or released and the amount of force being applied upon the handle during use will automatically be appreciated and understood by the user, and he she will very soon automatically adapt the applied force in order to emit the amount of steam necessary. Thus the user automatically develops a skill for the application of the correct amount of force that is based solely upon experience, practise and the development of a feeling thereto. | An ironing device includes a base, a handle moveable relative to the base, and a resilient member biasing the handle in an upper position and allowing movement of the handle upon exertion of a force thereon by a user towards a lower position. Further, a steam controller is operatively connected to the handle such that release of steam of the ironing device is intuitively controlled by the force exerted on the handle by the user. A console is connected with the base and is provided with at least one operating button. The handle includes a recess for accommodating the console, where the console and the handle are configured so that an operating button is operable with the same hand that holds the handle. | 3 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] Compounds, compositions and methods for the treatment of immunologically-related diseases and disorders such as autoimmune disorders and organ graft rejection.
[0003] 2. Related Art
[0004] Action of the immune system is known to be involved in immunologically-related diseases and disorders such as autoimmune disorders and in organ graft rejection (“OGR”). Hematopoietic, thymus-derived cells, (so-called “T cells”) have an important and pervasive role as regulators and effectors of the functions of the immune system. Hematopoietic cells, and T cells in particular have on their surfaces a major transmembrane glycoprotein designated CD45, characterized by a cluster of antigenic determinants. CD45 is also known as leukocyte common antigen (“LCA”). The cytosolic portion of CD45 has protein tyrosine phosphatase (“PTP”) activity and CD45 activity is known to be essential for TCR initiated T cell activation. Studies in CD45-deficient cell lines have shown that CD45 is a positive regulator of the T-Cell Receptor (“TCR”) and that CD45 functions in TCR regulation by dephosphorylating the src kinases p56 lck and p59 fyn , which allows autophosphorylation of the positive regulatory site on these enzymes; these reactions lead to downstream events and ultimately to T cell activation.
[0005] Available treatments for autoimmune disorders and OGR have therapeutic disadvantages. For example, Cyclosporin A, the drug most commonly used to treat OGR, has renal and CNS toxicity.
SUMMARY OF THE INVENTION
[0006] Potent inhibitors of CD45 have been discovered. Such inhibitors are useful for the treatment of various autoimmune disorders as well as for treatment of OGR. Inhibition of the phosphatase activity of CD45 by compounds of the present invention has been shown by incubating the cytosolic portion of CD45 with the compounds and p-nitrophenyl phosphate (pNPP), a phosphatase substrate. Spectrophotometric monitoring has shown that the liberation of p-nitrophenol from the substrate by CD45 is inhibited in the presence of the compounds disclosed herein. Inhibition of the phosphatase activity of CD45 by compounds of the present invention has also been shown using a p56 lck carboxy-terminal phosphorylated peptide as a substrate. Compounds of the present invention have also been shown to inhibit proliferation of T cells in a T-cell proliferation assay.
[0007] Compounds of the present invention are naphthalenediones in accord with structural diagram I:
[0008] wherein:
[0009] Q 1 at each occurrence is independently selected from hydrogen, hydroxy. halogen, C(O)O(C 1 -C 3 )alkyl and C(O)phenyl, and
[0010] Q 2 is selected from hydrogen, halogen, O—(C 1 -C 3 )alkyl, O—(C 1 -C 3 )alkenyl, phenyl, indolyl and naphthyl, where phenyl may be mono- or di-substituted with NO 2 or halogen, and indolyl may be substituted with (C 1 -C 3 )alkyl or phenyl.
[0011] Particular compound of the invention are 4-(4-bromo-phenyl)-[1,2]naphthoquinone; 4-(3,5-dichloro-phenyl)-[1,2]naphthoquinone; 4-(3-nitro-phenyl)-[1,2]naphthoquinone; 5,6-dioxo-5,6-dihydro-naphthalene-1-carboxylic acid methyl ester, and 5,6-dioxo-5,6-dihydro-naphthalene-2-carboxylic acid methyl ester.
[0012] Compounds of the present invention are ligands of CD45 which, when bound, inhibit the activity of the protein tyrosine phosphatase (PTP) activity of the cytosolic portion of CD45. Binding of a compound of the present invention to CD45 inhibits the activity of CD45 essential for TCR initiated T cell activation. Thus, compounds of the invention inhibit the positive regulation of the TCR that leads to downstream events and T cell activation. Compounds of the present invention are useful to suppress the action of the immune system in immunologically-related diseases and disorders such as autoimmune disorders and organ graft rejection and to inhibit the action of T cells as functional regulators and effectors of the immune system.
[0013] The present invention also encompasses compositions made with compounds described herein useful for the treatment of immunologically-related diseases and disorders and methods utilizing such compositions for treating such disorders.
DETAILED DESCRIPTION OF THE INVENTION
[0014] As used herein, (C 1 -C 4 )alkyl has its conventionally-understood meaning and particularly means linear or branched hydrocarbon chains having from one to four carbon atoms and thus includes methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, and the like.
[0015] As used herein, halo(C 1 -C 4 )alkyl has its conventionally-understood meaning and particularly means (C 1 -C 4 )alkyl as used herein wherein hydrogen atoms have been replaced by halogen atoms and thus includes monochloromethyl, trifluoromethyl, difluoroethyl, trifluoropropyl, perfluoro(C 1 -C 4 )alkyl, and the like.
[0016] As used herein, perfluoro(C 1 -C 4 )alkyl has its conventionally-understood meaning and particularly means (C 1 -C 4 )alkyl as used herein wherein each hydrogen atom has been replaced by a fluorine atom and thus includes trifluoromethyl.
[0017] As used herein, (CH 2 ) n has its conventionally-understood meaning and particularly means linear hydrocarbon chains having from one to n carbon atoms and thus includes methylene, ethylene, propylene, n-butylene groups, and the like.
[0018] As used herein, the terms halogen, halo, or halide have their conventionally-understood meanings and particularly mean chlorine, bromine, iodine or fluorine.
[0019] As used herein, the term “from the range 1 to 6” or the like, means any integral value in the stated range, in this example 1, 2, 3, 4, 5 or 6.
[0020] Definitions of terms:
[0021] DMF, N,N-dimethylformamide; THF, tetrahydrofuran; TLC, thin-layer chromatography; NMR, nuclear magnetic resonance; TFA, trifluoroacetic acid; HPLC, high performance liquid chromatography; DMAP, 4-dimethylaminopyridine; DMSO, dimethylsulfoxide; IC 50 , concentration giving 50% inhibition; CC 50 , concentration giving 50% cytotoxicity; ND, not determined.
[0022] HPLC method used: Analytical HPLC using an HP 1100 HPLC, with a C 18 Dynamax column (5cm×4.6 mm, 3 μM particle size, 100 Å pore size), flow rate of 0.5 mL/min, 20%-60% CH 3 CN in H 2 O over 7.5 min, holding at 60% CH 3 CN for 2.5 min, while monitoring at 254 and 210 nm.
EXAMPLES
Example 1
[0023] [1,2]-Naphthoquinone was purchased from Acros Organics and used as received.
Examples 2 to 4
[0024] The compounds of examples 2 to 4 were prepared substantially in accordance with the procedures disclosed in Takuwa, A.; Soga, O.; Iwamoto, H.; Maruyama, K. Bull. Chem. Soc. Jpn . 1986, 59, 2959-2961, which procedures are incorporated herein by reference. The physical properties of the compounds are disclosed in the reference.
Example 2
[0025] 4-Ethoxy-[1,2]naphthoquinone.
Example 3
[0026] 4-Methoxy-[1,2]naphthoquinone.
Example 4
[0027] 4-Allyloxy-[1,2]naphthoquinone.
Examples 5 and 6
[0028] The compounds of examples 5 and 6 were prepared substantially in accordance with the procedures disclosed in Perumal, P. T.; Bhatt, M. V. Synthesis 1980, 943-945, which procedures are incorporated herein by reference. The physical properties of the compounds are disclosed in the reference.
Example 5
[0029] 4-Chloro-[1,2]naphthoquinone.
Example 6
[0030] 4-Bromo-[1,2]naphthoquinone.
Examples 7 and 8
[0031] The compounds of examples 7 and 8 were prepared substantially in accordance with the procedures disclosed in Henrion, J.-C.; Jacquet, B.; Hocquaux, M.; Barre, G.; Hedayatullah, M.; Lion, C. Bull. Soc. Chim. Belg. 1996, 105, 415-418. which procedures are incorporated herein by reference. The physical properties of the compounds are disclosed in the reference.
Example 7
[0032] 4-(1-Methyl-1H-indol-3-yl)-[1,2]naphthoquinone.
Example 8
[0033] 4-(2-Phenyl-1H-indol-3-yl)-[1,2]naphthoquinone.
Example 9
[0034] 4-(2-Chloro-phenyl)-[1,2]naphthoquinone:
[0035] To a solution of 4-bromo-[1,2]naphthoquinone (350 mg, 1.48 mmol) in THF (20 mL) and H 2 O (5 mL) was added 2-chlorophenylboronic acid (231 mg. 1.48 mmol). followed by tri-o-tolylphosphine (45 mg, 148 μmol) and K 2 CO 3 (614 mg, 4.44 mmol). The mixture was deoxygenated with bubbling N 2 for about ten minutes, at which time the N 3 line was removed and tris(dibenzylideneacetone)dipalladium(0) (68 mg, 74 μmol) was added. The resultant mixture was heated to reflux for 2 hours under N 2 , at which point no starting bromide was detectable by TLC (hexanes:ethyl acetate, 1:1, v/v). The mixture was cooled to room temperature and the THF evaporated under reduced pressure. The dried material was dissolved in ethyl acetate, washed sequentially with saturated aqueous ammonium chloride, H 2 O and brine, dried over Na 2 SO 4 , filtered, and evaporated under reduced pressure. The isolated material was chromatographed on silica gel (hexanes-ethyl acetate, 4:1, v/v) and dried to yield the product, 4-(2-chloro-phenyl)-[1,2]naphthoquinone, as an orange solid. 1 H NMR (300 MHz, CDCl 3 ) δ 8.21 (1H, dd, J=6.9, 2.1 Hz), 7.56-7.52 (3H, m), 7.48-7.44(2H, m), 7.44 (1H, m), 6.91 (1H, dd, J=2, 6 Hz), 6.39 (1H, s); HPLC: 7.45 min.
[0036] Compounds of examples 10 to 14 inclusive were made by the method of Example 9, by utilizing the appropriate boronic acid.
Example 10
[0037] 4-(4-Bromo-phenyl)-[1,2]naphthoquinone:
[0038] Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (1H, dd, J=1.8, 7.2 Hz), 7.67 (2H, d, J=6.6 Hz), 7.63-7.60 (2H, m), 7.33 (2H, d, J=6.6 Hz), 7.25 (1H, dd. J=2, 8 Hz), 6.41 (1H, s); HPLC: 8.25 min.
Example 11
[0039] 4-Phenyl-[1,2]naphthoquinone:
[0040] Orange-red solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (1H, dd, J=1.8, 7.2 Hz), 7.62-7.52(5H, m), 7.46-7.44(2H, m), 7.30(1H, dd, J=1.2, 7.5 Hz), 6.43 (1H, s); HPLC: 6.90 min
Example 12
[0041] [1,1′]Binaphthalenyl-3,4-dione:
[0042] Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.40 (1H, dd, J=1.5, 7.5 Hz), 8.00 (1H, d, J 8.1 Hz), 7.96(1H d, J=8.1 Hz), 7.72(1H, d, J=8.4 Hz), 7.62 (1H, d, J=7.2 Hz), 7.57 (1H, d, J=7.8 Hz), 7.53-7.42 (4H, m), 6.83 (1H, d, J=8.3 Hz), 6.55 (1H, s); HPLC: 8.27 min.
Example 13
[0043] 4-(3,5-Dichloro-phenyl)-[1,2]naphthoquinone:
[0044] Orange solid; 1 H NMR (300 MHz. CDCl 3 ) δ 8.23 (1H, dd, J=1.8, 7.2 Hz), 7.67-7.56 (2H, m), 7.53 (1H, m), 7.41 (1H, m), 7.33 (1H, m), 7.20(1H, d, J=7.5 Hz), 6.40 (1H, s); HPLC: 9.0 min.
Example 14
[0045] 4-(3-Nitro-phenyl)-[1,2]naphthoquinone:
[0046] Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.41 (1H, d, J=7.2 Hz), 8.34 (1H, s), 8.27 (1H, m), 7.78 (2H, m), 7.63 (2H, m), 7.15 (1H, d, J=7.7 Hz), 6.46 (1H, s); HPLC: 5.78 min.
Examples 15 to 17
[0047] The compounds of examples 15 to 17 were prepared substantially in accordance with the procedures disclosed in Barton, D. H. R.; Brewster, A. G. Ley, S. V.; Read, C. M.; Rosenfeld, M. N. J. Chem. Soc. Perkin Trans. 1 1981, 1473-1476, which procedures are incorporated herein by reference.
Example 15
[0048] 6-Benzoyl-[1,2]naphthoquinone:
[0049] Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.23 (1H, d, J=7.8 Hz), 7.86 (1H, dd, J=1.5, 7.8 Hz), 7.83-7.79 (3H, m), 7.67 (1H, m), 7.57-7.51 (3H, m), 6.54 (1H, d, J=10.2 Hz); HPLC: 5.93 min.
Example 16
[0050] 5,6-Dioxo-5,6-dihydro-naphthalene-1-carboxylic acid methyl ester:
[0051] This compound was prepared using 5-carbomethoxy,-2-naphthol as a starting material. The starting material was prepared according to the method of Anderson, L. C.; Thomas, D. G. J. Am. Chem. Soc. 1943, 65, 234-238. Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.62 (1H, d, J=11 Hz), 8.29 (1H, d, J=7.8 Hz), 8.20 (1H, d, J=7.8 Hz), 7.58 (1H, t, J=7.8 Hz), 6.56 (1H, d, J=11 Hz), 3.99 (3H, s); HPLC: 3.69 min.
Example 17
[0052] 5,6-Dioxo-5,6-dihydro-naphthalene-2-carboxylic acid methyl ester:
[0053] This compound was prepared using 6-carbomethoxy-2-naphthol as a starting material. The starting material was prepared according to the method of Anderson, L. C.; Thomas, D. G. J. Am. Chem. Soc. 1943, 65, 234-238. Orange solid; 1 H NMR (300 MHz, CDCl 3 ) δ 8.17 (2H, m), 8.05 (1H, s), 7.52 (1H, d, J=10.2 Hz), 6.53 (1H, d, J=10.2 Hz), 3.99 (3H, s); HPLC: 3.61 min.
Example 18
[0054] 7-Hydroxy-[1,2]naphthoquinone:
[0055] This compound was prepared substantially in accordance with the procedures disclosed in Teuber, H.-J.; Gotz, N. Chem. Ber. 1954, 1236-1251, which procedures are incorporated herein by reference. Red solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 10.50 (1H, broad s), 7.56 (1H, d, J=9.8 Hz), 7.40 (1H, d, J=8.1 Hz, 7.31 (1H, d, J=2.7 Hz), 7.05 (1H, dd, J=8.1, 2.7 Hz), 6.16 (1H, d, J=9.9Hz); Anal. Calcd. For C 10 H 6 O 3 -0.1H 2 O: C, 68.26; H, 3.55. Found: C 67.96, 67.89; H, 3.64, 3.65.
Assays for Biological Activity
[0056] Method A:
[0057] Phosphatase Assay Using pNPP as Substrate:
[0058] CD45 enzyme was obtained from BIOMOL (Plymouth Meeting, Pa.). Phosphatase activity was assayed in a buffer containing final concentrations of 25 mM imidazole at pH 7.0, 50 mM NaCl, 2.5 mM ethylenediaminetetraacetic acid (“EDTA”), 5 mM dithiothreitol (“DTT”) and 10 μg/mL bovine serum albumin (“BSA”) using pNPP as a substrate. Compounds were tested in a range from 30 to 0.01 μM, with a final concentration of 1 or 5% dimethylsulfoxide (“DMSO”), depending on the compound solubility. Activity was measured by following the increase in absorbance at 405 nm using a SpectraMax Plus spectrophotometric plate reader (Molecular Devices, Sunnyvale, Calif.).
[0059] Method B:
[0060] Cytotoxicity Assay:
[0061] Calcein-AM (Molecular Probes, Eugene, Oreg.) uptake, as a quantitative measure of cell viability, was used to evaluate the toxic effect of compounds on T cells. Briefly, PBMC were treated for 3-7 days with 3-10 μg/ml PHA, a potent T-cell mitogen, to preferentially expand the T-cell population. (Bradley, Linda M. Cell Poliferation in Selected Methods in Cellular Immunology . Eds. Mishell B. B. and Shiigi. S. M., W. H. Freeman and Co. San Francisco, 1980.)
[0062] The T-cell lymphoblasts were purified by separation over Lymphoprep, plated at 2×10 5 /well in a round bottom 96-well plate containing RPMI with compound and incubated overnight at 37° C. in an incubator containing 5% CO 2 . The dilution scheme and culture media were the same as those used in the T-cell proliferation assay. After the incubation period. cells were washed with Dulbecco's phosphate-buffered saline (D-PBS) and incubated with 1 μM Calcein-AM for 30-45 min in D-PBS as described in the technical sheet provided with The LIVE/DEAD Viability/Cytotoxicity Kit from Molecular Probes. Percent viability was assessed on a fluorescent plate reader (excitation filter 485/20 nm; emission filter 530/25 nm) where the 100% control value is the fluorescence intensity observed in the absence of test compound.
[0063] Method C:
[0064] Phosphatase Assay Using lck 10-mer as Substrate:
[0065] Phosphatase activity was assayed in 96 well plates in a buffer containing final concentrations of 25 mM HEPES at pH 7.2, 5 mM DTT and 10 μg/mL BSA, using the lck carboxy-terminal peptide TEGQpYQPQP as the substrate (Cho, H., Krishnaraj. R., Itoh. M., Kitas, E., Bannwarth, W., Saito, H., Walsh, C. T. 1993. Substrate specificities of catalytic fragments of protein tyrosine phosphatases (HPTPb, LAR. and CD45) toward the phosphotyrosylpeptide substrates and thiophosphotyrosylated peptides as inhibitors. Protein Science 2:977-984). Compounds were tested in a range from 30 to 0.01 μM in a final concentration of 5% DMSO. Enzyme was incubated with substrate. with or without compound, at room temperature for 1.5 h. At the end of the incubation period, BIOMOL “Green Reagent” (BIOMOL, Plymouth Meeting, Pa.) was added to each well, the plates incubated at room temperature for 30 min and absorbance read at 620 nm.
[0066] Method D:
[0067] Cell Isolation and T Cell Proliferation Assay:
[0068] Whole blood was obtained from healthy human blood donors. Peripheral blood mononuclear cells (“PBMC”) were isolated using Lymphoprep density-gradient centrifugation (Nycomed Amersham, Oslo, Norway), washed, counted and resuspended at 2×10 6 cells/mL in RPMI 1640 medium containing glutamine, 0.1 mg/mL gentamycin and 10% heat inactivated human serum. PBMC were transferred to 96-well plates (2×10 5 cells/well) containing compound or vehicle control, with the final concentration of DMSO not to exceed 0.3% and incubated for 1 hour before addition of the activating anti-CD3 antibody, OKT3 (30 ng/mL). After 24 hours in culture, the cells were pulsed with [3H]thymidine (1 μCi/well) overnight and harvested the next day onto 96-well Packard GF/C filter plates using a Packard Cell Harvester (Packard Instruments, Meriden, Conn.). The filter plate was dried, the bottom of the plate sealed, 25 μL of Microscint 20 scintillation fluid added to each well, the top of the plate sealed with TopSeal-A, and the plate counted on a Packard TopCount. The data from the TopCount is transferred into Excel 5 (Microsoft, Redmond, Wash.) and formatted for EC 50 determination using Prism software (GraphPad Software, San Diego, Calif.).
[0069] Table 1 shows the inhibition of CD45 activity in the pNPP asssay and the lck assay certain compounds of the present invention. Inhibition in the T cell proliferation assay, as well as results from T cell cytotoxicity assay are shown.
TABLE 1 pNPP IC 50 Ick IC 50 T cell prolif. Example No. (μM) (μM) IC 50 (μM) CC 50 (μM) 1 3 >30 7 >30 2 2 ND >30 30 3 1.2 4.2 >30 ND 4 1.2 4.9 >30 >30 5 10 >30 >30 >30 6 8.7 >30 22 >30 7 5 19 1.5 >30 8 2.9 20 2 16 9 8 >30 0.3 124 10 7.7 >30 0.11 3 11 5 >30 0.15 12 12 22.5 >30 3.2 >30 13 5.5 ND 0.3 5.5 14 7.9 >30 0.2 4 15 22 >30 11 >30 16 11 >30 3.5 >30 17 7 >30 7 >30 18 4.9 ND >30 >30 | Substituted naphthalenediones in accord with structural diagram (I): compositions thereof and methods for the use thereof, for the treatment of T cell mediated conditions such as autoimmune diseases and organ graft rejection. In compounds of the invention, wherein: Q 1 at each occurrence is independently selected from hydrogen, hydroxy, halogen, C(O)O(C 1 -C 3 ) alkyl and C(O)phenyl, and Q 2 is selected from hydrogen, halogen, O—(C 1 -C 3 )alkyl, O—(C 1 -C 3 )alkenyl, phenyl, indolyl and naphthyl, where phenyl may be mono- or di-substituted with NO 2 or halogen, and indolyl may be substituted with (C 1 -C 3 )alkyl or phenyl. | 2 |
CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese application serial no. 2005-189234, filed on Jun. 29, 2005, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a liquid crystal display device, and in particular to a technology useful for application to a backlight of a liquid crystal display device.
[0003] Widely used as display sections of portable equipment such as mobile phones are TFT (Thin Film Transistor) type liquid crystal display modules each provided with a small-sized color liquid crystal panel having subpixels in the order of 240×320×3 in number.
[0004] FIG. 16A is a schematic exploded perspective view illustrating a rough configuration of a conventional liquid crystal display module. As shown in FIG. 16A , in the conventional liquid crystal display module, arranged in the order shown in FIG. 16A within a metal frame 16 , for example, a die cast frame made of magnesium alloy, are a liquid crystal display panel LCD, a mold 11 formed of synthetic resin, for example, and a light reflective sheet 12 . Disposed within the mold 11 are a light guide 10 , a group of optical sheets (upper and lower light diffusing sheets and a lens sheet) 15 , and a light source (white light emitting diodes) 13 .
[0005] The liquid crystal display panel LCD is fabricated by attaching together a glass substrate TFTSUB provided with thin film transistors, drain lines, gate lines and others (not shown) and a glass substrate CFSUB provided with a counter electrode, color filters and others (not shown) with a sealing agent (not shown) interposed therebetween, then filling a liquid crystal material (not shown) into a space between the two glass substrates TFTSUB, CFSUB, and sealing off the space, and then attaching polarizing sheets POL 1 and PLO 2 on the outer surfaces of the two glass substrates TFTSUB and CFSUB, respectively. In FIG. 16A , reference character DRV denote semiconductor chips for driving the subpixels of the liquid crystal display panel LCD
[0006] The frame 16 in FIG. 16A is required to be electro-conductive so as to prevent EMI (Electromagnetic Interference) and mechanically strong, and therefore the frame 16 is formed of a magnesium alloy die cast, for example.
[0007] FIG. 16B is a cross-sectional view of the conventional liquid crystal display module of FIG. 16A in the assembled condition taken along line XVIB-XVIB of FIG. 16A . The liquid crystal display panel LCD is attached to a recess formed in the mold 11 by using double-faced adhesive tapes 100 .
[0008] FIGS. 17A and 17B are illustrations for explaining the mold 11 shown in FIGS. 16A and 16B , FIG. 17A is a plan view of the mold 11 , and FIG. 17B is a cross-sectional view of the mold 11 taken along line XVIIB-XVIIB of FIG. 17A . As shown in FIGS. 17A and 17B , the mold 11 shown in FIG. 16A is of the shape of a frame (or a cylinder) having a rectangular cross section, and is formed with engaging portions la.
[0009] FIGS. 18A-18C are illustrations for explaining the frame 16 shown in FIGS. 16A and 16B , FIG. 18A is a plan view of the frame 16 , and FIG. 18B is a cross-sectional view of the frame 16 taken along line XVIIIB-XVIIIB of FIG. 18A , FIG. 18C is an enlarged view of an encircled portion A of FIG. 18B , and FIG. 18D is an enlarged perspective view of the encircled portion A of FIG. 18B . As shown in FIGS. 18A-18D , the frame 16 has a bottom portion 30 and a sidewall 31 formed along the peripheries of the bottom portion 30 , and the frame 16 has through holes 1 b therein extending continuously from the bottom portion 30 to the sidewall 31 .
[0010] FIGS. 19A-19C are illustrations for explaining a method of fixing together the mold 11 and the frame 16 shown in FIG. 16A , FIG. 19A is a plan view of an assembly of the mold 11 and the frame 16 , FIG. 19B is a cross-sectional view of the assembly of FIG. 19A taken along line XIXB-XIXB of FIG. 19A , and FIG. 19C is an enlarged view of an encircled portion B of FIG. 19B . Incidentally, the liquid crystal display panel LCD, the light guide 10 , the group of optical sheets 15 or the light source 13 are not shown in FIGS. 19A-19C for the sake of simplicity.
[0011] As shown in FIGS. 19A-19C , the mold 11 is fixed to the frame 16 by inserting the engaging portions la formed in the sidewall of the mold 11 into the through holes 1 b formed in the frame 16 , and engaging tips of the engaging portions la with the sidewall of the frame 16 (or hooking the tips of the engaging portions la to the sidewall of the frame 16 ).
[0012] Incidentally, the shapes of the mold 11 and the frame 16 are schematically illustrated in FIGS. 16A-19C and later-explained figures for explaining the features of the present invention clearly, and therefore they do not always represent the shapes of the mold 11 and the frame 16 in practical applications.
SUMMARY OF THE INVENTION
[0013] There was a problem with the method of fixing the method of fixing together the mold 11 and the frame 16 explained in connection with FIGS. 19A-19C , in that, as shown in FIG. 19C , light from the light source (white light emitting diodes) 13 (see FIG. 16A ) leaks in an X direction (a direction indicated by an arrow C in FIG. 19C ) and a Y direction (a direction indicated by an arrow D in FIG. 19C ) via the through hole 1 b formed in the frame 16 .
[0014] However, since it is necessary to visually check the engaging portions 1 a formed in the sidewall of the mold 11 and the through holes 1 b in the frame 16 , for the purpose of seeing whether the mold 11 and the frame 16 are fixed together properly after assembling of the liquid crystal display module, it was difficult to prevent the above-explained leakage of light.
[0015] The present invention has been made to solve the above-explained problems with the prior art, and it is an object of the present invention to provide a technology capable of reducing leakage of light from a backlight of a liquid crystal display device. The above-mentioned and other objects and novel features of the present invention will become more apparent by reference to the following detailed description taken in conjunction with accompanying drawings.
[0016] The following will explain briefly the summary of the representative ones of the inventions disclosed in this specification.
[0017] (1) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; a light reflective sheet disposed behind said frame-like mold; and a frame which houses said frame-like mold and said light reflective sheet, wherein said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said bottom portion is provided with a plurality of engaging through holes which are formed along said sidewall not to extend into said sidewall, said light reflective sheet is disposed on an upper surface of said bottom portion of said frame, and is provided with a plurality of cutouts disposed correspondingly to said plurality of engaging through holes such that said light reflective sheet does not lie over said plurality of engaging through holes, said frame-like mold is provided with a plurality of engaging protrusions which are disposed correspondingly to said plurality of engaging holes and protrude downward beyond a lower surface of said frame-like mold, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions into a corresponding one of said plurality of engaging through holes.
[0018] (2) The liquid crystal display device according to (1), wherein said frame-like mold and said frame are fixed together by engaging tips of said plurality of engaging protrusions with said sidewall of said frame.
[0019] (3) The liquid crystal display device according to (1), wherein said frame-like mold is provided with a step on said lower surface thereof for positioning an edge of said light reflective sheet such that said step does not lie over said plurality of engaging through holes.
[0020] (4) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; and a frame which houses said frame-like mold, wherein said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said bottom portion is provided with a plurality of engaging through holes which are formed along said sidewall not to extend into said sidewall, said frame-like mold is provided with a plurality of engaging protrusions which are disposed correspondingly to said plurality of engaging holes and protrude downward beyond a lower surface of said frame-like mold, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions into a corresponding one of said plurality of engaging through holes.
[0021] (5) The liquid crystal display device according to (4), wherein said frame-like mold and said frame are fixed together by engaging tips of said plurality of engaging protrusions with said sidewall of said frame.
[0022] (6) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; and a frame which houses said frame-like mold, wherein said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said frame is provided with a plurality of engaging through holes formed along said sidewall, each of said plurality of engaging through holes extends from said bottom portion into a portion of said sidewall, said frame is further provided with a wall-like protrusion parallel with said side wall protruding from an edge of each of said plurality of engaging through holes, said edge facing toward an inside of said frame, said frame-like mold is provided with a plurality of engaging protrusions protruding horizontally from a sidewall thereof, said plurality of engaging protrusions being disposed correspondingly to said plurality of engaging holes, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions of said frame-like mold into a corresponding one of said plurality of engaging through holes.
[0023] (7) The liquid crystal display device according to (6), wherein said frame-like mold and said frame are fixed together by engaging tips of said plurality of engaging protrusions with said sidewall of said frame.
[0024] (8) The liquid crystal display device according to (6), further comprising a light reflective sheet disposed on an upper surface of said bottom portion of said frame, wherein said light reflective sheet is provided with a plurality of cutouts disposed correspondingly to said plurality of engaging through holes such that said light reflective sheet does not lie over said plurality of engaging through holes.
[0025] (9) The liquid crystal display device according to (6), further comprising a light reflective sheet disposed on an upper surface of said bottom portion of said frame, wherein said frame-like mold is provided with a step on said lower surface thereof for positioning an edge of said light reflective sheet such that said step does not lie over said plurality of engaging through holes.
[0026] (10) The liquid crystal display device according to (8), wherein said frame-like mold is provided with a step on said lower surface thereof for positioning an edge of said light reflective sheet such that said step does not lie over said plurality of engaging through holes.
[0027] (11) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; a light reflective sheet disposed behind said frame-like mold; and a frame which houses said frame-like mold and said light reflective sheet, wherein said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said frame is provided with a plurality of engaging through holes which are formed along said sidewall, each of said plurality of engaging through holes extends from said bottom portion into a portion of said sidewall, said light reflective sheet is disposed on an upper surface of said bottom portion of said frame, and is provided with a plurality of cutouts disposed correspondingly to said plurality of engaging through holes such that said light reflective sheet does not lie over said plurality of engaging through holes, said frame-like mold is provided with a plurality of engaging protrusions protruding therefrom and disposed correspondingly to said plurality of engaging holes, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions of said frame-like mold into a sidewall-side portion of a corresponding one of said plurality of engaging through holes.
[0028] (12) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; alight reflective sheet disposed behind said frame-like mold; and a frame which houses said frame-like mold and said light reflective sheet, wherein said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said frame is provided with a plurality of engaging through holes which are formed along said side wall, each of said plurality of engaging through holes extends from said bottom portion into a portion of said sidewall, said light reflective sheet is disposed on an upper surface of said bottom portion of said frame, said frame-like mold is provided with a plurality of engaging protrusions protruding therefrom and disposed correspondingly to said plurality of engaging holes, said frame-like mold is further provided with a step on said lower surface thereof for positioning an edge of said light reflective sheet such that said step does not lie over said plurality of engaging through holes, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions of said frame-like mold into a sidewall-side portion of a corresponding one of said plurality of engaging through holes.
[0029] (13) The liquid crystal display device according to (12), wherein said light reflective sheet is provided with a plurality of cutouts disposed correspondingly to said plurality of engaging through holes such that said light reflective sheet does not lie over said plurality of engaging through holes.
[0030] (14) The liquid crystal display device according to (12), wherein said frame is further provided with a wall-like protrusion parallel with said side wall protruding from an edge of each of said plurality of engaging through holes, said edge facing toward an inside of said frame.
[0031] (15) The liquid crystal display device according to (12), wherein said frame-like mold and said frame are fixed together by engaging tips of said plurality of engaging protrusions with said sidewall of said frame.
[0032] (16) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses said liquid crystal display panel and said optical components; and a frame which houses said frame-like mold, wherein said frame-like mold is provided with a plurality of protrusions protruding from an upper surface of said frame-like mold, each of said plurality of protrusions is provided with an engaging through hole, said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said sidewall is provided with a plurality of engaging protrusions correspondingly to said engaging through holes, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions into a corresponding one of said engaging through holes in said frame-like mold.
[0033] (17) The liquid crystal display device according to (16), wherein said frame-like mold and said frame are fixed together by engaging tips of said plurality of engaging protrusions with vicinities of said engaging through holes in said frame-like mold.
[0034] (18) A liquid crystal display device comprising: a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates; optical components disposed behind said liquid crystal display panel; a frame-like mold which houses saidliquid crystal display panel and said optical components; and a frame which houses said frame-like mold, wherein said frame-like mold is provided with a plurality of protrusions protruding therefrom, said frame comprises a bottom portion and a sidewall formed along a periphery of said bottom portion, said sidewall is provided with a plurality of engaging recesses correspondingly to said plurality of engaging protrusions, and said frame-like mold and said frame are fixed together by inserting each of said plurality of engaging protrusions of said frame-like mold into a corresponding one of said plurality of recesses.
[0035] To be brief, the advantage provided by the representative ones of the inventions disclosed in this specification is that the liquid crystal display device in accordance with the present invention is capable of reducing the leakage of light from its backlight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] In the accompanying drawings, in which like reference numerals designate similar components throughout the figures, and in which:
[0037] FIG. 1A is a plan view of a mold in accordance with an embodiment of the present invention;
[0038] FIG. 1B is a side view of the mold of FIG. 1A ;
[0039] FIG. 2A is a plan view of a frame in accordance with an embodiment of the present invention;
[0040] FIG. 2B is a cross-sectional view of the frame of FIG. 2A taken along line IIB-IIB of FIG. 2A ;
[0041] FIG. 2C is an enlarged view of a circled portion, designated A, of the frame of FIG. 2B ;
[0042] FIG. 2D is a perspective view of the circled portion A of the frame 16 of FIG. 2B ;
[0043] FIG. 3A is a plan view illustrating a condition where the mold is inserted within the frame;
[0044] FIG. 3B is a cross-sectional view of the mold and the frame of FIG. 3A taken along line IIIB-IIIB of FIG. 3A ;
[0045] FIG. 3C is an enlarged cross-sectional view of a circled portion, designated B, of FIG. 3B ;
[0046] FIG. 3D is a cross-sectional view of a liquid crystal display module of Embodiment 1 in an assembled condition;
[0047] FIG. 4A is a rear plan view of a liquid crystal display module in accordance with an embodiment of the present invention;
[0048] FIG. 4B is an enlarged view of a circled portion, designated C, of FIG. 4A ;
[0049] FIG. 4C is an illustration for explaining a problem which may arise in the configuration of the embodiment shown in FIG. 3C ;
[0050] FIG. 5 is an illustration for explaining a shape of a light reflective sheet and a step of a mold of a liquid crystal display module in accordance with an embodiment of the present invention;
[0051] FIG. 6A is a plan view showing a condition in which the mold is fitted within the frame;
[0052] FIG. 6B is a cross-sectional view of the assembly of FIG. 6A taken along line VIB-VIB of FIG. 6A ;
[0053] FIG. 6C is an enlarged view of a circled portion, designated D, of FIG. 6B ;
[0054] FIG. 7A is a rear plan view of the liquid crystal display module;
[0055] FIG. 7B is an enlarged view of a circled portion, designated A, of FIG. 7A ;
[0056] FIG. 8A is an illustration for explaining a frame in accordance with still another embodiment of the present invention;
[0057] FIG. 8B is an illustration for showing a through hole made in a prior art frame explained in connection with FIGS. 17A to 19 C;
[0058] FIG. 9A is a plan view of a mold in accordance with still another embodiment of the present invention;
[0059] FIG. 9B is a cross-sectional view of the mold of FIG. 9A taken along line IXB-IXB of FIG. 9A ;
[0060] FIG. 10A is a plan view of a frame in accordance with an embodiment of the present invention;
[0061] FIG. 10B is a cross-sectional view of the frame of FIG. 10A taken along line XB-XB of FIG. 10A ;
[0062] FIG. 10C is an enlarged view of a circled portion, designated A, of FIG. 10B ;
[0063] FIG. 10D is a cross-sectional view of the frame of FIG. 10A taken along line XD-XD of FIG. 10A ;
[0064] FIG. 11A is a plan view of an assembly of the mold and the frame in accordance with an embodiment of the present invention;
[0065] FIG. 11B is an enlarged cross-sectional view of the assembly of FIG. 11A taken along line XIB-XIB of FIG. 11A ;
[0066] FIG. 11C is an enlarged view of a circled portion, designated B, of FIG. 11B ;
[0067] FIG. 12A is a plan view of a frame in accordance with an embodiment of the present invention;
[0068] FIG. 12B is a cross-sectional view of the frame of FIG. 12A taken along line XIIB-XIIB of FIG. 12A ;
[0069] FIG. 12C is a side view of a circled portion, designated A, of FIG. 12A ;
[0070] FIG. 13A is a plan view of a mold 11 in accordance with an embodiment of the present invention;
[0071] FIG. 13B is a cross-sectional view of the mold of FIG. 13A taken along line XIIIB-XIIIB of FIG. 13A ;
[0072] FIG. 14A is an plan view of an assembly of the mold and the frame in accordance with an embodiment of the present invention;
[0073] FIG. 14B is a cross-sectional view of the assembly of FIG. 14A taken along line XIVB-XIVB of FIG. 14A ;
[0074] FIG. 15A is a perspective view of a frame in accordance with an embodiment of the present invention;
[0075] FIG. 15B is an enlarged view of a circled portion, designated A, of FIG. 15A ;
[0076] FIG. 16A is a schematic exploded perspective view illustrating a rough configuration of a conventional liquid crystal display module;
[0077] FIG. 16B is a cross-sectional view of the conventional liquid crystal display module of FIG. 16A in an assembled condition taken along line XVIB-XVIB of FIG. 16A ;
[0078] FIG. 17A is a plan view of a conventional mold;
[0079] FIG. 17B is a cross-sectional view of the mold taken along line XVIIB-XVIIB of FIG. 17A ;
[0080] FIG. 18A is a plan view of the conventional frame;
[0081] FIG. 18B is a cross-sectional view of the frame taken along line XVIIIB-XVIIIB of FIG. 18A ;
[0082] FIG. 18C is an enlarged view of an encircled portion A of FIG. 18B ;
[0083] FIG. 18D is an enlarged perspective view of the encircled portion A of FIG. 18B ;
[0084] FIG. 19A is a plan view of an assembly of the conventional mold and the conventional frame;
[0085] FIG. 19B is a cross-sectional view of the assembly of FIG. 19A taken along line XIXB-XIXB of FIG. 19A ; and
[0086] FIG. 19C is an enlarged view of an encircled portion B of FIG. 19B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0087] The embodiments of the present invention will be explained in detail by reference to the drawings. The same reference numerals or symbols designate functionally similar components or portions throughout the figures for explaining the embodiments, and repetition of their explanation is omitted. Dimensions of certain of the components or portions are exaggerated for clarity.
[0088] Liquid crystal display modules of the embodiments in accordance with the present invention are TFT type liquid crystal display modules provided with a small-sized color liquid crystal display panel having subpixels on the order of 240×320×3 pieces, and they are used as display sections of portable equipment such as mobile phones and the like.
EMBODIMENT 1
[0089] As in the case of the liquid crystal display panel LCD illustrated in FIGS. 16A and 16B , a liquid crystal display panel LCD in accordance with Embodiment 1 is fabricated by attaching together a glass substrate TFTSUB provided with thin film transistors, drain lines, gate lines and others (not shown) and a glass substrate CFSUB provided with a counter electrode, color filters and others (not shown) with a sealing agent (not shown) interposed therebetween, then filling a liquid crystal material (not shown) into a space between the two glass substrates TFTSUB, CFSUB, and sealing off the space, and then attaching polarizing sheets POL 1 and PLO 2 on the outer surfaces of the two glass substrates TFTSUB and CFSUB, respectively.
[0090] Since the present invention does not relates to an internal structure of the liquid crystal display panel LCD, the explanation of the details of the internal structure is omitted. The present invention is applicable to liquid crystal display panels LCD having any types of structures.
[0091] In the liquid crystal display modules in Embodiment 1 and subsequent Embodiments, the explanation of components or portions similar to those in the conventional liquid crystal display module illustrated in FIGS. 16A and 16B is omitted.
[0092] FIGS. 1A and 1B are illustrations for explaining a mold 11 in Embodiment 1 , FIG. 1A is a plan view of the mold 11 , and FIG. 1B is a side view of the mold 11 .
[0093] As shown in FIGS. 1A and 1B , the mold 11 differs from the mold 11 shown in FIGS. 17A and 17B , in that the mold 11 of Embodiment 1 has a frame-like member (or a cylinder-like member) having a rectangular vertical cross section and is provided with protrusions 3 a protruding downward from the frame-like member (or the cylinder-like member) which are used for engaging.
[0094] FIGS. 2A to 2 D are illustrations for explaining a frame 16 in Embodiment 1, FIG. 2A is a plan view of the frame 16 , FIG. 2B is a cross-sectional view of the frame 16 of FIG. 2A taken along line IIB-IIB of FIG. 2A , FIG. 2C is an enlarged view of a circled portion, designated A, of the frame 16 of FIG. 2B , and FIG. 2D is a perspective view of the circled portion A of the frame 16 of FIG. 2B .
[0095] As shown in FIGS. 2A to 2 D, the frame 16 of Embodiment 1 has a bottom portion 30 and a sidewall 30 formed at the periphery of the bottom portion 30 , through holes 1 b are made in the bottom portion 30 of the frame 16 along the sidewall 31 such that through holes 1 b do not extend into the sidewall 31 .
[0096] As shown in a portion B of FIG. 2C and FIG. 2D , the frame 16 of Embodiment 1 differs from the frame 16 shown in FIGS. 18C and 18D , in that, in Embodiment 1, portions of the sidewall 31 adjacent to the through holes 1 b are extended to a plane flush with a lower surface of the bottom portion 30 .
[0097] FIGS. 3A to 3 D are illustrations for explaining a method of fixing together the mold 11 and the frame 16 in Embodiment 1. FIG. 3A is a plan view illustrating the condition where the mold 11 is inserted within the frame 16 , FIG. 3B is a cross-sectional view of the mold 11 and the frame 16 of FIG. 3A taken along line IIIB-IIIB of FIG. 3A , and FIG. 3C is an enlarged view of a circled portion, designated B, of FIG. 3B . For the sake of simplicity, the liquid crystal display panel LCD, the light guide 10 , the group of optical sheets 15 or the light source 13 are not shown in FIGS. 3A to 3 C. FIG. 3D is across-sectional view of the liquid crystal display module of Embodiment 1 in the assembled condition, and is similar to FIG. 16B illustrating the cross-sectional view of the conventional liquid crystal display module.
[0098] As shown in FIGS. 3A to 3 D, the mold 11 is fixed to the frame 16 by inserting the engaging protrusions 3 a provided to the mold 11 into the through holes 1 b made in the bottom portion 30 of the frame 16 , and engaging the tips of the engaging protrusions 3 a with the sidewall 31 of the frame 16 (or hooking the tips to the sidewall 31 ).
[0099] As explained above, there has been a problem in that in the case of the configuration illustrated in FIGS. 19A to 19 C, light from the light source (a white light emitting diode) 13 (not shown) leaks through the through holes 1 b made in the frame 16 in the X direction (the direction of the arrow C in FIG. 19C ) and the Y direction (the direction of the arrow D in FIG. 19C ). On the other hand, as shown in FIGS. 2D and 3C , in Embodiment 1, the through holes 1 b does not extend into the sidewall 31 of the frame 16 , and consequently, Embodiment 1 is capable of reducing the amount of the light from the light source 13 leaking in the X direction (the direction of the arrow C in FIG. 19C ) through the through holes 1 b made in the frame 16 .
EMBODIMENT 2
[0100] Prior to explaining Embodiment 2, a problem will be explained which may arise in Embodiment 1. FIGS. 4A and 4B are rear views of the above-explained liquid crystal display module of Embodiment 1, FIG. 4A is a rear plan view of the liquid crystal display module, and FIG. 4B is an enlarged view of a circled portion, designated C, of FIG. 4A . FIG. 4C is an illustration for explaining the problem which may arise in the configuration of Embodiment 1 shown in FIG. 3C .
[0101] In the configuration of Embodiment 1, as shown in FIG. 3C , a rectangular light reflective sheet 12 is disposed on the bottom portion 30 of the frame 16 . In this case, a step 33 is formed on a surface of the mold 11 on its light-reflective-sheet- 12 side for positioning the light reflective sheet 12 . As shown in FIGS. 3C and 4B , the edge portion (the edge portion of the long side) of the light reflective sheet 12 and the step 33 is disposed over the through hole 1 b made in the bottom portion 30 of the frame 16 . In FIG. 3C , in a case where there is no gap between opposing portions of the mold 11 and the light reflective sheet 12 , there arises no problem. However, in actuality, as shown in FIG. 4C , in some cases there is a gap 20 between opposing portions of the mold 11 and the light reflective sheet 12 due to dimensional tolerances of the components and variations in precision of manufacturing of the components, and therefore light from the light source 13 leaks toward the vicinities of the step 33 through the gap 20 .
[0102] As described above, in Embodiment 1, the edge portion of the light reflective sheet 12 and the step 33 are visible through the through hole 1 b in the bottom portion 30 of the frame 16 , the leakage of light in the vicinities of the step 33 is visible from the Y direction (the direction indicated by an arrow D in FIG. 4C ) outside of the frame 16 .
[0103] In the following, Embodiment 2 will be explained which is capable of reducing the above-explained light leaking in the Y direction from the vicinities of the step 33 .
[0104] FIG. 5 is an illustration for explaining the shape of the light reflective sheet 12 and the step 33 of the mold 11 of the liquid crystal display module in accordance with Embodiment 2, and is a plan view of the light reflective sheet 12 disposed on the mold 11 viewed from the side of the light reflective sheet 12 prior to fitting the mold 11 with the frame 16 . Cutouts 35 are formed at regions of the light reflective sheet 12 lying over the through hole 1 b in the bottom portion 30 of the frame 16 so that the light reflective sheet 12 does not lie over the through hole 1 b in the bottom portion 30 of the frame 16 . Further, the steps 33 of the mold 11 for positioning the light reflective sheet 12 are formed so that they do not to lie over the through hole 1 b in the bottom portion 30 of the frame 16 , considering the shape of the light reflective sheet 12 .
[0105] FIGS. 6A to 6 C are illustrations for explaining a method of fixing together the mold 11 and the frame 16 in accordance with Embodiment 2, FIG. 6A is a plan view showing a condition in which the mold 11 is fitted within the frame 16 , FIG. 6B is a cross-sectional view of the assembly of FIG. 6A taken along line VIB-VIB of FIG. 6A , and FIG. 6C is an enlarged view of a circled portion, designated D, of FIG. 6B . FIGS. 7A and 7B are views of the liquid crystal display module of Embodiment 2 viewed from its rear side, FIG. 7A is a rear plan view of the liquid crystal display module, and FIG. 7B is an enlarged view of a circled portion, designated A, of FIG. 7A .
[0106] Consequently, in Embodiment 2, as shown in a circled portion, designated E, of FIG. 6C and FIG. 7B , the edge portions (the edge portions of the long sides) of the light reflective sheet 12 or the steps 33 of the mold 11 are not visible through the through holes 1 b made in the bottom portion 30 of the frame 16 , and Embodiment 2 is capable of reducing the leakage of light from the vicinities of the steps 33 in the Y direction (the direction indicated by the arrow D in FIG. 4C .
EMBODIMENT 3
[0107] As in the case of the frame 16 shown in FIG. 18D and utilized for the prior art explained in connection with FIGS. 17A to 19 C, the frame 16 utilized for this Embodiment 3 is provided with through holes 1 b extending from the bottom portion 30 of the frame 16 into the sidewall 31 of the frame 16 . However, in Embodiment 3, the size of the through holes 1 b in the frame 16 are reduced such that the edge portions (the edge portions of the long sides) of the light reflective sheet 12 or the steps 33 of the mold 11 are not visible through the through holes 1 b made in the bottom portion 30 of the frame 16 .
[0108] FIG. 8A is an illustration for explaining the frame 16 in accordance with Embodiment 3, and shows a through hole 1 b made in the bottom portion 30 of the frame 16 . For comparison purposes, FIG. 8B is an illustration for showing the through hole 1 b made in the prior art frame 16 explained in connection with FIGS. 17A to 19 C. Here FIGS. 8A and 8B are enlarged views of the through holes 16 and their vicinities viewed from the rear side of the frame 16 .
[0109] Embodiment 3 shown in FIG. 8A is also capable of reducing light leakage from the vicinities of the step 33 (see FIG. 4C ) in the Y direction (the direction indicated by the arrow D in FIG. 4C ).
[0110] Incidentally, while FIG. 8A illustrates a case where Embodiment 3 is applied to the frame 16 provided with the through holes 1 b extending continuously from the bottom portion 30 into the sidewall 31 , Embodiment 3 is also applicable to the frame 16 provided with the through holes 1 b which are formed in the bottom portion 30 along the sidewall 31 , but which do not extend into the sidewall 31 (that is, the through hole 1 b are not made in the sidewall 31 ), as in the case of Embodiment 1.
[0111] Further, Embodiment 3 is applicable to the following two cases: one is a case where the light reflective sheet 12 is provided with the cutouts 35 such that the light reflective sheet 12 does not lie over the through holes 1 b made in the bottom portion 30 of the frame 16 as in the case of Embodiment 2; and the other is a case where the light reflective sheet 12 is not provided with the cutouts 35 .
EMBODIMENT 4
[0112] FIGS. 9A and 9B are illustrations for explaining the mold 11 in accordance with Embodiment 4, FIG. 9A is a plan view of the mold 11 , and FIG. 9B is a cross-sectional view of the mold 11 of FIG. 9A taken along line IXB-IXB of FIG. 9A . FIGS. 10A to 11 C are illustrations for explaining a frame 16 in accordance with Embodiment 4, FIG. 10A is a plan view of the frame 16 , FIG. 10B is a cross-sectional view of the frame 16 of FIG. 10A taken along line XB-XB of FIG. 10A , FIG. 10C is an enlarged view of a circled portion, designated A, of FIG. 10B , and FIG. 10D is a cross-sectional view of the frame 16 of FIG. 10A taken along line XD-XD of FIG. 10A . FIGS. 11A to 11 C are illustrations for explaining a method of fixing together the mold 11 and, the frame 16 in accordance with Embodiment 4, FIG. 11A is a plan view of an assembly of the mold 11 and the frame 16 , FIG. 11B is an enlarged cross-sectional view of the assembly of FIG. 11A taken along line XIB-XIB of FIG. 11A , and FIG. 11C is an enlarged view of a circled portion, designated B, of FIG. 11B .
[0113] As shown in FIG. 10D , Embodiment 4 provides a step portion 31 A in the sidewall 31 on the long sides of the bottom portion 30 of the frame 16 which is utilized in Embodiment 3 and which is a die cast frame formed of magnesium alloy, for example, and as shown in FIG. 10A Embodiment 4 provides the through holes 1 b at desired positions. This configuration of the frame 16 provides wall-like protrusions 36 capable of preventing leakage of light at positions where the through hole 1 b are made.
[0114] To realize the above-explained configuration, in Embodiment 4, regions of the frame 16 formed with the through holes 1 b are expanded outwardly as shown in FIG. 11A , and engaging portions 1 a formed on the sidewall are disposed at outside positions.
[0115] In Embodiment 4, as shown in FIG. 11C , the edge portions (the edge portions of the long sides) of the light reflective sheet 12 or the steps 33 of the mold 11 are not visible through the through holes 1 b made in frame 16 , and consequently, Embodiment 4 is capable of reducing light leakage from the vicinities of the step 33 in the Y direction (the direction indicated by the arrow D in FIG. 4C ).
EMBODIMENT 5
[0116] The reason why the above-described light leakage is that the edge portions (the edge portions of the long sides) of the light reflective sheet 12 and the steps 33 of the mold 11 are visible through the through holes 1 b made in the frame 16 .
[0117] Embodiment 5 and subsequent Embodiment 6 prevent light leakage from the gap between the steps 33 and the light reflective sheet 12 by configuring the edge portions (the edge portions of the long sides) of the light reflective sheet 12 and the steps 33 of the mold 11 so as not to be visible from the outside of the frame 16 .
[0118] FIGS. 12A to 12 C are illustrations for explaining a frame 16 in accordance with Embodiment 5, FIG. 12A is a plan view of the frame 16 , FIG. 12B is a cross-sectional view of the frame 16 of FIG. 12A taken along line XIIB-XIIB of FIG. 12A , and FIG. 12C is a side view of a circled portion, designated A, of FIG. 12A .
[0119] FIGS. 13A and 13B are illustrations for explaining a mold 11 in accordance with Embodiment 5, FIG. 13A is a plan view of the mold 11 , and FIG. 13B is a cross-sectional view of the mold 11 of FIG. 13A taken along line XIIIB-XIIIB of FIG. 13A .
[0120] FIGS. 14A and 14B are illustrations for explaining a method of fixing together the mold 11 and the frame 16 in accordance with Embodiment 5, FIG. 14A is an plan view of an assembly of the mold 11 and the frame 16 , and FIG. 14B is a cross-sectional view of the assembly of FIG. 14A taken along line XIVB-XIVB of FIG. 14A .
[0121] As shown in FIGS. 12A to 12 C, the frame 16 of Embodiment 5 is provided with protrusions 3 b on the sidewall 31 of the frame 16 for the engaging purpose. In Embodiment 5, as shown in FIGS. 13A and 13B , regions on the top of the mold 11 corresponding to the above-mentioned protrusions 3 b, respectively, are projecting outwardly, and through holes 1 c are made in those projecting regions.
[0122] As shown in FIGS. 14A and 14B , in Embodiment 5, the mold 11 is fixed to the frame 16 by inserting the engaging protrusions 3 b provided to the frame 16 into the through holes 1 c made in the mold 11 , and engaging the tips of the engaging protrusions 3 a with (or hooking the tips of the engaging protrusions 3 a to) the vicinities of the through holes 1 c in the mold 11 . In this configuration of Embodiment 5, recesses 37 are formed in the sidewall 31 of the frame 16 as shown in FIG. 12C . Each of the recesses 37 is formed so as to extend beyond opposite ends of a corresponding one of the engaging protrusions 3 b . As shown in FIGS. 14A and 14B , the projecting regions of the mold 11 each perforated with the through hole 1 c are fitted into the recesses 37 .
[0123] With the configuration of Embodiment 5, the edge portions (the edge portions of the long sides) of the light reflective sheet 12 or the steps 33 of the mold 11 are not visible from the outside of the frame 16 . Consequently, Embodiment 5 is capable of preventing the light leakage from the vicinities of the steps 33 of the mold 11 .
EMBODIMENT 6
[0124] FIGS. 15A and 15B are illustrations for explaining a frame 16 in accordance with Embodiment 6, FIG. 15A is a perspective view of the frame 16 , and FIG. 15B is an enlarged view of a circled portion, designated A, of FIG. 15A .
[0125] Embodiment 6 uses a frame and a mold similar to the prior art frame 16 and the prior art mold 11 explained in connection with FIGS. 17A to 19 C. As shown in FIGS. 15A and 15B , the frame 16 utilized for this Embodiment 3 is provided with recesses 1 d in an inner surface of the sidewall 31 of the frame 16 to be engaged with the tips 1 a of the engaging portions 1 a provided to the sidewall of the mold 11 .
[0126] In Embodiment 6, the mold 11 is fixed to the frame 16 by inserting the engaging portions 1 a (see FIGS. 17A and 17B ) provided to the mold 11 into the recesses 1 d formed in the inner surface of the sidewall 31 of the frame 16 , and engaging the tips of the engaging portions 1 a with the sidewall 31 of the frame 16 (or hooking the tips to the sidewall 31 ).
[0127] With the configuration of Embodiment 6, the edge portions (the edge portions of the long sides) of the light reflective sheet 12 (not shown) or the steps 33 (not shown) of the mold 11 are not visible from the outside of the frame 16 . Consequently, Embodiment 6 is also capable of preventing the light leakage from the vicinities of the steps 33 (see FIG. 4C ) of the mold 11 .
[0128] The invention made by the present inventors has been explained concretely based on the embodiments, and it is needless to say that the present invention is not limited to the above-described embodiments, and that various changes and modifications can be made without departing from the true spirit and scope of the present invention. | A liquid crystal display device includes a liquid crystal display panel having liquid crystal material sandwiched between a pair of substrates, optical components disposed behind the liquid crystal display panel, a frame-like mold which houses the liquid crystal display panel and the optical components, and a frame which houses the frame-like mold. The frame includes a bottom portion and a sidewall, and the bottom portion is provided with plural engaging through holes which are formed along the sidewall not to extend into the sidewall. The frame-like mold is provided with plural engaging protrusions which are disposed correspondingly to the engaging holes and protrude downward beyond a lower surface of the frame-like mold. The frame-like mold and the frame are fixed together by inserting each of the engaging protrusions into a corresponding one of the engaging through holes. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of International PCT Application No. PCT/EP2005/010018, filed Sep. 16, 2005, pursuant to 35 U.S.C. 119(a)-(d). This application also claims the benefit of prior filed U.S. provisional Application Ser. No. 60/725,943, filed Oct. 12, 2005, pursuant to 35 U.S.C. 119(e).
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a diaphragm pump for the transport of liquids.
[0003] Nothing in the following discussion of the state of the art is to be construed as an admission of prior art.
[0004] German utility model DE 33 10 131 A1 describes a diaphragm pump in the form of a double-diaphragm pump, having a pump housing which includes two product chambers and two pressure chambers which are respectively separated from one another by a diaphragm. The diaphragms are connected together by a common coupling rod which is guided through the two pressure chambers. When the pump is operated, compressed air is conducted alternatingly into one of the two pressure chambers, whereby the diaphragm of the pressure chamber being acted upon executes a discharge stroke into the adjacent product chamber, and the second diaphragm executes a suction stroke as a consequence of the linkage via the coupling rod. The pressure chambers are alternatingly acted upon and exhausted through provision of a control valve device which is disposed in parallel relationship to the coupling rod and cyclically clears individual control orifices.
[0005] When using diaphragm pumps in a sterile environment, for example in the pharmaceutical field or in biochemistry, stringent standards must be met. A precondition is that the pump can be completely emptied of any liquid before shutdown to prevent any residues of liquid, and the pump can be thoroughly purged with a flushing liquid.
[0006] It would therefore be desirable and advantageous to provide an improved diaphragm pump to obviate prior art shortcomings and to allow a complete drainage and purging of the pump.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, a diaphragm pump includes passageways for conduction of a liquid, and check valves for controlling a flow of liquid through the passageways, wherein the passageways have liquid-conducting surfaces which are all of slanted configuration.
[0008] According to another aspect of the present invention, a diaphragm pump includes passageways for conduction of a liquid, and check valves for controlling a flow of liquid through the passageways, wherein the passageways have liquid-conducting surfaces, with all neighboring liquid-conducting surfaces being at least partially connected to one another in a gradual manner.
[0009] According to still another aspect of the present invention, a diaphragm pump includes a check valve having a shutoff element for controlling a flow of liquid through a valve seat, and a device for random lifting of the shutoff element off the valve seat independently of a pressure state of the pump, with the device being constructed to generate a magnetic field for interaction with the shutoff element.
[0010] According to yet another aspect of the present invention, a diaphragm pump includes at least one pumping chamber intended for a liquid to be conveyed and fluidly communicating with an inlet and an outlet for intake and discharge of liquid, a pressure chamber, and a diaphragm which separates the pumping chamber from the pressure chamber, wherein the inlet and/or the outlet is/are shaped in such a manner as to produce a direct contact flow upon at least one portion of the diaphragm and/or a marginal zone of the pumping chamber.
[0011] To ensure clarity, it is necessary to establish the definition of several important terms and expressions that will be used throughout this disclosure.
[0012] The term “all” in connection with the surfaces is to be understood as relating to at least those surfaces which come into contact with the liquid.
[0013] The term “slanted” relates, when the pump is operative, to a surface disposition which is not perpendicular to the direction of the gravitational force or a force resulting from the gravitational force and a further force.
[0014] The term “liquid-conducting surface” relates to a surface which comes into contact with the liquid as a result of the gravitational force or a force resulting from the gravitational force and a further force, and thus represents the lower boundary surface or the lower surface segment (when a circular cross section is involved for example) of a chamber or line conducting the liquid.
[0015] The term “gradual” relates in particular to even transitions without any recognizable abutting edges; still, this term may also cover any bump that does not require a movement by the liquid in opposition to the gravitational force as the liquid flows through the pump. As a result of the provision of a gradual transition, residual liquid is prevented from settling upon any steps or elevations during drainage of the pump and from remaining in the pump. Valve seats of check valves in conventional pumps typically exhibit such steps where liquid is able to settle.
[0016] According to another feature of the present invention, not only the liquid-conducting surfaces of the diaphragm pump may be constructed slanted but any surface that comes into contact with the liquid.
[0017] Furthermore, the liquid being conveyed can flow against the product chamber(s) from the inlet and/or outlet of the respective product chamber in such a manner that a direct contact flow is generated upon at least one portion of the diaphragm and/or a marginal zone of the product chamber. In this way, the effectiveness of the purging process with flushing liquid can be improved during operation of the pump.
[0018] The term “direct contact flow” as used in the following description relates to a liquid flow which is targeted within the product chamber in particular upon certain areas which undergo little liquid exchange during purging. These areas are oftentimes encountered in the marginal zones of the product chamber(s) and in particular at the connection areas where the diaphragm is clamped to the housing of the product chamber(s).
[0019] The direct contact flow is thus different from a tangential flow in which the liquid is conducted at an acute angle in relation to a diaphragm surface from the inlet and/or outlet into the pumping chamber. A tangential flow is unsuitable to reach all areas. In contrast thereto, a direct contact flow in accordance with the present invention allows a routing of any cleansing medium (flushing agent) in a targeted manner to reach all areas.
[0020] According to another feature of the present invention, all areas within a product chamber can be contacted by inflowing liquid at an angle of 90°±20°, preferably of 90°÷10°, and currently preferred of 90°±5°, (relating to the entire area). This provides for an especially effective purging of these areas by generating turbulences within the liquid flow to positively affect the liquid exchange.
[0021] According to yet another aspect of the present invention, a check valve for application in a pump includes a valve housing having a first housing portion and a second housing portion, with the first housing portion being defined by an inside dimension which is smaller than an inside dimension of the second housing portion, with the valve housing forming a valve seat at a contact area of the housing portions, wherein the housing portions are disposed in offset relationship such that a transition between the housing portions is gradual in a region of the valve seat, and a shutoff element movably supported in the valve housing for cooperation with the valve seat.
[0022] According to another feature of the present invention, the housing portions of the valve housing may each have an inner cross section of circular configuration, with the shutoff element configured in the shape of a ball.
[0023] According to another feature of the present invention, the transition may be positioned on a gravity side of the check valve. Drainage of the entire liquid during emptying of the pump is ensured as a result of the gradual configuration of the valve seat on the one side of the check valve on which the liquid flows off as a result of the gravitational force (gravity side).
[0024] According to still another aspect of the present invention, a check valve for application in a pump includes a valve housing, a shutoff element movably supported in the valve housing and having at least one portion exhibiting a magnetic property, and a device for applying a magnetic field for lifting the shutoff element off a valve seat in opposition to a closing force. In this way, a magnetic field can be used to lift the shutoff elements of the check valve from the valve seat, independently of the pressure conditions produced by the pump. Suitably, the at least one portion of the shutoff element may be made of ferromagnetic material.
[0025] Opening of the check valve, when needed, through application of a magnetic force is beneficial because of the absence of any mechanical valve lifters which oftentimes are routed from outside through the valve housing to the shutoff body and thus have the disadvantage of constituting further (moving) structures inside the pump and requiring also an additional seal in the valve housing.
[0026] According to another feature of the present invention, the shutoff element may be implemented as a ball. Suitably, the ball includes an iron core. Ball check valves are characterized by a reliable closing so that the need for a particular guidance of the shutoff element can be eliminated. The ferromagnetic portion of the ball check valve may be designed in particular as ball core. As a result, the material of the ball jacket can be selected according to need, for example according to the liquid being conveyed. In addition, the use of elastic materials for the jacket can improve the sealing action of the ball in its valve seat. PTFE is currently a preferred material for the ball jacket. Ferromagnetic materials (in particular iron) are especially useful for the construction of the ball core. The provision of an iron core is also beneficial because of the increase in specific weight of the ball which may result, i.a., in an improvement of the suction effect. This can be influenced through dimensioning of the iron core.
[0027] According to another feature of the present invention, the device may include a permanent magnet for temporary attachment onto the check valve for application of the magnetic field. In other words, the permanent magnet is attached only for opening the check valve, regardless of the pressure conditions. When metallic valve housings with magnetic properties are involved, the permanent magnet normally adheres to the intended site automatically so that the need for further holding devices can oftentimes be eliminated.
[0028] The use of permanent magnets is also beneficial because the need for electricity is eliminated so that the check valves according to the invention are useful for the transport of inflammable liquids for example.
[0029] According to still another aspect of the present invention, a check valve for application in a pump includes a valve housing, and a shutoff element movably supported in the valve housing, wherein the valve housing forms a two-dimensional valve seat having a shape in conformity to a contour of the shutoff element in a contact zone between the valve seat and the shutoff element.
[0030] Suitably, the shutoff element is a ball. Thus, the valve seat has a ring surface which is formed two-dimensionally concave with a radius in correspondence to the ball radius. By matching the ring surface of the valve seat to the contour of the shutoff element, an increase in the effective sealing surface and thus of the sealing action is realized. In contrast thereto, conventional ball valves typically have only a valve seat in the form of a (sealing) edge.
[0031] According to yet another aspect of the present invention, a method of draining a pump with at least two check valves includes the step of lifting the check valves off their valve seat through temporary generation of a magnetic field.
BRIEF DESCRIPTION OF THE DRAWING
[0032] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0033] FIG. 1 is a cross section of a first embodiment of a double-diaphragm pump according to the present invention;
[0034] FIG. 2 is a side elevational view of the double-diaphragm pump of FIG. 1 ;
[0035] FIG. 3 is a cross section of a second embodiment of a double-diaphragm pump according to the present invention;
[0036] FIG. 4 is a perspective illustration, on an enlarged scale, of a housing of a check valve for incorporation in a double-diaphragm pump according to the invention;
[0037] FIG. 5 is a cross section of a third embodiment of a double-diaphragm pump according to the invention;
[0038] FIG. 6 is a side elevational view of the double-diaphragm pump of FIG. 5 ;
[0039] FIG. 7 is a cross section of a fourth embodiment of a double-diaphragm pump according to the invention; and
[0040] FIG. 8 is a cross section of a fifth embodiment of a double-diaphragm pump according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
[0042] Turning now to the drawing, and in particular to FIG. 1 , there is shown a cross section of a first embodiment of a double-diaphragm pump according to the present invention, including a pump housing 1 with two product (pumping or working) chambers 2 , 3 located in outer zones of the pump housing 1 for conveying a liquid via feed lines 4 disposed outside of the pump housing 1 , as also shown in FIG. 2 . The product chambers 2 , 3 are separated by respective diaphragms 5 , 6 from respective pressure chambers 7 , 8 . The diaphragms 5 , 6 are completely smooth, continuous, and made, for example, of PTFE or EPDM or other suitable material, in the absence of diaphragm disk and further seals.
[0043] In operation, compressed air is fed to the pump via a (not shown) feed line and alternatingly supplied by a control valve device, generally designated by reference numeral 9 either to the left pressure chamber 8 or to the right pressure chamber 7 . While one pressure chamber is acted upon, the other pressure chamber is respectively exhausted.
[0044] As compressed air is admitted into one of the pressure chambers 7 , 8 , a working stroke is executed by the respective diaphragm 5 , 6 into the product chamber 2 , 3 (the right chamber 2 in FIG. 1 ). The working stroke of the right diaphragm 5 thus decreases the effective volume of the product chamber 2 and pumps the liquid through a right outlet valve 10 in an area of a top pump outlet 11 .
[0045] At the same time, the left diaphragm 6 is drawn back into and exhausts the respective pressure chamber 8 as a consequence of a linkage between the two diaphragms 5 , 6 by a coupling rod 12 . As a result of the suction stroke, carried out by the diaphragm 6 , the effective volume of the left product chamber 3 is increased and liquid is drawn on an inlet side 22 on the bottom of the pump through a check valve 13 having a shutoff body in the form of a ball 14 which is thus lifted off a valve seat 15 to clear a passage. At the same time, the ball 14 of a check valve 17 on the outlet side is pulled into the valve seat 15 to close the outlet.
[0046] Suitably, the movement of the balls 14 of each check valve 10 , 13 , 17 is restricted by a stroke limiter 16 .
[0047] As soon as the right diaphragm 5 concludes its working stroke, compressed air is routed into the left pressure chamber 8 . The left diaphragm 6 thus commences its working stroke, whereas the right diaphragm 5 executes a suction stroke.
[0048] Oftentimes it is necessary to drain the pump before shutdown or change of the liquid being pumped. For this purpose, permanent magnets 18 are temporarily placed upon all valves 10 , 13 , 17 . For sake of simplicity, FIG. 1 show the attachment of a permanent magnet 18 only for the check valves 10 13 on the right-hand side of the double-diaphragm pump. The permanent magnets 18 generate a magnetic field to lift the balls 14 of the check valves 10 , 13 , 17 , which have a (not shown) ferromagnetic iron core, from their valve seats 15 . Thus, all supply lines and discharge lines are open regardless of the stroke position of the diaphragms 5 , 6 . Liquid can be bled from the pump—in the direction of the gravity in opposition to the pump direction.
[0049] A continuous operation of the pump at possibly reduced stroke number may hereby assist the emptying of the pump.
[0050] To prevent retention of liquid residues, all surfaces of the double-diaphragm pump in contact with the liquid have a slanted configuration. In other words, the double-diaphragm pump according to the present invention is devoid of any horizontal liquid-contact surfaces. Drainage of liquid may also be enhanced by reducing the mean surface depth of roughness. In addition, the double-diaphragm pump according to the present invention is devoid of any bumps between the liquid-conducting surfaces so the flow of liquid does not need to overcome any areas in opposition to the gravity during drainage.
[0051] The check valves 10 , 13 , 17 have each a valve housing which is configured in such a way that the draining liquid is not required to overcome a bump. The valve housing is hereby composed of two circular valve housing portions of different diameter and disposed in offset relationship so as to connect smoothly along a straight line in a lower region thereof.
[0052] In order to ensure a reliable and tight seat of the balls 14 , the ring-shaped valve seat 15 , i.e. the hereby formed plane, is not arranged perpendicular to the center axes of the two housing portions but assumes a slanted disposition.
[0053] Furthermore, the valve seats 15 are of two-dimensionally concave configuration at a radius in substantial correspondence with the radius of the ball. As a result, as shown in FIG. 4 , sealing surfaces are established between the valve seats 15 and the balls 14 which are able to improve the sealing action in comparison to sealing edges of conventional pumps. The valve seats 15 can be produced by a spherical miller which would be positioned in the present exemplified embodiment in parallel, slightly offset relationship to a longitudinal center axis of the smaller valve housing portion on this valve housing portion and impose the concave shape onto the valve seat 15 which has been formed already by the penetration of the two valve housing portions.
[0054] Turning now to FIG. 3 , there is shown a second embodiment of a double-diaphragm pump according to the invention. Parts corresponding with those in FIG. 1 are denoted by identical reference numerals and not explained again. The description below will center on the differences between the embodiments. In this embodiment, provision is made for tandem diaphragms 5 a , 5 b , 6 a , 6 b . As a consequence, blocking chambers 19 , 20 are defined within the tandem diaphragms 5 a , 5 b , 6 a , 6 b . This type of double-diaphragm is able to meet even extreme safety requirements.
[0055] In view of the modular structure, a double-diaphragm pump according to the invention may be retrofitted in a simple manner to a tandem pump.
[0056] FIGS. 5 show a cross section and a side view of a third embodiment of a double-diaphragm pump according to the invention. In the following description, parts corresponding with those in FIG. 1 will be identified, where appropriate for the understanding of the invention, by corresponding reference numerals each increased by “100”. The description below will center on the differences between the embodiments. The diaphragm pump according to FIG. 5 differs from the previously described embodiments in particular by the shape of the product chambers 102 , 103 as well as the course of the feed lines 104 . While the double-diaphragm pumps of FIGS. 1 and 3 have feed lines (inlet/outlet) 4 implemented as continuous duct which is provided with a connection to the product chambers 2 , 3 only on one side so as to realize a rectilinear, essentially laminar flow of liquid between inlet 22 and outlet 11 to effect enhanced flow resistance, the feed lines 104 of the double-diaphragm pump of FIG. 5 (like also in the double-diaphragm pumps of FIGS. 7 and 8 ) enter with their full cross section into the product chambers 102 , 103 . Furthermore, the feed lines 104 are bent shy of the entry into the product chambers 102 , 103 so that the flow of liquid is established at a relatively great, almost perpendicular angle in relation to the vertical planes of the diaphragms 105 , 106 . As a result, turbulences are generated within the liquid flows and a good liquid exchange is realized in the area of the ports of the product chambers 102 , 103 .
[0057] FIG. 5 shows that the flow in the lower feed line 104 of a product chamber 102 , 103 is deflected to a greater extent than the upper feed line 104 . As the risk of liquid deposits during drainage of the pump is greater in the area of the bottom inlet 22 , as viewed in gravity direction, the deflection of the upper feed line 104 , as viewed in gravity direction, can be made slighter, accompanied by reduced development of turbulences, so that the flow resistance of the pump can be positively affected.
[0058] The lower feed line 104 is deflected by about 89°. A feed line at an angle of not equal 90° (in relation to the horizontal) ensures that also the entry portion of the feed line 104 is (slightly) slanted to assist a drainage of liquid during emptying of the pump.
[0059] FIG. 7 shows a cross section of a fourth embodiment of a double-diaphragm pump according to the invention. Parts corresponding with those in FIG. 5 will be identified, where appropriate for the understanding of the invention, by corresponding reference numerals increased by “100”. The description below will center on the differences between the embodiments. In this embodiment, provision is made a lower feed line 204 which is angled in a same way as the upper feed line 204 . Thus, selection of different flow deflections can result in different generation of turbulences. In other words, the size of the flow deflection as well as the flow contact angle upon the respective areas within the product chambers 202 , 203 can be randomly selected and suited to the demanded purging effect and accompanying increase in flow resistance.
[0060] FIG. 8 shows a cross section of a fourth embodiment of a double-diaphragm pump according to the invention. Parts corresponding with those in FIG. 5 are denoted by identical reference numerals and not explained again. The description below will center on the differences between the embodiments. In this embodiment, provision is made for a tandem diaphragm 105 a , 105 b , 106 a , 106 b so as to define enclosed blocking chamber 119 , 120 adjacent to each product chamber 102 , 103 .
[0061] A double-diaphragm pump in accordance with the invention is suitable for pumping liquids also in a sterile environment, for example in the pharmaceutical field or in the field of biochemistry. These fields of application employed exclusively rotary pumps heretofore.
[0062] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0063] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein: | A diaphragm pump for conveying liquids for application in a sterile environment includes passageways for conduction of a liquid, and check valves for controlling a flow of liquid through the passageways. The diaphragm pump is constructed in such a way that all surfaces of the passageways in contact with the liquid being conveyed are disposed at a slant. In addition, all transitions between liquid-conducting surfaces have a gradual configuration. For drainage of the diaphragm pump, the shutoff elements of the check valves are lifted off their valve seat through temporary generation of a magnetic field. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for directly and selectively interconnecting, either mechanically, hydraulically, or pneumatically, two gas turbine engines for purposes of achieving both improved performance and economy of operation.
2. Description of the Prior Art
The relative simplicity, compactness, and light weight of the gas turbine engine cause it to be a preferred power plant for a variety of vehicles whether aircraft, watercraft, or landcraft. At the same time, gas turbines as previously used have been inherently inefficient when operated at less than their maximum power, and for many applications must so operate much of the time. Unfortunately, the thermal efficiency of gas turbines falls off very rapidly as the load is reduced, much more rapidly than in the case of conventional reciprocating internal combustion engines, and thus the specific fuel consumption rises proportionately. Indeed, in some instances, the high specific fuel consumption of the gas turbine engine under average operating conditions has outweighed the advantages of simplicity, compactness, and light weight, because the weight and volume of the extra fuel that had to be carried.
Various expedients have been attempted to raise the part power efficiency of gas turbines by changes in gas turbine engine designs including variable pitch blades in the compressor and turbine sections and by adding recuperators. However, such expedients have only partially improved the part power specific fuel consumption. One approach to solving the problem has been disclosed in U.S. Pat. No. 2,723,531 to Wosika et al. In that instance, efficiency was said to be greatly improved by employing in a power plant a plurality of small turbine units all adapted to be coupled to a single generator, and working only as many units as necessary to satisfy the power demand at anytime. For example, if two turbine units are employed, the specific fuel consumption can be reduced by almost one half, where the power plant must operate over a wide load range.
An early patent which relates to the use of multiple gas turbine engines of the turboprop type and to clutching arrangements between the engines and their associated propellers is disclosed in U.S. Pat. No. 2,838,913 to Peterson et al.
According to the invention disclosed in U.S. Pat. No. 3,416,309 to Elmes et al., an engine installation has at least two engines each of which is connected to drive at least one accessory mounted upon a respective gearbox through an output shaft. Power management control systems for multiple engine installations utilizing gas turbine engines are variously disclosed in U.S. Pat. Nos. 3,930,366 and 3,969,890 to Nelson, 3,963,372 to McLain et al. and to 4,137,721 to Glennon et al.
None of these patented systems, however, discloses an interconnection between the gas producers of the respective engines. It was in light of the state of the art as just mentioned that the present invention has been conceived and is now reduced to practice.
SUMMARY OF THE INVENTION
According to the present invention, two gas turbine engines are interconnected through a pneumatic, mechanical, hydraulic, or power link. This power link runs from the gas producer shaft of one engine to the gas producer shaft of the other engine either delivering or absorbing power directly to or from each other. The gas producer section of a gas turbine engine comprises a compressor directly coupled to a turbine which drives the compressor and a combustor positioned between the compressor and the turbine. The unit delivers hot gases to another turbine on a separate independent shaft which is the output power shaft for the engine. Through the use of clutches, swash plates or valves, selectable operating modes are achieved. Such a two engine system has been found to exhibit superior performance over a single engine system which includes maximum power boost and better fuel consumption at low powers.
The interconnecting power train is designed to allow the following operating modes:
(a) a primary engine and a significantly smaller secondary engine run independently of each other; either the primary engine or the secondary engine can drive auxiliary power units and deliver bleed air from a load compressor or its own compressor;
(b) the primary engine drives into the secondary engine or the secondary engine drives into the primary engine while simultaneously driving the auxiliary power units; and
(c) both engines can share the same engine required accessories including fuel pump, oil pump, and controls.
The arrangement of the invention yields the following operational benefits over a single gas turbine engine system:
(a) the secondary engine, being smaller, that is, having a lower power rating, can deliver auxiliary power and bleed air at a reduced fuel consumption than the larger primary engine which for the same purpose would have to operate at a low part power.
(b) the secondary engine can assist the compressor shaft of the primary engine and thereby provide power augmentation of the primary engine, the primary engine's boosted output power being greater than the input power of the secondary engine.
(c) the primary engine can drive the secondary engine, which is unfired, to provide bleed air from the compressor of the secondary engine; this occurs when the primary engine is required to operate for other reasons, for example, for propelling a vehicle.
(d) the secondary engine can start the primary engine (or visa versa) directly; in cold conditions, the secondary engine can be started initially, thereby reducing the size or number of batteries required.
Other and further features, advantages, and benefits of the invention will become apparent in the following description taken in conjunction with the following drawings. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory but are not to be restrictive of the invention. The accompanying drawings which are incorporated in and constitute a part of this invention, illustrate one of the embodiments of the invention, and, together with the description, serve to explain the principles of the invention in general terms. Like numerals refer to like parts throughout the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a system embodying the invention for producing power utilizing gas turbine engines; and
FIG. 2 is a presentation of the functions and drive modes of two gas turbine engines whose gas generators are coupled through a suitable on/off mechanism, all according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turn now to the drawings, and initially, to FIG. 1 which diagrammatically depicts a system 20 for producing power in accordance with the teachings of the present invention. The system 20 may be used for powering any one of a variety of vehicles including ships, aircraft, and land vehicles. In any event, a primary gas turbine engine 22 having a moderate power rating is seen to include a gas generator 23, which comprises a compressor 24, a combustor 26, and a turbine 28 which, by means of a primary drive shaft 30, is drivingly engaged with the compressor 24.
An output power section 35 including a power turbine 36 is provided at the aft end of the engine 22 but is independent of the turbine 28 and the other components comprising the gas generator. By way of an output shaft 38, the power turbine 36 can drive an external load. For example, if the system 20 is the power plant for a ship, the output shaft 38 would serve to drive the screws used to propel it through the water. In the event the vehicle being powered were an aircraft, the shaft 38 would be connected to a propeller or to a fan. In the event the system 20 were used in conjunction with a land vehicle, for example, a tank 39, the shaft 38 would be connected, through a transmission represented by a line 38A to the tracks of the tank.
The system 20 also includes a secondary gas turbine engine 40 which includes a compressor 42, a combustor 44, and a turbine 46 which is drivingly engaged with the compressor by way of a drive shaft 48. Indeed, the compressor 42 and the turbine 46 are fixed to the drive shaft 48 for unitary rotation therewith. The engine 40 is provided with bleed duct 50 having a bleed valve 52 therein for selectively drawing off pressurized air from the compressor 42. When the system 20 is used to power a land vehicle, and more specifically, the tank 39, a primary use for the bleed air is to supply the interior of the tank with "NBC" conditioned air, that is, air which is carefully filtered to remove any nuclear, biological, or chemical agents which would adversely affect the crew of the tank. For purposes of the invention, the valve 52 is operated by a vehicle crew member whenever NBC air is required.
The system 20 further includes an intermediate drive mechanism 54 for selectively, mechanically (in this example), coupling the gas generator of the engine 22 with the gas generator, or secondary, engine 40. To this end, an intermediate shaft 56 includes, at one end, an integral bevel gear 58 drivingly engaged with a bevel gear 60 fixed for rotation on the drive shaft 30. In like manner, at the opposite end of the intermediate shaft 56 is a bevel gear 62 fixed for rotation thereon drivingly engaged with a bevel gear 64 on the end of the gas producer shaft 48 of the secondary engine 40.
A suitable transmission 66, diagrammatically illustrated in FIG. 1 mechanically interconnects the intermediate shaft 56 with auxiliary power units 68 also diagrammatically depicted and representing those components which are external of the system 20 but necessary for the operation of the vehicle 39 being powered. Such devices might include hydraulic pumps and generators. The transmission 66 is also provided to couple system accessories 70 to the intermediate shaft 56. The accessories 70 are components which are necessary for the operation of the system 20 and include, for example, a fuel pump 72, an oil pump 74, and electrical or electronic controls 76.
The intermediate drive mechanism 54 includes a pair of clutches 78, 80 for selectively coupling the primary and secondary drive shafts 30, 48. That is, when both of the clutches 78, 80 are engaged, the drive shafts 30, 48 are drivingly coupled. Furthermore, the clutches 78, 80 are so positioned that the auxiliary power units 68 and the accessories 70 can be selectively powered by either the engine 22, or by the engine 40, or by both of them simultaneously.
The system 20 provides three primary benefits. In one instance, an outstanding feature resides in starting the larger, primary engine 22. Specifically, because the engine 40 is of a much smaller power rating, it can readily be started by means of a battery while battery starting of the engine 22 is much more difficult and requires much larger sized batteries which are heavy and cumbersome. Once the secondary engine 40 has been started, with clutch 78 engaged to simultaneously operate system accessories 72, 74, and 76, while the primary engine remains unfired, the clutch 80 can be engaged to thereby drivingly couple the shafts 30, 48. With the engine 40 thereby drivingly engaged with the gas generator of the primary engine 22, a mass flow rate of air through the primary engine is developed which is sufficient, once the combustors 26 are fired, to initiate operation of the engine 22. Thereafter, once self-sustained operation has been achieved, the clutches 78, 80 can remain engaged or be disengaged, as desired. In this regard, self sustaining operation is said to be achieved when starting a gas turbine engine as a result of the following sequence of events. The compresser and turbine are driven up to some defined part speed, at which the air flow through these units is sufficient enough to ignite and maintain a flame in the combustor and the power output of the turbine is great enough to drive and maintain the compressor at a fixed speed.
Consider a second benefit of the invention. In instances of operation of the vehicle 39 during which the output of the engine 22 is not required but the auxiliary power units 68 and accessories 70 are required, the clutch 80 can be disengaged while the clutch 78 is engaged. In this manner, the engine 40, with its substantially lower fuel consumption, becomes the operating power plant for the vehicle 39.
As a third benefit provided by the system 20, the engine 40 can be utilized to provide a significant boost for the output of the engine 22. It will be appreciated that, operating by itself, the power output to the shaft 38 of the engine 22 is limited by reason of the maximum operating limits including inlet temperature and speed permitted for the turbine 28. Exceeding these limits may result in a dangerous condition and shorten the life of the gas turbine engine. By introducing more air into and through the engine 22, that is, by increasing the mass flow rate by coupling the drive shaft 48 of engine 40 to the drive shaft 30 of engine 22, the air flow created by the compressor 24 can be significantly increased. In this manner, an increase in the rate of fuel delivery to the combustors 26 can also be accommodated without increasing temperature to the turbine 28 but increases power output by virtue of the greater mass flow passing through the engine. Since the power input to engine 22 works directly on its gas generator section 23, greater output power from the power turbine 36 and its output shaft 38 is achieved than the power input to engine 22 from engine 40.
Thus, by reason of the system 20, a small secondary engine 40 can be used to start a much larger primary engine 22; the secondary engine 40 can be utilized during idle periods to thereby offset the much greater fuel consumption of the primary engine 22; and by operating the engines 22, 40 in the manner just described, boost power during critical periods can be achieved readily without harming the engine 22 or requiring any substantial modification to its design.
All of the different modes of operation of the system 20 are depicted in FIG. 2.
The performance enhancement provided by the system 20 can be even better understood from the following examples:
EXAMPLE 1
Power Boost Enhancement While Providing NBC:
Engine 22 alone supplies 1450 sHP at an allowable 50° F. turbine inlet temperature increase while also supplying NBC air. With both engines 22 and 40 operating, and engine 40 being rated at 100 HP, engine 22 supplies power for vehicle propulsion only while engine 40 supplies all "non propulsion" power to auxiliary power units 68, NBC air from compressor 42 through valve 52, and approximately 50 HP into engine 22 through shaft 56 and clutch 80. This both eliminates the burden on engine 22 and boosts its vehicle propulsion power as follows:
(a) engine 22 alone: total propulsion horsepower=1450
(b) engine 22 plus engine 40: total propulsion horsepower=1660
Result: A 210 HP gain is achieved at the output shaft 38 from the 100 HP secondary engine 40.
EXAMPLE 2
Power Boost Enhancement Without Providing NBC:
With engines 22 and 40 operating as in Example 1 except that, in this instance, the burden of supplying NBC air is not required and engine 22 no longer is allowed to use the 50° F. turbine inlet temperature increase.
(a) engine 22 alone: total propulsion horsepower=1480
(b) engine 22 plus engine 40: total propulsion horsepower=1620
Result: A 140 HP gain is achieved at the output shaft 38 from the 100 HP of the secondary engine 40.
NOTE: In EXAMPLE 1, the elimination from engine 22 of the severe penalty to maximum power caused by NBC air bleed allows a much greater benefit in maximum power gain than occurs in the "no NBC air" situation of EXAMPLE 2.
EXAMPLE 3
Fuel Savings Enhancement At Idle:
With engine 22 turned off and vehicle 53 not moving, engine 40 supplies all non-propulsion power to auxiliary units 68 through clutch 78; assuming NBC air is not required, the much smaller secondary engine 40 now operates at part power to supply, for example, a 5 KW electric load in lieu of large engine 22 to accomplish the same task:
(a) Engine 22: fuel consumption=60 lbs./hr.
(b) engine 40: fuel consumption=30 lbs./hr.
Result: At idle, fuel consumption is reduced by 50% a period(.)
While preferred embodiments of the invention have been disclosed in detail, it should be understood by those skilled in the art that various other modifications may be made to the illustrated embodiments without departing from the scope of the invention as described in the specification and defined in the appended claims. | Two gas turbine engines are interconnected through a pneumatic, mechanical, hydraulic, or power link. This power link runs from the gas producer shaft of one engine to the gas producer shaft of the other engine either delivering or absorbing power directly to or from each other. The gas producer section of a gas turbine engine comprises a compressor directly coupled to a turbine which drives the compressor and a combustor positioned between the compressor and the turbine. The unit delivers hot gases to another turbine on a separate independent shaft which is the output power shaft for the engine. Through the use of clutches, swash plates or valves, selectable operating modes are achieved. Such a two engine system has been found to exhibit superior performance over a single engine system which includes maximum power boost and better full consumption at low powers. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to closure arrangements, and more particularly to a closure arrangement which includes container body and end members having plastic rim portions which are bonded to each other by a membrane interposed therebetween.
2. Description of the Prior Art
A prior art search directed to the subject matter of this application in the United States Patent and Trademark Office revealed the following United States Pat. Nos.: 2,200,200; 2,241,710; 2,620,939; 3,089,609; 3,301,464; 3,419,181; 3,445,027; 3,815,314; 3,892,351; 4,000,816; 4,094,460; 4,171,084; 4,215,797; 4,243,152.
None of the prior art patents uncovered in the search discloses a closure arrangement wherein a membrane comprising a metallic foil central panel, having heat activatable coatings on both sides thereof, is sandwiched between and used to bond the corresponding rim portions of container body and end members to each other.
SUMMARY OF THE INVENTION
This invention relates generally to containers and particularly containers of a tubular type having body and end members with plastic rims.
The invention is concerned with a means of securing the rim portions of container end and body members to each other.
It is a primary object of the invention to utilize a membrane for the dual purpose of providing a hermetic seal for the container and also for bonding the rims of container body and end members to each other.
A more specific object of the invention is a provision of a membrane comprising a central metallic foil panel coated on both sides with a heat activatable materials, such as plastic, which serves to bond the membrane member to both the container body and the container end.
These and other objects of the invention will be apparent from an examination of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a container body member and end closure member, embodying features of the invention;
FIG. 2 is a fragmentary vertical cross section of a portion of the structure illustrated in FIG. 1;
FIG. 3 is a view similar to that of FIG. 2 but illustrating the application of a separate cap to the end closure member;
FIGS. 4 and 5 are views similar to FIG. 3 but illustrate alternate forms of cap arrangements;
FIGS. 6 and 7 are views similar to FIGS. 1 and 2, respectively, but illustrate a modified form of the invention; and
FIG. 8 is a view similar to FIG. 7 but illustrating the closure arrangement with the removable portion of the closure shown in an open position.
It will be understood that, for purposes of clarity, certain elements may have been intentionally omitted from certain views where they are believed to be illustrated to better advantage in other views.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings for a better understanding of the invention, and particularly to FIGS. 1 and 3, it will be seen that there is provided a generally cylindrical container member, indicated generally at C, to which is secured an end member, indicated generally at E. End member E may include a separate overcap or lid, indicated generally at L.
The end member is secured to the container member by means membrane, indicated generally at M, which is described in greater detail hereinafter.
Container C may either be of all plastic or a combination of paperboard and plastic materials. In either case it has a plastic rim 12 formed at the upper or open end of a side wall 10.
Container rim 12 includes a radially outward extending, annular, horizontal flange 14 having an annular vertical flange 16 extending axially outward from its outer edge to form, with horizontal flange 14, a recess 17 for receipt of a rim portion of end closure member E.
It will be seen that end closure member E includes an annular rim portion, preferably formed of plastic, which has an annular, horizontal element 20 and integral, annular, vertical element 22 extending axially outward from the inner edge thereof Vertical element 22 may be provided with external threads 24 to accommodate a screw-on overcap L, as indicated in FIG. 3.
As an alternative to the screw cap arrangement vertical element 22 may be provided at its adjacent free edge with an annular flange 22 adapted to accommodate either the hinged lid L1, as shown in FIG. 4, or a snap-on lid L2, as illustrated in FIG. 5. The type of overcap is immaterial to the invention, because the invention in this case relates primarily to the manner in which the rim portion of the end member is attached to the rim portion of the container body member.
As best seen in FIG. 2, this attachment is accomplished by means of a relatively flat preferably arcuate membrane, indicated generally at M.
Membrane M includes a central panel or core 30 which is a thin layer of metallic foil. Central panel 30 is coated on both sides with heat activatable sealing materials such as polyethylene, polypropylene, or some simlar type of material. The coating on the outer surface is indicated at 32, and the coating on the inner surface is indicated at 34.
Still referring to FIG. 2, it will be seen that outer coating 32 comes in direct contact with the inwardly facing surface of the end member rim portion horizontal element 20, and inner coating 34 before it comes in contact with the outwardly facing surface of container body rim horizontal flange 14.
In order to effect a seal between the container end and body members the membrane is placed in position therebetween and heat is generated, through induction currents, which pass through the central foil portion of the membrane. The heat activates the adhesive compositions 32 and 34 causing a container body closure members to be bonded together and to effect a hermetic seal therebetween.
In order to have access to the interior of the container to dispense contents therefrom, after the overcap is removed, the membrane may be cut with a knife or pierced with some sharp object.
Referring now to FIGS. 6 through 8, it will be seen that a slightly modified form of the invention is shown. In this embodiment container C is substantially identical in construction to the container illustrated in the previously described embodiment. Membrane M' is similar to the membrane of the previous embodiment but slightly different as will be described hereinafter. The primary difference in the two embodiments, lies in the end closure member E' which includes a movable portion as hereinafter described.
As best seen in FIGS. 7 and 8, end closure member E' includes a preferably plastic outer rim portion indicated generally at 40 and an inner rim portion indicated generally at 42 which are hingedly attached at one location on their upper edges by a relatively narrow, thin web of plastic 44 which serves as a hinge.
Cylindrical outer rim portion 40 is generally L-shaped as seen in cross-section and includes a horizontal portion 40a adapted to be received within recess 17 of the rim of the container C and an axially outward extending vertical portion 40b formed integrally therewith.
Concentric, cylindrical inner rim portion 42 encloses and is secured to or formed integrally with a central panel 46, which may be formed of plastic or paperboard, as desired. As best seen in FIG. 8, the inner portion of the closure member E', because of its hinge relation to the outer portion, can be pivoted when lifted by the lift tab 48, at the opposite side of the closure member, and can be moved away from the container to provide an access to provide an access to the interior container.
As in the case of the previous embodiment the outer rim portion 40 of the end closure member E' is bonded to the horizontal flange rim of the container member C by means of a membrane indicated generally at M'.
Membrane M' includes a metallic foil central panel, indicated at 130, having a heat-activatable coating 132 on its outer surface and a heat activatable coating 134 on its inner surface.
The only differences between the membrane arrangement of this embodiment and that of the previously described embodiment is that the membrane of FIG. 7, instead of lying in a single plane as in the case of the earlier described embodiment, is offset, with a portion being disposed in an angle between part of the rim of the container and the sloping surface 42a of end closure member inner rim portion 42. Also the composition of the heat activatable material 132 which secures the membrane to the end closure member is such that it forms a stronger bond than the bond formed between coating 134 on the inner surface of the membrane and the related surface of the container rim. The purpose of this is to permit the membrane to have its central portion detached from its peripheral portion, as shown in FIG. 8, and also to remain adhered to the movable portion of the end member when it is separated from the adjacent portion of the container member as shown in FIG. 8 to permit the container end member, so it can be pivoted away from the container to afford access to the contents of the container.
Thus, it will be appreciated that in each of the embodiments of the invention there is provided a novel means to utilize a coated metallic foil membrane as both a hermetic seal and means of bonding a container closure member to a container body member. | An end closure arrangement for a tubular container including a metallic foil membrane having a heat sealable coating on both sides thereof bonding said membrane between adjacent container and end closure rim surfaces. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to mooring buoyant bodies, and more particularly to mooring said bodies to remove instabilities inherent in flotation.
There are many activities now being conducted in watercovered areas of the earth's surface. These areas include lakes, oceans, seas, rivers or other bodies of water, the terms for which can be used interchangeably for purposes of the invention. In the petroleum industry, for example, the search for new sources of oil and gas has been extended particularly to the world's oceans. The oceans and other bodies of water present numerous problems to such activities, the primary one of which is to develop buoyant bodies such as platforms as bases of operations. Due to wave action of the oceans, platform stability can be an important factor in some activities such as drilling oil and gas wells, in which movement of a drilling platform can bend or break drill pipes.
A number of types of offshore drilling platforms have been proposed. These include platforms supported by columns having their lower ends resting upon the ocean floor (U.S. Pat. No. 2,248,051 by Armstrong); floating elevated platforms supported by columns from a floating pontoon (U.S. Pat. Nos. 3,011,467 by Le Tourneau and 3,163,147 by Collipp); a permanent floating platform employing counterweights for adjustment to vertical oscillations and reduction of roll (U.S. Pat. No. 3,294,051 by Khelstovsky); and floating platforms provided with anchors with parallel anchor lines, which are also known as semi-submersible platforms and tension leg platforms (U.S. Pat. Nos. 2,399,611 by Armstrong, 3,154,039 by Knapp and 3,540,396 by Horton).
The prior platforms having columns resting on the ocean floor are stable but are limited to relatively shallow water, due to the expense involved in building tall support columns. This and related costs such as maintenance make such platforms uneconomical at water depths greater than 350 to 400 feet. The floating platforms are much less expensive than the columnar type, but they are subject to influence by wave action and are thus much more unstable. This is particularly true of the unanchored platforms but is nevertheless present to an undersirable degree in both the anchored and unanchored types disclosed by the prior art.
The platforms disclosed in Armstrong, Knapp and Horton are anchored, or moored, with cables in a parallelogram geometry in which all the cables extend parallel to each other to the ocean floor. The parallelogram geometry essentially eliminates rotational motions about axes in the plane of the platforms' horizontal surface. These rotational motions are of two types: pitch, which is rotation about an axis normal to the direction of ocean currents; and roll, which is rotation about an axis in the direction of the ocean currents. The parallelogram geometry does not, however, eliminate lateral, or translational motions of the platform. These translational motions include surge, which is movement in the direction of current flow, and sway, which is movement normal to the direction of current flow.
A second conventional geometry for mooring lines is catenary in which the platform is moored with cables anchored laterally from the normal parallelogram anchor positions. The catenary geometry is helpful in eliminating horizontal excursions of platform, but it inherently introduces rotational motions.
A combination of the two mooring gemoetries can be used to provide some of the advantages of both. The parallelogram geometry provides the primary restraint while the catenary provides the secondary. However, the catenary mooring is limited in the amount of restraint that it can provide without introducing rotational motions. Under extreme conditions the restraint can be so great as to cause the adjacent cable in the parallelogram configuration, known as a tension leg, to go slack and cause the platform to pitch or roll.
An object of the invention, therefore, is to provide improved means for eliminating rotational and translational motions from floating platforms or other bodies.
SUMMARY OF THE INVENTION
The invention embodies a system which stabilizes a buoyant body by mooring it with lines in at least a catenary configuration and vertically adjusting the attachment point of the lines on the buoyant body.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more fully understood by considering the exemplary embodiments illustrated in the following drawings:
FIG. 1 is a schematic representation of a buoyant body moored using both parallelogram and catenary configurations;
FIG. 2 is a schematic representation of restraint forces imposed upon the buoyant body of the catenary cables;
FIG. 3 is a partial view of a buoyant platform which illustrates one means for vertically adjusting the attachment point of a mooring line;
FIG. 4 is a more detailed side view of the adjustment apparatus of FIG. 3; and
FIG. 5 is a top view of the apparatus of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention may be used with the mooring configuration shown in FIG. 1. A platform 10 having legs 12 floats in a body of water 14. A derrick 15 sits atop platform 10. The platform can be moored to the ocean floor 16 by means of two sets of cables. A first set of cables 18 are attached to legs 12 of platform 10 and extend downwardly parallel to each other to floor 16 where they are attached to anchors 20. This is the parallelogram configuration. A second set of mooring lines 22, such as cables or chains, attached to legs 12 extend downwardly and outwardly and are tied to anchors 24 on floor 16. This is the catenary configuration. Only two cables in each set are shown in the view of FIG. 1, but a number of cables may be attached around the periphery of platform 10.
The rotational effect of catenary mooring is shown by means of the center of gravity 26 of platform 10 and force vector 28 resulting from restraint offered by cable 22. Since the force vector does not point in the direction of the center of gravity of the platform, a moment arm illustrated by arrows 30 is formed. The effect in the situation illustrated is a counterclockwise rotation about the center of gravity 26.
The manner in which the invention reduces rotation of the platform is illustrated in FIG. 2. Cable 22 is shown connected to leg 12 of platform 10 at three exemplary positions. In the first position, the cable, which is designated as 22a is connected at attachment point 32. In the second position the cable 22b is connected at point 34, and in the third position, cable 22c is connected at point 36. Each attachment point represents the optimum position for reducing the moment arm about the center of gravity 26 for each condition of mooring restraint provided by a cable 22. In each case the attachment point may be chosen such that the force vector provided by the mooring restraint for each condition, points in the direction of the center of gravity 26. The vector is designated 28a for cable 22a, 28b for cable 22b and 28c for cable 22c. The moment arm produced by the vector may thus be reduced or eliminated by providing a vertically adjustable attachment point on the platform so that the mooring configuration can be altered to suit wave and current conditions of the water as well as the topography of the floor to which the platform is anchored.
One type of mechanism for adjusting the mooring attachment point is shown in FIG. 3. A portion of platform 10 and one of its legs 12 is shown. Cable 22 threads through a block 42 and is connected to platform 10 at point 40. Block 42 is attached to a continuous chain 44, or the like, which is looped about a sheave 46 attached to the top of platform 10 and a sheave 48 attached to the bottom of the platform leg 12. Chain 44 is movable, and thus block 42 is vertically adjustable by means of a motor and gear mechanism 50, or the like. By adjusting the vertical position of block 42, the effective attachment point of cable 22 can thus be varied.
Block 42 and associated apparatus is shown in more detail in FIGS. 4 and 5. Block 42 includes a framework 50 having connected therein sheaves 52 and 54, one above the other. Projecting in front of the two sheaves by means of arms 56 are two vertically-disposed rollers 58 and 60. Cable 22 threads between the rollers 58 and 60 and around sheaves 52 and 54. The rollers 58 and 60, which together are known as a fairlead, prevent cable 22 from being pulled to the side and from the sheave track. Block 42 is secured to leg 12 of the platform by means of a double flange 62 having a center slot 64. A small neck 66 of framework 50 extends through slot 64. Neck 66 has flanges 68, which are wider than slot 64, inside double flange 62 to prevent movement of block 42 away from leg 12. Also attached to neck 66 are rollers 70 in a vertical line and in contact with leg 12. In addition, two other sets of rollers 72 and 74 are attached to framework 50 in a vertical line and arranged to roll along the lateral surfaces of double flange 62. The rollers facilitate movement of framework 50 through double flange 62. There are no rollers or bearings between flanges 68 and the front portion of double flange 62 since the combination of the outward restraint force provided by cable 22 and friction between the aforementioned flanges provides assistance in maintaining block 42 in a selected vertical position.
While particular embodiments of the invention have been shown and described, it is apparent that changes and modifications may be made without departing from the spirit and scope of the invention. It is the intention of the appended claims to cover all such changes and modifications. | Buoyant bodies such as those used for drilling oil and gas wells in water-covered areas are moored to the floor of the body of water with lines in the catenary configuration. Rotational motions induced by such configurations are reduced by providing for vertical adjustment in the point of attachment of the lines on the buoyant body. | 1 |
FIELD OF THE INVENTION
This invention relates generally to power plants having one or more gas turbines, and more particularly to a system for automatic control of the injection of coolant into the combustors of the gas turbine in order to reduce NOx emissions produced during the combustion process.
BACKGROUND OF THE INVENTION
The combustion of natural gas fuels and oil in the combustor of a gas turbine power plant is known to produce undesirable levels of nitrogen oxide emissions. In order to reduce the level of NOx emissions, coolant, such as steam or water, is injected into the combustor. As is commonly known, steam or water which is injected into a combustor reduces the temperature of natural gas fuel and oil as it combusts and burns and, as a result, the combustion process produces less NOx.
Systems are known, such as that disclosed in Martens et al, U.S. Pat. No. 4,160,362, for controlling the flow of steam and water into a combustor in order to reduce the emissions of NOx in the gas turbine exhaust. Martens recognizes the problem that over-injection of steam or water, beyond that which is necessary to achieve a desired level of NOx emissions, results in an unnecessary increase in mass flow throughout the turbine and decreases the cycle efficiency. Therefore, it is desirable to properly limit the flow of coolant into the combustors, without sacrificing the necessary reductions in NOx emissions, in order to run the power plant at high efficiency.
Generally, sensors are located in the turbine exhaust stack for measuring the amount of NOx produced. It is desirable to use the output of the NOx sensor as a parameter for input into the control systems employed to control the flow of steam and water into the combustor. However, sensors are unreliable due to the fact that in some circumstances they completely fail to operate.
Thus, in order to account for the unreliability of the NOx sensors, steam or water flow into the combustor is scheduled as a function of the turbine load. This function, known as a standard load versus flow curve, is determined from emissions tests actually conducted on the operational unit, or one similar. During field testing, based on a predetermined NOx set point, the flow rate of steam or water which actually produces NOx emissions at the desired NOx set point is plotted as a function of the turbine load. Accordingly, during actual operating conditions, the steam flow set point which is necessary to produce a desired set point level of NOx emissions at a specific turbine load is determined from the standard load versus flow curve. The parameters from this curve can then be used in a system for controlling the flow of coolant into the combustor.
However, changes in environmental conditions, i.e. ambient temperature in the area of the combustor, as well as the turbine operating conditions, such as the position of the inlet guide vanes, affect this standard load versus flow curve. These variables influence the amount of steam flow which is actually necessary to produce a desired NOx emissions level. Since these variables are not taken into account when the standard load versus flow curve is generated, this curve has a certain amount of error built into it. In order to account for this error, the actual NOx level measured by the sensor is used as a parameter in the control system to adjust the standard curve. However, as discussed below, this adjustment may be limited due to the fact that sensors are known to fail completely under some conditions.
During actual operating conditions at a specific turbine load, in order to produce the desired set point level of NOx, the steam flow set point is determined from the standard load versus flow curve. At the start of the control cycle, valves inject steam or water into the turbine combustors at this set point flow rate. However, due to the error in the standard curve, the actual level of NOx produced and measured by the sensor will most likely vary from the NOx set point. Thus, the control system must account for this error such that the valves inject more or less steam, as compared to the steam flow set point, to bring the NOx level measured by the sensor to the NOx set point.
Devices are known which may be used in coolant injection control systems for measuring the error attributable to the variable conditions associated with the standard load versus flow curve. One such device is a summer as disclosed in Martens. The measured error is used to adjust the steam flow set point derived from the standard load versus flow curve, in order to account for the variables which affect that curve.
For example, FIG. 1 shows an adjusted standard load versus flow curve representative of that which would be produced using a summing device in accordance with the prior art. The dashed lines represent the adjusted steam flow set points. As can be seen, summing devices provide the error in a discrete amount, wherein the magnitude of the error is the same at all points on the curve. Thus, such a device provides for straight line bias of the control system.
However, a problem has been recognized in that the use of devices which provide for straight line bias control in coolant injection systems is inefficient in some circumstances and may damage the gas turbine. As shown in FIG. 1, where a control system employs straight line bias control devices, the amount of error which the system measures, and thus the range of error within which the system operates, is the same When the turbine is at low load as it is when it is at high load. Thus, where the measured NOx level exceeds the NOx set point, the adjustment above the steam flow set point in order to account for the error will be the same, whether operating at high load or low turbine load. At high turbine load, the additional amount of steam flow may be only a small percentage increase above the steam flow set point. However, at low turbine loads, the additional amount of steam flow may be a large percentage increase above the relatively low steam flow set point. Where the control system responds to such an increase at low load conditions, the valves inject coolant at a level which may be beyond that which is necessary to reduce the amount of NOx emissions, thus reducing the turbine cycle efficiency. It is also possible that the over-injection of coolant may result in flame-out of the combustor, resulting in malfunctioning of the turbine and possible damage.
The problem created by the use of straight line bias control devices in the fluid injection system is compounded in the case where more than one gas turbine is connected to a single emissions stack, where the stack has only one NOx sensor for the plurality of gas turbines. For example, where two gas turbines are connected to a single stack, during start-up conditions where it is common for both turbines to be on line with only one turbine having steam injection at the time, the unit with steam injection in operation will be adjusting its steam flow based upon a combined NOx level from both units and the possibility of over-injection is increased. Also, where two gas turbines are connected to a single stack and both are on line, but each is operating at a different load, straight line bias of the control system, using a summation of the control variables, results in fighting between the units.
Therefore, there is a need for a system for automatic control of the flow of coolant into the combustors of a gas turbine power plant in order to reduce NOx emissions levels, wherein the control system employs devices which provide for a percentage bias of the system parameters. The present invention provides a system which satisfies this need.
SUMMARY OF THE INVENTION
In a gas turbine power plant having at least one gas turbine, where the gas turbine has at least one combustor burning natural gas fuel and/or oil, a system and method for controlling the flow of coolant injected into each combustor, the method comprising generating a signal indicative of the percent error between a predetermined NOx emissions set point and the measured amount of NOx emissions produced by the power plant. This signal is used to adjust a predetermined coolant flow set point in order to account for the error built into the standard load versus flow curve. A second signal is generated which is indicative of the percent error between the adjusted coolant flow set point and the measured amount of coolant flow injected by the coolant injection throttle valves. The flow of coolant through the throttle valves and into the combustor is controlled in accordance with this second signal. PID controllers are used to generate the percent error signal between the input parameters. The adjustment to the coolant flow set point may be limited so as to avoid over-injection of coolant into the combustors. This invention is particularly suited for use in a power plant where only NOx sensor is used in the control system for injecting coolant into two or more gas turbines.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a standard load versus flow curve representative of an error adjustment in accordance with prior art control systems.
FIG. 2 shows a front elevational view of an industrial gas turbine employed in power plant equipment arranged to operate in accordance with the present invention.
FIG. 3 shows a schematic representation of an overhead plan view of structure embodied in a system in accordance with the present invention.
FIG. 4 shows a flow diagram for a method in accordance with the present invention for operation of the structure shown in FIG. 3.
FIG. 5 shows a flow diagram for a method of practicing the invention.
FIG. 6 shows a standard load versus flow curve representative of an error adjustment in accordance with the present invention.
FIG. 7 shows a plot of control parameters in accordance with the present invention.
FIG. 8 shows another standard load versus flow curve representative of an error adjustment in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Combustion or gas turbine 100 constructed and arranged in accordance with the present invention is shown in FIG. 2. In the embodiment described herein, gas turbine 100 is preferably the W 501D5 type manufactured by Westinghouse Electric Corporation and is a simple cycle type having a rated speed of 3600 rpm. As will be apparent from the drawing, turbine 100 includes a two bearing single shaft construction, cold-end power drive and axial exhaust. Filtered inlet air enters multistage axial flow compressor 102 through flanged inlet manifold 104 from inlet ductwork 106. Pressurized compressor outlet air is directed into a combustion system 108 comprising a total of fourteen can-annular combustors 110 conically mounted within a section 112 of casing 114 about the longitudinal axis of the gas turbine 100.
Control of NOx emissions produced during the combustion of natural gas fuel and/or oil in combustor 110 is achieved by injecting coolant into combustor 110. In a preferred embodiment of the present invention, the coolant injected into combustor 110 is steam. In another embodiment, the coolant is water, and in a further embodiment the coolant is a mixture of steam and water.
FIG. 3 shows a schematic representation of an overhead plan view of structure embodied in a system in accordance with the present invention. In a preferred embodiment, two gas turbines 100, 100' are connected to a single exhaust emissions stack 120. Stack 120 contains one sensor 122 for measuring the combined level of NOx emissions produced by both turbines. Controller 124 measures the percent error between a predetermined NOx set point and the combined NOx emissions produced at sensor 122 by turbines 100, 100'. The output of controller 124 is used to adjust a predetermined coolant flow set point for each turbine 100, 100'. The adjusted coolant flow set point is input into a second controller 126, 126' for each turbine, along with the actual measured amount of coolant flow injected into each combustor 110, 110' by throttle valves 128, 128'. Controllers 126, 126' measure the percent error between the adjusted coolant flow set point and the actual measured amount of coolant flow. The percent error output of controllers 126, 126' is used to control the injection of coolant into combustors 110, 110' from throttle valves 128, 128' in order to maintain the NOx emissions levels at the desired NOx set point.
In a preferred embodiment, controller 124 and controllers 126, 126' are proportional integral and derivative, or PID, controllers. A PID controller recognizes any deviation between two input parameters and integrates the deviation between the two parameters to zero. As is commonly known, PID controllers operate within a range of error while integrating. The output signal of the controller travels over this range, either plus or minus, in order to try to bring the deviation between the two input parameters to zero. In accordance with the present invention, the PID controller operates within a range of error which is expressed as a percentage, either plus or minus, and the output signal represents a percent error. Thus, when the deviation between the two input parameters reads zero, the PID is satisfied and the output signal will be zero percent error. Accordingly, the control system bias is based on a percentage, rather than straight line bias control.
In accordance with the present invention, the range of the percent error of the PID controller is variable. At higher ranges, the output signal of the PID controller provides for larger adjustment of the coolant flow set point. In a preferred embodiment, PID controller 124 and controllers 126, 126' have a range of percent error between about -100% and +100%.
FIG. 4 shows a flow chart for a method for controlling the coolant flow into combustors 110, 110' in order to control the amount of NOx produced by gas turbines 100 100', for the embodiment shown in FIG. 3. At 300, a signal is generated by controller 124 which represents the percent error between a predetermined NOx emissions set point and the measured amount of NOx emissions produced by the power plant and measured at sensor 122. The signal generated at 300 is converted to a parameter indicative of that signal at 302. At 304, 304' the output at 302 is used to adjust the coolant flow set point of each gas turbine 100, 100' and a second parameter indicative of the adjusted coolant flow set point is produced. Accordingly, the output signal at 302 provides the same percentage adjustment in the coolant flow set point for both turbines 100, 100'.
At 306, 306' a second signal is generated by controllers 126, 126' which represents the percent error between the adjusted coolant flow set point parameter and the measured amount of coolant flow, for each gas turbine 100, 100'. At 308, 308' the flow of coolant through injection throttle valves 128, 128' and into combustors 110, 110' is controlled in accordance with the signals from 306, 306'.
Referring to FIG. 5, in order to generate the percent error between the NOx set point and the measured amount of NOx, the NOx set point is operator entered into the system at 310. The NOx set point is predetermined based upon government environmental pollution control standards. The actual combined level of NOx produced by both turbines 100, 100' is measured by sensor 122 in exhaust stack 120 at 312. The output parameters at 310 and 312 are input into a PID controller at 314. The percent error signal output from the PID controller at 314 is converted to a parameter indicative of this percent error at 316. Where the actual level of NOx measured at 312 is greater than the NOx set point at 310, the output of the PID controller at 314 will be a percent error which is positive. Accordingly, where the measured NOx level is less than the set point, the percent error will be negative.
The coolant flow set point for each turbine 100, 100', which is determined from the standard load versus flow curve and is based upon the turbine load and the desired NOx set point level, is read into the system at 318, 318'. The percent error parameter output at 316 is used to adjust the coolant flow set point from 318, 318' in order to account for the error built into the load versus flow curve. At 320, 320' the coolant flow set point is adjusted by multiplying the percent error output from 316 by the coolant flow set point from 318, 318' to arrive at the adjusted coolant flow set point. Where the percent error output from the PID controller at 314 is positive, the adjustment to the coolant flow set point will be a percentage increase in that set point, and a negative percent error results in a decrease in the coolant flow set point. FIG. 6 shows an adjusted load versus flow curve in accordance with the present invention. The dashed lines represent the range of error within which the system operates, based upon the adjusted coolant flow set point at 320 or 320'. As shown, the magnitude of the error adjustment at low turbine loads is small, compared with that at high turbine loads. Thus, the possibility of over-injection of coolant at low loads is decreased, as compared to straight line bias control systems. Where two units are in operation at different loads, each unit will contribute by the same percentage to the reduction of NOx emissions levels. Also, the cycle efficiency, considering the increased mass flow caused by the addition of coolant, is maximized over the entire load capability of the turbine, while the necessary reductions in NOx emissions are provided for.
The adjustment to the coolant flow set point at 320, 320' may be limited to ensure that coolant is not over-injected into the combustors in the case of complete failure of an NOx sensor, possibly to the point of flame-out in the combustor. A percentage change in the coolant flow set point is predetermined. This predetermined percentage change represents the maximum adjustment to the coolant flow set point at the maximum percent error output of the PID controller. FIGS. 7 and 8 illustrate the effect of such a limitation. Assume, for example, that the PID controller has a range between -100% to +100% error. Without any limitation on the adjustment, a percent error of +100% which is read from the PID controller at 314 amounts to an adjustment, or increase, in the coolant flow set point of 100% of that set point. Accordingly, a linear relationship between the two parameters is formed, as shown by the dashed lines in FIG. 7. With a limitation, assuming that the adjustment to the coolant flow set point is limited to a percentage change of ±10%, a percent error of +100% which is read from the PID controller at 314 amounts to an adjustment, or increase, in the coolant flow set point of 10% of that set point. Once again, a linear relationship between the two parameters is formed, as shown by the dotted lines in FIG. 7. The effect of such a limitation is shown by the standard load versus flow curve in FIG. 8. As shown by the dotted lines, the adjustment to the coolant flow set point is limited to the range of the predetermined percentage change in the coolant flow set point and is less than the adjustment without a limitation.
The magnitude of the percentage change in the coolant flow set point is variable and is selected to limit the amount of coolant flow in order to avoid over-spraying in the combustor. In a preferred embodiment, the percentage change in the coolant flow set point is ±10%. This assures that the maximum amount of steam flow can be 10% above the steam flow set point, thus preventing the possibility of over-spraying to the point of a flame out, while also insuring that emissions are well within acceptable levels when steam injection is in operation. Other magnitudes for the percentage change are within the scope of this invention and the value may be selected based upon the accuracy of the standard load versus flow curve.
At 326, 326' the actual flow level of coolant which is injected into combustors 110, 110' by valves 128, 128' for each turbine 100, 100' is input into the system. This measured amount of coolant flow and the adjusted coolant flow set point from 320, 320' are input into a second PID controller at 328, 328' for each turbine. At 328, 328' the PID controller generates a percent error signal.
The percent error output at 328, 328' is used to control the demand on the coolant injection throttle valves at 330, 330'. Where the adjusted coolant flow set point at 320, 320' is greater than the actual flow level of coolant at 326, 326', the NOx measured is greater than the NOx set point. Accordingly, the percent error signal output at 328, 328' provides for a percent increase in that amount in the demand on the throttle valve, such that more coolant is injected into the combustor in order to reduce the level of NOx emissions. Where, the adjusted coolant flow set point at 320, 320' is less than the actual flow level of coolant at 326, 326', the NOx measured is below the NOx set point value, and the error signal provides for a decrease in the demand on the throttle valve. Although actual NOx emission levels below the set point is a desirable situation, the demand on the throttle valve will be decreased by the percentage in order to reduce any unnecessary mass flow throughout the turbine. Thus, the control system in accordance with the present invention provides for control of the NOx levels produced by the turbine, while providing for maximized turbine cycle efficiency.
Control of the flow of coolant injected into combustor 110 in accordance with the present invention is not limited to percentage bias control. Accordingly, control wherein the range of error in the standard load versus flow curve is non-constant over the range of operational load of the gas turbine is within the scope of this invention.
Although particular embodiments of the present invention have been described and illustrated herein, it is recognized that modifications and variations may readily occur to those skilled in the art. Consequently, it is intended that the claims be intended to cover such modifications and equivalents. | A gas turbine power plant has coolant injected into the combustors in order to reduce the level of nitrogen oxide produced by the combustion of natural gas fuel and/or oil. A control system controls injection of coolant into the combustors in order to reduce NOx emissions, while improving turbine cycle efficiency and avoiding the possibility of over-injection of coolant to the point of flame-out in the combustor. PID controllers are used to provide percentage error bias in the control system, whereby adjustment of coolant injection follows turbine load in a manner that increases turbine efficiency. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of U.S. patent application Ser. No. 12/485,474 filed on Jun. 16, 2009. This U.S. patent application has a subject matter which is incorporated herein by reference and provides the basis for a claim of priority of invention under 35 USC 119(a)-(d).
The invention described and claimed hereinbelow is also described in German Patent Application DE 10 2008 028 859.4 filed on Jun. 19, 2008. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to a self-propelled harvesting machine that is especially adapted for the harvesting of crop material to be used for technical purposes, in particular for energy-related purposes.
The present invention also relates to a method of harvesting of crop material with a self-propelled harvesting machine, to be used for technical purposes, in particular, for energy related purposes.
Due to rapidly increasing costs for fossil fuels, techniques for obtaining fuel from sustainable raw materials have recently become the focus of greater public interest.
One problem that exists with most of the techniques used to obtain fuel from biomass is the high water content of the biomass in its fresh state. When fresh biomass must be hauled to a stationary facility where it is processed into fuel, large quantities of water that are present in the biomass are also transported, thereby resulting in high transport costs and, ultimately; high energy expenditures. If this factor is added to the energy “balance sheet” for a fuel obtained from biomass, the result is low efficiency, and even negative efficiency in certain circumstances. Therefore, it is important to minimize the distances covered between the field and the processing facility, and to minimize the amount of mass that is hauled.
To reach this goal, DE 10 2004 003 011 A1 provides that the processing system be brought to the crop material on the field, as part of a self-propelled harvesting machine, and that the crop material be processed into fuel directly on the field. This known harvesting machine includes a processing module for fragmentizing and compressing the harvested biomass, thereby separating the harvested biomass into a solid portion and a portion composed of plant juices. The portion of solid material obtained in this manner is then dried, in order to reduce its water content to the extent that the material may be processed further in an oiling module to obtain gasoline, Diesel oil, and heavy oil. In order to process the harvested biomass into fuel during the harvesting process itself, the processes mentioned must take place quickly, which, in the case of drying in particular, is not possible without the addition of a considerable amount of energy from an external source. Since the energy used in this case for drying also reduces the efficiency of the entire process to a considerable extent, it is important to remove so much moisture from the biomass by mechanical means that the drying may take place using a minimal amount of energy, or so that the drying unit and step may be eliminated entirely.
SUMMARY OF THE INVENTION
It is therefore an object of present invention to provide a self-propelled harvesting vehicle for crop material for technical use and a method of harvesting of crop material with a self-propelled harvesting vehicle, which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a self-propelled harvesting vehicle, comprising a crop material pick-up device; a fragmentation means for fragmenting the crop material: and a mechanical dehydration device for removing an aqueous portion of the crop material, which mechanical dehydration device includes a first dehydration means that is located upstream of the fragmentation means, and a second dehydration means that is located downstream of the fragmentation means.
Another feature of the present invention resides, briefly stated, in a method of harvesting a crop material with a self-propelled harvesting vehicle, comprising the steps of picking-up a crop material with a pick-up device; fragmenting the crop material with a fragmentation means; and removing an aqueous portion of the crop material with a mechanical dehydration device including a first dehydration means located upstream of the fragmentation means and a second dehydration means located downstream of the fragmentation means.
Given that the water that is weakly bound in the cellular structure of the harvested plant material is removed in the first dehydration means (step), and the plant material is then fragmentized, a material is obtained that has a cellular structure that has been weakened due to the removal of water which took place in the initial dehydration means (step). Water that is released from the plant cells in the second dehydration means (step) may enter the open spaces—which were created in this manner—in the cellular structure relatively easily up to an interface with the particular piece of plant material, and then exit the remaining solid material. Given that the first mechanical dehydration step and the fragmentation process open up the biomass in this manner for the subsequent, second dehydration step, it is possible to obtain a dehydrated biomass having a particularly low content of residual water in a short period of time and using very little drive energy from fresh biomass. The first dehydration means preferably utilizes at least one pair of compression rollers which forms compression gap through which the harvested biomass passes.
The second dehydration means, in which the fragmentized biomass is dehydrated further, preferably utilizes a decanter or a screw extruder, both of which are suited for use to rapidly process large quantities of fragmentized material.
A heating device may be provided in order to heat the biomass that passes through the second dehydration means (step). The heating opens up the cellular structure of the material further, thereby further facilitating the dehydration process. Since this heating means (step) is only used to further open up the cells of the biomass, but not to evaporate the moisture that remains, the output required of the heating device is minimal compared to the heat output that would be required to dry the biomass using the conventional method.
The dehydration device and the fragmentation means (step) are preferably designed or may be operated such that the second dehydration means (step) yields dehydrated crop material having a dry-mass portion of at least 60%, and even better, of at least 70%. This dehydrated crop material is composed essentially of cellulose, regardless of the type of plant that was harvested.
A heat-treatment means (step) preferably is provided downstream of the second dehydration means (step). This heat-treatment means (step) may include, in particular, a thermochemical reactor for carbonizing the dehydrated crop material into gaseous and/or liquid and/or solid reaction products.
If, as mentioned above, a heating device is provided for heating the crop material that passes through the second dehydration means (step), the heat dissipated from this reactor may be used to supply the heating device.
The heat-treatment means (step) may also include a drying means (step). The drying means (step) may be used simply to obtain crop material that has been dehydrated further, thereby rendering it easy to haul and store; it may also take place upstream of the thermochemical reactor in order to supply it with highly dehydrated raw material for carbonization.
In order to dry the crop material obtained in the second dehydration means (step) quickly and efficiently, the drying means (step) may include means for adding a hot thermal transfer material to the crop material to be dried.
When the heat-treatment means (step) includes the reactor, the thermal transfer material is preferably a reaction product of the reactor. The reaction product generally leaves the reactor at a high temperature, and it is desirable to cool the reaction product before transferring it to a tank for storage.
The reactor generally yields gaseous, liquid, and/or solid reaction products, i.e. gas, oil, and/or coke. When gaseous reaction products, as the thermal transfer material in the drying means (step), are blown into the biomass to be dried, they mix with water vapour from the biomass, but they do not remain in the biomass to a noteworthy extent, thereby eliminating the need to use special devices for separating the reaction product from the biomass. It is also feasible to add solid reaction product (coke) to the mixture in order to heat the biomass. In this case, it is difficult to separate the two before they enter the reactor. In this case, the coke is simply returned to the reactor together with the fresh biomass.
The thermal transfer material that is added is preferably liquid (oil). This ensures that heat is transferred very rapidly and effectively from the thermal transfer material to the biomass via wetting and mixing.
In this case, a separation means (step)—provided in the form of a compressor, in particular—is preferably situated between the drying means (step) and the reactor in order to separate the oil from the biomass, and to remove the oil, as the yield of the process. It is therefore unnecessary to reheat the oil by passing it through the reactor once more. Only a remaining portion of the oil that was not removed in the separation means (step) passes through the reactor once more. Since this remaining portion does not become lost when it passes through the reactor, it is not necessary to place high requirements on the extent to which separation is carried out in the separation means (step).
Even if the heat treatment means (step) does not include the reactor, it is expedient to include the separation means (step) to remove the thermal transfer material, in order to recover it, reheat it, and transfer it to the drying means (step).
It may be advantageous to supply hydrogen gas to the reactor in order to reduce the content of oxygen remaining in the oil that is obtained, or to adjust the ratio of oxygen to carbon in the oil that is obtained, and, therefore, to adjust the length of its carbon chain to a desired value.
An electrolysis means (step), in which the aqueous portion that is removed in the dehydration device is electrolyzed, may be used to obtain the hydrogen.
A condensation means (step) is preferably provided in order to capture the reaction products that were released in the reactor as vapor. The condensation means (step) is also used to capture water that was carried in with the biomass or that was produced in the reactor, and that negatively impacts the quality of the condensate. In order to release a water-rich condensate obtained in the condensation means (step) from hydrocarbon portions, the condensate may be sent through a filter, to which coke obtained in the reactor may be added, as the filter material. In this manner, purified water may be deposited directly onto the field, as excess water from the mechanical dehydration means (step). The coke, which is saturated in the filter with organic components, may be sent to the reactor, directly or indirectly.
Gaseous reaction products, in particular those that remain after the passage through the condensation means (step) since they are non-condensable, are preferably used in the harvesting vehicle itself as energy carriers, in particular to heat the reactor.
A concentration means (step) which captures the aqueous portion that was removed in at least one of the dehydration means (step) may also be provided, in order to separate the aqueous portion into a portion that is enriched with dissolved substances, and into a portion from which dissolved substances were removed. While the enriched portion is generally collected in a tank of the harvesting vehicle for further processing, the portion from which dissolved substances were removed is preferably left on the field, as described above.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view schematically showing processing devices of a harvesting vehicle of the present invention, with which a method of harvesting of the present invention is implemented, in accordance with a first embodiment of the invention; and
FIG. 2 is a view substantially corresponding to the view of FIG. 1 , and showing the inventive harvesting vehicle and method in accordance with a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An external view of the harvesting vehicle according to the present invention is not shown, since its external design—provided it is not that of a conventional combine harvester or a forage harvester—depends essentially only on the requirement that the devices shown in FIGS. 1 and 2 be accommodated therein. Akin to a conventional forage harvester or combine harvester, the harvesting vehicle includes a ground drive, on the front of which a crop material pick-up device is mounted in a replaceable manner. The crop material pick-up device is identical to that of a conventional forage harvester or combine harvester, and it may be used in a replaceable manner thereon and on the harvesting vehicle according to the present invention.
The harvesting vehicle has a mechanical dehydration device which includes a first dehydration means performing a first dehydration step. The first dehydration means includes two compression rollers 1 which form a gap toward which the harvested biomass is conveyed by the pick-up device. Depending on the type of plant material involved, when the biomass passes through compression rollers 1 , it loses approximately half of its water; while the portion of the dry mass in the freshly picked-up biomass is between 10% and 30%, the portion of dry mass that remains after the biomass passes through compression rollers 1 has increased to 18% to 46%.
The harvesting vehicle further includes a fragmentation means which performs a fragmentation step. The biomass which was pre-dehydrated using compression rollers 1 then passes through the fragmentation means formed as a chopping means 2 which, as in the case of a forage harvester, may include a rotating cutting roller and stationary knives which interact therewith. The fragmentation is more intensive than it is in the case of a forage harvester, e.g. due to the knives being placed more closely together, or due to the biomass remaining in chopping means 2 for a longer period of time, with the result that, when the material leaves the chopping means, particles having a typical maximum size of 4 mm are obtained.
The fragmentized material obtained in the chopping means (step) 2 is sent to a second dehydration means (performing a second dehydration step) of the mechanical dehydration device 3 , e.g. a decanter or a sieve centrifuge. In conjunction with the intensive fragmentation, this makes it possible to increase the portion of dry mass to 88% to 98%. The fibrous, cellulose-rich solid material obtained in this manner, the mass of which now comprises only approximately 10% to 30% of the biomass that was originally picked up, is collected in a bunker 12 on board the vehicle. It has a much higher specific energy content than that of the fresh biomass, thereby making it cost-effective to transport it further to a stationary processing facility. Due to the reduction in weight, the route along which the dehydrated material may be transported in a cost-effective manner is three to ten times longer than it is in the case of fresh, non-dehydrated biomass. The surface area from which a central processing facility may be supplied in a cost-effective manner, and the income from material that may be processed in a cost-effective manner surrounding a facility of this type is therefore increased approximately 10 to 100-fold. This results in considerable economies of scale for the operation of the facility.
To improve the water-removal process in second dehydration means (step) 3 , it may be provided that the biomass passes through the second dehydration means in the warmed state, e.g. by designing the walls themselves as heat exchangers 14 , the walls being the walls which are in contact with the biomass and which belong to a conveyance path on which the biomass is conveyed between chopping means 2 and second dehydration means, or the walls of second dehydration means 3 .
In the simplest case, the water that is removed in dehydration means 1 And dehydration means 3 could be deposited directly onto the field. It is expedient, however, to also remove any remaining components in a concentration means (step) 4 that are economically useful, such as sugars, proteins, starches, lipids, acids, or mineral elements, e.g. using a membrane filter or several filters of this type which are connected in series. Using known filtration technologies, it is possible in this manner to generate a flow which is enriched with valuable components and has a dry-mass portion of up to 80 per cent, the remainder being water from which the valuable components have been largely removed, the water being deposited onto the field.
In a post-drying means 5 (performing post-drying step), the portion of solid material in the enriched flow may be increased to up to 90 per cent. The concentrate which is obtained in this manner is collected in a tank 15 on-board the harvesting vehicle for further use, e.g. as feed, as a raw material for the chemical industry, or as a raw material for fermentation processes to create biogas or ethanol.
FIG. 2 shows an embodiment of the harvesting machine according to the present invention, in the case of which the processing carried out on-board the harvesting machine is more extensive than that carried out in the embodiment depicted in FIG. 1 . Dehydration means 1 , 3 which utilize compression rollers and a decanter or a centrifuge, chopping means 2 situated therebetween, and concentration means 4 for concentrating the valuable components in the pressed-out liquid are the same as those shown in the embodiment in FIG. 1 .
A flash pyrolysis reactor 6 is also located on-board the vehicle; it is supplied with the dehydrated, solid material that was obtained from the fresh biomass and that is composed mainly of cellulose. This material is heated in reactor 6 in the absence of air, thereby converting it in a continual process into water, various hydrocarbons, and a residual portion of solid material that is composed essentially of carbon, and is referred to as coke. The reaction products that are released as gas at the high temperature of reactor 6 are sent to a condensation means (step) and are condensed into fractions having a different boiling point. In condensation means 8 , non-condensable gas supplies burner 16 which heats reactor 6 .
Fractionated condensation takes place in condensation means (step) 8 ; parameters of the fractionation are defined such that a fraction essentially contains all of the water that entered reactor 6 with the biomass and that was created via the pyrolysis reactions that took place therein, while at least one further fraction which is referred to as product oil is composed essentially only of hydrocarbons. If product oil is obtained, it passes through heat exchanger 14 —which was mentioned with reference to FIG. 1 —of the decanter or centrifuge 3 —into a tank 10 , except for a portion, preferably a fraction that condenses at a high temperature, which is redirected in entirety or partially to condensation means 8 so that it may be added in a drying means (step) 7 to the dehydrated biomass obtained in second dehydration means (step) 3 . Drying means 7 may include kneading or stirring tools to mix the oil with the dehydrated biomass. The high temperature of the product oil causes the moisture remaining in the biomass to evaporate, thereby making it possible to remove a mixture of product oil and essentially anhydrous biomass at the outlet of post-drying means (step) 7 .
Before this mixture reaches reactor 6 , it passes through a separation means (step) 9 in which the product nil is removed from the biomass under pressure. The product oil which is removed in this manner is collected in tank 10 along with the portion of product oil that was obtained in condensation step 8 and that was not sent to drying means (step) 8 .
According to a preferred development, a filter 11 is provided in order to clean the condensate fraction that was obtained in condensation means (step) 8 and that is composed essentially of water. As the filter substrate, filter 11 uses a portion of the coke from reactor 6 which is conveyed continually through filter 11 in the counter-flow to the aqueous fraction, thereby saturating the aqueous fraction with the organic components. The water that is obtained via filtration may be deposited onto the field if necessary, after undergoing a post-cleaning means (step); the coke that is saturated with the organic portions may be collected together with the remaining coke from reactor 6 in a bunker 12 , as the combustible material, or, depending on the extent of its saturation with water or organic material, it may be returned directly to reactor 6 , as shown in FIG. 2 , or it may be returned by the long route via drying means (step) 7 , to remove the organic components via distillation in reactor 6 and add them to the product oil.
According to another development of the present invention, an electrolysis cell 13 is provided, which is supplied with the enriched portion obtained in concentration means and step 4 . Electrolysis cell 13 is supplied with frequency-modulated direct current in order to obtain a high yield of hydrogen using a reduced amount of energy. The hydrogen obtained via electrolysis is supplied to pyrolysis reactor 6 . The increase in the hydrogen supply in reactor 6 attained in this manner improves the conversion of the oxygen bound in the biomass to water, thereby yielding an oil from the flash pyrolysis that contains less oxygen and is therefore of higher quality.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions and methods differing from the types described above.
While the invention has been illustrated and described as embodied in a self-propelled harvesting vehicle for crop material and method of harvesting for technical use, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current, knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A self-propelled harvesting vehicle includes a crop material pick-up device, a fragmentation unit for fragmentizing the crop material, and a mechanical dehydration device which is used to remove an aqueous portion of the crop material, and which is divided into a first dehydration unit that takes place upstream of the fragmentation unit, and a second dehydration unit that takes place downstream of the fragmentation unit; and a method of harvesting is performed by the thusly arranged units. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Application No. 60/344,111 filed Dec. 27, 2001, which is hereby incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a shipping system for a group of distributed users to allow an administrator or group of administrators to maintain and control shipping by its users.
BACKGROUND OF THE INVENTION
[0003] An unsatisfied need has long existed in the package shipping industry for a shipping system that allows an organization to monitor and control the shipping activities of its users.
[0004] In the past, individuals within an organization that wanted to ship a package had to manually complete a shipping label and present the package to a carrier or other shipping drop-off location. The organization tracked these shipments by keeping copies of the shipping labels on file. This manual process was both cumbersome and time-consuming.
[0005] With the advent of the Internet, new shipping systems were introduced that allowed an individual to input shipping information to the shipping system and have a shipping label delivered to their browser. The shipping label could then be printed and affixed to the package. These electronic shipping systems were an improvement on the manual process, but they still did not allow an organization to monitor and control the shipping activity of its users. In addition, a user of one of these systems could not associate a particular package shipment with a particular client; therefore, the organization had to again manually review the shipping activities to bill the shipping charge to a particular client or department.
[0006] Another shipping system that was developed to address some of these concerns is the ship-ticket shipping system. In these systems, a user generates a ship-ticket on a personal computer and prints the ticket on a local printer. The ship-ticket is not a shipping label but has the shipping information encoded on the ticket as a bar code. The ship-ticket is affixed to the package and the package is delivered to shipping center or mail room of the organization where the bar code is scanned and the shipping information is electronically captured into a central shipping system. A shipping label is then generated by the central shipping system and affixed to the package. As with Internet shipping systems, a ship-ticket system automates the shipping process and eliminates the manual process of completing shipping labels. Moreover, because the ship-ticket passes through a central shipping system of the organization, the organization can monitor and control the shipping activities of its users. However, the process is cumbersome in that it requires an additional step of scanning a first label to generate a second label.
[0007] An unsatisfied need thus exists in the industry for an improved shipping system for organizations.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention addresses the above needs and achieves other advantages by providing a system and method for controlling a user's access to a carrier's shipping services for delivery of a package. The system controls the user's access to the carrier's services by either limiting the locations from which a package can be shipped to fewer than those described by the carrier's service area, or by limiting the user's ability to select shipping service levels to fewer than those provided by the carrier. For instance, the system can limit the ship from location to one or more business locations of an organization. Such limitation may be by way of displaying a limited collection of the ship from locations, or by pre-populating and locking ship from information submission fields on a web page. In an example of limiting the service levels, the service levels available to the user may be limited to only ground shipping when the carrier is capable of providing both air and ground shipping. Preferably, the distributed-user shipping system resides on a client server or mobile computer that is connected to the carrier's server and transmits various shipping location information and service level selections to the carrier to facilitate shipping of packages by geographically distributed users while controlling the scope of shipping services provided.
[0009] In one embodiment, the present invention includes a system for controlling a user's access over a network to a carrier server for coordinating shipping services provided by the carrier. In this embodiment, the carrier has a service area including a plurality of access locations at which it is willing to access the package to initiate shipping. The control system includes a ship to information system that is configured to record ship to information describing a destination location to which the package is to be delivered by the carrier. A ship from information system of the control system is configured to limit the user's selection of access locations. In particular, the number of access locations useable by the user are limited to a collection of access locations that are fewer than all of the access locations in the carrier's service area. For instance, in the case of a user who is an employee of an organization, the access locations may be limited to one or more work locations of the user. The ship from information system is also configured to record ship from information describing one of the limited access locations selected by the user. The control system further includes an order placement system that is configured to connect via the network to the carrier server and to transmit the ship from and ship to information to the carrier over the network to initiate shipping by the carrier of the package.
[0010] The ship from information system may be further configured to display a plurality of ship from information fields for recording the access selection. In this case, selection of one of the limited selection of access locations is alternatively, or further, ensured by pre-populating the information fields with portions of the access location and locking the fields so that the pre-populated access location portions cannot be modified by the user. In addition, the ship from information system may be configured to validate that the recorded ship from information describes one of the limited collection of access locations. In yet another alternative, selection of one of the limited collection of access locations is ensured by displaying only the limited collection of access locations in a menu for selection by the user.
[0011] Various components of the control system may be centrally located, or distributed over networked computer servers. In one aspect, the ship from, ship to and order placement systems reside on a client server which is connected via the network to the carrier server. In an alternative aspect, portions of the ship from, ship to and order placement systems reside on a mobile computers, such as a laptop computer. If part of the system is operated on the mobile computer, the ship from information system can be further configured to detect use by a traveling user operating the mobile computer and to make an exception that allows selection of any access location for the ship from information.
[0012] In yet another aspect, the control system includes a label generating system that is configured to generate a shipping label image. The shipping label image includes the ship to and ship from information and is useable by the user to print a shipping label for attachment to the package. In the case of a traveling user using a mobile computer to operate the system, the shipping label image may further include return address information that is different than the ship from information.
[0013] In another embodiment of the present invention, the control system includes a ship to information system configured to record ship to information submitted by the user that describes a destination location to which the package is to be delivered by the carrier. A ship from information system is configured to record ship from information submitted by the user that describes an access location from which the package is to be delivered by the carrier. The control system also includes a service level system configured to limit the user's selection of service levels to a collection of service levels that are fewer than all of the shipping service levels provided by the carrier and to record the service level selection by the user. An order placement system is configured to connect via a network to a carrier server and to transmit the ship from information, ship to information and service level selection to the carrier over a network to facilitate package delivery.
[0014] The service level system may be further configured to display the limited collection of service levels, such as in a menu, for selection by the user. For additional or alternative confirmation, the service level system may be further configured to validate that the recorded service level selection is one of the limited collection of service levels.
[0015] Similar to the above-described embodiment, the control system may be distributed over several networked computers, or may be on a single server. For instance, the ship from, ship to, service level and order placement systems may reside on a client server is which connected via the network to the carrier server. As another example, the portions of the system reside on a mobile computer.
[0016] In another aspect, the service level system is further configured to limit the shipping service level selection to an extent determined by the user's membership to a group of users all having the same limited collection of available shipping service levels. For instance, the carrier may offer ground and air shipping, but the users in the group would be limited by the distributed-user shipping system to just ground shipping.
[0017] Elements of each of the control system embodiments and aspects may be combined with each other, such as by limiting both the service level and ship from access location selected by the user. Beyond such combinations, the control system may include other aspects such as shipment billing and control of the destination location of each shipment. A billing system may record billing information from the customer, such as a client and matter account number, and transmit the billing information to the carrier using the order system so as to facilitate billing for delivery services by the carrier. The ship to information system can include aspects such as locked pre-population fields and validation engines to limit the destination locations to fewer than all of the destinations to which the carrier will deliver a package.
[0018] In another embodiment, the present invention includes a method of administering access by a user to a carrier's shipping services for delivery of a package. In this embodiment, the user is a member of an organization having a plurality of locations. The administration method includes sending organization information to the carrier over the network wherein the organization information includes an address of one of the locations and a shipping account number. The account number is validated by comparing the account number to a list of valid account numbers and by determining if the address corresponds to the address listed for the account number. Once validated, the location is added to a limited collection of ship from locations accessible by the carrier from which the user is permitted to ship the package. The limited collection of ship from locations describes fewer locations than a plurality of locations accessible by the carrier within its service area.
[0019] In another aspect, after validation the location may be associated with a department of the organization wherein the user is a member of the department and will be able to ship from the newly associated location. The administration method can also include displaying and sorting lists of previous shipping activity by one or more users. The lists may include, and be sorted using, ship to information, ship from information, transmission date, shipping date, shipping method (i.e., service level), user group or organization.
[0020] In still another embodiment, the present invention includes another method of administering access to a carrier's shipping services for delivery of a package. The administration method includes establishing a plurality of user groups each including at least one user. A limited collection of the carrier's shipping services is created including fewer shipping services than all the shipping services offered by the carrier. Then, the limited collection of shipping services is associated with the user group. The administration method further includes facilitating the user's access to the limited collection of shipping services by communicating shipping requests each containing one of the limited collection of shipping services selected by the user to the carrier.
[0021] In yet another embodiment, the present invention includes, a graphical user interface (such as the graphics displayed on a computer monitor) for controlling a user's access to a carrier's shipping services for delivery of a package. In this embodiment, the carrier has a service area describing a plurality of access locations at which the carrier is willing to access the package to initiate shipping. The graphical user interface includes a ship to information panel having a plurality of fields for recording portions of a destination location to which the package is to be delivered by the carrier. Also, a ship from information panel is included that has a plurality of fields pre-populated with portions of one of the plurality of access locations. The fields are locked against modification by the user to limit the user to shipping from the locked access location.
[0022] Each of the various embodiments of the present invention have several advantages. Generally, the distributed user shipping system allows tight control of shipping activities to be administered, especially over the ship from location and the level of service selected by the users. Limiting the ship from locations reduces the incidence of misuse of an organization's shipping accounts. Further, use of more expensive carrier service levels, such as overnight air shipping, can be reduced or eliminated. Shipping costs that are incurred can be billed directly to clients or departments based on account numbers, such as a cost center code, or department names. The shipping label system allows for the convenient generation of shipping labels bearing the ship to and ship from information, for immediate attachment to a package. Administrative aspects of the system allow for easy creation and modification of various user groups and organization locations each having different service levels and ship from locations available for shipping requests.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0024] [0024]FIG. 1 illustrates the architecture of a distributed user shipping system.
[0025] [0025]FIG. 2 shows the process flow that allows a user to ship a package using the distributed user shipping system.
[0026] FIGS. 3 A- 3 G illustrate a graphic user interface of a distributed user shipping system that allows a user to ship a package.
[0027] FIGS. 4 A- 4 C illustrate a graphic user interface of a distributed user shipping system that establishes administration detail, user groups and users.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0029] A. Architecture
[0030] [0030]FIG. 1 illustrates a distributed user shipping system 10 in accordance with an embodiment of the present invention. In this example, the distributed user shipping system 10 includes a plurality of users 15 in communication with a client server 20 and/or a computer network 25 such as the Internet. One or more traveling users 30 may also be in contact with the network 25 and/or the client server 20 . The distributed user shipping system 10 also includes a carrier server 35 in communication with the network 25 and with the client server 20 via the network 25 .
[0031] In one embodiment, a distributed user shipping application 40 resides on the client server 20 and is in communication with the network 25 . Similarly, a carrier shipping application 45 resides on the carrier server 35 and communicates with the distributed user shipping application 40 via the network 25 . Further, in this example a shipping label engine 50 and account database 55 also reside on the carrier server 35 and are in communication with the carrier shipping application 45 . Although each of these system components are described herein as residing on either the client server 20 or carrier server 35 , it will be readily apparent to one of ordinary skill in the art that one or all of the above-described components may reside on another server or function separately.
[0032] B. Package Shipment
[0033] [0033]FIG. 2 illustrates one process by which a user 15 may obtain a shipping label 100 for a package or letter using the distributed user shipping system 10 of the present invention. In a first step 200 , a user 15 enters the necessary shipping information into the distributed user shipping application 40 . FIG. 3A illustrates a graphical user interface (GUI) login screen shot 201 that a user 15 might use to access the distributed user shipping application 40 . Upon entering a valid user name and password, the user 15 is presented with a list of options. If the user 15 elects to ship a package, the user sees a GUI information entry screen 202 similar to that shown in FIG. 3B. In an alternative embodiment, the user 15 does not receive a list of options and instead is presented with a GUI shipping confirmation screen 203 shown in FIG. 3C.
[0034] The GUI of FIG. 3B is separated into three parts: a ship to information section 110 , a ship from information section 115 , and a package information section 120 . Each of the sections has a plurality of entry fields for entry of portions of the section's respective information. In general, the user 15 is prompted to input the destination shipping information for the package in the ship to information section 110 . The fields in the ship from information section 115 are pre-populated with the user address information that has previously been associated with the user name and password. Alternatively, these fields may be populated with a location address for the organization to which the user is associated. If the user is designated as a traveling user 40 (described below), a drop-down menu may be available that allows the traveling user 40 to select one of several addresses for the ship from information section 115 . In one embodiment, the user is not given the opportunity to change the information in the ship from information section 115 . In an alternative embodiment, these fields are user-modifiable. The information in the ship to and ship from sections is sufficient to ship a letter in the distributed user shipping system 10 . If the user 15 is shipping a package, the user 15 is prompted to populate those fields shown in the package information section 120 .
[0035] In one embodiment, a user 15 has the option of entering a nickname for the recipient of the letter or package in a ship to nickname field 125 . When this field is populated, the distributed user shipping application 40 will compare the nickname against a database of recipients and will populate the ship to information section 110 of the GUI 202 with the recipient information stored in the database. By checking the save address field 130 shown in FIG. 3B, a user 15 can add or modify an entry in the recipient database.
[0036] In one embodiment, the user 15 also has the option of associating the shipment with a particular client or department. In this embodiment, the user 15 is prompted to enter a cost center code 135 and a department name 140 , one or both of which may be used to associate the shipment. For example, a user 15 can bill the cost of the shipment to the client identified in these fields. As another example, the user 15 may be responsible for multiple matters for a single client and may use these fields to associate the shipment with a particular matter for the client. One of ordinary skill in the art will readily recognize that these and other fields can be used to allow a user 15 and an organization to accurately monitor, control and track package shipments. To illustrate, if the organization is a law firm, the cost center code 135 and department name 140 fields may be renamed as client and matter number fields respectively. In this way, the law firm can track the package shipments for each client and matter combination and charge the shipping costs appropriately. One of ordinary skill in the art will recognize that these and other fields can be added to allow an organization to track shipments made by its users. In alternative embodiments, one or both of these fields may be designated as “required” before a package can be sent and the information used to populate these fields may be validated.
[0037] Returning to FIG. 2, after entering the required shipping information the distributed user shipping application 40 sends the shipping information to the carrier shipping application 45 in step two 204 . In one embodiment, the shipping information is transmitted over the Internet but it will be readily apparent to one of ordinary skill in the art that that the information can be sent via any type of electronic communication, including wireless technology. In step three 205 , the carrier shipping application 45 performs a series of validation routines on the shipping request. In one embodiment, the carrier shipping application validates the destination shipping address to confirm that the destination address exists and has been properly entered. In addition, the carrier shipping application 45 may validate that the user 15 is permitted to perform the shipping activity requested. For example, a user 15 may submit a request for a package delivery service level, such as overnight shipping, but may only be authorized to request a lesser service level. In an alternative embodiment, some or all of these validation routines may occur at the client server 20 and may be performed by the distributed user shipping application 40 or another application. For example, a user 15 that is authorized to ship packages using only select service levels may not see those package shipping service levels that the user 15 is not authorized to use.
[0038] If one or more of the validation procedures fail, an error code is returned to the user. Once the shipping information passes the validation routines, the process proceeds to step four 206 where the user 15 is shown the GUI shipping confirmation screen 203 as shown in FIG. 3C and is prompted to confirm that the shipping information is correct. If the information is incorrect, the user 15 has the option to modify the shipping information via an Edit Package Info button 207 . Once the shipping information is correct, the user 15 proceeds by clicking on a Ship This Package button 208 .
[0039] Returning again to FIG. 2, a shipping label 100 is generated 209 when the user 15 clicks on the Ship This Package button 208 . To generate the shipping label 100 , the distributed user shipping application 40 passes the shipping information to the carrier shipping application 45 . The carrier shipping application 45 passes the shipping information to a shipping label engine 50 configured to create shipping labels. The process of generating shipping labels from shipping information is well known in the art and is beyond the scope of this disclosure. Once the shipping label 100 is generated, the shipping label engine 50 passes the shipping label 100 back to the carrier shipping application 45 , which, in turn, transmits the label back to the distributed user shipping application 40 and the user 15 in step six 210 .
[0040] [0040]FIG. 3D illustrates a GUI label screen 211 that a user 15 receives in response to a valid request for a shipping label 100 . FIG. 3D is divided into two parts and includes a shipping label instruction area 150 and a shipping label 100 . In this example, the shipping label instructions tell the user how to print and fold the label and where to drop if off for pickup. The shipping label instruction area 150 also contains prompts that allow the user 15 to ship another package, view shipped packages and logoff. If a View Shipped Packages button 212 is activated, the user 15 receives a GUI package listing screen 213 similar to that shown in FIG. 3E.
[0041] [0041]FIG. 3E illustrates a GUI screen that allows a user 15 to obtain detail about packages that have been shipped. In one embodiment, every shipping label 100 generated by the distributed user shipping system 10 includes a unique package tracking number 160 . As a package travels through the carrier system to its destination address, the package tracking number 160 is scanned at various carrier sortation and routing facilities and a carrier database is updated with information on the progress of the package. The GUI package listing screen 213 shown in FIG. 3E shows the user 15 a list of shipment recently sent. In one embodiment, the user 15 sees a list of shipments made by that particular user. In this embodiment, the user 15 has the ability to expand or shrink the list by requesting a search on past shipments of one day, one week, one month or six months. Of course, additional search parameters are available and may be readily implemented with the present invention. In an alternate embodiment, a user 15 can search past shipments by organization, client, user name, date range, destination address, shipping method or using multiple other search parameters that will be readily apparent to one of ordinary skill in the art.
[0042] For each shipment listed in FIG. 3E, the user 15 has the option to view the shipment status by clicking the package tracking number 160 or can view package detail information by clicking on a detail button 214 . FIG. 3F illustrates a GUI package tracking information screen 215 available to a user 15 and FIG. 3G illustrates a package detail information screen 216 that can be obtained. In addition, Void Package 217 and Reprint Shipping Label 218 options are also illustrated in FIG. 3G. In one embodiment, the user 15 has an option of voiding a shipping label 100 that was mistakenly generated and thereby avoids paying the shipping fee. In this embodiment, the carrier debits a shipping account in the amount of the shipping fee when the shipping label 100 is generated. The shipping account is thus charged even if the shipping label 100 is never affixed to a package and placed in the carrier system. However, a carrier will credit a shipping account for the shipping fee associated with a shipping label 100 when a user 15 clicks on the Void Package link 217 . In one embodiment, a user has predetermined time after the creation of a shipping label 100 to void the transaction and/or reprint the label. In a preferred embodiment, the predetermined time is 24-hours.
[0043] C. Administration
[0044] The following paragraphs describe an administration system in accordance with an embodiment of the present invention. One aspect of the distributed user shipping system 10 is an application that permits the users 15 of an organization or other group to automate their shipping activities and associate shipments with a particular client, matter or department. Another aspect of the system is an administration application that permits a organization to monitor and control the shipping activities of those users 15 .
[0045] In one embodiment of the present invention, an organization or other distributed group of users 15 initiates a distributed user shipping system 10 by registering with one or more carriers and identifying an organization administrator. The organization administrator is the highest-level user of a distributed user shipping system 10 and has the highest level of authorization within the organization. In one embodiment, an organization has only one organization administrator, but it will be readily apparent to one of ordinary skill in the art that the present invention can be equally advantageous with multiple highest-level users. The requirements to register an organization administrator may vary from carrier to carrier. In one embodiment, an organization administrator registration requires an organization name, organization address, administrator name, administrator address, administrator phone number and an administrator email.
[0046] Other information and/or shipping transaction options may also be required to register an organization administrator. The organization administrator registration process may also require that the organization administrator determine what information the users 15 must supply to request a shipping label 100 . A law firm, for example, might require that its users 15 include a billing client and matter number every time that a shipping label 100 is generated. The designation of mandatory fields labeled client and matter, therefore, may be part of the organization administration registration process.
[0047] Additional layers of user administration are also available with the present invention. In one embodiment, an organization has the ability to determine the number of layers of administration. In an alternative embodiment, the number of administrations layers is predetermined. In still another embodiment of the present invention, there is just one administrator.
[0048] In one embodiment of the present invention, a second administration layer is a location administrator 175 . Location administrators 175 might be used in the case of a company with multiple offices spread out throughout a geographical area. In some cases the locations might be located in separate states, or even across continents. In another example, the separate locations may be different departments on a college campus, or even different departments within a single office building.
[0049] [0049]FIG. 4A illustrates a GUI location creation screen 219 to prompt a user 15 to create a new location. In a preferred embodiment, there is at least one location associated with every organization. In this illustration, the addition of a new location requires the organization name, administrator name, phone number, email address, facsimile and printer type for the location. In addition, the street address, city, state and zip for the location is required. In one embodiment, a carrier account number 180 is also required for a location administrator 175 . Carrier account numbers 180 are generally tied to a zip code or other geographical area as shipping costs are based upon the distance between pickup and delivery points. For this reason, a carrier account number 180 in this embodiment is specified for each organization location rather than at the organization administrator level.
[0050] When a new location is added to the system, the distributed user shipping application 40 sends the organization location information to the carrier shipping application 45 . The carrier shipping application 45 compares the carrier account number 180 for the new location and the address of the new location against an account database 55 of valid customer account numbers. If the carrier account number 180 is valid for the location zip code, the location information and/or location administrator 175 is added to the distributed user shipping system 10 . If the carrier account number 180 is not a valid account number and/or is not valid for the specified location address, an error code is returned and the new location/location administrator 175 is not added.
[0051] In one embodiment, only the organization administrator has authority to create a new location. In alternative embodiments, some or all of the location administrators 175 may be authorized to create new locations.
[0052] Another layer of administration in a distributed user shipping system 10 of the present invention is a user group 185 . In one embodiment of the present invention, a user group 185 determines the shipping service level that will be permitted for those users 15 associated with that user group 185 . In alternative embodiments, additional user authorizations may be determined by the user group 185 including, without limitation, the ability to generate shipment reports, to access other user shipment information, to create new users or administrators, or to use a organizational or global shipping address database. Additional rights related to package shipping may be determined at the user group 185 level and will be obvious to one of ordinary skill in the art. FIG. 4B illustrates a GUI group creation screen 220 that might be used to define a user group 185 . In this example, users 15 within this particular user group 185 will be able to ship letters and packages based on the service levels selected.
[0053] [0053]FIG. 4C illustrates a GUI new user screen 221 to create a new user 15 . In the illustrated embodiment, a new user 15 must be associated with an organization, location and user group 185 . A name, login name, password and user-type 190 are also required fields in this embodiment. In this illustration, the user-type field 190 is designated as regular. In a preferred embodiment, a regular user 15 is authorized only to ship packages. In contrast, if a user-type 190 of administrator were assigned, the user 15 would be authorized to perform predetermined administrative functions as well as having authorization to ship packages. The GUI new user screen 221 thus provides for the creation of different administration levels including the organization administrator and one or more location administrators. One of ordinary skill in the art will readily recognize that additional administration levels can be created and assigned in this way.
[0054] In one embodiment, a user may be designated as a traveling user 30 . Traveling users 30 are those users authorized to ship a package from a remote location. In one embodiment, a traveling user 30 is authorized to ship only from one of the locations associated with the organization. In another embodiment, a traveling user 30 is authorized to generate a shipping label 100 and ship a package from any location. For example, a corporate organization may employ a number of salespeople whose job entails traveling to meet clients. These employees may need access to the distributed user shipping system 10 and may need to ship packages while on the road.
[0055] With reference to FIG. 1, a traveling user 30 is illustrated in communication with the network 30 rather than directly connected to the client server 20 . In this embodiment, because the user is designated as a traveling user 30 he or she can use the distributed user shipping system 10 to ship a good from a remote location. In one embodiment, the distributed user shipping application 40 resides on a mobile computer used by the traveling user 30 . In another embodiment, the traveling user 30 accesses the distributed user shipping application 40 on the client server 20 from a remote location.
[0056] In operation, if a user is designated as a traveling user 30 the user has the option of changing the ship from information on the system. In one embodiment, the new ship from information will be reflected on the return address on the shipping label 100 . In another embodiment, however, the return address on the shipping label 100 is not changed and remains the default return address as would appear for any user. From a carrier perspective, when a traveling user 30 ships a package the cost of the shipment is based upon the modified ship from information and therefore is not necessarily calculated based on the return address on the shipping label 100 .
[0057] Each of the various embodiments of the present invention have several advantages. Generally, the distributed user shipping system 10 allows tight control of shipping activities to be administered, especially over the ship from location and the level of service selected by the users 15 . Limiting the ship from locations reduces the incidence of misuse of an organization's shipping accounts. Further, use of more expensive carrier service levels, such as overnight shipping, can be reduced or eliminated. Costs that are incurred can be billed directly to clients or departments based on account numbers, such as the cost center code 135 , or department names 140 . The shipping label engine 50 allows for the convenient generation of shipping labels bearing the ship to and ship from information for immediate attachment to a package. Administrative aspects of the system 10 allow for the creation and modification of various user groups and organization locations each having different service levels and ship from locations available for shipping requests.
[0058] [0058]FIGS. 1, 2, 3 A- 3 G and 4 A- 4 C are block diagrams, flowcharts and control flow illustrations of methods, systems and program products according to the invention. It will be understood that each block or step of the block diagram, flowchart and control flow illustration, and combinations of blocks in the block diagram, flowchart and control flow illustration, can be implemented by computer program instructions. These computer program instructions may be loaded onto a computer or other programmable apparatus to produce a machine, such that the instructions which execute on the computer or other programmable apparatus create means for implementing the functions specified in the block diagram, flowchart or control flow block(s) or step(s). These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the block diagram, flowchart or control flow block(s) or step(s). The computer program instructions may also be loaded onto a computer or other programmable apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the block diagram, flowchart or control flow block(s) or step(s).
[0059] Accordingly, blocks or steps of the block diagram, flowchart or control flow illustration support combinations of means for performing the specified functions, combinations of steps for performing the specified functions and program instruction means for performing the specified functions. It will also be understood that each block or step of the block diagram, flowchart or control flow illustration, and combinations of blocks or steps in the block diagram, flowchart or control flow illustration, can be implemented by special purpose hardware-based computer systems which perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.
[0060] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A system and method is described for controlling user access to a carrier's shipping services for delivery of a package. The system controls the user's access to the carrier's services by either limiting the selection of locations from which a package can be shipped to fewer than those described by the carrier's service area, or by limiting the user's ability to select shipping service levels to fewer than those provided by the carrier. Such limitation may be by way of displaying only a limited collection of ship from locations and service levels, or by pre-populating and locking ship from information submission fields on a web page. The distributed-user shipping system may reside on a client server or mobile computer that is connected to the carrier's server and transmits various shipping location information and service level selections to the carrier to facilitate shipping of packages while controlling the scope of shipping services provided. | 6 |
This invention concerns force sensors, and relates in particular to sensors in which the variation of a flexing beam's natural resonance frequency when the beam is put under tension is used to indicate the amount of that tension.
BACKGROUND OF THE INVENTION
Vibrating beam force sensors are quite well known--the basic idea was described over twenty years ago--and since the early 1960's, these devices (in which in essence a beam or strip of a piezoelectric material mounted at either end is piezoelectrically driven into flexural vibration while under tension, a change in the vibrational frequency indicating a change in the tensioning forces), have found a wide range of uses.
Unfortunately the simplest form of the device, a single strip-like beam mounted at either end--tends to have a relatively low Q (the factor used to indicate the amount of energy locked in the vibrating structure relative to the amount of energy that must be fed in to maintain the vibrations), and the energy is lost mainly by transfer to the mountings at either end. Much effort has gone into designing beam-like structures that do not suffer from the low Q problem--that do not cause a large proportion of the input energy to be passed to and absorbed by the mountings--and much of this effort has centered on the idea of providing some sort of counterbalanced vibrating element such that the vibrations of both this and the beam effectively cancel each other at the mountings, so that no energy is transferred to the mountings and the whole structure has a high Q.
Although these counterbalanced, or compensated, structures do undoubtedly have the desired high Q, they are nevertheless all quite complex, and difficult and costly to manufacture. One such structure, put forward in the early 1960's, uses the tuning fork principle (two similar members vibrating to and from each other, in antiphase) by having two beams mounted at their ends in common mountings and disposed one above but spaced from the other. Like the arms of a tuning fork, the two beams flexurally vibrate in their common plane--that is, towards and away from each other. Because they are in antiphase (180° out of phase) the vibrations sent to each mounting by one beam are exactly equal but opposite to those sent by the other beam, and so they cancel out, and no energy is transferred to the mountings. Another structure, suggested in the early 1970's, tries to solve the Q problem by securing the beam to each mounting via a torsion member at right angles to the beam's long axis, and by then providing a counterweight beam section beyond each torsion member. Yet another structure, also suggested in the 1970's, proposed a variant on the last one, mounting the beam at each end via two "isolator springs" spaced above and below the beam plane and then having two counterweights extending from these towards the beam center. Structures such as these are not only difficult and expensive to manufacture from the raw piezoelectric material blank, but in some cases the positioning thereon of the necessary electrodes (both by which the beams can be driven and by which the vibration's actual frequency can be observed) is made particularly irksome because of the complex shapes involved.
It appears that all of the high Q structures suggested so far involve balancing beams or counterweights that are in the vibrational plane of the "main" beam, and flex in that plane. This seems to have made all these structures unnecessarily complex, and it is the hope of the present invention that it can provide a mechanically simpler, and cheaper, but no less efficient beam structure by placing counterbalancing beams not above and below the main beam but on either side thereof.
SUMMARY OF THE INVENTION
In one aspect, therefore, this invention provides a piezoelectric beam structure for a vibrating beam force sensor, of the type wherein a beam or strip of a piezoelectric material mounted at either end is piezoelectrically driven into flexural vibration while under stress, a change in the vibrational frequency indicating a change in the stressing force, wherein the structure has at least three coplanar beams spaced side by side and supported between common mountings one at either end for flexural vibration in a plane normal to the beams' common plane.
Each beam is of a strip-like nature (similar to a rule/ruler), having length, breadth (or width) and depth (or thickness); the length is large relative to the breadth, and the breadth is large relative to the thickness. The plane of the beam may therefore loosely be defined as that plane in which the length and breadth dimensions exist. In the beam structure of the invention, the planes of all the beams lie in a common plane. Each beam is intended to flex (vibrate) in the direction of its depth--thus, normal to its plane. In the invention, each beam is intended to flex normal to the common plane. The two outer beams (the counterbalance beams) are, however, intended in operation to flex in antiphase, i.e., opposite in phase, to the center beam (the main beam), whereby the energy transferred by the main beam to its mounting is equal but opposite to--and thus is cancelled by--the energy fed to the same mounting by the two counterbalance beams.
In use the beam structure will have associated therewith the various electrodes necessary for its operation. Their nature and positioning will be fairly conventional, and this is discussed further hereinafter.
The inventive beam structure may be fabricated from any piezoelectric material used or suggested for use in the art, and it is one considerable advantage of the invention that it allows the use of relatively small, and cheap, portions of these materials. Typical piezoelectrics suitable for use are single crystal quartz, lithium niobate, lithium tantalate and aluminum orthophosphate.
The inventive structure has three coplanar beams spaced side-by-side. Alternatively, there could be any number of beams (provided there are at least three)--there could, for example be four (with two inner main beams and two outer counterbalance beams), five (with one central main beam, two inner counterbalance beams, and two outer counterbalance beams perhaps in phase with the central main beam)--but three seem quite satisfactory.
As has been mentioned hereinbefore, the three beams are coplanar, and spaced side-by-side. This means (amongst other things) that the structure as a whole can be made simply by taking a piezoelectric strip blank having the length of a beam plus its mountings and the breadth of the structure's three beam combination and simply removing material therefrom so as to form two side-by-side slots therein running parallel with the blank's long axis (and suitably spaced either side thereof); these two slots naturally define three parallel beams. Methods of so forming the beam structure are discussed in more detail hereinafter.
The three beams are supported between common mountings one at either end. These mountings are in fact very conveniently portions of piezeolectric material integral with the beams themselves, and are the means by which the structure itself is mounted in or on the device in which it is to act as the active component of a force sensor. It may be desirable for the mountings to be necked--to have an axial portion of less breadth than the rest--between where it joins the beam structure and where it is itself mounted in or on the device.
Being supported between common mountings the three beams generally are of the same length (which is whatever is suitable for the desired fundamental flexural frequency--0.250 inch (6.35 mm) seems quite acceptable). However, the three beams are preferably not the same breadth; to ease the problem of matching the energy in the main beam to that in the two counterblance beams it is preferred that the mass, and thus the breadth, of each of the latter two be half that of the former one. With 6.35 mm long, 0.125 mm thick beams, a main beam breadth of 0.040 inch (1 mm) and a counterbalance beam breadth of 0.020 inch (0.5 mm) were satisfactory.
Structures with larger length-to-breadth ratios tend to have the higher Q values.
The beam structure of the invention may be manufactured in a number of ways. One may employ an air-abrasion technique, in which the piezoelectric material blank is held between a backing plate and a slotted mask and a jet of abrasive particles is blown through the slots in the mask to remove the unwanted material. Air abrasion can cause damage to the material surfaces which significantly increases mechanical power losses in the vibrating beams, and hence reduces the attainable Q factor, but these losses can be greatly reduced by a subsequent chemical polishing.
Another manufacturing method uses a photolithographic process. This technique involves depositing a suitable mask onto the piezoelectric material blank, and etching away the unprotected material with an appropriate etch solution. When the piezoelectric material is quartz, a suitable mask is an evaporated gold-on-nichrome layer electroplated with gold to increase the thickness and reduce the penetration of the etch through pinholes, and a satisfactory etch is hot aqueous ammonium bifluoride.
In a force sensor device using an inventive beam structure the latter is mounted (at either end) so that the force applied to the device, and to be measured, is transmitted to the beams. One such device has the beam structure mounted across a shallow slot in the surface of a cantilever beam; application of force to the free end of the cantilever produces a strain in the beam structure which can be calculated with reasonable accuracy from the device geometry. The material of the cantilever should have a thermal coefficient of linear expansion in the strain direction that is closely matched to that of the beam structure in order to minimize the temperature coefficient of vibration frequency, and to guard against the possibility of cracking the piezoelectric material at extremes of temperature. Indeed, the cantilever could be of the same material and crystal orientation as the beam structure, in which case the stress induced by temperature change would be zero. Even then, however, there could be a temperature-dependent frequency change, so ideally the cantilever is made from a material with a thermal expansion coefficient such that the actual differential expansion produces a stress which in turn produces a frequency shift that effectively cancels the temperature coefficient of the unstrained device.
A quite different type of mounting is one wherein the beam structure is fixed across the free ends of two rigid levers pivoted together, the force to be measured being applied to the levers to separate them (and thus produce a strain in the beam structure). A somewhat similar type of mounting particularly suitable for measuring pressures is one wherein the beam structure is attached to a diaphragm via a short pillar at either end of the beam structure. The pressure to be measured is applied to the diaphragm, and acts to rotate the pillars about their points of attachment to the diaphragm, thus producing a strain in the beam structure.
Examples of these two mounting systems are discussed hereinafter with reference to the accompanying drawings.
The inventive beam structure is fabricated from a piezoelectric material, and is driven into flexure by electrical signals delivered to electrodes mounted on the structure. The mechanism by which flexural vibrations occurs is now well known. Briefly, however, it involves producing an electric field across the depth of the beam between an electrode on one face and a matching electrode on the other face so causing the volume of the piezoelectric material between the electrodes to distort sideways in shear, and the forces arising from this distortion then cause the beam to move bodily up (or down). The beam will thus flex at the frequency of the applied signals, and this flexing will have maximum amplitude when the signal frequency is a resonance frequency of the beam.
It is conventional to place a pair of driving electrodes near but to one side of the beam center, to place a pair of pick-up electrodes in the equivalent position on the other side of the beam center, and to use the signal obtainable at the pick-up electrodes in a feedback loop to direct the driving signal's frequency to, and maintain it at, a chosen beam reasonance frequency. Any force applied to the beam changes its reasonance frequency, and this can be used as a measure of that force. In the inventive beam structure, of course, each of the three (or more) beams may have its own driver and pick-up electrode pairs, which may be formed in position by any of the usual techniques, and the signal circuit used (an example of which is discussed further hereinafter with reference to the accompanying drawings) applies the counterbalance beam signals in antiphase to the main beam signals. Moreover, it is possible--and, indeed, desirable--to have all the electrodes on one surface of the beam structure combined into a common electrode (advantageously maintained at earth potential). Furthermore, it is possible--surprising though this may seem at first--to drive only either the main beam or the counterbalance beams rather than all three, for the energy fed into the flexing of one of these is transferred laterally across the end mountings into the other, and provided the driving frequency is correctly chosen this transferred energy will itself drive the other into anti-phase flexure. One interesting corrollary of this is that the driving electrodes can be decoupled from the pick-up electrodes by placing one on the main beam and the other on one of the counterbalance beams.
The advantages of the beam structure of the invention over those presently used in the prior art may be summarized as follows:
1. Because of the relatively small size of the beam structure it can be made from cheaper starting materials, it uses less quartz to produce a smaller device, and several devices can be made from each blank, so spreading the processing costs per device.
2. Because of the mechanical simplicity of the beam structure it can be made using photolithographic processes, and the electrode pattern deposited very simply.
3. Because the beam structure is inherently thin, it can be mounted on assemblies themselves cheap to construct.
The invention exends, of course, to a force sensor when employing a beam structure as described and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the invention are now described, though only by way of illustration, with reference to the accompanying drawings in which:
FIGS. 1A and B show plan views of two different piezoelectric beam structures of the invention;
FIGS. 2A, B and C show side elevation, part section and part plan views respectively of a beam structure like that of FIG. 1A mounted on a cantilever beam;
FIGS. 3A and B each show in elevation a beam structure like that of FIG. 1A mounted in different ways on a diaphragm;
FIGS. 4A and B show the electrode distribution on two beam structures each like that of FIG. 1A; and
FIG. 5 shows in block diagram form a circuit for use with a beam structure of the invention.
DETAILED DESCRIPTION
Two shapes for the beam structure of the invention are shown in outline in FIGS. 1A and B. That of FIG. 1A is a strip 10 of piezoelectric material that has had two centrally located narrow slots 11T,B cut into it parallel to but spaced either side of the strip long axis; the strip material between and outside the slots are the beams--the main beam 12 in the center and the two counterbalance beams 13T,B on either side. The three beams have at each end a common mounting 14L,R which is contiguous with the strip end portions 15L,R by which the strip is mounted in or on the device in which it is used.
The strip of FIG. 1B is a wider, longer version of that of FIG. 1A with the addition of a neck 16L,R of material separating each beam mounting 14L,R from the relevant strip end portion 15L,R.
FIGS. 2A, B and C show (in side elevation, part section and part plan respectively) a beam structure like that of FIG. 1A mounted over a slot in a cantilever. The cantilever 21 is rigidly mounted at one end on a support 22, and moves up and down (as viewed) under the influence of force F. Along the cantilever a slot or notch 23 is cut in the surface, and bridging that slot (and affixed to the cantilever surface portions on either side) is an inventive beam structure 24 in accordance with the present invention. The details of this are shown more clearly in FIGS. 2B and C (the former shows how the beam structure 24 is free to flex).
An alternative type of mounting arrangement employs a flexible frame such as that shown in FIG. 3A. Forces applied at the ends of the frame 31 are coupled more-or-less directly into the beam structure 32 but no large forces are generated by differential thermal expansion. A flimsy structure of this kind would probably be most appropriate in an atmospheric pressure transducer, where one end of the frame is attached to a rigid mount 33 and the other is attached to a pressure diaphragm 34. The force produced by the pressure diaphragm is coupled into the beam structure by the magnification ratio given by the relative lengths of the lever arms 35, 36, and provided that the cross piece 37 is relatively thin no large forces will be generated in the beam structure by thermal expansion.
A simpler structure suitable for measuring pressures is shown in FIG. 3B. A beam structure 32 (like those in FIGS. 1A and 1B, shown in side elevation), is attached via pillars 38 to a diaphragm 34 itself mounted on a support 39. The pillars 38 are preferably formed integrally with the diaphragm and/or with the beam structure 32. Applied pressure P acts to rotate the pillars, and therefore to extend the beam structure.
Two layouts for the beam structure electrodes are shown in FIGS. 4A and B. In FIG. 4A each beam is driven and carries a pick-up electrode; the main beam 12 has a drive electrode 41 just to the left (as viewed) of its center line and a pick-up electrode 42 just to the right, while each counterbalance beam 13T,B has its own drive 43T,B and pick-up 44T,B electrode. Each of the drive and pick-up electrodes is connected via a thin conducting track (as 45) to a pad (as 46) to which in use a wire to the relevant circuitry is attached.
The electrode layout of FIG. 4B has a single drive electrode 41 driving the main beam and a single pick-up electrode 44T on the upper right (as viewed) counterbalance beam. By correctly choosing the driving frequency for the main beam the two outer beams automatically flex in antiphase--and having the pick-up electrode on one of these electrically decouples it from the drive electrode.
In both FIGS. 4A and B, the opposite bottom side of the beam structure not seen carries a single common electrode extending over the whole surface, illustrated as electrode 48 in the fragmented corner of FIG. 4B.
When in use in a force sensor device, the beam structure is maintained in vibration by means of a tracking oscillator circuit which follows the changes in resonance frequency of the vibrating beams produced by the applied strain, so that the drive frequency is always identical to the mechanical resonance frequency. The well-known circuit shown schematically in FIG. 5 can be used for this. The circuit consists of a charge amplifier 51 followed by an amplifier 52 with a band-pass characteristic chosen to reject frequencies outside the operating range and with a gain sufficient to ensure operation of the driving phase-locked loop integrated circuit chip 54--which may be a CD 4046. The band-pass characteristic of the amplifier 52 is necessary to ensure that the device does not oscillate either at higher harmonics or at some resonance frequency of the whole structure.
The voltage-controlled oscillator in the phase-locked loop is centered on the middle of the operating frequency range, and locked to the beam mechanical resonance frequency by the amplifier's output signal. The square wave output from this oscillator is filtered by active filter 55 to remove the harmonics, and re-applied to the beam structure's drive electrode.
The loop phase shift of the circuit is arranged so that the oscillator frequency is set at the resonance frequency of the beam structure and tracks the changes in resonance frequency produced by the applied strain. The oscillator output provides the strain-dependent output signal of the sensor. | A piezoelectric beam structure for a vibrating beam force sensor in which three coplanar beams of piezoelectric material are spaced side by side and supported between respective common mountings at either end. The two outer counterbalancing beams in operation flex in opposite phase to the center main beam, with each beam flexing in a direction normal to the beam plane. A force sensor which includes this piezoelectric beam structure. | 6 |
ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and is subject to Public Law 96-517 (35 U.S.C. 200 et seq.). The contractor has not elected to retain title to the invention.
TECHNICAL FIELD
This invention relates to an expandable table top and table for use in constricted areas. More particularly, this invention relates to a novel apparatus for conducting group working, dining, recreational and social activities in a microgravity environment of a pressurized, habitable spacecraft module. More particularly, it relates to an improved table top and table for a space station wardroom which will be the center of such group crew activities on board a space station or other microgravity environment. Most especially, it relates to a table apparatus that adjusts and reconfigures to accommodate crew user groups of different numbers and diurnal shift sizes, to accommodate anthropometrically crew members of different sizes and to accommodate ergonomically a wide range of activities by both individuals and groups of space crew members in a microgravity environment.
BACKGROUND ART
The first wardroom tables were part of sailing ships in the 17th, 18th and 19th centuries. Wardrooms served as the place where the ship's officers gathered for meals and meetings, where they received guests and entertained. When the ship prepared for battle, the crew would sprinkle sand on the floor of the wardroom to provide better footing when wet with blood, and the wardroom table would serve as an operating table in the temporary surgery. Thus, from the earliest applications, the wardroom and its table has been a multipurpose facility.
However, the changes in use of the wardroom and its furnishings in the old sailing ships did not involve changes in the configuration of the table itself, and never were there any ergonomic or anthropometric considerations beyond the most normative rules of thumb. The typical wardroom table was a simple rectangular surface with curbs of a few inches in height to prevent plates, cups and silverware from sliding off in rolling seas. In the 19th century, a few tables were built into gimballed frames which allowed them to remain relatively level while the ship rolled and pitched.
However, this gimballing arrangement did not enhance the anthropometric or ergonomic accommodations and in fact militated against these considerations for the individual crew members as the table would apppear to swing relative to the ship's movements, in order that the food and beverages remain on a fairly level surface and not spill.
Wardroom tables have been part of the manned systems support of two prior space stations, the US Skylab, which flew in 1973, and the Soviet Mir, which was launched in 1986. Both these tables designs are static, fixed and passive and attempt to meet anthropometric neutral body posture requirements principally by embodying dimensional comprises to suit the range of crew member sizes and crew activities that were anticipated to fly on each of these spacecraft.
The Skylab table consisted of three rectangular tops oriented at 120 degrees apart to accommodate the three crew members that would occupy the Skylab at one time [Skylab Experience Bulletin No. 18 entitled "Evaluation of Skylab 1VA Architecture", December 1975, Johnson Space Center Report No. 09552, page 11, FIG. 7]. Recessed into the surfaces of these tops were receptacles to hold food containers and restrain them from floating away.
On Mir, the table is a long, flat rectangle, attached at one end to an interior bulkhead. The table surface is made up of several storage compartment lids which hold various tools and implements. There is a row of receptacle openings along each of the long edges of the Mir table to restrain food containers, but they appear to be intended more for short-term stowage than for convenient eating [Aviation Week & Space Technology, July 20, 1987 Issue, pages 58-60]. This arrangement suggests that the primary purpose of the Mir table is to serve as a work bench, at which eating may be considered as a secondary function.
On commercial airliners, each passenger seat is outfitted with a tray table that generally either deploys out from a recess in the back of the seat in front of the passenger or deploys, pivots and unfolds from the armrest of the passenger's seat. These airline tray tables are designed to provide limited working, eating and drinking accomodations to individual passengers on realtively short duration trips which rarely last in excess of 15 or 20 hours on the same aircraft.
In addition to the above prior art, there is a substantial body of prior art dealing generally with the construction of tables. For example, the following issued U.S. patents disclose various forms of tables having changeable configurations or other special features and to related apparatus: U.S. Pat. No. 1,618,523, issued Feb. 22, 1927 to Feldman et al.; U.S. Pat. No. 1,735,535, issued Nov. 12, 1929 to Feldman; U.S. Pat. No. 1,781,602, issued Nov. 11, 1930; 2,014,745, issued Sept. 17, 1935 to Regli; U.S. Pat. No. 2,322,039, issued June 15, 1943 to Greitzer; U..S. Pat. No. 2,394,866, issued Feb. 12, 1946 to McClune; U.S. Pat. 2,517,018, issued Aug. 1, 1950 to Nicholson; U.S. Pat. No. 3,123,935, issued Mar. 10, 1964 to Williams; U.S. Pat. No. 3,198,145, issued Aug. 3, 1965 to Duncan; U.S. Pat. No. 3,361,508, issued Jan. 2, 1968, to Chassevent; U.S. Pat. No. 3,512,740, issued May 19, 1970 to Podwalny; U.S. Pat. No. 3,875,872, issued Apr. 8, 1975 to Kayner; U.S. Pat. No. 3,877,668, issued Apr. 15, 1975 to Von Sande; U.S. Pat. 4,050,549, issued Aug. 9, 1977 to Sadler; U.S. Pat. No. 4,387,650, issued June 14, 1983 to Pizzi; U.S. Pat. No. 4,579,311, issued Apr. 1, 1986 to Spranza. However, none of these patents disclose a table which will meet the needs of the multipurpose table for a wardroom in a space station or similar confined environment.
The principal disadvantages of the prior art stem from the circumstance that they appear to have been designed from the perspective of serving a very limited range of anthropmetric sizes and ergonomically narrow notions of activities. The Skylab table was designed and built before NASA had any solid information on neutral body posture, in fact virtually all of our microgravity and neutral body posture data come from the Skylab program [Skylab Experience Bulletin No. 17 entitled "Neutral Body Posture in Zero-G, July 1975, Johnson Space Center Report No. 09551, page 21]. The Mir table appears to be equally oblivious to neutral body posture data, but this is probably because it is intended as such a generally purpose work-bench that a flat, fixed surface is the lowest common denominator practical design solution.
Neither the Skylab nor the Mir tables, nor any of the tables disclosed in the above mentioned United States patents, provide dynamic accommodations for variations in crew size, activities or viewing orientations. Neither table adjusts to accommodate differences in anthropometric size or ergonomic differences due to the characteristics of different activities such as eating, writing, working on a computer or conducting a meeting or videoconference. Neither table is designed to fold or stow out of the way easily to allow passage of large objects.
In case of the airline passenger tray table, the design is intended for short term service to one passenger. The airline tray table is not intended to enhance social or group communication with the other passengers and in fact may make it more difficult. These tray tables also make passenger movement extremely difficult and after being served a passenger generally must remain captive in his seat until a flight attendant clears away the debris of his meal. Because these tray tables are extremely confining, uncomfortable and inconvenient for the passengers to use, and do not accommodate and anthropometric adjustments to different sizes of people or ergonomic adjustments for different types of tasks or activities, they are not suitable for a long duration space mission in a microgravity environment.
SUMMARY OF THE INVENTION
General Purpose of the Invention
The space station wardroom table represents the first effort to take a comprehensive architectural design approach to the problem of group activity ergonomics for space station crew members in the space station wardroom. This multi-purpose table will support crew meetings, meals and work activities. The table is designed for use in a pressurized, habitable microgravity by a crew from one to 8 persons. The table top can be configured to accommodate the nominal crew shift size of 4 crew members for daily use and has extension surfaces to provide expansion that will accommodate both crew shifts at one time for a total of eight crew members around the table at equal distances from the center.
A table top for use in constricted areas in accordance with the invention has a plurality of support arms abutting at one end to form a hub. The support arms are arranged in equidistant, spaced-apart relation to each other at the ends distal to the hub. A plurality of work surface leaf sections mounted between said support arms are individually pivotable through 360 degrees about their longitudinal axes. The table top preferably additionally has a plurality of distal leaves, each distal leaf being attached to the distal end of one of the arms. The distal leaves are preferably pivotable between an upright position level with the support arms and a stored position below the support arms.
The table top is dynamic in operation with individual work surfaces that crew members can unfold manually and adjust to suit various crew group sizes, types of operational use, and physical and visual comfort preferences. These dynamic features of work surface deployment and rotation or tilt accommodate the wide range of tasks and activities that would be carried out by the space station crew, each of which has different anthropometric, ergonomic and neutral body postural implications. The table can be folded up at the center post to stow out of the way if a large piece of equipment must be moved through the wardroom.
The wardroom table top reconfigures to accommodate a wide range of crew activities including eating, meetings, planning and scheduling sessions, training sessions, videoconferences, entertainments such as viewing videotapes, observations out the windows in the wardroom and use of individual work stations. The reconfiguration capability is a result of the synergism between the extension of the expansion surfaces and their rotation or tilt capability. The deployment mechanisms are simple and easy to operate.
The primary design objectives for the wardroom table are to provide a compact, efficient and safe design which is responsive to the fluctuating need for up to 8 crew positions and which must function comfortably and easily in the weightless environment. Secondary design objectives are to integrate functional support features including task lighting, storage pockets, object/implement restraints, handholds/push-offs and data/communications controls and interfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a wardroom table system installed in a space station wardroom in accordance with the invention.
FIG. 2 is a side view of the wardroom table system in upright position shown in FIG. 1.
FIG. 3 is a side view of the wardroom table system folded at the centerpost clevis joints into a partially stowed position as an alternate arrangement from that shown in FIGS. 1-2.
FIG. 4 is an enlarged, partial isometric view of a portion of the wardroom table system shown in FIGS. 1-4.
FIG. 5 is a perspective view of the wardroom table system in an arrangement for four crew members.
FIG. 6 is a perspective view of the wardroom table system in another arrangement for four crew members.
FIG. 7 is a perspective view of the wardroom table system in an arrangement for eight crew members.
FIG. 8 is a perspective view of the wardroom table system in another arrangement for eight crew members.
FIG. 9 is a perspective view of a portion of the wardroom table system in an arrangement for one crew member.
FIG. 10 is a top plan view of another embodiment of a wardroom table system in accordance with the invention.
FIG. 11 is an isometric view of the wardroom table system of FIG. 10.
FIG. 12 is a side cross section view of the wardroom table system of FIGS. 10 and 11.
FIG. 13 is a side cross section view of another arrangement of the alternate embodiment of FIGS. 10-12.
FIG. 14 is an exploded perspective view of a portion of the wardroom table system of FIGS. 10-13.
DETAILED DESCRIPTION OF THE INVENTION
Identification of Component Parts & Explanation of Mode of Operation
The wardroom table of the present invention is comprised of parts that can be assembled or disassembled easily in less than an hour. The entire table can be packed in a shipping case 20"×20"×56". In a preferred form, the wardroom table is lightweight and easily transportable, with the entire shipping unit, with case weighing 48 kg.
WARDROOM AND WARDROOM TABLE ENSEMBLE
Turning to FIG. 1, the complete wardroom table assembly 1 is shown installed in a space station wardroom 3. The wardroom is outfitted furnished with such amenities as windows 5, a flat panel video display screen 7, stowage compartments 9, and lighting elements 11. This wardroom ensemble is installed within a space station pressurized space station module which typically takes the form of a cylindrical pressure vessel (not shown). The wardroom ensemble component racks, floors and ceiling are mounted to the structural pressure vessel shell by means of a structural standoff (not shown). The wardroom floor 17 attaches to these standoffs to provide a structural span to which the wardroom table base may be secured. The wardroom communicates through one or more bulkhead doorways or hatchways 23 with an adjacent compartment such as the exercise facility 25. Adjacent to the wardroom 3 is the galley 27 which provides food storage and preparation facilities including a freezer, refrigeration, heating or warming oven, dish and utensil storage and washing facilities, clean-up and waste disposal accommodations.
FIG. 1 shows a view of the space station wardroom table 1 being used by several crew members at the same time. The crew have positioned the table work surfaces in their several deployed, working and stowed positions. These surfaces and their positions relate to how the crew members are using them looking at the crew members in counterclockwise sequence as follows:
Crew member 31 is using a primary work surface assembly 300, which is mounted between the primary support arms subassemblies 200. Primary work surface subassembly 300 is comprised of two surfaces, the octagonal primary work surface 34 and the rectangular primary work surface extension leaf 35, which connects to the octagonal primary surface by means of a piano hinge 36. Crew member 31 is operating a small portable work station or computer 37 which is restrained temporarily to the deployed rectangular extension leaf 35.
Crew member 41 has just completed deploying secondary support arm subassembly 400 and secondary work surface assembly 500 which consists of the right and left rectangular secondary work surfaces tops 42 and 43 which connect by piano hinges 44 to the secondary extension arm 45 which pivots from the cambracket joint mechanism 38 which is part of the secondary support arm assembly 400 at the end of the primary support arm 33.
Crew member 51 is placing a food tray 52 on an octagonal primary work surface 53 to which it will be passively restrained by the restraint devices f(not shown). She has rotated work surface 53 so that the reverse side from the one chosen by crew member 31 is facing up, that is, the one without the recessed deployable primary work surface extension leaf corresponding to 35.
Crew member 61 is deploying secondary work surfaces 62. He has operated the cam bracket locking mechanism to pivot surfaces 62 about 180 degrees from its stowed position for which the stowed position 65 of secondary support arm subassembly 400 and secondary work surface subassembly 500 is typical, shown at the diagonally opposite corner of the table from secondary work surfaces 62 and 63. Next, crew member 61 will unfold the hinged half tops 62 and 63 which open to form a flat surface similar to 42 and 43 and 73 and 74.
Crew member 71 is eating a meal from a tray 72 which is temporarily restrained to secondary work surface 73 which is deployed in flat a position.
Observe that crew members 31, 51 and 71 each have their feet inserted in a pair of foot restraints 80 in the outer ring 81 of eight foot restraints which correspond to the eight positions for the full space station crew at the wardroom table 1. In addition to the outer ring of pairs of restraints 80 there is an inner ring of four pairs of foot restraints 82 which correspond to the four crew positions for the nominal diurnal crew shift of four crew members.
The table top configuration is mounted to the floor by means of a center post subassembly 100, which is comprised of a base plate 21, straight cylindrical pipe sections 85, a telescoping center section 86 which provides for height adjustments and one or more clevis joint mechanisms 87 which allow the center post subassembly 100 to be folded up so that the table can be stowed out of the way if the crew needs to move a large piece of equipment through the wardroom. The top of the center post is closed off by center post cap 88.
Additional accessories, which are shown attached to the wardroom table at the top open slot 90 in the top of primary support arm subassembly 200, include a handhold body restraint 91 and an adjustable and pointable task light 92. Mounted between the primary support arm subassemblies 200 adjacent to the center post top cap 88 is a triangular utility connection support panel 94. Restrained temporarily on one of these panels 94 facing directly this view of the wardroom is a calculator 95. Other functions of these utility connection panels include providing mounting receptacles or openings for electrical power, computer data system, communications system, audio systems, video system, compressed utility gases such as compressed air or nitrogen, a fiber optic heliostat and liquid beverage dispenser connections, shown as sockets 98.
TABLE SUB-ASSEMBLIES
The wardroom table parts may be described in five groups or sub-assemblies, each of which is closely integrated. The assembly process primarily involves combining the 5 subassemblies. These subassemblies are: The post subassembly [100 series], the primary arm subassembly [200 series], the primary work surface subassembly [300 series], the secondary arm subassembly [400 series]and the secondary work surface subassembly [500 series].
Turning to FIGS. 2 and 3, FIG. 3 shows the deployment of the center post mechanism and FIG. 2 shows the table in its upright position. In FIG. 3, it can be seen that center post subassembly 100 can be folded up at the two clevis joints 107 and 117 to allow passage of a large piece of equipment through the wardroom. In FIG. 2, the picture plane is orthogonal to the primary support arms subassemblies 200 and in FIG. 3, the picture plane is orthagonal to the primary work surface 321 subassemblies 300 which are mounted at 45 degrees in plan from the outer ends of the primary support arms 200.
The primary support arms subassemblies 200 is shown in both section and elevation views attached to the center post subassembly 100. FIG. 3 illustrates the rotational movement of the primary work surface subassembly 300 and the deployment of the primary work surface extension leaves 327. FIG. 2 shows the secondary support arm subassembly 400 in its two principal positions, stowed position 404 and pivoted about 180 degrees to the deployed position 406. FIG. 2 also shows the secondary work surface assembly 500 in its two positions also, folded and deployed position. In FIG. 3, where entire wardroom table assembly 1 is shown in stowed a position, the center post assembly 100 is shown in partly folded position, the primary work surfaces 300 are shown in horizontal position with the primary work surface extension leaves 327 folded to stow in their recesses, the secondary arm assemblies 400 are pivoted to stow in position 404 under the primary support arm assemblies 200 and the primary work surfaces 500 are locked in folded position.
CENTER POST SUB-ASSEMBLY
The center post assembly, best seen in FIGS. 2-3, is composed of several moving and fixed parts including a base plate 101, upper and lower parts formed by straight cylindrical tube sections 104, lower and upper joints or clevis joint mechanisms 107 and 117, and a middle part formed by telescoping center section mechanism 109 and welded gusset plates 151. The middle part 109 is hollow and receives a telescoping tube 104t on the upper part.
The post baseplate 101 attaches to bolt holes 106 at an attachment hard point in the wardroom floor deck by means of four bolts (not shown). A section of cylindrical tubing 104 is welded as a post stub to the baseplate 101 at its bottom end 103 and at its upper end 105 is open to receive the clevis joint mechanism 107. Above clevis joint mechanism 107 is telescoping section 109 that allows adjustment of the height of the table. Above telescoping section 109 is a second clevis joint mechanism 117.
Above clevis joint 117, 4 aluminum plate gussets 151 are welded to a straight section of the standard diameter center post tube 104. Each of the gussets 151 are drilled with two or more holes 153 which serve as cantilever connection points. At the very top end of center post tube 104 is a plug cap 155 which is the same as 88 in FIG. 1.
PRIMARY SUPPORT ARM ASSEMBLY
The primary support arm assembly is best illustrated in FIGS. 8--8 and 14. The primary support arm subassembly 200 is comprised of all fixed parts, including the double plate support arms 201 with spacer blocks 209, the right and left hand primary surface rotation brackets 227 and the bifurcated arm extension 217.
The primary arm subassembly 200 attaches to the center post subassembly 100 at the gusset plates 151. The primary arm structure 201 is comprised of two parallel and identical cantilever plates 203 that attach to the gusset plates with removable pins or bolts 205 through holes 207 which correspond to the holes 153 in the gusset plates 151. The two structural cantilever plates 203 are held apart at a fixed distance by spacer blocks 209 at each end to create a gap. The parallel top edges 213 of plates 203 act as a track to which the crew can attach various apparati such as lights, hand hold restraints or equipment restraints. FIG. 1 shows such apparati attached to track 213. The spacer blocks 209 may be individual parts of they may be integrated into the function of the gusset plate 151 at the proximal end 215 and the bifucated arm extension 217 at the distal end 219 of primary support arm subassembly 200. The bifucated arm extension 217 is fixed to the cantilever plates 203. Two primary work surface brackets 227 are attached to the throat 229 of the bifucated arm extension 217 as shown in FIGS. 10 and 14.
PRIMARY WORK SURFACE SUBASSEMBLY
The primary work surface subassembly is illustrated in FIGS. 1, 10, 11 and 14. The primary work surface subassembly 300 is comprised of fixed and moving parts including the rotation wheel mechanism 301, the octagonal primary work surface 321, piano hinge 341 and the rectangular primary work surface extension leaf 327. Rotation wheel mechanism 301 consists of a rotating sleeve 303, a rotating stud 305 and two quick release marine type shear pins 309 and 361. The rotating stud 305 is attached to the edge o octagonal primary work surface 321 as best seen in FIG. 14. Sleeve 303 is free to rotate about the fixed stud 245 except that it may be locked into various rotational position by inserting a pin 361 through the alignable holes 363 in the wheel portion of sleeve 303.
The octagonal primary work surface 321 is shaped as a somewhat flattened octagon to permit it to rotate 360 degress through the space between two adjacent primary support arm subassemblies 200. Various positions for work surface 321 are shown in FIGS. 1 and 7-11.
Work surface 321 has two faces, an active, contoured obverse face 323 and a passive, flat reverse face 325. The obverse face 323 incorporates a recess 326 into which the primary work surface extension leaf 327 stows and it may include other contoured recesses for installing special communications equipment, or food and beverage restraint receptacles. The primary work surface extension leaf 327 attaches to primary work surface 321 by a piano hinge 341 about which it can swing 180 degrees to that it is self-stopping against primary work surface 321.
SECONDARY SUPPORT ARM SUBASSEMBLY
The secondary support arm assembly 400 is shown in FIGS. 1 and 6-12. The secondary support arm subassembly 400 consists primarily of moving parts including the cambracket position locking mechanism 401, the secondary arm extension square tube 417, and the end plate locking mechanism 431. The secondary support arm subassembly 400 connects to the primary support arm subassembly at the bifurcated arm extension 217 where a dowel axle 403 passes through holes 222 in the two lobes 224 of 212 and the corresponding hole 422 in the cambracket cam 405. Dowel axle 403 is held into place by release pins 414 thorugh holes at each end of 403 and on either side of 217.
The rotary position of the cam 405 relative to the lobes 224 is secured by a quick release locking pin 407 that is inserted through holes 226 in the lobes 224 and through the corresponding alignable hole 426 in the cam 405. Cam 405 has two end lobes; a wide lobe 409 with two or more holes 426 in it for deploying the subassembly 400 at various angles and a narrow end lobe 411, with one hole 426 in it for securing subassembly 400 in stowed position. Cam 405 has a square plug end 413 which inserts into the proximal square end 415 of the square tube 417.
At the distal end 419 of square tube 417 is attached the end plate locking mechanism 431. This end plate locking mechanism 431 is used to determine the position of the secondary surfaces of subassembly 500. A square plug 433 projection of the end plate 435 inserts into the square opening of distal end 419. End plate 435 is trapezoidal in shape with locking pin holes in each of its four corners. These two pairs of holes correspond to the two locking positions of each of the leaves; right hand leaf 501 and the left hand leaf 503 of the secondary work surface subassembly 500. The pair of holes 441 at the narrow trapezoidal base end 443 of the end plate 435 correspond to the folded or stowed position 507 of the two leaves 501 and 503. The pair of holes 445 at the wide trapezoidal base end 447 of the end plate 435 correspond to the unfolded or deployed position 509 of the two leaves 501 and 503.
SECONDARY WORK SURFACE SUBASSEMBLY
The secondary work surface assemblies are illustrated in FIGS. 1 and 6-12. The secondary work surface subassembly 500 includes the right and left rectangular "butterfly leaves" or half tops 501 and 503 respectively, the piano hinges 511 and the left and right end locking tabs 531 and 533. For commonality and interchangeability of parts, tops 501 and 503 may be identical to the rectangular primary work surface extension leaf 327 in size and shape and means of attachment by a piano hinge.
The right leaf 501 and the left leaf 503 both attach to the secondary support arm square tube by means of piano hinges 511 by using machine screws 513. The screw heads of the machine screws (not shown) act as measured stops to control the maximum swing of the butts of the piano hinges 511 to 180 degrees. The minimum swing of the right two leaves 501 and 503 also have the end locking tabs 531 screwed to them where their locking pin holes 535 will align with the corresponding position holes 441 and 445 in the end locking plate 435. A quick release detent pin 551 is inserted through these holes when aligned to secure the right leaf 501 and the left leaf 503 in either the folded position 507 or the unfolded position 509.
OPERATIONAL MODES FOR INDIVIDUAL ADJUSTMENTS
The possibilities for individual adjustment of the wardroom table apparatus become apparent. The table is intended to be comfortable, compact and easy to use by each individual member of the crew. Comfort is achieved by the overall plan configuration which ensures good sightlines and vocal distances for all participants, and by the extending and angled surfaces which ensure compliance with the 5th-to-95th percentile anthropometric size range. Compactness is achieved by ensuring that the table surface positions fold away when not in use (assuming that only the 4 inner positions are regularly used by a single crew shift) to free as much volume as possible around the table for crew movement. Ease of use is achieved by ensuring that all mechanisms, controls and accessories are simple and obvious to use and that maintenance, repair and cleaning duties are as straightforward as possible.
PRIMARY WORK SURFACE ADJUSTMENT
The primary work surface assembly 300 serves crew shifts of all sizes, with or without the use of the secondary work surfaces.
FIG. 9 shows the octagonal primary work surface 321 mounted to its rotation disk mechanisms at either end of its longitudinal axis. The crew members may adjust position of the octagonal primary work surface by manually removing the two quick release detent shear pins 361 (see FIG. 14) from the rotation disk mechanism, 301, rotating the octagonal primary work surface 321 to the desired angle and then replacing the pin. In FIG. 9, the primary work surface 321 is show rotated approximately 45 degrees and from the horizontal.
The crew may adjust the primary work surface subassembly 300 further by releasing the rectangular primary work surface extension leaf 327 from its recess 326 in the obverse face 323 of the octagonal primary work surface 321 and swinging it into the desired position. The crew members secure the extension leaf 327 into position by tightening the captive set screw and slotted slide device on the side edges of the extension leaf. In FIG. 9, the extension leaf in useby a crewmember is shown deployed at an angle of about 150 degrees from the octagonal primary work surface 321 itself.
SECONDARY WORK SURFACE ADJUSTMENT
The deployment and stowage operation of the secondary work surface subassembly 500 is more complex than that of the primary work surface subassembly 300 because it must stow completely out of the way of the smaller crew shift whereas the primary work surface subassembly 300 is always accessible and available for use. The secondary work surface subassembly 500 will be used principally when the primary work surfaces are already occupied by other crew members.
FIG. 6 shows the secondary work surface in stowed position beneath the primary support arm. In this stowed position, the two "butterfly" leaves or half-tops 501 and 503 are folded at the piano hinges which attach then to the secondary support arm. Referring now to FIG. 14 the cambracket 405 is plug connected into the end of the secondary support arm square tube. In this deployed position 404, the narrow lobe 411 of the cambracket (shown in FIG. 14) with one hole in it upward points to align with the two corresponding holes in the bifurcated arm extension 217. Below the bifurcated arm extension wide lobe 409 of cambracket 405 is visible with three alignment holes (426) for the various possible deployment positions 404 and 406 of the secondary support arm. The cambracket and the secondary support arm subassembly 400 and the secondary work surface subassembly 500 rotate about dowel axle 403 which passes through the rotation center point of bifurcated arm extension 217.
Note that when second and work surface subassembly 500 is rotated to the stowed position, the positions of the narrow and wide lobes of the cambracket will be reversed.
FIG. 14 shows both the secondary support arm subassembly 400 and the secondary work surface subassembly 500 fully unfolded, opened and deployed. The back edges of piano hinges 511 are visible longitudinally along the square tube 417 of the secondary support arm, and in fact the two butts of each of the piano hinges 511 are pressed together in a self-stopping closed position. At the outermost end of the secondary support arm, the end plate locking mechanism 431 is fully visible, with the two secondary work surface position pins 551 visible in the lower locking position holes 441 alignment holes, securing the tops into the open position and the upper locking position holes 445 are empty.
WORKBENCH MODE
FIG. 5 shows the wardroom table system configured in "work bench" mode for a crew of four people. In this mode, the four primary work surfaces all are arranged in horizontal rotation positions so that the overall table top is as flat and horizontal as possible. All of the primary work surface 321 extension leaves and of the secondary work surface assemblies are stowed completely to provide for a flat and fairly compact workbench. A small portable computer is restrained to the backside 350 of the stowed secondary extension leaf 327. The work surface arrangement of FIG. 5 would accommodate a group of two to four space crew members eating a meal together or working with the same materials, documents or equipments, when the crew members need a common reference and restraint surface in the microgravity environmnent. The wardroom table arrangement of FIG. 5 provides a small degree of temporary personal space and personal territory to crew members as their positions are defined implicitly by the diagonal positions of the primary support arm subassemblies 200 and the primary work surface subassemblies 300.
TRAINING MODE
FIG. 7 shows the wardroom table system arranged in "training" mode, which is similar to the arrangement described in FIG. 5 with one significant change. The crew members have rotated the primary work surface assemblies 300 about 65 degrees from the horizontal. In this arrangement, the worksurfaces are especially oriented to accommodate the visual sightline requirements for humans working in microgravity such that the neutral body that the human body assumes when experiencing the effects of "weightlessness" causes the sightline from the human eye to drop about 23 to 27 degrees below the horizon line. Thus, with the work surface tops oriented at 65 degrees from the horizontal, any object such as a document or computer restrained to said surface face 323 will be approximately orthagonal to the sightline of a space crew member with his or her feet in the inner ring of foot restraint pairs 82 shown in FIG. 1 and who assumes the neutral body posture of the microgravity environment. The wardroom table system arrangement shown in FIG. 7 also provides a small degree of personal space and personal territory as similar to that shown in FIG. 13, but the arrangement of FIG. 7 also offers a small degree of temorary privacy as none of the crew members restrained in positions at the primary work surfaces 323 and 327 can easily see the objects or materials restrained to the primary work surfaces 323 and 327 of the other three crew positions.
CONFERENCE MODE
FIG. 6 shows the wardroom table system 1 in another variation of the arrangement of the configuration shown in FIG. 5. In FIG. 6, the crew members have unfolded, extended and deployed all the rectangular leaves of both the primary work surface assemblies 300 and the secondary work surface assemblies 500. As in FIG. 13, all these work surfaces are positioned to share a common horizontal reference plane and as such constitute an extension of "work bench" mode into "conference" mode. Conference mode as shown in FIG. 6 accommodates up to eight space crew members around the wardroom table system 1 in a manner that optimizes direct eye contact and interpersonal communication. Conference mode provides a level and equal meeting place for all the space crew members to gather to discuss activities, socialize or share meals. Like the workbench mode of FIG. 13, the conference mode provides a small degree of temporary personal space and territory which are suggested implicitly by the triangular gaps between the primary work surface extension leaves 327 and the secondary work surface subassembly 500 around the outer perimeter of the table system.
PLANNING MODE
FIG. 8 shows the wardroom table system 1 arranged in "planning" mode during which the full complement of eight crew members must make extensive use of documents and possibly computer systems so that it is desirable to optimize the ergonomics of neutral body posture for visual sightlines to the work surfaces. Planning mode is a variation of the conference mode shown in FIG. 6 in which the crew members have totaled the work surfaces to angles of approximately 45 degrees which offer a compromise between the optimal sightlines or view angles for discussions between crew members and the crew members' use of the work surfaces in the microgravity environment. Like the training mode shown in FIG. 7, planning mode offers a small degree of temporary personal space, territory and privacy to the crew members.
INDIVIDUAL WORK STATION MODE
FIG. 9 represents the wardroom table system 1 in "individual work station" mode, a special adaptation of the planning mode shown in FIG. 8. Temporary individual work station mode occurs when a space crew member adapts to his or her use two or more of the work surface positions of conference mode. FIG. 9 shows a space crew member who has configured three work surface positions for his transitory personal use, specifically one primary work surface subassembly 300 which he is facing as he adjusts the primary work surface extension leaf's 327 position, and the two secondary work surface assemblies 500 which are already deployed on either side of him from planning mode. The crew member has customized or personalized further the ergonomic features of his temporary individual work station arrangement by adjusting the position of the outer half tops, 501 to his right and 503 to his left, in each of the adjacent secondary work surface assemblies. The crew member has moved these two outer half tops into folded or stowed positions 507 so that they form a right angle with the other two tops in unfolded position 509. This "el" arrangement 510 of the two pairs of half tops gives the crew member added convenience and functionality for his temporary individual work station to attach equipment, materials or documents where he can easily see or reach them. This temporary individual work station mode affords the crew member the a greater degree of temporary personal space, territory and privacy that the other modes described in FIGS. 5-8.
ALTERNATE EMBODIMENTS OF THE INVENTION
An alternate and optimal embodiment of the invention is illustrated in FIGS. 10-11 and 14, which show a different pattern for the primary and secondary work surfaces. In this alternate embodiment, the rectangular primary work surface extension leaves 327 and rectangular secondary work surface top halves 501 and 503 are replaced by a system of larger, hexagonal tops. These larger hexagonal tops provide several advantages over the simpler rectangular tops. The hexagonal tops provide a more consistent and uniform outside perimeter edge to the table in the eight crew member configuration, a larger work surface area, identical crew stations for each of the eight members of the full crew at the wardroom table and a geometry which is more harmoniously integrated.
A further advantage of this alternate embodiment configuration is that it takes more full advantage of the 360 degree rotation capability of the octagonal primary work surfaces. It allows the food restraint devices or receptacles that are potentially part of the extension leaf to be usable equally in both the four crew member and the eight crew member configurations. The arrangements of this alternate embodiment also make a clear distinction between surface tops that are to be used for eating meals and the opposite sides of those same surface tops that are used as part of work stations.
When the alternate embodiment primary work surface assembly 399 is to be used for meals in the four crew configuration (right side of FIG. 12) 380, it is rotated so that the piano hinge 341 faces toward the center post and the food restraint surface 358 of the hexagonal extension leaf 357 faces upward while the leaf remains folded into the corresponding recess 358 in the octagonal primary work surface 351. In this configuration 380, the food restraint surface 358 is conveniently accessible to crew members using the inner ring of four pairs of foot restraints.
When the primary work surface subassembly 399 is to be used for meals in the eight crew configuration 390, it is rotated 180 degrees so that the piano hinge 341 faces away from the center post and the food restraint surface 358 of the hexagonal extension leaf 357 faces down while the leaf 357 remains folded into the corresponding recess 356 in the octagonal primary work surface 351. Then the crew member releases a catch or detent locking device and swings the hexagonal primary work surface extension leaf 357 on the piano hinge 341 up to 180 degrees out of its recess 356 and locks it into the desired configuration 390 using the slotted slide and captive set screw device. In this configuration 390, the food restraint surface 358 is conveniently accessible to crew members using the outer ring of eight pairs of foot restraints.
As best seen in FIGS. 12 and 13, when the primary work surface subassembly 399 is to be converted from use as a food restraint configuration 380 or 390 to use as a work station or integrated computer terminal operation, the crew member can rearrange it by unlocking the rotating sleeves 303 from the rotation studs 305 at both of the axial ends of the primary work surface assembly 399. Then the crew member simply turns the work surface 351 around to reverse the positions of the rotation studs 305 at the two ends of the primary work surface assembly 399 and then reconnects them to the opposite rotation sleeves 303. After this readjustment to the folded work station configuration 382, the piano hinge 341 faces away from the center post and the food restraint surface 358 which is integrated into the hexagonal extension leaf 357 faces up. Then the crew member releases a catch or detent allow the hexagonal extension leaf 357 to swing on the piano hinge 341 up to 180 degrees out of its recess 356 in the octagonal primary work surface 351 so that the food restraint surface 358 faces down and the flat work surface 355 or recessed keyboard 371 faces up to form the unfolded work station configuration 392. The crew member with his feet in the outer ring of pairs of foot restraints can now see and conveniently use the flat panel computer video display terminal 372 which may be installed in a recess 374 in the octagonal primary work surface 351 and the keyboard 371 which is on the backside of the food restraint surface of the same hexagonal extension leaf.
In this alternate embodiment, when the food restraint surface is in use, the computer terminal and keyboard installed in these panels are protected by the arrangement of panels and leaves as follows: When in the four crew member configuration 380, the hexagonal extension leaf 357 is folded into its corresponding recess in the octagonal primary work surface 351, which corresponds to the workbench mode of FIG. 5. In this alternate embodiment of the workbench mode that the flat panel video display terminal 373 and the associated keyboard 371 are both protected and hidden and are shielded directly from spills of food or drink or inadvertent impacts. When in the eight crew member configuration 390, corresponds to the conference mode shown in FIG. 6, the flat panel video display terminal 373 and the keyboard 371 are both positioned on the opposite sides of the work surface that are in use and are thus shielded indirectly from spills of food or drink or inadvertent impacts. Since diurnal crew shifts of four crew members will use the wardroom table in groups of four for probably 2/3 of all meals, the superior protection of the 4 crew configuration will be available most of the time.
The alternate embodiment secondary work surface half tops 561 and 563 of the alternate embodiment secondary work surface subassembly 599 also take advantage of the hexagonal extension leaf geometry to create the wardroom table perimeter edge with minimal gaps or spaces between surfaces. To create the secondary work surface halves 561 and 563, the basic hexagonal extension leaf 357 is cut in half and a small strip of material removed from both of the cut halves to leave room for the secondary support arm square tube 417 to which the plane hinges 511 and end plate locking mechanism 431 will be attached.
Advantages of the Invention Over Prior Art
This design approach replaces the conventional concept of a unified table surface with a group of independent surface elements which can be rotated, unfolded and angled to suit a wide range and mixture of operational anthropmetric and ergonomic requirements for space station or other space craft crew members in the microgravity environment. Virtually every feature described above that goes beyond a fixed, flat rectangular table surface is an advantage over the prior art. | A table top for use in constricted areas has a plurality of support arms abutting at one end to form a hub. The support arms are arranged in equidistant, spaced-apart relation to each other at the ends distal to the hub. A plurality of work surface leaf sections mounted between the support arms are individually pivotable through 360 degrees about their longitudinal axes. The table top additionally has a plurality of distal leaves, each distal leaf being attached to the distal end of one of the arms. The distal leaves are pivotable between an upright position level with the support arms and a stored position below the support arms. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates to a device used for the purpose of muscular and spinal therapy.
BACKGROUND OF THE INVENTION
[0002] Placing pressure on both the right and left of the spine, while relaxed and without pressure directly on the spine itself has been known to give relief to patients with certain back problems. However, applying pressure in this manner has only been achieved by another person pressing on the patient's back while the patient lies face down, or by placing spherical objects, which are fixedly held together, under the patient while the patient is lying face up. When the patient relaxes, the spherical objects apply pressure to the right and left of the spine, using the patient's body weight. Recently, two spherical objects held together have also been used directly on the spine, as the spherical objects were placed parallel to the spine, stretching the front of the spine and its ligaments.
[0003] In the case of the spherical objects, it has been known to use tape or glue or even old socks to hold the spherical objects so that they do not move away from their desired position. Glues and tapes create a very sticky mess and the spherical objects becomes very dirty, picking up lint or dirt from the carpet or floor due to the adhesive. Wrapping the spherical objects in a sock and knotting the end or binding the open end with a string or tape, resulted in the sock stretching and the sock had to be torn off to readjust or rewrap the spherical objects with another sock. Often it was necessary to throw the dirty, taped spherical objects away, due to their negative appearance to patients.
SUMMARY OF THE INVENTION
[0004] It is therefore the object of this invention to create a device comprising two spheres, held together, without the negative results of the prior art.
[0005] The invention comprises two spheres held in a sleeve made of an elastomeric material which holds the spherical objects together in the proper position, yet is comfortable to the touch and firm enough for a patient to lie upon. The spherical objects are removable, and the outer sleeve washable. No glues, adhesives, knots of material, or zippers to catch a patient's hair, when using it in the neck area, are needed. The sleeve utilizes a plastic “cinch lock” attached to a nylon cord that is run through the hem at one end of the sleeve, to allow the opening of the end of the sleeve for removal of the spherical objects. At the other end of the sleeve, the elastic material is tapered to a smaller diameter and a non-stretch stitch is sewn in, to stop the spherical objects from exiting that end of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is perspective view of the invention;
[0007] FIG. 2 is a side elevational view;
[0008] FIG. 3 is a back view; and,
[0009] FIG. 4 is a top view.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Referring now to the drawings, there is shown a sleeve 10 inside of which is held two spherical objects, or balls, 12 and 14 . One end of sleeve 10 has a cinch lock 16 comprising a cord 18 and a locking device 20 . Cord 18 passes through hem 22 at one end of sleeve 10 . When cinch lock 16 is tightened sufficiently, spheres 12 and 14 are held tightly in sleeve 10 . When cinch lock 16 is released, spheres 12 and 14 can be removed from sleeve 10 .
[0011] At the other end, sleeve 10 is tapered to a smaller diameter 24 by use of a non-stretch stitch 26 to sufficiently hold spheres 12 and 14 from exiting that end of sleeve 10 . Stitch 28 (shown in FIG. 3 ) closes sleeve 10 , in the vertical direction.
[0012] Placing the spinal therapy unit of this invention along the spine while lying down on a flat horizontal surface, face up, with one spherical object 12 to the right and the other spherical object 14 to the left of the spine, encased by the sleeve 10 , the spherical objects 12 and 14 create a lift from the flat horizontal surface, at the point of contact with the back, while not placing pressure directly on the spine, due to the area void of mass created by the curvature of spherical objects 12 and 14 . This lift area allows the spine to bend and stretch the front of the spine, due to the arc created by spherical objects 12 and 14 , enclosed by sleeve 10 .
[0013] When the tendons and muscles are shortened by excess stress or repetitive misuse, they compress the spine and place undue pressure on the discs (pliable “spacers” that the body lubricates with fluid that allows the spine to bend and twist comfortably). Compression causes the discs to swell due to irritation created by the pressure, and adds to the problem of pressure created by the shortened muscles and tendons. This often creates a chronic spinal problem, as the swollen body parts apply pressure on the nervous system, also part of the spine, resulting in pain and discomfort.
[0014] The stretching of these tendons and muscles is optimally done by the spinal therapy unit of this invention. Simultaneously applying pressure on the muscle tissue along the right and the left of the spine, the spinal therapy unit also massages the muscles comfortably, yet firmly, as the patient can “roll” back and forth over the surface of the unit, which increases blood flow and reduces fatigue in the area. Lactic acid (a waste product of the muscle after exertion, that causes contraction and restricts oxygen and blood flow) is able to be released from the muscles, due to the massaging effect, which increases blood flow. Continued use of the spinal therapy unit, optionally combined with other medical and physical therapy, has proved to reduce, and in some instances relieve, all discomfort. It is important that the spheres are kept adjacent to one another, and are soft enough to be comfortable, yet firm enough to lift the spine and create the desired curvature from the horizontal position.
[0015] Other positions may be used that will give the spinal therapy unit even more benefits. Placing the spinal therapy unit along the spine, and actually lying directly on it face up, places pressure directly on the spine, and when the correct size is used, it presses and positions the spine in a position to stretch two vertebrae at a time. This is a more advanced position.
[0016] The massage position can also be achieved by standing up with the spinal therapy unit placed against a wall, with one spherical object to the right and the other spherical object to the left of the spine, encased by the sleeve. Gentle lifting of the body with knees slightly bent applies pressure on the unit and concurrently massages the muscles to the right and left of the spine.
[0017] Sleeve 10 is preferably a cylinder of neoprene, although it can be made of other elastomeric fabric. It is designed to be compact, washable, and have an appealing look and feel. At one end, cord 18 , preferably made of nylon, is passed through hem 22 and when tightened and secured by a cord lock 20 , holds the two spheres 12 and 14 together, yet, by releasing cord lock 20 , allows the removal or insertion of the spheres for replacement or cleaning of sleeve 10 and/or spheres 12 and 14 , or the replacement of the two spheres with spheres of a different size.
[0018] At the opposing end, sleeve 10 is tapered to a smaller diameter and sewn with a non-stretch stitch 26 . This allows minimal flexibility and prevents the spherical objects from exiting at that end. All other stitching is of a stretch nature and moves with the elastomeric fabric. When the spinal therapy unit is complete, with the correct size spherical objects in place, the tapered end is not apparent and looks very neat, matching the opposite side when the nylon cord is cinched down and the cord lock is secured.
[0019] Neoprene is the preferred material for the sleeve, because it has the proper elastomeric properties and is easy to clean. It may be from about ½ mm thick to about 5 mm thick. The spherical balls are preferably made of semi-hard rubber so that they have some flexibility but still maintain their shape, in order to press on the sides of the spine for proper massage. The stiffness of the spheres may vary depending on what works best for the patient. The spheres may be tennis balls or wooden spheres, although something in-between in hardness is usually preferable, such as rubber or a polymer. The spheres may vary in size from about 1 inch in diameter up to about 16 inches in diameter, depending upon the needs of the patient. | A spinal therapy device comprising an elastomeric sleeve having an opening at each end, a pair of spherical objects held together within said sleeve, means to substantially close one end of the sleeve and means to releasably close the other end of the sleeve. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation, under 35 U.S.C. §120, of copending international application No. PCT/EP2006/001809, filed Feb. 28, 2006, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. DE 10 2005 009 978.5, filed Mar. 4, 2005; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a self-supporting spatial unit having non-supporting outer wall elements which are placed on the outer sides of the spatial unit. The self-supporting spatial unit has first and second rectangular, substantially closed longitudinal frames which are connected releasably to one another via crossmembers, to which the outer wall elements are fastened releasably.
On account of the rising prices for residential and commercial buildings, in particular for privately owned homes, as a consequence of higher requirements on thermal insulation and high costs for operating a construction site, building construction systems have been developed, in which a building can be constructed in a simple and inexpensive manner with prefabricated spatial units.
For instance, German Utility Model DE 93 12 109 U1 discloses a building construction which contains prefabricated spatial units and in which the spatial units contain a steel skeleton having a rectangular base frame, a rectangular ceiling frame and four vertical supports which connect the frames. In order to form a living space, in the case of spatial units which are disposed above one another or next to one another, their outer faces are enclosed by thermally insulating and soundproof multiple-part outer wall elements in a lightweight construction. The lowermost outer wall element being supported on supporting strips which are disposed on the base frame. In order to form a floor or a ceiling, guides are provided in the base and ceiling frames, into which guides individual plate elements made from concrete can be inserted. Here, the frame construction which is formed from the spatial units is supported on the subsoil via strip foundations, the base frame resting directly on the foundations.
A further spatial unit which is formed from a self-supporting steel skeleton is described in published, non-prosecuted German patent application DE 40 03 961 A1, the steel skeleton containing an upper frame and a lower frame and supports which are situated between the former. Here, the ceiling and the base tub are mounted on profiles, in particular Z profiles, which are disposed horizontally in the upper and lower frames.
Furthermore, published, non-prosecuted German patent application DE 198 54 401 A1 discloses construction frames which can be stacked, are made from steel and have an upper and a lower frame, vertical carriers which transfer the loads from the upper to the lower frame being distributed over the longitudinal and transverse sides of the upper and lower frames. Here, the walls are formed by lining elements which are attached to the vertical carriers, the outer walls being provided additionally with an insulating element. In order to form window and door apertures, the vertical carriers are delimited, furthermore, by additional horizontally extending intermediate carriers.
Furthermore, published, non-prosecuted German patent application DE 29 20 421 A1 describes a construction frame having outer walls which are attached to the frame and in which a floor plate and a ceiling plate are connected to one another via shelved vertical supports and form a spatial unit.
On account of the complicated construction of the spatial units which are known from the prior art with a high number of different components, the building constructions which are formed from the spatial units can be constructed only with high technical expenditure and can be adapted only with difficulty to the changing requirements of the constructor. Furthermore, the spatial units have thermal bridges, in particular in the region of the connection of the outer wall elements, which thermal bridges necessitate a high heating warmth requirement in the building constructions which are constructed from the spatial units.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a self-supporting spatial unit having non-supporting advanced outer walls which overcomes the above-mentioned disadvantages of the prior art devices of this general type, which can be used flexibly and can be constructed with low technical expenditure, and which also satisfies high requirements with respect to thermal insulation.
With the foregoing and other objects in view there is provided, in accordance with the invention a self-supporting spatial unit. The spatial unit contains crossmembers having outer edges, first and second rectangular, substantially closed longitudinal frames connected releasably to one another via the crossmembers and has outer edges, and outer wall elements having outer edges and fastened releasably to the first and second longitudinal frames. The outer wall elements are substantially of a size corresponding to a height, a width or length of the spatial unit and terminate flushly at the outer edges with the outer edges of the longitudinal frames and of the crossmembers such that end sides of adjacent ones of the outer wall elements define recesses each in a form of a bent-in corner in a corner region of the spatial unit. Corner elements are fastened releasably in the recesses, the corner elements seal with respect to an outside an interior of the spatial unit delimited by the outer wall elements.
According to the invention, the self-supporting spatial unit contains the first and second rectangular, substantially closed longitudinal frames. The first and second longitudinal frames are connected releasably to one another via crossmembers. Here, the three-dimensional frame construction which is formed by the crossmembers and longitudinal frames advantageously has only a low weight. Outer wall elements, floor terminating elements and roof elements which are placed releasably on the outer upper, lower, longitudinal and/or broad sides of the spatial unit terminate flushly with the outer edges of the spatial unit which is formed from longitudinal frames and crossmembers, the outer wall elements, floor terminating elements and roof elements being of a size which corresponds substantially to the height, the width or the length of the spatial unit. In the following text, for the sake of simplicity, the floor terminating element which is disposed on the lower side of the spatial unit and the roof element which is disposed on the upper side of the spatial unit will largely likewise be denoted as an outer wall element.
The end sides of the adjacent outer wall elements form a recess in the corner region of a spatial unit, which recess has the form of a bent-in corner having a preferably rectangular cross section. In order to seal the interior which is delimited by the outer wall elements with respect to the outer sides of the spatial unit, corner elements are fastened releasably in the recesses.
On account of the releasable fastening of the crossmembers to the longitudinal frames, of the outer wall elements to the outer sides of the spatial unit and of the corner element in the recess, the spatial unit can be dismantled completely into its individual parts, it being possible for the individual components to be exchanged, reused or recycled in an inexpensive and environmentally friendly manner after dismantling.
The outer wall elements are, in particular, light, self-supporting, non-reinforcing and thermally insulated components which serve only to protect the space which is enclosed by the outer wall elements against weather influences, but do not assume a static function. As the spatial unit which is formed from the longitudinal frames and crossmembers automatically assumes the function of statics and reinforcement and the outer wall elements are placed releasably on the outer side of the spatial unit, the construction of the outer wall elements and the corner elements can be kept simple, as a result of which they can be manufactured inexpensively industrially in mass production.
Here, it is possible, for example, that the outer wall elements have a carrying frame made from wood, into which thermally insulating elements, window and door surfaces can be integrated. Fastening points are required only for fastening the outer wall elements releasably to the spatial unit, it being possible, however, for these to be realized, for example, via screw or plug-in connections in a simple manner. The corner elements are preferably provided with thermal insulation and, like the outer wall elements, mainly serve to protect against weather influences. Here, that section of the corner element which extends from outer side to outer side of the outer wall elements can have a rectangular, circular, oval, arcuate and/or polygonal cross section, the cross section of the corner element preferably corresponding to the shape of the recess for accurate insertion of the corner element into the recess. It is therefore possible in this context, for example, in the case of a bent-in corner in the corner region of the spatial unit that the corner element has a polygonal cross section having a circular section and two limb faces which are disposed at a right angle with respect to one another, in each case one limb face of the corner element facing in each case one end face of an outer wall element. Furthermore, in the region of the roof, there can be provision, in particular, for the corner element to have a rainwater gutter in the section which extends from the outer wall element to the roof element.
Furthermore, for the individual coloring of the spatial unit, there can be provision for the outer wall elements and corner elements to be available in a range of different colors. For example, it is therefore conceivable that the outer wall elements and corner elements are offered in different styles, such as a country house style or a Bauhaus style, the outer wall elements and corner elements preferably having the same construction and differing only in terms of color and design decor elements.
According to the invention, the spatial unit has a length which is twice as great as the width of the spatial unit. This results in the advantage that, during construction of a building construction, the spatial units can be disposed both with adjacent longitudinal edges parallel to one another and with adjacent longitudinal and broad sides perpendicular or transverse with respect to one another. Here, the outer sides of two spatial units which are oriented with adjacent longitudinal sides parallel to one another and a third spatial unit which is disposed at a right angle with respect to this on the broad sides or end sides of the two spatial units which lie parallel to one another form the shape of a rectangle in plan view. In this way, a large number of possible combinations of the spatial units affords a large number of possible designs for a building which is formed from spatial units. For the further individual design of buildings, however, the spatial units can also have dimensions which deviate from this. It is thus possible, for example, that individual spatial units are only half as long and/or wide as other spatial units.
In a manner according to the invention, the spatial units have a height and width of less than 350 cm, and a length of less than 650 cm, a length of 530 cm and a width of 265 cm having proved particularly advantageous for transport, in particular on trucks. As a result, the spatial unit can be manufactured industrially at a manufacturing location with low costs and can be transported inexpensively to the respective construction site, in particular by truck, after manufacture on account of the low weight of the spatial unit. The outer wall elements which are to be attached can have, for example, a thickness of approximately 30 cm in this case.
Furthermore, the dimensions according to the invention of the spatial unit and the associated transportability results in the advantage that the spatial unit and the outer wall elements and corner elements which are attached to it are not assigned fixedly to one construction plot. It is thus conceivable, for example, that, if the constructor moves to a different location, the spatial unit can be dismantled and taken along together with the outer wall elements and corner elements, and including the readymade foundations, in order to be constructed again at a different location.
In order to obtain a self-supporting spatial unit without reinforcing elements, the crossmembers are connected according to the invention in a flexurally rigid manner to the longitudinal frames via an end plate connection. Here, depending on the embodiment and size of the spatial unit, end plates can be provided both on the longitudinal frames and on the crossmembers. Here, the crossmembers are preferably connected to the longitudinal frames via a screw connection, with the result that the spatial unit can advantageously be dismantled for transport with, in particular, relatively small transport vehicles, and can be extended for a redesign. Here, the end plate connection is configured structurally in such a way that the maximum bending moments and transverse forces, such as occur, for example, in a multistory arrangement of the spatial units above one another, can be transmitted from the crossmembers to the longitudinal frames. In addition, in one advantageous embodiment of the invention, the longitudinal frames have reinforced corners, with the result that no further shelving or reinforcing elements are required for the statics of the longitudinal frame.
In a difference from known shoring, factory halls or residential buildings of modular construction, the construction of buildings from the self-supporting spatial units according to the invention results in the advantage that they can be realized easily according to the kit principle. For example, the outer wall elements and corner elements of a spatial unit can be added to, replaced or changed in a modular manner in the manner of a kit, without taking consideration of the statics.
According to the invention, the longitudinal frame includes a first lower and a second upper longitudinal carrier which are connected in a flexurally rigid manner to one another via a first and second support which have a preferably square hollow profile and are disposed in the end region of the longitudinal carriers. Here, for example, the connection of the first and the second supports to the longitudinal carriers can be effected releasably via a screw connection or else fixedly via a welded connection, an end plate connection preferably being provided between the longitudinal carrier and the support for transmitting the bending moments and the transverse forces. Here, the supports preferably have a length which corresponds to the height of the spatial unit, with the result that the longitudinal carriers are connected to the supports over their end sides. However, the supports can also be shorter, the longitudinal carriers have a length which corresponds to the length of the spatial unit.
In one further advantageous embodiment of the invention, there can be provision, for example, for the longitudinal frames to have two supports of different lengths in order to form a spatial unit having an inclined roof surface. Here, according to the invention, the longitudinal frames are connected to one another via crossmembers and have upper longitudinal carriers which are inclined at an angle with respect to the horizontal. For a relatively great inclination angle of the roof surface, it is also possible as an alternative to this to connect two longitudinal frames of different heights to one another via crossmembers. Here, the outer wall element rests as a roof surface on the longer upper longitudinal carriers and the shorter upper crossmembers which extend at an angle with respect to the horizontal.
According to the invention, in order to support the self-supporting outer wall elements which are disposed on the longitudinal and broad sides of the spatial unit, at least one supporting strip is disposed on the lower longitudinal carriers and/or on the lower crossmembers, onto which supporting strip the outer wall element is placed releasably.
Here, according to the invention, the supporting strip has the shape of an elbow, the outer wall element being supported on one limb and it being possible for the other limb of the elbow to be screwed and welded to the lower longitudinal carrier, or the other limb being connected on the lower longitudinal carrier. Furthermore, depending on the weight of the outer wall element, the supporting strip can be composed either of a metal sheet or of a plastic material, a plastic material being advantageous for avoiding thermal bridges, on account of the relatively low coefficient of thermal conductivity.
Instead of a supporting strip, however, lugs or recesses can be provided on the lower longitudinal carriers and/or the lower crossmembers, into which lugs or recesses hooks or journals engage which are disposed for this purpose in the lower region of the outer wall elements.
According to the invention, the outer wall element is connected to the upper longitudinal carrier via a connecting device, in particular a screw connection, it also being possible, however, for the outer wall element to be connected on the upper longitudinal carrier. This results in the advantage that the outer wall element can be mounted and also dismantled simply. During mounting, the outer wall element is placed here, for example, first on a supporting strip which is disposed on the lower longitudinal carrier and/or crossmember or is connected in the lugs or recesses which are disposed on the lower longitudinal carrier and/or crossmember, in order then to be screwed against the upper longitudinal carrier.
The first lower longitudinal carrier has an open, preferably U-shaped cross section in a further embodiment according to the invention, the opening of the cross-sectional shape preferably being directed into the interior of the spatial unit. During the manufacture of the longitudinal frames and the spatial units, the upper longitudinal carriers and crossmembers preferably have the same profile shape as the lower longitudinal carriers and crossmembers, as a result of which only a minimum number of different profile cross sections are to be kept in the store, in an advantageous manner for manufacturing.
The selection of an open cross section for the longitudinal carriers and/or crossmembers advantageously affords the possibility of inserting a prefabricated floor element into the first lower longitudinal carrier and/or a prefabricated ceiling element into the second upper longitudinal carrier, which results in a time advantage during completion of a spatial unit. During the assembly of a spatial unit from longitudinal frames with longitudinal carriers which extend over the length of the spatial unit, it is possible, for example, before assembly of the last lower crossmember to insert the floor element via the broad side of the crossmember which has not yet been assembled, the open cross sections of the lower longitudinal carriers serving as guide. Here, according to the invention, the floor element is self-supporting and substantially flexurally rigid, with the result that advantageously no additional reinforcing elements are required in the region of the floor. A further advantage of this embodiment of the invention relates in that the floor element is also transportable on account of its flexural rigidity and can be delivered to a construction site as a prefabricated component which is manufactured in a large number.
In a further advantageous embodiment, a vapor barrier which, according to the invention, extends beyond the end sides of the outer wall elements is provided on that side of the outer wall elements which faces the interior. Here, the vapor barrier is disposed between an inner lining and a thermal insulation layer of the outer wall element, it also being possible, however, for the inner lining to be configured as a composite plate having an integrated vapor barrier. In the corner region of the spatial unit, the vapor barriers which preferably contain a coated paper film or a plastic film extend into the recess from the end face, the vapor barriers which extend beyond the end sides being connected to one another, for example, by an adhesive bond, in order to seal the interior which is enclosed by the outer wall elements. In particular in the case of a great temperature gradient between the inner side and the outer side of the outer wall elements, the vapor barrier advantageously prevents the entry of damp ambient air into the interior of the outer wall element and corner element, as a result of which the formation of condensation and therefore a reduction in the thermal insulation capacity of the outer wall elements and corner elements on account of wetting of the thermal insulation layer is avoided. As a result of the connection of the vapor barriers of the adjacent outer wall elements in the corner regions of the spatial unit, the interior which is enclosed by the outer wall elements is advantageously closed off in a windproof and vaporproof manner. This is preferably valid for all end faces of the outer wall elements, that is to say the lower, upper and lateral end faces of each outer wall element.
Furthermore, according to the invention, there can be provision for those vapor barriers of two adjacent outer wall elements which extend beyond the end sides in the corner region of the spatial unit to be connected to one another via a self-adhesive film. The self-adhesive film which assumes the role of a vapor barrier in the region of the recess is preferably a conventional adhesive tape which, after mounting of the outer wall elements, is adhesively bonded to their end sides, fixes the vapor barriers on the respective end side of the outer wall elements and extends from the end side of one outer wall element via the bent-in corner to the end side of the adjacent outer wall element. The simple mounting of a self-adhesive film of this type results in the advantage that the region of the recess can be sealed inexpensively, the self-adhesive film preferably having a fold in the region of the adjacent edges of the end sides, which fold makes a relative movement possible of the outer wall elements with respect to one another, for example as a result of thermal expansion, and in the process prevents ripping of the self-adhesive film.
According to a further embodiment of the invention, the corner element contains at least one thermal insulation layer and one lining. The thermal insulation layer is enclosed by the lining and the end sides of the outer wall elements which adjoin one another in the corner region of the spatial unit. The lining which is composed, in particular, of sheet metal, plastic material or wood closes off the thermal insulation layer to the outside and therefore prevents its being wetted or damaged. During the mounting of the corner element, after the introduction of the thermal insulation layer into the recess, the lining is preferably fastened in the recess with a screw or clamped connection, the fastening points not being predefined. This results in the advantage that the corner element can contain standardized components and can be fastened simply and accurately in recesses having different dimensions.
As an alternative, however, the corner element can also contain a plastic hollow profile, in particular made from polyurethane, which is filled with thermally insulating material, the cross section of the hollow profile having at least two limb faces which are assigned to the end faces of the outer wall elements.
In a further advantageous embodiment of the invention, the corner elements can be adhesively bonded into the recesses. After mounting of two adjacent outer wall elements in the corner region of a spatial unit, the corner element can therefore be adhesively bonded to the faces which are assigned to the end sides of the outer wall elements. The adhesive bond between the corner element and the end sides of the outer wall elements can be produced, for example, by single-component or multiple-component liquid adhesive, by way of a self-adhesive double-sided adhesive tape or else by way of hot-melt adhesive, it being possible for the adhesive bond to be of releasable configuration, in particular by a separating thread or separating wire which is introduced into the adhesive bond, for subsequent dismantling of the outer wall elements and of the corner element. The adhesive bond between the end side of an outer wall element and the corresponding face of a corner element is severed here by tautening of the separating thread which is preferably incorporated in the adhesive in a wave-shaped and loose manner. As a result, the outer wall elements and the corner element can advantageously also be reused after dismantling.
In order to support the spatial unit on the subsoil, foundations are provided in the corner region of the spatial unit, on which foundations the spatial unit is supported. The foundations are preferably prefabricated individual or strip foundations which are made from reinforced concrete, are to be placed only at the locations provided for this purpose on the building plot and are preferably configured in multiple pieces for easier transport. After dismantling and transporting away of the spatial unit, this results in the advantage that the foundations can also be removed and reused, with the result that the subsoil can be used in a lasting manner and can be returned to the original state with low costs.
Furthermore, according to the invention, there can be provision for at least one leveling element which serves to equalize different heights of the foundations to be disposed between the spatial unit and the foundations. When the foundations are sunk, this results in the advantage that there is a greater tolerance in relation to the height of the individual foundations and, in the case of uneven subsoil or else when a foundation is sunk, the height difference can also still be equalized retrospectively by the leveling element and the spatial unit can be oriented horizontally.
If a building construction is made having at least one first and one second spatial unit which are connected to one another, the spatial units can be disposed next to one another or above one another and also next to one another and above one another according to the invention. In order to increase or reduce the building construction, the spatial units are advantageously connected releasably to one another according to the invention. Here, the free outer sides of the building construction are substantially enclosed by the outer wall elements which are disposed above one another and next to one another. A large number of different possible combinations of the first and second spatial units results in the further advantage that the constructor is given a high degree of flexibility in the configuration of his building construction.
According to a further embodiment according to the invention, the spatial units can be disposed at a spacing from one another, it being possible for coupling elements to be fastened releasably between the adjacent end sides of the outer wall elements of the spatial units which are disposed spaced apart from one another. Here, the coupling elements serve, in particular, to seal the interior which is enclosed by the outer wall elements in the region between the spatial units which are disposed spaced apart from one another, and can be a constituent part of the outer walls of the building construction which are defined by the outer wall elements and face the side, roof and floor.
As the spatial units according to the invention can be used to construct a building construction, the ground plan of which has a shape which deviates from the rectangular shape, such as an L shape, T shape or even a star shape, this results in the advantage of high variability in the design of the ground plan.
Like the outer wall elements, the coupling elements also have a carrying frame and thermal insulation which are protected against mechanical damage and weather influences by an enclosing outer lining. As the coupling elements do not assume a loadbearing function and as a consequence only have to support themselves, they can advantageously be manufactured industrially in large numbers on account of their simple construction.
Here, the shape of the coupling elements is dependent on the shape of the ground plan, in particular the angle between the end sides of the outer wall elements of the spatial units which are disposed spaced apart from one another, and on the spacing between the spatial units. In the case of an L-shaped ground plan, the building construction has, for example, a bent-in corner having two outer wall elements which are disposed at a right angle with respect to one another and the adjacent end sides of which are connected to one another via the coupling element. For this purpose, the coupling element has two side faces which are disposed at a right angle with respect to one another, face the end sides of the outer wall elements and are connected releasably to the latter.
In order to seal in a windproof and vaporproof manner the interior which is enclosed by the outer wall elements and coupling elements, the coupling elements contain vapor barriers which extend beyond the sides of the coupling elements which face the end sides of the outer wall elements. The vapor barriers which are composed, in particular, of a paper film or plastic film are preferably adhesively bonded to the vapor barriers of the adjacent outer wall elements, but can also be connected to the latter in another way.
The spacing between the adjacent spatial units preferably lies in a range from 20 cm to 50 cm and is dependent on the thickness of the adjacent outer wall elements of the spatial units which are disposed spaced apart from one another and also on the angle with respect to one another. As the outer wall elements preferably have a thickness of 30 cm, a spacing of 30 cm has proven particularly advantageous, for example, for an L-shaped ground plan of the building construction.
The intermediate space which is obtained by the spacing apart of the spatial units can advantageously be used as an additional living space or for installation of a fitted cupboard. For this purpose, a single-piece or multiple-piece floor element and/or ceiling element are/is fastened releasably between the adjacent spatial units to the latter. Here, the floor element or the ceiling element can either be connected to the longitudinal frames and/or crossmembers of the adjacent spatial units or else can be screwed to the latter.
Furthermore, it is conceivable that the intermediate space between the spatial units serves to accommodate supply and discharge lines, such as gas lines, wastewater lines and fresh water lines.
For reasons of noise insulation and for unimpeded thermal expansion, a damping element which is composed, in particular, of neoprene is provided according to the invention between the spatial units which are disposed next to one another or above one another.
In a further advantageous embodiment of the invention, in order to seal joints which are disposed between the end sides of the outer wall elements, a sealing band or tube which contain, in particular, a permanently elastic polyurethane foam plastic or EPDM which is impregnated with bitumen is disposed in the joints. Here, the sealing band serves as wind seal and, furthermore, prevents ingress of moisture into the interior of the building construction and into the intermediate spaces which are situated between the outer wall elements and the outer sides of the spatial unit.
Furthermore, in order to avoid the formation of condensation water in the region of the outer wall elements, coupling elements and/or corner elements, a rear-ventilated facade which is disposed spaced apart is provided according to the invention in front of the outer wall elements. This results in the advantage that an outer water-repellent surface can be omitted in the outer wall elements, it being conceivable that, for example, thermal insulation mats from rock wool are integrated into the outer wall elements and the outer wall elements can face the rear-ventilated facade directly without an additional covering.
The spatial units can be divided in a manner according to the invention by inner wall elements within the interior which is enclosed by the outer wall elements. The inner wall elements are preferably a dividing wall system which is known from the prior art and is made from wood material plates, or lightweight partition walls which have a frame construction made from wood with advanced gypsum plasterboards.
Other features which 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 self-supporting spatial unit having non-supporting advanced outer walls, it is nevertheless not intended to be limited to the details shown, since 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 and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1A is a diagrammatic, exploded, three-dimensional view of a single spatial unit according to the invention having a floor, outer wall elements and corner elements;
FIG. 1B is a diagrammatic, three-dimensional view of the spatial units according to the invention which are disposed above one another and next to one another and have outer wall elements and corner elements;
FIG. 2 is a diagrammatic, sectional view of a corner region of the spatial unit according to the invention having outer wall elements which are disposed on the outer sides of the spatial units and having a corner element which is adhesively bonded in the corner region;
FIG. 3 is a diagrammatic, sectional view of a section of two adjacent spatial units having outer wall elements which are disposed on the outer sides of the spatial units;
FIG. 4 is a diagrammatic, sectional view of a section of two spatial units which are disposed spaced apart next to one another and have outer wall elements which are disposed on the outer sides of the spatial units and a coupling element which is disposed between the outer wall elements;
FIG. 5 is a diagrammatic, sectional view of a section of three spatial units which are disposed spaced apart from one another in the region of a bent-in corner of the building construction according to the invention, having outer wall elements which are disposed on the outer sides of the spatial units and a coupling element which is disposed in the region of the bent-in corner;
FIG. 6 is a diagrammatic, sectional side view of a section of two spatial units which are disposed above one another and have outer wall elements which are fastened to the outer sides of the spatial units and a floor element which is inserted into the upper spatial unit;
FIG. 7 is a diagrammatic lateral sectional view of a spatial unit according to the invention in the region of the support of the spatial unit on a single foundation; and
FIG. 8 is a diagrammatic sectional view of the transition according to the invention from an outer wall element which is disposed horizontally and forms a roof surface to a vertically disposed outer wall element.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1A thereof, there is shown a spatial unit 1 having a first and a second rectangular, substantially closed longitudinal frame 2 , 4 which are connected releasably to one another via four crossmembers 6 , the spatial unit 1 containing, in particular, steel profiles. Here, the crossmembers 6 have in each case at their ends an end plate 8 , by way of which they are connected to the longitudinal frames 2 , 4 in the corner region of the latter. As the applicant has discovered, a screw connection (not shown further in FIG. 1A ) of the longitudinal frames 2 , 4 to the end plate 8 of the crossmembers 6 has proven particularly advantageous for the transmission of bending moments and transverse forces between the crossmembers 6 and the longitudinal frames 2 , 4 . Furthermore, the releasable connection of the longitudinal frames 2 , 4 and the crossmembers 6 affords the advantage that the spatial unit 1 can be transported simply in a manner which is dismantled into individual parts.
The longitudinal frames 2 , 4 contain in each case a first lower and a second upper longitudinal carrier 10 a , 10 b , 12 a , 12 b which are connected by way of their end sides via a support 14 a , 14 b , 16 a , 16 b which is disposed at a right angle with respect to the former, to form a self-supporting, independent frame. The supports 14 a , 14 b , 16 a , 16 b are preferably formed from a square hollow profile and have a length which corresponds substantially to the height of the spatial unit 1 . Like the crossmembers 6 , the longitudinal carriers 10 a , 10 b , 12 a , 12 b can likewise be welded by way of an end plate connection to the respective upper or lower end of the supports 14 a , 14 b , 16 a , 16 b with one limb face of the square hollow profile of the support 14 a , 14 b , 16 a , 16 b , or else can be screwed releasably to the supports 14 a , 14 b , 16 a , 16 b or else can be plugged. Here, the interior of the square hollow profile of the support 14 a , 14 b , 16 a , 16 b can advantageously be used to accommodate electrical or other supply and discharge lines.
The longitudinal carriers and crossmembers 6 , 10 a , 10 b , 12 a , 12 b have an open U-shaped cross section (which cannot be seen in FIG. 1A ) having a substantially identical profile height, the openings of the U-shaped cross section of the crossmembers and longitudinal carriers 6 , 10 a , 10 b , 12 a , 12 b pointing in the direction of the interior of the spatial unit. Before the two longitudinal frames 2 , 4 are connected via the lower crossmembers 6 , a self-supporting floor element 18 can advantageously be inserted into the open cross sections of the profiles of the lower longitudinal carriers 10 a , 10 b , the floor element 18 resting on the lower limb faces (not shown in FIG. 1A ) of the U-shaped cross section of the crossmembers and longitudinal carriers 6 , 10 a , 10 b , 12 a , 12 b . Here, the self-supporting floor element 18 is, in particular, a trapezoidally corrugated sheet and is configured structurally to be flexurally rigid in such a way that it remains virtually flat in the case of a ceiling loading which is customary for residential and commercial buildings, and does not sag. In the same way, however, the floor element 18 can also be composed of a large number of individual rod-shaped or bar-shaped individual elements, as a result of which the transport and mounting are again simplified.
In order to protect the interior of the spatial unit 1 against weather influences, self-supporting non-reinforcing outer wall elements 20 , 22 can be disposed both on the longitudinal sides and broad sides and on the upper and lower sides of the spatial unit 1 , the length and height of the outer wall elements 20 , 22 corresponding substantially to the height and length or height and width of the spatial unit 1 . Here, the outer edges of the outer wall elements 20 , 22 terminate substantially flushly with the outer edges of the spatial unit 1 .
During the mounting of the outer wall elements 20 , 22 on the longitudinal side and broad side of the spatial unit 1 , they are placed releasably on supporting strips 24 which are attached in the lower region of the spatial unit 1 , and are screwed to the spatial unit 1 in the upper region of the outer wall element 20 , 22 , the supporting strips 24 preferably being disposed on the lower crossmembers and longitudinal carriers 6 , 10 a , 10 b . Here, the supporting strips 24 can be a metal sheet which is disposed on the crossmembers and longitudinal carriers 6 , 10 a , 10 b or an elbow, which are screwed, welded or fastened in another way to the lower longitudinal carriers 10 a , 10 b and the lower crossmembers 6 . Furthermore, the outer wall elements 20 , 22 are preferably screwed to the upper crossmembers and longitudinal carriers 6 , 12 a , 12 b , but can also be connected to lugs (not shown in FIG. 1A ) which are attached to the crossmembers and longitudinal carriers 6 , 12 a , 12 b.
The outer wall elements 20 a , 20 b which are disposed on the upper and lower side of the spatial unit 1 and are not shown in FIG. 1A for illustrational reasons are preferably connected to the crossmembers and longitudinal carriers 6 , 10 a , 10 b , 12 a , 12 b via a screw connection, but can also merely rest on the latter or be attached to them.
According to the invention, the bent-in corner or recess which is produced in the corner region of the spatial unit 1 after mounting of two adjacent outer wall elements 20 , 22 is closed or filled by a corner element 26 , the corner element 26 being adhesively bonded, screwed or fastened via a clamped connection to the end sides of the outer wall elements 20 , 22 .
In this context, FIG. 1B shows a two-story building construction 54 which contains in each case two spatial units 1 . 1 , 1 . 2 , 1 . 3 , 1 . 4 which are disposed next to one another and above one another with parallel adjacent longitudinal sides and two spatial units 1 . 5 , 1 . 6 which are disposed above one another at a right angle with respect to the former on the broad sides. The spatial units 1 . 1 , 1 . 2 , 1 . 3 , 1 . 4 , 1 . 5 , 1 . 6 are enclosed by outer wall elements 20 , 20 a , 20 b , 22 on their outer sides which extend in the horizontal and vertical directions and by corner elements 26 in the corner region, the outer wall elements 20 , 20 a , 20 b , 22 and the corner elements 26 either forming a flat surface which is shown in FIG. 1B or it being possible for them to merge in a stepped manner into one another, as is shown, for example, in FIG. 2 . Here, the outer wall and corner elements 20 , 20 a , 20 b , 22 , 26 which are disposed on the spatial units 1 . 1 , 1 . 2 , 1 . 3 , 1 . 4 , 1 . 5 , 1 . 6 form the shape of a closed rectangle in the plan and side views.
FIG. 2 shows the corner region of the spatial unit 1 having outer wall elements 20 , 22 which are disposed on the outer sides of the spatial unit 1 and bear against the outwardly pointing limb faces of the associated support 14 a , 14 b , 16 a , 16 b and the crossmembers and longitudinal carriers 6 , 10 a , 10 b , 12 a , 12 b . Here, a sealing band 28 a is disposed between the outer wall elements 20 , 22 and those limb faces of the supports 14 a , 14 b , 16 a , 16 b which face the outer wall elements 20 , 22 , in order to prevent the exchange of air masses of different temperatures and the ingress of moisture into the interior of the space which is enclosed by the outer wall elements 20 , 22 , and in order to reduce the transmission of sound.
A corner element 26 is inserted into the bent-in corner of the spatial unit 1 of FIG. 2 , which corner element 26 has thermal insulation 26 b which bears against the end sides of the outer wall elements 20 , 22 and is protected against damage and moisture to the outside by a lining 26 a . A line such as a rainwater pipe 26 c which is enclosed by the thermal insulation 26 b can be disposed in the interior of the corner element 26 . The outer lining 26 a is fastened in the recess via a screw connection 26 d , the position of the fastening points in the recess not being predefined. Here, the lining 26 a preferably contains a resilient metal sheet or plastic which is capable of adaptation to the relative displacement of the outer wall elements 20 , 22 with respect to one another, for example as a result of thermal expansion.
A vapor barrier 34 which is connected to those vapor barriers (not shown in FIG. 2 ) of the outer wall elements 20 , 22 which protrude beyond the end faces of the outer wall elements 20 , 22 is disposed between the end sides of the outer wall elements 20 , 22 and the corner element 26 . Here, the vapor barrier 34 extends from the end face of the outer wall element 20 to the end face of the outer wall element 22 and in this way seals the corner region of the spatial unit in a wind proof and vapor proof manner. The vapor barrier 34 is preferably a conventional adhesive tape which is adhesively bonded onto the end faces of the outer wall elements 20 , 22 and to their vapor barriers.
As a result of the arrangement of the corner element 26 in the bent-in corner of the spatial unit 1 and the further sealing by the sealing band 28 a and the vapor barrier 34 , an interior 32 which is delimited by the outer wall elements 20 , 22 is advantageously closed off to the outside and protected against weather influences.
FIG. 3 shows two spatial units 1 . 7 , 1 . 8 which are disposed next to one another and have outer wall elements 20 which are disposed on the outer side. As has already been shown in FIG. 2 , a sealing band 28 a is also provided here on those limb faces of the supports 14 b , 16 b which face the outer wall elements 20 , for unimpeded thermal expansion of the outer wall elements 20 . Here, the outer wall elements 20 which are disposed on the outer sides of the spatial units 1 adjoin one another with their end sides, the joint which is situated between the end sides of the outer wall elements 20 being filled by a further sealing band 28 b or sealing tube which contains, in particular, a permanently elastic polyurethane foam plastic or EPDM which is impregnated with bitumen, and the vapor barriers (not shown in FIG. 3 ) of the outer wall elements 20 being connected to one another at this location. As shown in FIG. 3 , the outer wall elements 20 are screwed to the upper longitudinal carriers 12 a , 12 b , the upper longitudinal carriers 12 a , 12 b having non-illustrated recesses and the outer wall elements 20 having non-illustrated threaded sections which are integrated into the outer wall elements 20 and by way of which the outer wall elements 20 can be fastened to the longitudinal carriers 12 a , 12 b via a screw connection. In order to couple the adjacent outer sides of two spatial units 1 . 7 , 1 . 8 , the adjacent crossmembers 6 can be connected releasably to one another via a screw connection 36 .
In the same way as FIG. 3 , FIG. 4 also shows two spatial units 1 . 7 , 1 . 8 which are disposed next to one another and have outer wall elements 20 which are fastened to the outer side of the spatial units 1 . 7 , 1 . 8 , the spatial units 1 . 7 , 1 . 8 which are shown in FIG. 4 are disposed spaced apart from one another, however. Here, a spacing B between the spatial units 1 . 7 , 1 . 8 lies in the range which corresponds approximately to the thickness of the outer wall elements 20 .
A coupling element 56 which is connected to the end sides of the outer wall elements 20 is disposed between those end sides of the outer wall elements 20 of the spatial units 1 . 7 , 1 . 8 which are disposed spaced apart from one another which lie opposite one another and face one another. In the same way as the outer wall elements 20 , 22 , the coupling element 56 also has a carrying frame which is provided with a thermal insulation layer and a vapor barrier 34 . Here, the vapor barrier extends beyond the sides which face the end sides of the outer wall elements 20 and is preferably connected to the vapor barriers 34 of the outer wall elements 20 via an adhesive bond in a manner which is impermeable to wind and vapor. As weather protection, the coupling element 56 is lined from the outside with a stapled or screwed protective covering 60 made from metal or plastic, whereas, for example, a lightweight plate made from gypsum plasterboards can be disposed toward the side of the interior 32 as inner lining 58 between the vertical carriers 14 a , 14 b . In order to fasten the coupling element 56 , it is either screwed to the outer wall elements 20 or attached releasably to the latter via a plug-in connection.
FIG. 5 shows a further arrangement of spatial units 1 . 7 , 1 . 8 , 1 . 9 , as can be used, for example, in building constructions having an L-shaped ground plan. Here, the arrangement which is shown in FIG. 4 and contains the spatial units 1 . 7 , 1 . 8 which adjoin one another with their broad sides spaced apart was extended by a further spatial unit 1 . 9 which adjoins the longitudinal side of the spatial unit 1 . 8 in a spaced apart manner. For this purpose, the coupling element 56 which is shown in FIG. 4 and the outer wall element 20 which is disposed on the longitudinal side of the spatial unit 1 . 8 have been replaced by the coupling element 56 which is shown in FIG. 5 and the outer wall element 22 which is disposed on the broad side of the spatial unit 1 . 9 .
The outer walls 20 , 22 which are fastened releasably to the outer sides of the spatial unit 1 . 7 , 1 . 9 lie virtually at a right angle with respect to one another and define a bent-in corner, in which a coupling element 56 is disposed between the end sides of the outer wall elements 20 , 22 . The spacing B between the spatial units 1 . 7 , 1 . 8 , 1 . 9 advantageously corresponds substantially to the thickness of the outer wall elements 20 , 22 , with the result that the coupling element 56 is enclosed to the outside almost completely by the end sides of the outer wall elements 20 , 22 which are disposed diagonally with respect to one another. As has already been shown in FIG. 3 , a protective covering 60 , a facade component (not shown in FIG. 5 ) or a facade element is fastened as weather protection on that side of the coupling element 56 which is directed outward. Inner linings 58 which preferably contain gypsum plasterboards are disposed in the direction of the interior 32 between the vertical carriers 14 a , 14 b , 16 a of the spatial units 1 . 7 , 1 . 8 , 1 . 9 .
As has also already been shown in FIG. 4 , the vapor barrier 34 extends beyond those sides of the coupling element 56 which face the end sides of the outer wall elements 20 , 22 , which vapor barrier 34 is connected to the vapor barriers 34 of the outer wall elements 20 , 22 in a manner which is impermeable to wind and vapor, in particular by an adhesive bond.
FIG. 6 shows a vertical section through two spatial units 1 . 1 , 1 . 3 which are disposed above one another, a floor element 18 being disposed in the other spatial unit 1 . 3 . Here, in the outer wall elements 20 which are disposed on the outer sides of the spatial unit 1 . 3 , the upper outer wall element 20 is supported on the limb face of a supporting strip 24 which is disposed in the lower region of the upper spatial unit 1 . 3 , and is additionally screwed against the lower longitudinal carrier 10 a , 10 b via a screw connection 36 . The supporting strip 24 has an L-shaped cross section, the vertical limb of which is screwed to the lower longitudinal carrier 10 a , 10 b of the upper spatial unit 1 . 3 . A sealing band 28 b is disposed between those end sides of the upper and lower outer wall elements 20 which lie opposite one another, which sealing band 28 b prevents the ingress of moisture into the interior of the space 32 which is enclosed by the outer wall elements 20 , and connects the vapor barriers (not shown in FIG. 6 ) of the outer wall elements 20 to one another. Further sealing bands 28 a having smaller cross-sectional dimensions are disposed between the outer wall elements 20 and the longitudinal carriers 10 a , 10 b , 12 a , 12 b . For the unimpeded thermal expansion of the outer wall elements 20 , the sealing bands 28 a , 28 b also assume the function of the formation of an expansion joint, in addition to sealing.
As FIG. 6 shows, furthermore, the floor element 18 is enclosed in that frame of the upper spatial unit 1 . 3 which is formed by the first lower longitudinal carriers 10 a , 10 b and crossmembers 6 . Here, the floor element 18 has a trapezoidally corrugated sheet 40 as loadbearing component, on which an insulating layer 30 for thermal and sound insulation is attached. In addition, heating elements of an underfloor heating system 38 can also be provided above the insulating layer 30 , onto which heating elements a floor 42 is applied as uppermost layer in a known manner. Here, both electrical connections 44 and the installations for heating and water technology are advantageously laid in the floor element 18 , with the result that the connection points for the respective consumers, such as the inflow and outflow for a washing machine, can also be provided in the floor element 18 . Furthermore, this also results in the advantage that the outer wall elements 20 , 22 can be mounted and dismantled in this way without consideration of any supply lines, as all the supply lines are accommodated in the floor.
Instead of a single-piece floor element 18 , the latter can also be of multiple-piece configuration according to one embodiment which is not shown, as a result of which the transport of the floor element is made considerably easier.
The ceiling of the lower spatial unit 1 . 1 can be a suspended ceiling (not shown in greater detail in FIG. 6 ) which is disposed within the frame which is formed by the upper crossmembers 6 and the upper longitudinal carriers 12 a , 12 b of the lower spatial unit 1 . 1 . Here, it is advantageously possible to utilize the electrical connections 44 which are situated in the floor element 18 which is disposed above it for the ceiling lighting, as a result of which complicated laying of additional electrical lines within the suspended ceiling is no longer required. For this purpose, the floor element 18 can be provided with electrical connections 44 both on the upper side and on the lower side.
Furthermore, a rear-ventilated facade 52 which is disposed spaced apart, is connected in a punctiform manner to the outer wall element 20 , 22 and can extend over the height of the spatial unit or else of the entire building construction 54 is provided in front of the outer wall elements 20 , 22 . Here, the rear-ventilated facade 52 serves to avoid the formation of condensation in the region of the outer wall elements.
Furthermore, FIG. 6 shows the connection of the crossmember 6 to the longitudinal carrier 12 a , 12 b of the longitudinal frames 2 , 4 . Here, both the longitudinal carrier 12 a , 12 b and the crossmember 6 have end plates 8 which are screwed to one another. The end plates 8 are dimensioned in such a way that, in the case of a multistory configuration, the maximum bending moments and transverse forces which occur can be transmitted with adherence to the standard safety requirements.
FIG. 7 shows a vertical section through the lower region of a spatial unit 1 . 1 . As also already shown in the case of the upper spatial unit 1 . 3 in FIG. 6 , a floor element 18 which is provided with electrical and heating technology installations is also disposed here in the lower region of the spatial unit 1 . 1 , and a vertical outer wall element 20 , 22 is placed onto an elbow 24 on the outer side of the spatial unit 1 . 1 .
The spatial unit 1 . 1 , and all further spatial units 1 . 3 which are disposed above it in the case of a multistory building construction, are supported on in each case one multiple-part individual foundation 46 which is disposed in the corner region below the lowermost spatial unit 1 . 1 and, for easier transport, contains, in particular, a plurality of foundation segments 46 a , 46 b , 46 c which are disposed above one another. In order to equalize a different height of adjacent individual foundations, a leveling element 48 is disposed between the individual foundation 46 and the spatial unit 1 . 1 . The leveling element 48 which is shown only diagrammatically in FIG. 7 can contain a threaded spindle, via which the level equalization preferably of each spatial unit 1 . 1 , 1 . 2 , 1 . 5 can be carried out manually subsequently. For this purpose, the leveling element 48 is screwed to the spatial unit 1 . 1 and the individual foundation 46 , but can also be set into the concrete of the individual foundation 46 .
For the thermal insulation of the building construction which is formed from the spatial units 1 with respect to the subsoil 50 , floor-side outer wall elements which are provided with thermal insulation, as floor terminating elements 20 a preferably have the same width and the same length as the associated spatial units 1 . 1 , 1 . 2 , 1 . 5 and terminate flushly with the outer edges of the frame which is formed from the crossmembers and longitudinal carriers 6 , 10 a , 10 b are provided below the spatial units, for example below the lower spatial units 1 . 1 , 1 . 2 , 1 . 5 which are shown in FIG. 1B . Here, the floor terminating element 20 a can be attached to the lower spatial unit 1 . 1 or can be connected to the latter via a non-illustrated screw connection. The flush termination of the floor terminating element 20 a and the outer wall element 20 , 22 with the outer edge of the spatial unit results in a bent-in corner in the corner region, which bent-in corner, as shown in FIG. 2 , can be filled in turn by a floor-side corner element 26 . The floor-side corner element 26 has thermal insulation 26 b which is enclosed by the end sides of the vertical outer wall element 20 , 22 , the floor terminating element 20 a and an outer lining 26 a.
As was already also the case in the corner region (see FIG. 2 ) of the spatial unit 1 , the lining 26 a is fastened releasably in the recess via a screw connection 26 d . In order to seal the floor-side corner region of the spatial unit 1 . 1 , a vapor barrier 34 extends from the end side of the outer wall element 20 , 22 to the end side of the floor terminating element 20 a and connects the vapor barriers (not shown in greater detail in FIG. 7 ) of the outer wall element 20 , 22 and the floor terminating element 20 a to one another.
In the same way as for the thermal insulation with respect to the subsoil 50 , roof-side outer wall elements which are provided with thermal insulation (denoted as roof elements 20 b in the further text) and corner elements 26 are disposed on the upper sides of the upper spatial units 1 . 3 , 1 . 4 , 1 . 6 which are shown in FIG. 1B , for thermal insulation of the roof surface of the building construction 54 . Here, FIG. 8 shows a detail from the corner region of a spatial unit 1 . 3 with the transition from a vertical outer wall element 20 , 22 to a horizontal roof element 20 b which is supported on the second upper longitudinal carrier 12 a , 12 b and the crossmember 6 . As has also already been shown in the previous figures, sealing bands 28 a are disposed between the outer wall element 20 , 22 or roof element 20 b and the support 14 a , 14 b , 16 a , 16 b , the second upper longitudinal carrier 12 a , 12 b and the crossmember 6 , in order to seal the expansion joints. Here, the roof element 20 b lies on the frame which is formed by the second upper longitudinal carriers and crossmembers 12 a , 12 b , 6 , and is preferably connected to the latter via connecting means (not shown in FIG. 8 ), such as screw connections or plug-in connections. Here, the roof element 20 b contains a construction of thermal insulation and roof covering which is known from the field of flat roofs.
As has already been shown in FIG. 2 and FIG. 7 , the recess which results in the shape of a bent-in corner as a result of the flush termination of the roof element 20 b and the outer wall element 20 , 22 with the outer edge of the spatial unit 1 . 3 in the corner region is filled with a corner element 26 . Here, the corner element contains an outer lining 26 a which extends from the end side of the outer wall element 20 , 22 to the end side of the roof element 20 b and closes off to the outside thermal insulation 26 b which is disposed in the bent-in corner. In order to discharge rainwater, the outer lining 26 a has a section in the form of a rainwater gutter 26 e which discharges the rainwater which collects on the roof surface. Furthermore, in order to seal the roof-side corner region of the spatial unit 1 . 3 , a vapor barrier 34 is provided which connects the vapor barrier (not shown in FIG. 8 ) of the outer wall element 20 , 22 to that of the roof element 20 b and seals the corner region of the spatial unit 1 . 3 in a manner which is impermeable to wind and vapor. | A self-supporting module contains first and second rectangular, generally closed longitudinal frames, which are detachably interconnected by crossmembers and to which external wall elements are detachably fixed. The module is characterized in that the external wall elements have dimensions corresponding generally to the height and the width or length of the module and that the outer edges of the elements run flush with the outer edges of the longitudinal frames and crossmembers in such a way that in the corner region of the module, the end faces of adjoining external wall elements define a recess in the form of re-entrant corner. Corner elements are detachably fixed in the recesses, the elements sealing the interior of the module that is delimited by the external wall elements in relation to the exterior. | 4 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 909,828, filed Sept. 19, 1986 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to extra-corporeal, blood handling machines which are connected to the blood stream to process blood outside the body and, more specifically, it relates to the interconnections between flexible components which are used to contain blood flow such as blood tubing and the connectors which are used in blood handling machines such as ventricular assist, artificial kidney and heart-lung machines.
2. Description of the Prior Art
A serious problem plagues extra-corporeal, blood handling machines. While circulating blood, the machines tend to generate dangerous blood cell aggregates such as clots in areas of blood stasis and thrombi in areas of flow disturbances. (For the purposes of this application, the terms clot and thrombus will be used interchangeably.) The problem is serious because the presence of small blood clots within the human cardiovascular system can seriously impair the patient, resulting in strokes, organ impairment and even death.
The medical community is aware that the connectors that connect blood tubing to other components in the blood circuits involving these machines have been a primary site of blood clot generation. In an effort to solve the clotting problem which exists at those junctions, two different but related avenues of research have been pursued. Both avenues concern the blood compatibility of blood contacting surfaces. However, neither avenue has produced satisfactory results. Therefore, an acceptable solution to the blood clotting problem at the junctions has remained elusive.
One avenue of research has involved efforts to create an environment in the blood tubing connectors which simulates the environment found in the living body. The blood vessels of the body are coated with an intima consisting of an endothelial lining backed by connective tissue. Since blood clotting is not a problem along the intact intima, a segment of the medical community has believed that it can solve the clotting problem by encouraging pseudo intimas to grow on the inner surfaces of the connectors. This approach has had limited success but it also has presented other unacceptable problems. Once a pseudo intima is established, it may fail by delaminating from the substrate. If the pseudo intima does not delaminate, it continues to grow thicker with time. However, since the pseudo intima does not have its own blood vessels, the base layers eventually die and slough off into the blood flow. In either case, the deterioration of the pseudo intima presents a problem as serious as the blood clots.
Another avenue of research has focused on an effort to find better blood-compatible materials out of which connectors and tubing can be constructed. An underlying rationale for this approach is that the chemical composition of the connector materials elicits the clotting problem. In this search, thousands of materials have been examined for better blood-compatibility. As of yet, however, better materials have not been found which alone solve the clotting problem.
Since no satisfactory way has been found to eliminate the sources of blood clots around the tubing-connectors, two methods have been used to remove the clots before they cause serious damage. One method filters the clots out of the blood after it passes through the machine; the other method dissolves the clots by administering anticoagulants. Both methods are unsatisfactory solutions to the problem. Removal of blood clots through filtering tends to activate clotting mechanisms within the filter itself and generate other clots which threaten harm to the patient. The alternative of dissolving clots with anticoagulants forces the doctor to delicately balance two life-threatening phenomena. Administering too much anticoagulant can cause spontaneous internal bleeding, especially in the patients that may be platelet depleted; whereas administering too little will not effectively eliminate the clots. It is difficult to arrive at a dosage that avoids both problems.
SUMMARY OF THE INVENTION
The principal object of this invention is to reduce blood clot/thrombus formation in the vicinity of the junctions between flexible components such as blood tubing and the connectors used in extra-corporeal, blood handling systems.
It has been found that the clotting problem associated with the tubing-connector junctions, stems from the fluid mechanics of the blood flow at these junctions and that the solution to this problem is to structurally modify these junctions as described herein. It has been known that blood which is permitted to come to a quasi-stagnant state on the surface of a foreign material tends to form clots which attach to that surface and then grow by accretion. Normally, the blood inside blood handling systems flows continually, so blood stagnation would not appear to be a problem. Nevertheless, tubing-connector junctions, which had been in service on such machines, were closely examined upon retrieval to determine if the blood-stagnation mechanism might be causing the clotting.
These examinations reveal that clots have been forming at locations where discontinuities exist on the inner walls of the junctions. In particular, the discontinuities are located around the ends of the connectors at the junctures where they meet the inside walls of the tubing. These discontinuities result in annular pockets at these junctures. Typically, they are caused by an excessively wide edge on the connectors or by pockets or gaps which are caused by separations between the tubing and the connector. The separations appear to result from bending strains on the tubing which distort it from its normally circular cross section at its juncture with the connector. In any case, I have discovered that the discontinuities have sufficiently disrupted the blood flow at the surface to permit blood to come to a quasi-stagnant state long enough to form clots which then grew and could detach into the blood stream.
More specifically, on smooth surfaces within blood handling machines, a mechanism for preventing clot formation is present during normal system operation. The blood flow rate along the smooth surfaces of the tubing walls reduces the possibility of clot formation by (a) limiting the time that blood clotting constituents can spend near the surface in order to generate a clot and (b) exerting a shear force which prevents blood corpuscles from sticking at any one place on the wall long enough to form clots. As long as the shear force is above a critical level, clot generation is not a problem on the tubing walls. However, at discontinuities in the wall, such as at the tubing-connector junctions, residence times of the blood constituents increases and the shear forces are reduced compared to those associated with normal blood flow rate along a smooth wall. Thus, blood corpuscles which are caught in those regions are more likely to come to rest in quasi-stagnant locations at the discontinuities and reside there for longer times than they would on a smooth wall. If a discontinuity is large enough, the residence times become longer than a critical level and a clot forms and grows by accretion at that point. Thus the large discontinuities cause serious clot generation problems.
The invention reduces the magnitudes of the discontinuities at junctions between blood tubing and connectors. The invention accomplishes this result by means of an improved connector, specifically the portion of the connector that couples to the tubing. The connector has a collar and a conventional tubing coupler which has a coupling section for coupling to another connector and a tubing section that joins the connector to the tubing. The tubing section of the tubing coupler has barbs. The tubing section has the same inside diameter as the tubing, and, in addition to circular ridges that form the barbs on it, this end has a tapered portion that terminates in a thin edge. The tubing is fitted tightly over this end where it conforms to the taper and is held securely in place by the ridges. In the assembled connection, the thin edge lies inside the tubing and defines the juncture of the inner surfaces of the tubing coupler and the tubing. The collar has a tapered section with a tapered inner surface which matches to the tubing coupler. The matching inner surface of the collar compresses the tubing against the tubing coupler and forms a seal at the juncture near the thin edge. Preferably, the collar also has a tubular neck section that extends away from the tubing coupler and which snugly encircles the tubing. The neck section prevents the tubing from flexing in the vicinity of the tubing-connector juncture and tends to hold the collar in place.
The invention minimizes the discontinuities at the juncture in the following ways. First, the thin edge at the outer end of the tubing section is made smaller than the largest permissible depth of the discontinuity. Secondly, the seal formed by the compression of the tubing between the tapered portion of the tubing coupler and the matching inner surface of the collar closes any pre-existing gaps between the tubing and the tubing section which might result from misalignment. The compression also tends to shrink the annular pocket at the juncture. Finally, the neck section prevents bending strains on the tubing from reaching the thin edge and creating new discontinuities by deforming the tubing away from the tubing coupler at that location.
The performance of a system using the connectors embodying the invention is markedly superior to the performance of the same system using prior connectors. Empirical evidence confirms that the invention essentially eliminates blood clot generation at these points. Typically, clots leave clearly visible tracks or imprints at the locations where they form and from which they detach to disperse into the cardiovascular system. Upon disassembly of prior tubing-connector junctions after months of operation, such tracks or imprints provide abundant evidence of the blood clot formation which has occurred. In contrast, with connectors embodying the invention, the unctions are devoid of blood clots and blood clot indicating tracks, even after months of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is pointed out with particularity in the appended claims. The above and further objects and advantages of this invention may be better understood by referring to the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a detailed cross-sectional view of the completely assembled connector embodying the invention with the cross-section being taken along the axis of the connector;
FIG. 1A is an enlarged view of the tubing-connector juncture;
FIG. 2 is a cross-sectional view of the collar which is part of the connector with the cross-section being taken along the axis of the collar;
FIG. 3 is a cross-sectional view of a connector of the present invention in combination with an artificial valve;
FIG. 3A is an enlarged view of the valve-connector juncture;
FIG. 4 is a cross-sectional view of the collar of the connector shown in FIG. 3;
FIG. 5 is a cross-sectional view of a connector of the present invention in combination with a blood-pump bladder;
FIG. 5A is an enlarged view of the bladder-connector juncture; and
FIG. 6 is a cross-sectional view of the collar of the connector shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in a cross-sectional view a blood tubing connection which embodies the invention. The connection, which is used in an extra-corporeal, blood-handling system comprises a tubing coupler 1, a flexible tubing 2 and a collar 7. The tubing coupler 1 is generally tubular in shape. It has a tubing section 1A with an outer end lC with a uniform inside diameter D1 and it has a coupling section 1B. The tubing coupler 1 has a continuous inside surface 3 with a uniform inside diameter D1. The coupling section 1B mates with another connector (not shown); thus its design depends upon the structure of the connector with which it mates. The tubing section 1A has an outer surface 4 over which the tubing 2 fits. The outer surface 4 consists of a tapered portion 4A and ridges 4C and 4D that are contoured to form annular barbs. The tapered portion 4A meets the inside surface 3 at a taper angle φ to form a thin edge 5 at the outer end 1C of the tubing section 1A. The thickness of the edge 5 is defined by a radius of curvature R (FIG. 1A). The tubing coupler is made from a material, such as polycarbonate, which is blood compatible and is also rigid so that the tubing coupler is not easily deformed during normal usage.
The flexible tubing 2 has a uniform outside diameter D2, a uniform inside diameter D3 which is equal to the inside diameter D1 of the tubing section 1A, and a wall 6. The tubing 2 is typically made from a transparent polyvinyl chloride material which is flexible and which is sufficiently elastic to permit the tubing 2 to stretch slightly so that it can be forced over the outer surface 4 of the tubing coupler 1. When the tubing 2 is fitted over the tubing section 1A, a juncture 14 is formed in the vicinity of edge 5 where the tubing 2 and the tubing section 1A meet.
The collar 7, which is more clearly illustrated in the cross-sectional view of FIG. 2, is of unitary construction and has at least two sections: a taper section 9 and a tubular neck section 10 extending from the narrow end thereof. The section 9 has a length approximately equal to the length of the tapered portion 4A of the tubing coupler 1 and has an inside surface 9A which has a taper angle Ω. The angle Ω is preferably from zero degrees to 5 degrees greater than the angle φ.
The neck section 10 has an inside diameter D4. The diameter D4 is slightly smaller than the outside diameter D2 of the tubing 2 but still large enough to permit the tubing 2 to pass through it. For example, D4 can be selected to be approximately equal to 0.95 times the diameter D2.
The components are assembled by first sliding the collar 7, neck section 10 first, over the tubing 2. Then the tubing 2 is forced onto the tubing section 1A of the tubing coupler 1 so that it conforms to the outer surface 4 of the tubing section 1A, as illustrated in FIG. 1. In this mounted configuration, the tubing 2 flares out over the tapered portion 4A and the ridges 4C and 4D tend to hold the tubing in place so that it does not slide off the tubing coupler 1. Next the collar 7 is pushed into an engaged position over the connection formed by the tubing 2 and the tubing coupler 1 so that the inner surface 9A compresses the tubing 2 against the tapered portion 4A of the tubing coupler 1. Since the inside diameter D4 of the neck section 10 is slightly smaller than the outside diameter D2 of the tubing 2, the neck section 10 compresses the tubing 2 which passes through the neck section 10.
The compression of the tubing 2 between the inside surface 9A and the tapered portion 4A forms a seal at the juncture 14 of the tubing 2 and the tubing coupler 1. Since the angle Ω is equal to or slightly larger than the angle of taper φ and D2 is slightly smaller than D4, the compression of the tubing is greatest near the edge 5 of the tubing coupler 1. This causes the seal to focus around the edge 5. The compression thus urges the tubing 2 to conform with the surface of th tubing section 1A at and in the vicinity of edge 5, i.e. at the juncture 14 of the tubing 2 and the tubing coupler 1. Further, it prevents the tubing 2 from separating from the tubing coupler 1 at the edge 5, thereby essentially eliminating any gaps, which might be caused by the tubing 2 not properly conforming to the tapered portion 4a, e.g. because of misalignment when the tubing and tubing coupler are joined together.
The presence of some discontinuity in the tubing-connector junction is unavoidable. In particular, a discontinuity, in the form of an annular pocket 16 (FIG. 1A), will exist at edge 5 where the inside surface 3 of the tubing coupler 1 meets the tubing 2. For example, because of material and fabrication limitations, there is a practical lower limit on the radius R. Experience has shown that, for tubing couplers made of polycarbonate, an edge with a radius R of at least about 0.005 inches will possess a desirable durability. This, together with the fact that the tubing 2 cannot have an absolutely sharp bend where it meets the taper portion 4A, makes a small discontinuity unavoidable. However, experimental studies have indicated that if the discontinuity is smaller in the radial direction than about 0.015 inches, blood clotting problems will not occur at that location under the blood flow rates experienced in extra-corporeal blood handling machines. Therefore, if the edge 5 is thin, i.e. if the radius R lies in a range of about 0.005 to 0.010 inches, the discontinuity caused by the edge 5 will not generate clots.
Also, for practical reasons, the angle φ should lie in the range from about 15 degrees to 25 degrees. If the angle φ is made much smaller than 15 degrees, the tapered portion 4A will be impractically long and the tubing coupler will become too thin and weak near the edge 5 of the tubing section 1A. On the other hand, if the angle φ is made much larger than 25 degrees, forcing the tubing 2 onto the tubing coupler 1 will become difficult and the large angle will tend to deform the tubing 2 so that it does not naturally conform to the tapered portion 4A in the vicinity of edge 5.
The neck section 10 on the collar 7 serves a dual purpose. Since the neck section 10 compresses the tubing 2, it tends to reduce the size of the annular pocket 16 and thus the size of discontinuity in the juncture region 14 which disrupts the blood flow in that region. In addition, the neck section 10 isolates the juncture region 14 from strains caused by inadvertent or unavoidable flexing of the tubing 2. If the tubing 2 is permitted to flex in the vicinity of the juncture region 14, the tubing 1 may be pulled away from the tubing coupler 1 thus creating new discontinuities or gaps in the vicinity of the edge 5 which act as blood clot generation sites. The neck section 10 assures that this does not occur.
An optional feature is a gripping section 8 at the large end of the taper section 9 of the collar 7. This provides a means for holding the collar 7 in place when it is properly engaged. The gripping section 8 may take a number of different forms, one of which is shown in FIG. 2. As illustrated, it includes an annular recess 11. In addition, at equally spaced locations around the circumference of the section 8, there are slots 12A-D which extend the length of the gripping section 8. Circling the inside surface of the gripping section are grooves 15A-C. By binding the gripping section 8 with a tie rap (not shown) disposed within the annular recess 11, it may be compressed to grasp the tubing 2 and firmly anchor the collar 7 in place in the engaged position. The grooves 15A-C provide an articulated surface which further assists in anchoring the collar 7 so that it will not slide away from the engaged position.
The invention illustrated by means of the embodiment described above has general and obvious applicability to other connections within the blood circulatory path of extracorporeal blood handling systems. Wherever a flexible component through which blood flows is connected to another component, the resulting discontinuity at the point where the flexible component meets the connector creates a site at which serious blood clotting problems tend to occur. The invention disclosed herein can be utilized at those junctions to minimize or eliminate the clotting problems. For example, FIGS. 3 and 3A illustrate another connection which embodies the invention. They show a cross-section of a connector which is used to connect a valve assembly into the blood flow path of an extra-corporeal blood handling system. The connector comprises a valve assembly 20, a coupler 22 and a collar 24. Blood which passes through the valve assembly 20 is transmitted to other components in the extracorporeal blood handling system through the coupler 22.
The valve assembly 20, similar to an artificial heart valve, includes a plurality of valve leaflets 26 supported inside a conduit 28 which has a wall 30. The conduit 28 is made of a flexible, polymeric material that is compatible with blood such as a polyurethane elastomer.
Coupler 22, to which the valve assembly 20 is coupled, is generally tubular in shape and is made of a rigid, blood compatible material such as polycarbonate. The coupler 22 has an inside surface 34 defining a bore 36 which extends through the coupler and provides a passage through which blood can flow. At one end of the coupler 22, there is a coupling section 22B which mates with another component in the blood handling system such as a blood pump (not shown in the illustrations). At the other end of the coupler 22, there is a connecting section 22A to which the valve assembly 20 attaches. The connecting section 22A has an outer surface 32 which has a tapered portion 32A that meets the inside surface 34 to form a thin rounded edge 38 at the distal end 22C of conduit 22. Tapered portion 32A tapers inward at taper angle φ from the axis of bore 36, corresponding to the same taper angle in the previous embodiment. The rounded edge 38 has a radius of curvature R2. At the distal end 22C, just inside edge 38, the bore 36 has a diameter D5. When the flexible conduit 28 is connected to the coupler 22, the wall 30 of conduit 28 fits over and conforms to the tapered portion 32A in the vicinity of distal end 22C.
As illustrated in FIG. 4, the collar 24 is ring shaped and has an inner surface 40 with a tapered portion 40A, which tapers outward at taper angle Ω from the bore of the collar, corresponding to the same taper angle in the previous embodiment. In this embodiment, taper angle Ω is preferably from 5 to 10 degrees greater than taper angle φ. The inner tapered portion 40A of the collar 24 has a length approximately equal to the length of the outer tapered portion 32A of the coupler 22. The tapered portion 40A restricts down to an inside diameter of D6 which is no larger than the sum of the diameter D5 of the bore 36 at the outer end 22C plus twice the thickness of the wall 30. The diameter D6, however, is not so small as to distort the generally circular shape of the conduit 28 when it is passed through the collar 24 as described hereinafter.
Collar 24 also includes a tubular neck section 41 which has an inner diameter through its length equal to or less than the diameter D6 at the narrowest point of tapered portion 40A. Neck section 41 limits the flexing of conduit 28 in the vicinity of the juncture region 44, and thereby minimizes disturbances in the flow of blood through this region.
The components are assembled in a manner similar to the assembly procedure described above for the blood tubing connector. Conduit 28 is inserted through collar 24 so that it is encircled by the collar. Then, conduit 28 is fitted over connecting section 22A of coupler 22 so that it closely conforms to the tapered portion 32A of the outer surface 32 and forms a juncture 44 in the vicinity of edge 38 where conduit 28 meets coupler 22. Next, collar 24 is pushed down over the connection formed by conduit 28 and coupler 22 so that the inner surface 40A compresses the wall 30 against the tapered portion 32A.
To facilitate assembly of conduit 28 over outer tapered portion 32A, taper angle φ should preferably fall within the range of 15 to 25 degrees. Due to the relative size of the two taper angles φ and Ω, coupled with the size limitation on the diameter D6, collar 24 focuses the compression of conduit 28 near the outer end 22C of coupler 22. Thus, as with the blood tubing connection described above, the compression of the conduit 28 between the inner tapered portion 40A of the collar 24 and the outer tapered portion 32A of the coupler 22 forms a seal at the juncture 44 in the vicinity of the edge 38.
The seal prevents the conduit 28 from separating from the connecting section 22A, thereby preventing gaps from forming in the vicinity of the edge 38 which would create generation sites for blood clots. In addition, the compression of the conduit 28 in the vicinity of the juncture 44 encourages conduit 28 to conform to the tapered portion 32A around the edge 38 thereby reducing any discontinuity that exists at the juncture 44. If the radius of curvature R2 of the edge 38 is greater than about 0.005 inches but less than about 0.010 inches, the edge 38 will be durable enough to resist deforming under use and, at the same time, small enough to not provoke serious blood clotting problems in the vicinity of the edge 38 when the collar 24 is in place.
A variety of methods, well known to those skilled in the art, can be used to retain the collar 24 in the assembled position. One such method is illustrated in FIG. 3. A retaining ring 46 is threaded onto the valve coupler 22 and holds the collar 24 in place.
Yet a third embodiment of the invention is illustrated in FIGS. 5 and 5A, which show a cross-section of a bladder connection used on a blood pump. As illustrated, the bladder connection comprises a bladder 50, a bladder coupler 52 and a bladder collar 54.
The bladder 50 is generally tubular in shape with an opening at either end. It has a wall 60 and is made of a flexible, polymeric blood-compatible material such as a polyurethane elastomer. The inside of bladder 50 forms a chamber 50A through which blood passes. By periodically compressing and expanding bladder 50, blood is forced out of and drawn into bladder chamber 50A. When one end of bladder 50 is coupled to a one-way valve, such as the valve 20 illustrated in FIG. 3, the periodic compressions and expansions of the bladder propel the blood in one direction through the blood handling system to which it is attached. The means for compressing and expanding bladder 50 are not illustrated in the figures but such means are well known to persons skilled in the art.
The bladder coupler 52 is generally tubular in shape and is made of a rigid, blood-compatible material such as polycarbonate. The coupler 52 has an inside surface 64 defining a bore 66 which extends through coupler 52 and provides a passage through which blood can flow. At one end of coupler 52, there is a coupling section 52B which mates with another component in the blood handling system such as a blood tubing. At the other end of coupler 52, there is a connecting section 52A which connects to the bladder 50. The connecting section 52A has an outer surface 62 which has a tapered portion 62A that meets the inside surface 64 to form a thin rounded edge 68 at the distal end 52C of the coupler. Tapered portion 62A tapers inward at taper angle φ from the axis of bore 66, as with the correspondingly identified coupler taper angles in the previous embodiments. Also as in the previous embodiments, taper angle φ is
preferably within the range of 15 to 25 degrees. The rounded edge 68 has a radius of curvature R3. At the distal end 52C, just inside edge 68, the bore 66 has a diameter D7. When bladder 50 is connected to bladder coupler 52, wall 60 of bladder 50 fits over and conforms to tapered portion 62A in the vicinity of the distal end 52C.
The bladder collar 54, which is more clearly illustrated in the cross-sectional view of FIG. 6, is ring shaped and has an inner surface 70 with a taper portion 70A
which tapers outward at taper angle Ω from the axis of the bore of the collar, as with the correspondingly identified collar taper angles in the previous embodiments. In this embodiment, as in the previous valve-connector embodiment, the angle Ω is preferably from 5 to 10 degrees greater than the angle φ. The tapered portion 70A restricts down to an inside diameter D8 which is no larger than the sum of the diameter D7 of bore 66 at outer end 52C plus twice the thickness of bladder wall 60. The diameter D8, however, is not so small as to adversely distort bladder 50 when it is inserted through the collar 54 as described hereinafter.
Bladder collar 54 also includes a tubular neck section 71 which has an inner diameter through its length equal to or less than the diameter D8 at the narrowest point of tapered portion 70A. As described in relation to the previous embodiment, neck section 71 limits the flexing of bladder 50 in the vicinity of the juncture region 74, and thereby minimizes disturbances in the flow of blood through this region.
In the assembled connection, the bladder collar 54 functions in substantially the same manner as the collars 7 and 24 described in the other embodiments above. The assembly of the bladder connection, however, is slightly different from the previously described procedures since the bladder 50 is typically supported in a blood pump housing prior to connection to other components in the blood handling system. To facilitate assembly, collar 54 is incorporated into the blood pump housing and provides the means for supporting bladder 50 so that it can be connected to coupler 52 when the pump is put in the blood handling system. Thus, the end of bladder 50 which is to be connected to coupler 52 is inserted through bladder collar 54 in the direction of restriction so that bladder 50 extends out the other side of collar 54. The end of bladder 50 is then folded back over collar 54 so that it encircles the outside circumference of the end of collar 54. With the bladder thus fitted into collar 54, wall 60 of bladder 50 conforms to the inner surface 70A of the tapered section 70 and collar 54 supports bladder 50.
To connect the blood pump into the blood handling system, bladder coupler 52 is inserted into bladder collar 54 so that the tapered portion 62A of the coupler outer surface 62 compresses the bladder wall 60 against the inner tapered portion 70A of the collar. When assembled thusly, a juncture 74 is formed in the vicinity of the thin rounded edge 68 where bladder 50 meets coupler 52. As in the other embodiments, the compression of the bladder wall 60 between the inner tapered portion 70A and the outer tapered portion 62A forms a seal in the vicinity of the edge 68. Again, it is preferable that the radius of curvature R3 be greater than about 0.005 inches but less than about 0.010 inches to achieve acceptable durability and at the same time maintain the discontinuities in the assembled connection within acceptable limits. If R is kept substantially around this range, the discontinuity between the bladder wall 60 and the inside surface 64 of the coupler 52 in the assembled connection will not constitute a serious blood clot generation site.
In the embodiment illustrated in FIG. 5, the collar 54 is held in place by a retaining ring 76 which is threaded onto collar 54 and urges coupler 52 into collar 54. The retaining ring 76 assists in maintaining a constant compression of the bladder in the vicinity of juncture 74 and prevents collar 54 from being dislodged from coupler 52. Of course, the retaining ring 76 is merely illustrative of one of many alternatives methods of holding the collar 54 in place.
The connections described herein, which embody the invention, do not exhibit the serious blood clotting problems which are typically associated with connections found in the prior art. The invention substantially reduces the occurrence and magnitude of discontinuities at the point where the flexible component meets the coupler so that the connection does not provide a generation site for blood clots.
If blood handling systems are assembled without the benefit of this invention, the blood clotting problems at component connection locations are typically quite serious. A frequently selected solution to the clotting problem at such points has been to avoid using couplers within the blood handling system wherever possible. A good example, is found within the blood pump itself. Some pumps comprise a combination of bladders and valves hooked in series. Instead of using connectors to couple these components together, the entire assembly is fabricated as one continuous, unitary structure. By providing a smooth continuous inner wall through the structure, the unitary construction avoids the discontinuities caused by using couplers and thus avoids a major cause for blood clotting. However, fabricating unitary construction blood pumps is substantially more difficult and therefore considerably more expensive than using coupled components. With the use of the invention described herein, blood pumps can be produced much less expensively without paying a penalty of significantly greater blood clotting problems. | A connector for connecting a flexible conduit which is used to contain blood flow in a extra-corporeal blood handling system to a second component in said system. The connector includes a dual-acting coupler with a first coupling section for joining to the flexible conduit and a second coupling section, which can be of conventional design, for joining to the second component. The first coupling section includes an outer tapered portion which tapers inward to a rounded thin edge at the end of the coupler. The connector further includes a generally ring-shaped compression collar having an inner tapered portion for encircling the outer tapered portion of the coupler, with the angle of taper of the inner tapered portion of the collar being at least as large as the angle of taper of the outer tapered portion of the coupler. When the collar is assembled over the tapered portion of the coupler with the flexible conduit therebetween, the two facing tapered portions compress the flexible conduit and focus the compression in the vicinity of the rounded edge of the coupler. This forms a tight seal at the juncture of the conduit and the coupler, thereby minimizing any gaps in the wall at the juncture which can cause blood coagulation by flow stagnation. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a heavy-duty electric switch of the gas current blow-out type which includes a stationary compression cylinder provided, at one end, with a stationary nozzle made of an electrically insulating material. In the cylinder there is coaxially arranged a stationary hollow contact pin. The switch further comprises an annular piston which can be driven into the compression cylinder for compressing the gas therein and which is mechanically coupled with a movable hollow contact pin cooperating with the stationarily supported hollow contact pin. During opening of the switch, the movable hollow contact pin is displaced in the same direction as the piston.
Switches of the above-outlined types are known and are disclosed, for example, in German Laid-Open Application (Offenlegungsschrift) No. 2,316,009. In contradistinction to other gas current blow-out switches which in most cases have a driven nozzle, the above-named Offenlegungsschrift discloses a stationarily arranged nozzle. The driven member, in turn, is a compression piston for compressing the gaseous extinguishing medium, in most cases SF 6 which, during opening of the switch, moves in a cylinder in the direction of the nozzle. When a predetermined pre-compression has been reached, contact separation takes place. The movable contact which is mechanically coupled to the piston and is moved by the same mechanism, is displaced in the same direction as the piston and is separated from the stationary contact supported in the cylinder.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved mechanical coupling between a drive mechanism, a compression piston and a movable contact in a high-voltage, heavy-duty switch which operates with high breaking capacity for high rated currents for providing a satisfactory pre-compression and a subsequent rapid separation of the contacts.
It is a further object of the invention to provide, for an electric switch of the above-outlined type, a drive linkage which transmits the force of a grounded, preferably hydraulic, drive mechanism to the piston and the movable contact.
It is still another object of the invention to further improve the breaking capacity of switches of the type outlined above, by the provision of a synchronous, current-responsive triggering mechanism.
These objects and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the gas current blow-out switch has a stationary, electrically conducting compression cylinder, a stationary hollow power contact pin supported in and coaxially with the compression cylinder and an annular piston surrounding the stationary power contact pin and slidably received at one end of the cylinder for compressing an arc-extinguishing gas in the cylinder. A nozzle is stationarily affixed to the cylinder for bounding the cylinder at the other end thereof. A movable hollow power contact pin is supported coaxially with the stationary contact pin; the movable contact pin has a closed position in which it engages the stationary contact pin and an open position in which it is separated from the stationary contact pin and in which compressed gas from the cylinder flows between the separated contacts. The switch further has an electrically conducting stationary tube arranged in axial alignment with and spaced from the compression cylinder; a contact bridge slidably supported by and being in continuous electric contact with the stationary tube and the movable contact pin. The contact bridge has a closed position in which it electrically contacts the compression cylinder and an open position in which it is separated from the compression cylinder. The tube and the contact bridge constitute a movable rated current contact and the compression cylinder constitutes a stationary rated current contact. There is further provided an insulator cylinder surrounding the compression cylinder and being slidable thereon; the insulator cylinder is coupled to the contact bridge for shifting the latter into its open position upon motion of the insulator cylinder in one direction. A spring is connected to the contact bridge and the movable contact pin to urge the latter towards its open position upon displacement of the contact bridge towards its open position. A carriage is shiftably arranged on a support and a drive member -- operated by an externally actuated mechanism -- is secured to the carriage and is displaceable between two limits with respect to the carriage. The drive member is arranged for displacing the carriage after the drive member reached either one of the limits. The drive member is connected to the piston for effecting displacement of the piston by the drive member. The carriage is connected to the insulator tube for effecting displacement of the insulator tube by the carriage.
By virtue of the above-outlined arrangement there is achieved a rated current separation which is delayed with respect to the motion of the piston. Further, by means of a spring-effected non-rigid coupling between the rated current contact and the power contact and by virtue of the short-period locking of the power contact with subsequent synchronous triggering, the circuit breaking capacity is significantly increased.
Expediently, a drive linkage is provided for moving the piston and the movable contacts. The drive linkage comprises a pull rod which lies in the pole column and which is guided in a support, a first push rod which is articulated to the upper end of the pull rod and a second push rod which is articulated to the lower end of the first push rod.
Further, for the current-dependent locking of the movable contact pin there is provided a synchronous triggering device which operates only when a predetermined value of the short-circuited current is exceeded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal schematic sectional view of one pole of a two-pole heavy duty switch according to a preferred embodiment of the invention, shown in a closed position.
FIG. 2 is a schematic enlarged detail of FIG. 1.
FIG. 3 is a schematic sectional view taken along line A--A of FIG. 2.
FIG. 4 is a diagram illustrating the current change during circuit breaking.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, there is illustrated only the right-hand pole of a two-pole switch arranged on an insulator column. The left-hand pole corresponds to the mirror-image of the right-hand pole. Further, for a better visibility of the components essential for understanding the invention, the gas-tight outer housing of the switch pole and the pole column are not shown. The housing and the pole column are filled with an extinguishing gas at a pressure of approximately 3 atmospheres.
The pole includes external current terminals 40 and 41 which are electrically connected with a hollow stationary contact pin 10 and with a hollow movable contact pin 11, respectively. The contact pin 10 is secured within an electrically conducting compression cylinder 1. The compression cylinder 1, the stationary contact 10 and the movable contact 11 are arranged coaxially with respect to one another.
One end of the cylinder 1 is closed off by an annular piston 6 which surrounds the stationary contact pin 10 and is slidable with respect thereto and with respect to the cylinder 1. The other end of the compression cylinder 1 is closed by a nozzle 5 which has a central opening slidably and sealingly receiving the movable contact pin 11.
An electrically conducting stationary tube 2 is supported coaxially with and spaced from the compression cylinder 1. An electrically conducting contact bridge 3 is slidably received at 33 in the stationary tube 2 and is in continuous electric contact with the movable contact pin 11. The contact bridge 3 has an advanced, or closed position (shown in FIG. 1) in which its contact terminus 32 is in engagement with the cylinder 1 and a withdrawn, or open position in which it is spaced from the cylinder 1. An insulator tube 4 is slidably received on the compression cylinder 1. The contact bridge 3 is displaced by the insulator tube 4 by virtue of a mechanism described below.
The electric connection between the terminal 41 and the movable contact pin 11 is effected by means of a coil 19 and an annular slide contact 20 which is arranged in the inside of the hollow contact pin 11. Further, the current terminals 40 and 41 are, for conducting the rate current, connected with one another through the wall of the cylinder 1, the rated current contact 32, the contact bridge 3, the slide contact 33 and the tube 2.
For performing the circuit breaking operation, a pull rod 7 made of insulating material and positioned in the pole column (not shown) and guided in a support 37, is moved downwardly by means of a drive mechanism (also not shown). To the upper terminus of the pull rod 7 there is articulated a first push rod 8 which, at its other end, is secured to a drive pin 34. The push rod 8 need not be made of insulating material. The drive pin 34 is supported in a slot of a carriage 9 which is displaceable on a support 36. The drive pin 34 is coupled with the piston 6 by means of a second push rod 38.
Upon downward motion of the pull rod 7, the piston 6 is, by means of the push rods 8 and 38, displaced towards the right as viewed in FIG. 1. As a result, the gas enclosed in the annular space between the cylinder 1 and the stationary contact pin 10 is compressed. A premature escape of the gas is prevented by the movable contact 11 sealingly engaging the stationary nozzle 5.
The linkage system 7, 8 and 38 designed according to the invention is advantageous in that the pulling force generated in the pull rod 7 and necessary for the circuit breaking operation, does not increase despite the significantly increased pressure exerted on the piston 6 at the end of its displacement. For this reason, a compression of the gas up to a very small residual volume is possible. Since the push rod 8 forms, at the end of the compressing motion of the piston 6, an angle of approximately 90° with the pull rod 7, the linkage system is adapted to take up the further increasing counterpressure caused by an arc drawn between the opened contacts 10 and 11 and exerted on the piston 6.
After the pin 34 abuts the right-hand terminus (limit position) of the slot in the carriage 9, at which time there is already achieved a certain pre-compression of the gas in the cylinder 1, the carriage 9 is moved by and with the pin 34. The thrust generated upon the start of carriage motion is taken up by a damping device, not shown. The motion of the carriage 9 is transmitted to the contact bridge 3 by means of the insulating cylinder 4 affixed to the carriage 9. The rated current separation occurs as the contact 32 separates from the cylinder 1. Only after completing the interruption of the rated current is the movable contact 11 displaced towards the right by means of a radial projection 39 arranged on the contact bridge 3 and a biased disc spring stack 12 engaging the radial projection 39 and an annulus 18 affixed to the outer face of the movable contact 11. By this time the gas prevailing in the cylinder 1 is compressed to a very small residual volume. The arc drawn between the contacts 10 and 11 is put out by a powerful gas blast as the compressed extinguishing gas escapes through the separated hollow contacts 10 and 11.
The circuit making operation is carried out in a reverse manner. For this purpose, the pull rod 7 is moved upwardly. In the illustrated embodiment of the drive, the pull rod 7 has to be so designed that it is also able to transmit pushing forces which, however, are significantly smaller than the pulling forces generated during circuit breaking. The pull rod 7 can be completely relieved of pressure forces if, for example, between the stationary support 37 and the upper terminus of the pull rod 7 there is inserted a compression spring (not shown).
As a result of the rearward motion of the piston 6 (that is, towards the left, as viewed in FIG. 1), the cylinder 1 is again charged with gas. Such charging can be assisted by check valves (not shown) arranged in the piston 6 or the nozzle 5.
The closing (leftward) motion of the rated current contact 32 and the power contact 11 occurs subsequent to the partial filling of the cylinder 1, after the pin 34 has abutted against the left-hand terminus (limit position) of the slot in the carriage 9. The contact bridge 3 is moved back into its closed, circuit making position by the insulating cylinder 4 affixed to the carriage 9 and the contact bridge 3. The movable contact pin 11 is shifted back into its circuit making position by the radial projection 39 in cooperation with a ring 13 attached to the pin 11. An engagement of the contact pins 10 and 11 occurs before the closing of the rated current contact 32.
In order to further increase the circuit breaking capacity of the switch designed according to the invention, a synchronous triggering device generally indicated at 35 is provided for the current-dependent blocking of the movable contact 11. The device 35 is illustrated on an enlarged scale in FIGS. 2 and 3.
The purpose of the synchronous triggering device is to ensure that in case of circuit breaking operations for interrupting a high-intensity current (for example, in excess of 40 kA) caused by a short circuit, the separation of the contacts 10 and 11 occurs at an accurately defined part of the current half-wave, that is, at a moment shortly after the current maximum. In this manner, the switch is capable of interrupting the current at the next subsequent zero point of the current intensity.
In the description which follows, the structure and the mode of operation of the synchronous triggering device will be explained in conjunction with FIGS. 1-4.
As a predetermined value of the short-circuited current is exceeded, a solenoid armature 15 affixed to one end of a locking pin 17 is attracted by a solenoid annulus 14 (attached to the tube 2) against the force of a spring 16. As a result, the lower end of the pin 17, the path of travel of which is substantially normal to that of the contact pin 11, projects into a recess or groove of the ring 18 affixed to the contact pin 11 and thus the pin 11 is immobilized.
By means of the shoft-circuited current flowing through the tube 2, a further locking pin 25, which is provided at one end with a plate 27, is pushed upwardly by electrodynamic forces against the force of a spring 26, with a frequency of 100 Hz, assuming a 50 cycle current. It will be understood that the plate and the spring, if necessary, should be adjusted to provide for a 120 Hz vibration in case of a 60 cycle current. To ensure that a repelling effect is generated, the tube 2 is provided with a slot 23 as shown in FIG. 3. As may be observed, the plate 27 is in an at least partial overlap with the slot 23.
The pin 25 has, at its lower terminus, a lug 24 which in its lower position, projects into a recess or groove 22 of a short-circuiting ring 21. The spring 26 is so designed that approximately between the moments t 2 and t 3 (FIG. 4) the pin 25 is in its upper position and between moments t 3 and t 4 it is in its lower position. The curve F represents the repelling force exerted on the plate 27. This force is proportionate to the square of the short-circuited current I.
There is further provided a camming pin 28 which has a skewed free end that is adapted to project into an opening 30 provided on the locking pin 17. The other, right-hand terminus of the camming pin 28 is connected with the short-circuiting ring 21. The latter is adapted to be repelled by the electrodynamic force of the short-circuited current which flows in the adjacent coil 19 after the separation of the rated current contact 32. The short-circuiting ring 21 is repelled against the force of a spring 29. It is seen that the path of travel of the camming pin 28 is substantially normal to that of the locking pin 17, while the path of travel of the locking pin 25 is substantially normal to that of the camming pin 28.
The course of the circuit breaking operation for a short-circuited current in excess of 40 kA will now be described in connection with FIG. 4.
At moment t 1 the flow of the short-circuited current starts. The locking pin 17 is pulled downward and thus blocks the contact pin 11. Simultaneously, the locking pin 25 begins to vibrate with a frequency of 100 Hz (assuming a 50 cycle current). The magnetic system 14, 15, together with the locking pin 17 is, however, so designed that the pin 17 does not vibrate but, due to its inertia, dwells in its lower position.
Let it be assumed that approximately at moment t 5 the switch receives the command signal to start the circuit-breaking operation. The separation of the rated current contact 32 may occur at the assumed moment t 6 , several half-waves after the beginning of the short-circuited current flow. Immediately after the separation on the rated current path, the short-circuited current diverts itself onto the still-locked contact pins 10 and 11. The current thus will drop to zero in the principal current path 1,3,2. The insulator cylinder 4 moves further forward (that is, towards the right as viewed in FIG. 1) and compresses the spring 12. The current now flowing through the coil 19 exerts a repelling force on the short-circuiting ring 21 which, however, is still locked by the pin 25. The lug 24, which is hooked into the recess or groove 22, prevents an upward motion of the pin 25.
At moment t 8 , shortly before the short-circuited current passes through the zero value, the spring 29 forces the camming pin 28 towards the right against the decreasing repelling force generated by the current flowing through the coil 19. As a result, the pin 25 is released (unlatched) and is moved upwardly by the spring 26. Since the current is zero in the principal current path, the pin 25 remains in its upward position.
Assuming that the interruption of the rated current occurs at moment t 7 (rather than at moment t 6 as previously assumed), the pin 26 is, in the course of its vibration, in its upper position and remains there. The repelling force generated by the current flowing through the coil 19 has not yet reached the magnitude which is sufficient to move the camming pin 28 towards the left against the force of the spring 29.
Whether the rated current is interrupted at moment t 6 or t 7 , the released pin 28 moves, approximately at moment t 9 , by virtue of the force generated by the current flowing in the coil 19, against the force of the spring 29 towards the left. The skewed terminal face of the pin 28 which constitutes a cam face and which projects into the opening 30 of the pin 17 drives the pin 17 in the upward direction against the force of the spring 16 as well as against the force exerted by the pin 11 due to the attracting force of the magnet ring 14. As a result, the contact pin 11 is released by the locking pin 17 at moment t 9 and is accelerated towards the right by the armed spring 12. The pin 17 is, by means of another camming pin 42 which projects with its skewed terminal face into the opening 31 of the pin 17, moved upwardly for safety reasons in the open end position of the contact bridge 3 independently from the pin 28. The path of travel of the camming pin 42 is substantially normal to that of the locking pin 17.
The separation of the contacts 10 and 11 occurs at moment t 10 . A damping mechanism (not shown) is provided for braking the motion of the contact pin 11 which is of lightweight structure.
During the period t 10 -t 11 an electric arc burns between the pins 10 and 11 which is exposed to a powerful gas blast as the highly compressed gas escapes from the cylinder 1 through the separated, hollow contacts 10 and 11. As a result, the arc is extinguished as the short-circuited current passes through its subsequent zero value at moment t 11 .
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A gas current blow-out switch has an electrically conducting compression cylinder, a stationary hollow power contact pin supported in the cylinder and a piston surrounding the pin and slidably received in the cylinder for compressing an arc-extinguishing gas therein. A nozzle is affixed to the cylinder for bounding one end thereof. A movable hollow power contact pin is supported coaxially with the stationary contact pin to assume open and closed positions. The switch has an electrically conducting stationary tube axially aligned with and spaced from the compression cylinder; a contact bridge slidably supported by and being in continuous electric contact with the stationary tube and the movable contact pin. The contact bridge has a closed position in which it electrically contacts the compression cylinder and an open position in which it is separated therefrom. An insulator cylinder which surrounds the compression cylinder and is slidable thereon, is coupled to the contact bridge for shifting the latter into its open position upon motion of the insulator cylinder in one direction. A carriage is shiftably arranged on a support and an externally actuated drive member is secured to the carriage and is displaceable between two limits with respect to the carriage. The drive member displaces the carriage after the drive member reaches either one of the limits. The drive member is arranged to displace the piston and the carriage is arranged to displace the insulator tube. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to the field of well logging instrument conveyance devices. More specifically, the invention relates to devices used to move a well logging instrument through the interior of a pipe string so that the well logging instrument can be deployed in a wellbore.
[0005] 2. Background Art
[0006] Well logging instruments are used, among other purposes, to make measurements of physical properties of Earth formations that have been penetrated by a wellbore. Well logging instruments typically include one or more types of sensors to make the measurements of the physical properties. Signals from the sensors may be communicated to the Earth's surface by various forms of signal telemetry, and/or may be stored in various types of recording device disposed within the well logging instrument.
[0007] As the well logging instrument is moved along the wellbore, a record of the signals generated by the sensors is made with respect to time and/or depth of the sensors within the wellbore. There are a number of different devices known in the art for moving the well logging instrument along the wellbore. The instrument may be affixed to the end of an armored electrical cable, which is unwound from w winch or similar spooling device to extend the instrument into the wellbore by the action of Earth's gravity. The instrument is withdrawn by rewinding the cable onto the winch. The well logging instrument may be moved along the wellbore by coupling it to the end of a coiled tubing, and unspooling and spooling the coiled tubing to move the instrument into and out of the wellbore. The instrument may also be coupled to the end of a threadedly coupled pipe, called a pipe “string.” The pipe string with the instrument attached to the lower end thereof is extended into the wellbore by threadedly coupling segments of pipe end to end. The pipe string is withdrawn from the wellbore by threadedly uncoupling segments of pipe.
[0008] U.S. patent application Publication No. 2004/0074639 filed by Runia discloses another device for moving the well logging instrument along the wellbore. The system comprises a tubular conduit or pipe extending from the Earth's surface into the wellbore containing a body of wellbore fluid. A well logging instrument string is included that is capable of passing from a position within the conduit to a position outside the conduit at a lower end part thereof and capable of being suspended by the conduit in said position outside the conduit. In some embodiments the well logging instrument may include a pressure pulse device arranged within the conduit in a manner that the pressure pulse device is in data communication with the logging tool. The pressure pulse device is capable of generating pressure pulses in the body of wellbore fluid, the pressure pulses representing data communicated by the logging tool string to the pressure pulse device during logging of Earth formation by the logging tool string.
[0009] In using the device disclosed in the Runia '639 publication it has been found desirable to be able to control the speed of movement of the well logging instrument inside the conduit, particularly when the conduit is disposed in a vertical or nearly vertical wellbore. Conversely, it is necessary to provide some mechanism to move the well logging instrument along the interior of the conduit when the wellbore is highly inclined form vertical such that Earth's gravity is incapable of moving the well logging instrument sufficiently.
SUMMARY OF THE INVENTION
[0010] A deployment device for controlling rate of movement of an instrument inside a conduit according to one aspect of the invention includes a mandrel having a coupling to affix the deployment device to the instrument and a controllable brake disposed in the mandrel, the brake controllably actuatable to maintain the mandrel and instrument at a selected speed within the conduit.
[0011] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 schematically shows a first embodiment of the logging system of the invention, using a casing extending in the wellbore.
[0013] FIG. 2 schematically shows a second embodiment of the logging system of the invention, using a drill string extending in the wellbore.
[0014] FIG. 3 schematically shows the embodiment of FIG. 2 during a further stage of operation.
[0015] FIG. 4 shows one embodiment of a deployment device according to the invention.
[0016] FIGS. 4A and 4B show alternative arrangements of a motor and a traction drive wheel.
[0017] FIG. 4C shows an alternative type of motor that may be used in some embodiments according to FIG. 4A or 4 B.
[0018] FIG. 5 shows an alternative braking mechanism for a deployment device.
DETAILED DESCRIPTION
[0019] FIG. 1 shows a wellbore 1 formed in an Earth formation 2 , the wellbore being filled with drilling fluid. The wellbore 1 has an upper portion provided with a casing 4 extending from a drilling rig (not shown) at the Earth's surface 8 into the wellbore 1 to a casing shoe 5 , and an open lower portion 7 extending below the casing shoe 5 . A conduit, which in the present embodiment is a tubular drill string 9 containing a body of drilling fluid 10 and having an open lower end 11 , extends from the drilling rig (not shown) into the wellbore 1 whereby the open lower end 11 is disposed in the open lower wellbore portion 7 . A well logging instrument 12 capable of being lowered or raised through the drill string 9 , is retrievably suspended in the drill string 9 by a deployment device 12 A, which will be explained in more detail with reference to FIG. 4 . The well logging instrument 12 includes one or more types of sensors, including, for example, a formation tester (FT) tool 14 having retractable arms 16 . The logging instrument may include a fluid pressure pulse device 18 arranged at the upper end of the FT tool 14 , whereby the FT tool 14 extends below the lower end part 11 of the drill string 9 and the pressure pulse device 18 is disposed within the drill string 9 . The FT tool 14 may be powered by a battery (not shown) and can be provided with an electronic memory (not shown) or other recording medium for storing measurement data, which for the FT tool 14 may include measurements of fluid pressure in the Earth formation 2 at selected depths therein.
[0020] It is to be clearly understood that the FT tool 14 shown in FIG. 1 is only an example of a well logging sensor or instrument that may be used with a deployment device according to the invention. It is within the scope of this invention that any known well logging sensor or instrument that can be moved through the inside of a tube or conduit may be used with a deployment device according to the invention. Such sensors and/or instruments include, without limitation, acoustic sensors, electromagnetic resistivity sensors, galvanic resistivity sensors, seismic sensors, Compton-scatter gamma-gamma density sensors, neutron capture cross section sensors, neuron slowing down length sensors, calipers, gravity sensors and the like.
[0021] The fluid pressure pulse device 18 has a variable flow restriction (not show) which is controlled by electric signals transmitted by the FT tool 14 to the pressure pulse device 18 , which signals represent part of the data produced by the FT tool 14 during the making of measurements of the earth formation 2 . The upper end of the deployment device 12 A may be provided with a latch 20 for latching of an armored electrical cable (not shown) to the device 12 A for retrieval from the bottom of the drill string 9 .
[0022] A wellhead 22 is typically connected to the upper end of the casing 4 and is provided with an outlet conduit 24 terminating in a drilling fluid reservoir 26 provided with a suitable sieve means (not shown) for removing drill cuttings from the drilling fluid. A pump 28 having an inlet 30 and an outlet 32 is arranged to pump drilling fluid from the fluid reservoir 26 into the upper end of the drill string 9 .
[0023] A control system 34 located at the Earth's surface is connected to the drill string 9 for sending or receiving fluid pressure pulses in the body of drilling fluid 10 to or from the fluid pressure pulse device 18 .
[0024] A second embodiment shown in FIG. 2 is largely similar to the first embodiment, except with respect to the following aspects. The drill string is provided with a drill bit 40 at the lower end thereof, a measurement-while-drilling (MWD) device 42 is removably arranged in the lower end part of the drill string 9 , and the logging instrument 12 is shown as being lowered through the drill string 9 . The drill bit 40 is provided with a passage 44 in fluid communication with the interior of the drill string 9 , which passage 44 is provided with a closure element 46 removable from the passage 44 in outward direction and connected to the MWD device 42 . The lower end of the logging instrument 12 and the upper end of the MWD device 42 are provided with respective cooperating latching members 48 a , 48 b capable of latching the logging tool string 12 to the MWD device 42 . Furthermore, the deployment device 12 A may be provided with pump cups 50 for pumping the logging instrument 12 through the drill string 9 , either in downward or upward direction thereof.
[0025] The closure element 46 has a latching mechanism (not shown) for latching the closure element 46 to the drill bit 40 . The latching mechanism is arranged to co-operate with the latching members 48 a , 48 b in a manner that the closure element 46 unlatches from the drill bit 40 upon latching of latching member 48 a to latching member 48 b , and that the closure element 46 latches to the drill bit 40 , and thereby closes passage 44 , upon unlatching of latching member 48 a from latching member 48 b.
[0026] In FIG. 3 shows the embodiment of FIG. 2 during a further stage of operation whereby the logging instrument 12 has been latched to the MWD device 42 and the closure element 46 has been unlatched from the drill bit 40 . The drill string 9 has been raised a selected distance in the wellbore 1 so as to leave a space 52 between the drill bit 40 and the wellbore bottom. The logging instrument 12 is suspended by the drill string 9 in a manner that the FT tool 14 extends through the passage 44 to below the drill bit 40 , and that the pressure pulse device 18 is arranged within the drill string 9 . The MWD device 42 and the closure element 46 consequently extend below the logging tool string 12 .
[0027] During normal operation of the embodiment of FIG. 1 , the drill string 9 is lowered into the wellbore 1 until the lower end of the string 9 is positioned in the open wellbore portion 7 . Next the logging instrument 12 is lowered from surface through the drill string 9 by means of the deployment device 12 A, whereby during lowering the arms 16 are retracted. Lowering continues until the FT tool 14 extends below the drill string 9 while the pressure pulse device 18 is positioned within the drill string 9 , in which position the logging instrument 12 is suitably supported. The arms 16 are then extended against the wall of the wellbore and the FT tool 14 is induced to make its measurements of the Earth formation 2 . The measurement data may be stored in the electronic memory, and part of the logging data may be transmitted by the FT tool 14 in the form of electrical signals to the pressure pulse device 18 , which signals induce controlled variations of the variable flow restriction.
[0028] Simultaneously with operating the logging instrument 12 , drilling fluid is pumped by pump 28 from the fluid reservoir 26 into the drill string 9 via inlet 30 and outlet 32 . The controlled variations of the variable flow restriction induce corresponding pressure pulses in the body of drilling fluid present in the drill string 9 , which pressure pulses are monitored by the control system 34 . In this manner the system operator can monitor the well logging operation and can take corrective action if necessary. For example, incorrect deployment of the arms 16 of the RFT tool can be detected in this manner at an early stage.
[0029] After the logging run has been completed, the logging instrument 12 may retrieved through the drill string 9 to surface by wireline connected to latch 20 . Optionally the drill string 9 is then removed from the wellbore 1 .
[0030] During normal operation of the embodiment of FIGS. 2 and 3 , the drill string 9 is operated to drill the lower wellbore portion 7 whereby the closure element 46 is latched to the drill bit 40 so as to form a part thereof. The MWD device 42 induces fluid pressure pulses in the body of drilling fluid 10 representative of selected drilling parameters such as wellbore inclination or wellbore temperature. The use of MWD devices is known in the art of drilling, and will not be explained in more detail in this context.
[0031] When it is desired to log the earth formation 2 surrounding the open wellbore portion 7 , the logging tool string 12 is pumped down the drill string 9 using pump 28 until the logging tool string 12 latches to the MWD device 42 by means of latching members 48 a , 48 b . During lowering of the string 12 , the arms 16 of the FT tool 14 are retracted. Then the drill string 9 is raised a selected distance until there is sufficient space below the drill string for the FT tool 14 , the MWD device 42 and the closure element 46 to extend below the drill bit 40 . Upon latching of latching member 48 a to latching member 48 b , the closure element 46 unlatches from the drill bit 40 . Continuous operation of pump 28 causes further downward movement of the combined logging tool string 12 , MWD device 42 and closure element 46 until the logging tool string 12 becomes suspended by the drill string. In this position (shown in FIG. 3 ) the FT tool 14 extends through the passage 44 into the space 52 below the drill bit 40 , and the pressure pulse device 18 and closure element 46 extend below the FT tool in the space 52 .
[0032] The arms 16 are then extended against the wall of the wellbore and the FT tool 14 is operated to measure the Earth formation 2 . The measurement data are stored in the electronic memory, and part of the data are transmitted by the FT device 14 in the form of electrical signals to the pressure pulse device 18 , which signals induce controlled variations of the variable flow restriction of the MWD device 42 .
[0033] Simultaneously with operating the logging tool string 12 , drilling fluid is pumped by pump 28 from the fluid reservoir 26 into the drill string 9 via inlet 30 and outlet 32 . The controlled variations of the variable flow restriction induce corresponding pressure pulses in the body of drilling fluid present in the drill string 9 , which pressure pulses are monitored by the control system 34 . Thus, the operator is in a position to monitor the logging operation and to take corrective action if necessary (similarly to the embodiment of FIG. 1 ).
[0034] After measuring has been completed, the instrument 12 may be retrieved to surface through the drill string 9 by wireline connected to latch 20 at the top of the deployment device 12 A. During retrieval the closure element 46 latches to the drill bit 40 (thereby closing the passage 44 ) and the latching members 48 a , 48 b unlatch. Alternatively the instrument 12 can be retrieved to surface by reverse pumping of drilling fluid, i.e. pumping of drilling fluid down through the annular space between the drill string 9 and the wellbore wall and into the lower end of the drill string 9 . Optionally a further wellbore section then can be drilled, or the drill string 9 can be removed from the wellbore 1 .
[0035] As will be readily appreciated by those skilled in the art, during deployment of the well logging instrument 12 into the drill string 9 , and during removal therefrom, it is desirable to be able to control the speed of movement of the instrument 12 within the drill string. A deployment device 12 A according to the invention is configured to control the speed of motion of the instrument 12 along the interior of the drill string 9 , and where appropriate, can provide motive power to move the instrument 12 along the interior of the drill string 9 during deployment or withdrawal of the instrument 12 .
[0036] One embodiment of the deployment device 12 A will now be explained with reference to FIG. 4 . The deployment device 12 A includes a generally cylindrically shaped mandrel 50 that can traverse the interior of the drill string ( 9 in FIG. 1 ) or other pipe or conduit extended into the wellbore. The mandrel 50 may include a fishing neck 52 or similar latching device at its upper end to enable retrieval of the device 12 A under particular circumstances such as by wireline (electrical cable), or coiled tubing, for example should such retrieval prove necessary. The lower end of the mandrel 50 includes a threaded connector 54 or other mechanism to couple the deployment device 12 A to the upper end of the well logging instrument ( 12 in FIG. 1 ). A pressure sealed compartment 50 A disposed in a portion of the mandrel 50 , which may be an enclosure or a separate module or “sub” 56 , includes power and control electronics disposed therein. Such electronics may include a rechargeable battery 62 , a programmable, microprocessor based system controller 58 and a motor driver 60 .
[0037] In the present embodiment, the motor driver 60 can generate alternating current used to operate drive motors, as will be further explained. The motor driver 60 may also induce alternating current in such drive motors such that the motors provide electrically regenerative braking. The controller 58 can provide control signals to operate the motor driver 60 such that a substantially constant, or other controlled speed of movement of the deployment device 12 A along the interior of the drill string can be maintained.
[0038] In the present embodiment, the drive motors can be induction motors formed by combination of high magnetic permeability steel traction wheels 66 that are held in frictional contact with the interior wall of the drill string (or other conduit) by a biasing device such as bow springs 64 acting on the wheels' axles. The wheels 66 may each be disposed proximate to a corresponding induction coil 68 . One or more of the wheels 66 may include embedded permanent magnets 67 to assist in regenerative braking, as will be further explained. The particular biasing device shown in this embodiment is not intended to limit the scope of the invention. Alternative biasing devices may be used in other embodiments, such as pressurized hydraulic or pneumatic cylinders, coil springs, and shape memory metal springs, for example.
[0039] As the deployment device 12 A moves downward inside the pipe or conduit by gravity, the rate of descent may be controlled by suitable current being passed through the induction coils 68 by the motor driver 60 so as to electrically brake the wheels 66 . Electrical power may be generated by such braking, and the generated power may be conditioned and supplied to the battery 62 to maintain its charge. Conversely, when it is necessary to supply motive power to move the device 12 A and the well logging instrument ( 12 in FIG. 1 ) coupled thereto along the interior of the conduit, such as in highly inclined wellbores, the motor driver 60 may supply suitable alternating current to the induction coils 68 to cause the wheels 66 to turn, thus moving the mandrel 50 . The amount and rate of rotation and/or braking force may be selected by the controller 58 to maintain any selected rate of motion of the mandrel 50 along the inside of the conduit. Rate of motion of the mandrel 50 may be determined using, for example an accelerometer 57 or similar device in signal communication with the controller 58 .
[0040] The present embodiment includes components intended to cause the wheels 66 to act as the rotors in an induction motor. It will be appreciated by those skilled in the art that the wheels 66 may be driven by alternative arrangements of a motor rotationally coupled to the wheels 66 . FIG. 4A shows one possible arrangement. One or more of the wheels 66 may in such embodiments include a ring gear 69 formed inward of the outer surface of the wheel 66 . A spur gear 75 coupled to the output shaft of a motor 73 may be placed in contact with the ring gear 69 to cause wheel rotation by operation of the motor 73 . The arrangement shown in FIG. 4A may also provide regenerative braking as the wheel 66 rotates the motor 73 .
[0041] Another arrangement is shown in FIG. 4B , in which the wheel 66 includes a ring gear 69 A disposed on a surface proximate the wheel axle. A motor 73 A may have on its output shaft a worm gear 75 A in contact with the ring gear 69 A. Rotation of the motor 73 A will thus drive the wheel 66 . The arrangement shown in FIG. 4B may be advantageous when it is desirable not to enable motion of the deployment deice ( 12 A in FIG. 1 ) except by operation of the motor 73 A.
[0042] An alternative type of motor that may be used in embodiments such as shown in FIGS. 4A and 4B will now be explained with reference to FIG. 4C . The motor ( 73 in FIG. 4A or 73 A in FIG. 4B ) in the present embodiment can be an hydraulic motor 73 B. The hydraulic motor 73 B has its inlet and outlet lines, 173 B, 273 B, respectively, coupled to a two-port, three-way valve 94 . The three way valve 94 may be actuated by a solenoid 96 . The solenoid 96 may be operated by a circuit corresponding to the controller and motor driver ( 58 , 60 , respectively in FIG. 4 ). In the center position, shown in FIG. 4C , the three way valve 94 couples the inlet line 173 B to the outlet line 273 B of the motor 73 B to enable the motor to be rotated freely by the wheel ( 66 if the embodiment of FIG. 4 A is used) which it drives. Thus, when the three-way valve 94 is in the center position, the deployment device may move relatively unhindered.
[0043] When it is determined that braking force is needed, the three-way valve 94 is moved to the leftmost position in FIG. 4C . The outlet line 273 B of the motor 73 B is then coupled to an accumulator 90 . The accumulator 90 can be conventional in design and include a piston 92 A biased by a spring 92 B to maintain hydraulic pressure on one side of the piston 92 A. Thus, the motor 73 B pumps fluid against pressure in the accumulator 90 so as to provide resistance to rotation by the wheel. Fluid to be pumped by the motor 73 B is supplied by the three way valve 94 connecting the inlet line 173 B of the motor 73 B to a reservoir 92 . When used as a brake, the motor 73 B will provide some regenerative charging of the accumulator 90 .
[0044] When it is determined that motive force is required for the deployment device, the three way valve 94 may be moved to the right hand position in FIG. 4C , so as to couple the inlet line 173 B of the motor 73 B to the pressurized fluid in the accumulator 90 , thus driving the motor 73 B.
[0045] In some embodiments, pressure charge may be maintained in the accumulator 90 by a separate pump 73 C which may be driven by a separate motor, or a turbine exposed to flow of fluid in the wellbore or other type of drive mechanism. The pump 73 C transfers fluid from the reservoir 92 to the accumulator 90 to maintain pressure therein. The outlet line of the pump 73 C may include a check valve 98 to prevent leak off of pressure through the pump 73 C when the pump is not operating.
[0046] Another embodiment of a braking mechanism that may be used in substitution of or in addition to the inductive traction device explained above will now be explained with reference to FIG. 5 . The mandrel 50 may include near the upper end fluid inlet ports 76 which admit drilling fluid from inside the conduit (drill string) as the deployment device s moved downwardly through the conduit. Fluid may be urged to flow through the inlet ports 76 by a seal cup 80 or similar fluid deflecting device disposed on the outside of the mandrel 50 . The moving fluid travels inside the mandrel 50 and past blades on a turbine 70 . The pitch of the turbine blades may be adjusted by a pitch controller 72 . The pitch controller 72 may be under functional control of the controller ( 58 in FIG. 4 ). Adjusting the blade pitch to be more parallel with the fluid flow direction decreases the amount of fluid flow that is converted to rotation of the turbine 70 , and consequently, the amount of resistance to fluid flow created by the turbine 70 . Conversely, within certain limits adjusting the blade pitch to be more transverse to the fluid flow will increase the resistance to fluid flow and the amount of flow energy converted to rotational energy of the turbine 70 . The turbine 70 may be rotationally coupled to a generator or alternator 74 to convert rotational energy into electric power to charge the battery ( 62 in FIG. 4 ). The controller ( 58 in FIG. 4 ) may continuously operate the pitch controller 74 to adjust the turbine blade pitch such that a selected speed of movement of the instrument ( 12 in FIG. 1 ) is substantially maintained.
[0047] It will be readily appreciated by those skilled in the art that other forms of regenerative braking may be used to control the speed of motion under gravity of a logging instrument inside a conduit. Such regenerative braking may include rotating a hydraulic pump to convert motion into hydraulic pressure, for example.
[0048] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A deployment device for controlling rate of movement of an instrument inside a conduit includes a mandrel having a coupling to affix the deployment device to the instrument and a controllable brake disposed in the mandrel, the brake controllably actuatable to maintain the mandrel and instrument at a selected speed within the conduit. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns treatment of mammals to retard ischemic bowel disease. Bowel ischemia and reperfusion is commonly associated with a sudden increase of generated free-radicals, accompanying neutrophil infiltration and accompanying cell death or loss of morphology which may result in the death of the mammal. Ischemia refers to the stoppage of blood flow to a particular organ or muscle. Reperfusion refers to the restoration of blood flow to the affected organ or muscle.
According to the present invention, providing the mammal with pyruvate prior to, and/or during the onset of bowel ischemia will significantly inhibit the neutrophil infiltration to the affected bowel. During reperfusion of the ischemic bowel, the presence of pyruvate in the bowel will significantly retard neutrophil infiltration and villi deterioration.
2. Description of the Prior Art
Pyruvate has a number of useful applications in medical treatment. Pyruvate has been described for retarding fatty deposits in livers (U.S. Pat. No. 4,158,057); for diabetes treatment (U.S. Pat. No. 4,874,790); for retarding weight gain (U.S. Pat. Nos. 4,812,879, 4,548,937, 4,351,835); to increase body protein concentration in a mammal (U.S. Pat. No. 4,415,576); for treating cardiac patients to increase the cardiac output without accompanying increase in cardiac oxygen demand (U.S. Pat. No. 5,294,641); for extending athletic endurance (U.S. Pat. No. 4,315,835); for retarding cholesterol increase (U.S. Pat. No. 5,134,162); for inhibiting growth and spread of malignancy and retarding DNA breaks (application Ser. No. 08/194,857, filed Feb. 14, 1994); and for inhibiting generation of free radicals (application Ser. No. 08/286,946 filed Aug. 8, 1994). Pyruvate in various forms has been proposed for enteral administration and for parenteral administration. Typically pyruvates are available in the form of salts, e.g., calcium pyruvate and sodium pyruvate; pyruvate analogs of amino acids, e.g. pyruvyl-amino acids such as pyruvyl-glycine, pyruvyl-alanine, pyruvyl-leucine, pyruvyl-valine, pyruvyl-isoleucine, pyruvyl-phenyl-alanine, pyruvyl-proline, and their amides. See U.S. Pat. Nos. 5,283,260 and 5,256,697 for pyruvyl-amino acids.
Pyruvate may be administered to a mammal enterally or parenterally to super physiologic levels in the mammal. The amount of administered pyruvate preferably is from 1 to 20 per cent of the mammal's caloric intake. For enteral dosage, the pyruvate may be dispersed or dissolved in a beverage product or may be included in cookies, candies or other foods. The pyruvate may be introduced as an aqueous solution parenterally. A preferred administration procedure is an aqueous energy maintenance drip which includes not only sugars but also the selected pyruvate or pyruvates. See U.S. patent application Ser. No. 08/286,946 filed Aug. 8, 1994. Regardless of the administration procedure, according to this invention, the presence of super physiological pyruvate in a mammalian bowel or circulatory system will retard development of free-radicals during an ischemia incident in the mammal's bowel and during reperfusion.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of the measured chemiluminescence resulting from intestinal free-radical generation during ischemia and subsequent reperfusion, comparing a placebo (PL), a pyruvate (PY) treatment and a base line condition.
FIG. 2 is graphical representation of the neutrophil count for two mammals, one of which has received pyruvate (PY) treatment and the other of which is a placebo (PL). These are compared to a base line condition, prior to the ischemia onset. The neutrophil count was made at 30 minutes reperfusion following bowel ischemia.
FIG. 3 includes three microphotographs showing intestinal villi under different conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Ischemia is a condition in which the flow of blood has been interrupted to a particular region of the mammal anatomy, e.g., muscles or organs. Bowel ischemia is commonly encountered in the course of surgery, mechanical accidents, and intestinal disorders.
Restoration of the flow of blood to the ischemic anatomy is called reperfusion. At the onset of bowel reperfusion a sudden increase of free-radicals is identified. The free-radical production of the mammal remains high for extended periods, e.g., one to two hours following onset of reperfusion. The high level of free-radicals usually causes irreversible damage to the affected anatomy. The elevated free-radical production in the bowel results in cell necrosis (cell death), a decreased morphology and death of the mammal. See "Oxygen Free Radicals in Tissue Damage" Merrill Tarr et al, Birkhauser Boston, 1933. Morphology is the form and structure of the mammal.
A patient, treated with pyruvate prior to the onset of bowel ischemia will not display the elevated free-radical development, but instead will maintain free-radical development at a level which is normal or lower than base line level, throughout the ischemia and subsequent reperfusion. The neutrophil infiltration is retarded and the morphology is retained.
EXAMPLE 1
The small intestine of each of six laboratory rats was tied to closure. The bowel downstream from the closure received directly for ten minutes before and during treatment either:
PLACEBO (PL) a liquid diet preparation containing aqueous polyglucose; or
PYRUVATE (PY) a liquid diet preparation containing aqueous polyglucose with 10% of the energy (caloric) content of the polyglucose being displaced by a mixture of sodium and calcium pyruvate constituting 10% (by energy) of the liquid diet, i.e., 10% of the caloric intake.
The superior mesenteric artery which supplies blood to the intestines was occluded in each of the six laboratory rats to cause bowel ischemia. The ischemia continued for 45 minutes at which time the mesenteric artery occlusion was released and reperfusion of the affected bowel commenced.
A portion of the intestine of each laboratory rat was removed:
(A) Immediately following ischemia;
(B) After 30 minutes reperfusion;
(C) After 60 minutes reperfusion.
Each intestine portion was analyzed for free radicals by chemiluminescence (measured in intensity/mg protein) and examined by light microscopy. Chemiluminescence measurements are described by Simmonds, N.J. et al, GASTROENTEROLOGY 1992, Vol 103, Pages 186-196.
The baseline chemiluminescence value for the rats was obtained prior to the testing at 684,000±68,200 chemiluminescence units, a direct correlation to the free-radical population. The values for the Placebo (PL) and for the Pyruvate (PY) treatment are indicated in TABLE I and graphically presented in FIG. 1.
TABLE I______________________________________FREE-RADICAL CONTENT OF INTESTINE OFLABORATORY RATS FOLLOWING BOWEL ISCHEMIA(Measured in chemiluminescence units) PLACEBO PYRUVATE TREATMENT______________________________________Post Ischemia 409,000 ± 76,200 59,700 ± 10,400(Immediate)Reperfusion 933,000 ± 298,000 69,800 ± 20,400(30 minutes)Reperfusion 543,000 ± 309,000 62,200 ± 15,900(60 minutes)______________________________________
The significant reduction of free-radicals (as measured by chemiluminescence) resulting from Pyruvate treatment (PY) of the mammal is illustrated in FIG. 1 wherein the vertical cross-hatch areas representing Pyruvate treatment (PY) are significantly lower than the horizontal cross-hatch areas representing the Placebo (PL). The reduction is apparent at the end of the ischemia and throughout the observed reperfusion.
The placebo intestine segment, after reperfusion, was discolored and appeared necrotic. All of the placebo segments displayed petechiae (small hemorrhagic spots) while the pyruvate segments did not show petechiae.
In further tests, with bowel ischemia for 30 minutes followed by reperfusion for 30 minutes, laboratory rats were fed as described in EXAMPLE 1. The placebo rats had the described standard diet. The pyruvate treatment rats had the pyruvate-modified standard diet
(A) Prior to and during the ischemia; or
(B) Only after the onset of the ischemia.
The neutrophil infiltration of the intestine was measured and graphed on FIG. 2. The baseline condition in FIG. 2 indicates the population of neutrophil in the intestine prior to any evaluations. The two bars labeled indicate the neutrophil population at the end of 30 minutes reperfusion following 30 minutes ischemia.
(A) Where pyruvate had been introduced into the rat prior to the onset of ischemia the neutrophil infiltration (PY) was reduced below the base condition, whereas the placebo (PL) showed increased neutrophil infiltration.
(B) Where the pyruvate diet was commenced immediately following the onset of ischemia, similar results are observed.
From FIG. 2 it appears that the pyruvate is beneficial in retarding neutrophil infiltration in both situations i.e., when supplied prior to and during the ischemia and also when supplied only after onset of the ischemia or the onset of reperfusion.
For visual evidence of the effect of ischemia on intestines, two laboratory rats were evaluated. One rat, PL, received the described standard diet and the other rat, PY, received the described pyruvate modified standard diet. The superior mesenteric arteries of both rats were blocked to create bowel ischemia for 60 minutes.
At the end of the 60 minutes of reperfusion, the rats were sacrificed and microphotographs were obtained of a cross-section through the small intestine, which is covered with small villi, extending into the interior of the intestine from the muscle wall. These microphotographs are produced in FIG. 3, including:
FIG. 3a--shows the 200 magnification cross-section of a slice of small intestine of a normal rat without ischemia illustrating normal, healthy villi.
FIG. 3b--shows the 100 magnification cross-section from the intestine of the placebo rat (PL) illustrating badly deteriorated villi extending from the muscle wall. The morphology is severely diminished.
FIG. 3c--shows the 100 magnification cross-section from the intestine of the pyruvate-treated rat (PY) illustrating healthy villi. The villi retain morphology.
Thus it appears that the pyruvate treated animal maintains healthy villi and retains morphology during intestinal ischemia which is destructive of intestinal villi and reduces morphology in a similar, untreated animal.
Treatment--A patient experiencing bowel ischemia, or about to experience bowel ischemia, should receive a super physiologic dosage of pyruvate by a drip tube extended through the patient's nose to the patient's stomach, or by beverage or food containing pyruvate, or by parenteral intravenous drip. All of these delivery systems will establish the desired super physiologic level of pyruvate in the patient. | Treating mammals having ischemic bowel with a therapeutic quantity of pyruvate enterally or parenterally will retard neutrophil infiltration and retain morphology during and following the bowel ischemia. The pyruvate is introduced into the patient enterally or parenterally during the bowel ischemia or the succeeding bowel reperfusion and, preferably, prior to the bowel ischemia. The pyruvate dosage is from 1% to 20% by weight of the patient's caloric intake. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to the preparation of cyclobutenoarenes. In a specific aspect, the invention relates to the purification of benzocyclobutenes prepared by the pyrolysis of o-methylbenzyl halides.
The four-membered ring of benzocyclobutenes is known to open at elevated temperature to form a very reactive diene which rapidly dimerizes and polymerizes. Molecules containing two or more benzocyclobutene groups are therefore useful as heat-curable thermosetting resins. Also, elastomers or thermoplastics containing benzocyclobutene substituents crosslink on heating. In order to economically prepare such useful benzocyclobutenefunctional resins or polymers, however, an economic method of generating the benzocyclobutene structure in pure form is needed. In the past, the benzocyclobutene structure has been synthesized most commonly by pyrolysis of substituted or unsubstituted o-methylbenzyl halides at temperatures above 650° C. and pressures below 2 mm Hg.
Benzocyclobutenes produced by vacuum pyrolysis tend to be quite heavily contaminated with isomeric styrenes and the phenylacetylenes formed by dehydrogenation of the styrenes. Formation of styrene and phenylacetylene tends to be a particularly severe problem at pyrolysis tube temperatures of 800° to 900° C., at which the highest conversions of o-methylbenzyl halides to benzocyclobutene per pass are obtained.
Because of their similar boiling points, styrenes and phenylacetylenes are extremely difficult to separate from benzocyclobutenes by distillation. For example, benzocyclobutene boils at 146°-148° C. at atmospheric pressure, while the boiling points of styrene and phenylacetylene are 145°-146° C. and 142°-44° C., respectively. If the styrene and phenylacetylene are not removed from the benzocyclobutene, problems tend to occur in subsequent functionalization reactions for the preparation of precursors of bisbenzocyclobutene resins or benzocyclobutene-functional monomers.
For example, a standard method of benzocyclobutene functionalization involves initial bromination of the side chain. If the benzocyclobutene undergoing bromination contains styrene or phenylacetylene, these impurities tend to form di- or tetrabromides, respectively, under the bromination conditions. Such side-chain brominated materials tend to lose HBr at the high pot temperatures of the subsequent distillation procedure. The HBr damages the vacuum pump, and HBr elimination also yields monobromostyrenes, which boil at temperatures close to the bromobenzocyclobutene product and hence contaminate the distilled material.
It would thus be desirable to find new methods to recover benzocyclobutene from a reaction product mixture containing benzocyclobutene and similar-boiling by-products such as styrene and phenylacetylene.
SUMMARY OF THE INVENTION
According to the invention, crude cyclobutenoarene is contacted with an aqueous acid solution under conditions effective to convert organic impurities such as isomeric styrenes and/or phenylacetylene into less volatile compounds, such as hydrated forms or oligomers oi such compounds, which can be separated from the cyclobutenoarene by distillation. In a pre-erred embodiment, a crude pyrolysis reaction product mixture containing benzocyclobutene is contacted with an aqueous solution of concentrated sulfuric acid for a time effective to chemically convert the styrene and phenylacetylene impurities into a mixture of oligomers and water addition products such as alcohols and ketones, which are less volatile than the benzocyclobutene and from which the benzocyclobutene can be separated by distillation.
DETAILED DESCRIPTION OF THE INVENTION
The invention process involves the separation of a cyclobutenoarene from a reaction product mixture which includes the cyclobutenoarene and at least one other similar-boiling compound. In a specific embodiment, the invention involves the recovery of benzocyclobutene from a pyrolysis reaction product mixture which includes various aromatic by-products of pyrolysis, such as styrene and phenylacetylene. For simplicity, the invention will be discussed in terms of such a pyrolysis reaction product mixture from which benzocyclobutene is recovered, with the understanding that the invention applies generally to the separation of cyclobutenoarenes from similar-boiling contaminants.
In the recovery of benzocyclobutene from a pyrolysis product mixture, the product mixture is contacted with an aqueous acid solution. The acid solution contains a sufficient acid concentration to effect hydration, or other addition reactions, on the contaminant materials, e.g., hydration of the double bond of styrene or the triple bond of phenylacetylene. The acid solution must not be so strong, however, as to cause extensive loss of benzocyclobutene through attack on the aromatic ring (for example, sulfonation) or opening of the four-membered ring. At extremely high acid concentration, such side reactions will occur to such an extent that the acid phase will not separate from the organic phase on standing, and an emulsion will form if additional water is added in an attempt to force phase separation.
Suitable acids include strong inorganic acids, such as sulfuric acid, alkane or arene sulfonic acids, HBF 4 , HPF 6 and HSbF 6 , for example. The preferred acid, because of its commercial availability and demonstrated effectiveness, is sulfuric acid. Preferred aqueous acid solutions for the invention process are mixtures of 100 parts by weight commercial concentrated sulfuric acid (95-98 percent H 2 SO 4 ) with about 8 to about 25 parts by weight of water. The amount of aqueous acid solution used can range from about 5 to about 300 weight percent, based on the weight of the crude reaction product mixture, preferably from about 10 to about 100 weight percent.
In order to effect recovery of the benzocyclobutene from the reaction product mixture, the crude benzocyclobutene is mixed with the aqueous acid solution with agitation to promote intimate contact between the organic phase and the acid phase, for a time sufficient to convert a substantial portion of any styrene and phenylacetylene present to higher-boiling products. With good agitation, a contact time of about one to two hours will generally be sufficient, although this will vary, with shorter contact times possible with more vigorous agitation, higher temperature, and higher acid concentration in the aqueous phase. It is preferred to carry out the reaction at or slightly above room temperature, generally from about 20° to about 70° C., and atmospheric pressure, although higher or lower temperatures and pressures may sometimes be useful. The contacting of the reaction product mixture with the acid solution results in a two-phase organic/aqueous system in which the organic phase contains the benzocyclobutene and the products of hydration or other conversion reactions of aromatic by-products present in the reaction product mixture, and the aqueous phase contains the acid.
The organic phase is then separated from the aqueous phase. To facilitate separation of the phases and removal of acid from the organic phase, additional water may be added to the system prior to phase separation. After optional drying of the recovered organic phase, pure benzocyclobutene is recovered from the organic phase by distillation or other separation technique.
The invention purification process can be employed in the preparation of cyclobutenoarenes by the pyrolysis of o-alkylarylmethyl halides at temperatures above about 650° C. and pressures below about 2 mm Hg. A mixed pyrolysis product stream is passed to a condensation zone wherein product cyclobutenoarene, unreacted starting material and pyrolysis by-products such as isomeric styrenes and phenylacetylenes are condensed, preferably in the presence of water for aqueous condensation of HCl, as a liquid product mixture. The mixture can be subjected to distillation to separate the cyclobutenoarene (accompanied by styrenes and phenylacetylenes present) from unreacted starting material The impure cyclobutenoarene can then be treated according to the above-described process for recovery of purified cyclobutenoarene from such by-products as styrene and phenylacetylene. Preferably, however, the crude pyrolysis product containing cyclobutenoarene, styrene, phenylacetylene and o-alkylarylmethyl halide is treated with aqueous acid as the first step of cyclobutenoarene purification. The acid will convert the styrene and phenylacetylene to less volatile materials without significantly affecting the cyclobutenoarene or o-alkylbenzyl halide starting material. The mixture can then, after optional drying, be distilled directly to provide a pure cyclobutenoarene fraction.
EXAMPLE 1
This example illustrates the use of sulfuric acid-water mixtures for removing styrene and phenylacetylene from benzocyclobutene (BCB) and the effect of water concentration on the effectiveness of such removal. A series of mixtures of reagent grade concentrated sulfuric acid (95.8% H 2 SO 4 ) and water were prepared as shown in Table 1 below. Subsequently, 1.5 grams of each sulfuric acid-water mixture were mixed in a glass vial with 5 grams of a batch of crude benzocyclobutene (o-methylbenzyl chloride pyrolysis product). The vials were shaken vigorously and then placed on a tumbler for two hours at room temperature (approximately 25° C.).
At the end of the two-hour period, an amount of water (usually 1.5 grams) was added to each mixture in order to increase the volume of the aqueous phase and make it easier to separate from the organic phase. (Separation became more difficult with decreasing water concentration in the sulfuric acid solution used for the original treatment, possibly because of sulfonation of some of the aromatic rings. More water had to be added to separate the phases in some of these materials, and some formed emulsions which could not be separated at all.) The phases were then separated and the organic phase was dried over calcium oxide. The organic phase--calcium oxide mixtures were centrifuged and the organic phase was decanted and analyzed by gas chromatography. Results are shown in Table 1 below.
TABLE 1__________________________________________________________________________Composition of Volume ofaqueous acid: water added Organic phase composition, GC peak area %.sup.a g conc. g for phase Phenyl- o- o-MethylbenzylRun # H.sub.2 SO.sub.4 water sepn., mL BCB acetylene Styrene Xylene chloride__________________________________________________________________________1 10 0 5.sup.b2 10 0.5 5.sup.b7 10 0.75 4.sup. 38.77 0.04 0.84 39.153 10 1.0 1.5 41.35 0.04 0.02 0.82 38.104 10 1.5 1.5 46.52 0.03 0.82 39.938 10 2.0 1.5 45.30 0.03 0.79 38.965 10 2.5 1.5 46.79 1.25 1.34 0.81 38.996 10 4.0 1.5 47.06 3.22 2.36 0.82 38.00__________________________________________________________________________ .sup.a Gas chromatographic conditions: 60 meter column, 0.25 mm diameter, coated with 0.25 μm thick film of Supelco SPB5; nitrogen carrier gas (200 kPa gauge pressure, 120 mL/min split flow, ratio = ˜200:1); initial temp. 40° C.; final temp. 300° C.; heating rate 5° C./min.; injector temp. 220° C.; flame ionization detector, detector temp. 280° C.; sample dissolved at 1.5% in isooctane, 2 μL injected using autosampler. .sup.b Formed stable emulsion which would not separate on standing.
From the data in Table 1, it can be seen that, for the conditions described, there is an optimum range of water concentration in the aqueous sulfuric acid mixtures for purification of crude benzocyclobutene. If the water concentration is too high (runs 5 and 6, Table 1), substantial amounts of styrene and phenylacetylene remain in the treated solution, with the amounts of unreacted styrene and phenylacetylene increasing with increasing water concentration. If the water concentration is too low (runs 1 and 2, Table 1), the system forms an emulsion (probably from sulfonation of the benzocyclobutene) and the aqueous acid phase cannot be mechanically separated from the organic phase, even when large amounts of water are added. At optimum intermediate water concentrations in the aqueous acid phase, very little unreacted styrene and phenylacetylene remain but the two phases can be easily separated. Near the lower boundary of optimum water concentration (runs 7 and 3, Table 1) some of the benzocyclobutene appears to be lost to sulfonation or other reactions as shown by the lowered relative size of the benzocyclobutene gas chromatographic peak. Within this region, the benzocyclobutene loss increases with decreasing water concentration.
EXAMPLE 2
This example shows the effect of contact time on styrene and phenylacetylene removal from crude benzocyclobutene by a mixture of 100 parts of reagent grade concentrated sulfuric acid (95.8% H 2 SO 4 ) and 15 parts of water. Three sample vials (as in Example 1) were each filled with 2.5 grams of this aqueous acid mixture and 10 grams of the same crude benzocyclobutene mixture used in Example 1. The vials were shaken vigorously, placed on a rotating tumbler, and tumbled for different lengths of time at room temperature. Three grams of water were then added to each mixture and the aqueous and organic phases were mechanically separated. The organic phase was dried over calcium oxide, separated from the calcium oxide by centrifugation, and then analyzed by gas chromatography (conditions given in footnote to Table 1). Results are shown in Table 2 below.
TABLE 2__________________________________________________________________________Contact time betweenorganic phase and Organic phase composition, GC peak area %.sup.a aqueous acid Phenyl- o- o-MethylbenzylRun # solution, minutes BCB acetylene Styrene Xylene chloride__________________________________________________________________________1 20 47.09 2.90 2.07 0.82 37.922 40 48.10 0.36 0.35 0.83 39.243 80 47.23 0.04 0.03 0.82 39.78__________________________________________________________________________ .sup.a Gas chromatographic conditions same as in footnote (a) to Table 1.
One can see from Table 2 that, for the conditions described, a contact time of an hour or more gave best removal of styrene and phenylacetylene with little if any increased loss of benzocyclobutene.
COMPARATIVE EXAMPLE 3
A batch of crude benzocyclobutene (approximately 3700 mL in volume) was prepared by combining the organic phases from a series of vacuum pyrolyses of o-methylbenzyl chloride. The crude benzocyclobutene contained 38.5% benzocyclobutene, 2.0% phenylacetylene, 1.2% styrene, 0.4% o-xylene, and 48.0% o-methylbenzyl chloride by gas chromatography (conditions given in footnote to Table 1). The mixture was mixed with 5% of EPON® Resin 828 (a nonvolatile scavenger for any HCl which would be formed during the distillation). It was then distilled at approximately 20 mm Hg (2700 Pa) at a 10:1 reflux ratio through a 30-plate Oldershaw column 5.1 cm in diameter. The distillation results are given in Table 3 below.
As shown in Table 3, most of the distillation cuts containing predominantly benzocyclobutene were heavily contaminated with styrene and phenylacetylene. Only in one benzocyclobutene cut (cut #5) were the concentrations of each of these two impurities each below 1%. This cut contained less than 11% by volume of the crude material. (Compositions of distillation cuts after cut #6 are not shown, since these consisted predominantly of the starting material, o-methylbenzyl chloride, which is significantly less volatile than benzocyclobutene, styrene and phenylacetylene.)
TABLE 3__________________________________________________________________________Boiling Cut composition, GC peak area %.sup.crange, °C..sup.a Volume Phenyl o- o-MethylbenzylCut # begin end %.sup.b BCB acetylene Styrene Xylene chloride__________________________________________________________________________CT.sup.e 1.81 151 153 5.2 68.9 17.1 8.1 3.82 153 154 5.2 85.1 7.8 4.8 1.63 154 154 4.5 89.5 5.4 3.7 1.14 154 154 10.6 93.8 3.0 2.5 0.65 154 154 10.7 98.3 0.6 0.8 0.16 154 206 11.3 45.3 0.03 0.06 41.67 206 204 6.28 204 205 6.29 205 206 6.010 206 206 13.211 206 205 5.9KR.sup.d 26.5__________________________________________________________________________ .sup.a Corrected to one atmosphere pressure. .sup.b Volume percentages add to over 100%, possibly because of expansion due to demixing which accompanies distillation. .sup.c Gas chromatographic conditions were same as in footnote (a) of Table 1. .sup.d Kettle residue after distillation. .sup. e Material collected in dry ice trap during distillation.
EXAMPLE 3
A batch of crude benzocyclobutene was prepared by combining the organic phases from a series of vacuum pyrolyses of o-methylbenzyl chloride and performing a simple distillation to remove nonvolatile impurities. The crude benzocyclobutene contained 48.9% benzocyclobutene, 3.6% phenylacetylene, 2.6% styrene, 0.8% o-xylene, and 39.8% o-methylbenzyl chloride by gas chromatography (conditions given in footnote to Table 1). A 1000-gram portion of the crude benzocyclobutene was then mixed with a blend of 250 grams commercial concentrated H 2 SO 4 and 37.5 grams water in a bottle with vigorous magnetic stirring. The temperature had risen to 55° C. approximately 5 minutes after the crude benzocyclobutene and aqueous acid were mixed. Thirty minutes after mixing, the temperature of the mixture had risen to 62° C. although no external heat was applied. Additional water (300 g) was then added to the mixture and the aqueous and organic layers were allowed to separate. The organic layer was then dried over calcium oxide.
Analysis by gas chromatography (conditions given in footnote to Table 1) showed that the acid-treated organic layer contained 41.0% benzocyclobutene, 0.04% phenylacetylene, 0.85% o-xylene, and 36.6% o-methylbenzyl chloride, with styrene undetectable. The acid-treated organic layer was mixed with 5% of EPON® Resin 828 (a nonvolatile scavenger for any HCl which would be formed during the distillation) and was then distilled at approximately 20 mm Hg (2700 Pa) at a 4:1 reflux ratio through a 30-plate Oldershaw column 2.54 cm in diameter. The distillation results are given in Table 4 below.
One can see that styrene and phenylacetylene contamination was almost nonexistent in the benzocyclobutene cuts obtained by distillation of the acid-treated material. Styrene and phenylacetylene were not regenerated to any significant degree in the distillation pot from the products of their previous reaction with aqueous acid. (As in Table, #3, composition of distillation cuts after cut #5 are not shown, since these consisted predominantly of the starting material, o-methylbenzyl chloride, which is a significantly less volatile than benzocyclobutene, styrene or phenylacetylene.)
TABLE 4__________________________________________________________________________Boiling Cut composition, GC peak area %.sup.crange, °C..sup.a Volume Phenyl o- o-MethylbenzylCut # begin end %.sup.b BCB acetylene Styrene Xylene chloride__________________________________________________________________________CT.sup.e 0.21 149 152 5.2 89.73 0.36 6.972 152 152 4.6 96.39 0.09 2.813 152 151 9.6 98.57 0.02 1.174 151 153 10.5 99.01 0.02 0.275 153 202 4.9 54.90 0.03 0.03 27.656 202 203 5.97 203 203 5.18 203 203 4.99 203 203 5.210 203 203 5.311 203 202 5.712 202 185 2.5KR.sup.d 39.0__________________________________________________________________________ .sup.a Corrected to one atmosphere pressure. .sup.b Volume percentages add to over 100%, possibly because of expansion due to demixing which accompanies distillation. .sup.c Gas chromatographic conditions were same as in footnote (a) of Table 1. .sup.d Kettle residue after distillation. .sup. e Material collected in dry ice trap during distillation. | A process for the recovery of a cyclobutenoarene such as benzocyclobutene from a mixed reaction product is disclosed. The mixed reaction product is contacted with an aqueous acid solution so as to convert impurities to species such as oligomers and water addition products which have sufficiently reduced volatility that they can be separated from cyclobutenoarene by distillation. The cyclobutenoarene is then recovered from the organic phase. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for making molds for making metal castings, which molds are made from a liquid to pasty composition, which contains in an aqueous phase a binder and, in addition, at least one mineral solid substance, particularly cristobalite, said apparatus comprising two approximately concentrically arranged containers, which are arranged one over the other and adapted to be vacuum-tightly sealed and to be connected to a vacuum pump by lines which are adapted to be shut off, which apparatus also comprises a plurality of pipe lengths, which are arranged in a circular array and interconnect the containers and are adapted to be shut off by respective shut-off valves and serve to transfer the composition from the upper container into the lower container and have inlets, which are open at the bottom of the upper container to a distributing space, which is defined on one side by the cylindrical vertical shell of the upper container and on the other side by a flow guiding surface, and have outlets which are disposed in the lower container over respective cups, which are to be filled.
2. Description of the Prior Art
In a known apparatus of that kind the composition is mixed by means of rotating mixing members in the upper container under a reduced pressure and by said mixing members is also caused to flow or urged into the inlets of the pipe lengths. In the lower container the composition falls from the pipe lengths into the cups to fill the same also under a reduced pressure. The mixer is entirely disposed in the upper container and comprises a drive motor having an output shaft which extends almost as far as to the cover and which carries revolving stirring blades, which extend in a stirring compartment between the housing of the drive motor and the cylindrical shell of the upper vessel. By means of an at least partly perforate, profiled sheet metal element the stirring compartment is separated from a compartment that is disposed in the upper portion of the upper vessel and in which rotatable blades are disposed, which are mounted on the output shaft and can be operated to transfer a pulverulent mixture, e.g., of dry gypsum and cristobalite, from the upper compartment into the water-containing stirring compartment through the perforations of the profiled sheet metal element so that the composition can be formed in the lower compartment. Because the mixing members rotate in the upper container, the known apparatus must be filled to a relatively high degree if an intensive mixing of the composition is to be effected within a tolerable time and a cleaning of the apparatus with a reasonably small loss of material is to be permitted. But a processing of the composition also in small quantities will be required, e.g., in the making of small, high-quality casting molds, particularly if the setting time is shortened by the use of chemical accelerators.
It is also known to provide only one evacuated vessel for a venting of the cups when they are filled under atmospheric pressure. In that case the composition is formed by stirring under atmospheric pressure outside the evacuated vessel. Compared to the operation of the known filling apparatus which has been described first hereinbefore and in which the cups are filled at the same time the processing described in the second place, which is often adopted in small plants, involves a relatively high expenditure of time and labor.
SUMMARY OF THE INVENTION
It is an object of the invention so to improve a filling apparatus of the kind described first hereinbefore that it meets the requirements for an economical series production of molds and also meets the requirements arising in practice regarding the batchwise processing of quantities which vary within an extremely large range.
That object is accomplished in accordance with the invention in that an approximately rotationally symmetrical flow guiding body having a closed peripheral surface is concentrically disposed in the upper vessel and a distributing space, which is free of internal fixtures and is defined by the cylindrical shell of the upper container and the peripheral surface of the flow guiding body extends from the cover of the upper container to the inlets of the pipe lengths and terminates at said inlets as an annular mouth space.
In that arrangement the cups are filled in an evacuated filling container and a separate additional evacuated container is provided, which serves only to divide the composition into batches and to supply the composition to the cups under a vacuum and for this reason contains no mixing means at all. The additional container is a mere distributing and venting container, i.e., virtually a multiple hopper, for distributing the composition in proper batches to the cups. The residence time of the composition will depend on the consistency of the composition and on an optionally adjustable pressure difference between the filling container and the other evacuated container, which serves as a multiple hopper. A prolongation of that residence time by mixing means which might be required will inherently be avoided.
In that arrangement the division of the composition into batches for filling respective cups, which division is effected as the composition flows into the pipe lengths, and the filling operation proper are effected under a vacuum. The mixing of the components of the composition to form the latter is performed outside the evacuated space. This will result in the following advantages:
Stirring equipment which is most powerful and inexpensive can be used for the external mixing to form the composition. Such stirring equipment is available on the market as mass-produced equipment. Besides, the time required for the distribution in the upper container and for the filling operation in the lower container may be shortened so that the conditions for the use of chemical accelerators are improved. The distributing compartment, which is provided in the upper container and does not contain any rotating stirring member, is designed to permit a processing of batches of widely varying amounts so that the apparatus can comply with the processing requirements of a wider range of customers. On the other hand that advantage of the apparatuses of the kind described first hereinbefore which resides in that venting is effected during the distributing and filling operations is preserved as well as the possibility to suck pasty compositions to the cups through the pipe lengths under the action of a pressure drop between the upper and lower containers. The apparatus can be manufactured at lower cost and the process can be performed within a shorter time because the stirring to form the composition by stirring blades arranged in the upper container takes some more time, as a rule, than the external stirring by means of a powerful stirrer which is available on the market. In that connection it may be mentioned that a shortening of the processing time will also promote the quality of the casting molds, particularly if chemical accelerators are used. The following fact is of special significance in comparison with the apparatus described first hereinbefor: If the composition is stirred in the upper container, as is the case in the known apparatus, parts of the dry, unmixed powder mixture may enter one or more cups as they are filled. This is so because small quantities of the dry powder mixture may be deposited on the upper portions of the stirring blades and on the walls above the surface level of the composition which is being stirred in the upper container, i.e., in the upper portion of the upper container. During the filling operation, small shakes may cause the still dry material to fall into the stirred composition. Defects in the castings will be caused by such dry material when it has entered the cups.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation showing the apparatus in an operative position, partly broken away.
FIG. 2 is a top plan view showing the apparatus of FIG. 1.
FIG. 3 is a vertical sectional view showing on a larger scale a detail of FIG. 1.
FIG. 4 is a horizontal sectional view taken on line IV--IV in FIG. 3.
FIG. 5 is a horizontal sectional view taken on line V--V in FIG. 3 and
FIG. 6 is a view that is similar to FIG. 1 and shows the apparatus during the cleaning operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An illustrative embodiment of the invention will now be described more in detail with reference to the drawing.
The apparatus 10 is used to make molds for making metal castings, e.g., to make molds for centrifugal casting or other casting processes, which molds are made by a lost-wax process. The casting molds are made from a liquid to paste composition, which in an aqueous phase contains, e.g., gypsum as a binder and at least one further mineral substance, particularly a high-temperature modification of quartz, usually described as cristobalite. The apparatus comprises means for mixing the composition and for filling the composition into vessels, such as cups 40, in which the composition sets to form the casting molds. Those devices are mounted on a bench 12 together with a vacuum pump and with cleaning devices. As is particularly apparent from FIGS. 1 and 3, two cylindrical containers 13 and 14 which are adapted to be vacuumtightly sealed are arranged one over the other on the bench. Said containers are interconnected by line sections 43, 45; 47, which are adapted to be shut off, to a vacuum pump 15. One line section 47 extends from one side of a tee fitting 46 that is mounted on the vacuum pump 15, and that line section 47 is connected to a vacuum port 35 of the lower container 14. The line section 45 extends from the other side of the tee fitting 46 and opens into a tubular port 44 that is provided in the top deck of the bench. From the tubular port 44, a further line section 43 extends to a tubular port 25 of the upper container 13, which is adapted to be tightly sealed by a cover 21 and a sealing ring 22. The reduced pressure in the container 13 can be eliminated by means of an air inlet plug valve 26 that is provided in the cover 21. The line sections 45 and 47 are adapted to be connected by couplings, which will automatically close the tubular ports when the line sections are detached. The cover 21 of the upper container 13 and the cover 31 of the lower container 14 are provided with respective manometers 24; 34, which will indicate the underpressure in the associated container. By means of feet 33 the container 14 is mounted on a lower deck of the bench 12. The two containers 13, 14 communicate with each other through vertical pipe lengths 28, which are arranged in a circular array. Each pipe length is adapted to be shut off by means of a shut-off valve, which consists of a ball plug valve. The inlets 27 of the pipe lengths 28 are mounted in the bottom of the container 13, as is particularly apparent from FIGS. 3 and 4. End portions 29 of the pipe lengths 28 extend into the interior of the lower container 14 and terminate over respective cylindrical cups 40. Each cup 40 consists of two interfitting parts consisting of a rubber base 41 and a cylindrical metal tube 42. The cups 40 are arranged in a circular array on a bottom 37 of a tray 36. The tray 36 with all cups 40 can be removed from and introduced into the lower container 14 by hand by means of a handle 38. The handle 38 has a shank, which has a screw-threaded extension 39 that is anchored in a central projection of the bottom 37. The lower container 14 has a cylindrical shell 30, which is immovably held in the frame of the bench 12. As is particularly apparent from FIG. 3, the switch 49 for the vacuum pump is mounted on the top deck of the bench and is connected to the vacuum pump by the cable 48. Beside the lower container 14, the lower deck of the bench 12 contains a cylindrical washbasin 16, which has an outlet fitting 55, which terminates over a collecting vessel 17, which stands on the floor. The collecting vessel 17 is divided into a main chamber 17a and an overflow chamber 17b. The latter is provided with an outlet fitting 57, which is connected to a water drain 5.
A rotationally symmetrical flow guiding body 23 is provided in the upper container 13 and is rotationally symmetrical with respect to the axis of symmetry of the upper container 13. In the illustrative embodiment shown on the drawing the flow guiding body 23 has the shape of a hyperboloid of revolution that has a vertical longitudinal axis. The horizontal base surface of the flow guiding body 23 rests on the bottom of the container 13. Alternatively, the flow guiding body 23 may have the shape of a cone, which has a rounded apex and has a base surface which rests on the bottom of the container 13. Alternate shapes of the flow guiding body 23 may be hybrids of hyperboloidal and frusticonical shapes (FIG. 3). The flow guiding body 23 has a closed peripheral surface. A distributing space 58 which contains no internal fixtures is defined by the cylindrical shell of the upper container 13 and the peripheral surface of the flow guiding body 23 and extends from the cover 21 to the inlets 27 of the pipe lengths 28. Over said inlets 27 the distributing space 58 terminates in the form of an annular mouth space 58'. The flow guiding body 23 is preferably screw-connected to the bottom of the container 13 and extends into the upper half of the height of the container 13. In the lowermost one-third of the height of the flow guiding body 23 its peripheral surface includes with the vertical an angle which is smaller than 15 degrees.
As a result, the mouth space 58' adjoining the inlets 27 is defined by an approximately vertical peripheral surface portion of the flow guiding body 23. The cover 31 rests via the sealing ring 32 on the top rim of the cylindrical shell 30 of the lower container 14 and is engaged on its underside by radial flanges of the end portions 29. As a result, the cover 31 is connected by the pipe lengths 28 to the upper container 13 to form a structural unit with the upper container 13 and the flow guiding body 23. That unit can be shifted as such from an operative position shown in FIGS. 1 to 3 to a cleaning position shown in FIG. 6. In that cleaning position that unit is arranged with the cover 31 resting on the top rim of the washbasin 16. That rim is designed like the top rim of the shell 30 of the lower container 14. A water supply line 52 is connected by a water port 51, which is adapted to be uncoupled, and a water hose 53 to a spray nozzle 54. As is apparent from FIG. 6 the pipe lengths 28 are open during the cleaning operation so that the dirty water can flow through the outlet fitting 55 of the washbasin 16 into the main chamber 17a of the collecting vessel 17. In that main chamber the coarse particles of the composition which have been flushed out settle to form a sediment 56. The water from which coarse solid particles have been removed flows through the overflow chamber 17b and the outlet fitting 57 into the drain 5.
The mode of operation of the apparatus will now be described: The cups 40 are placed in a circular array on the bottom 37 of the tray 36 when the latter is outside the container 14. By means of the handle 38 the tray 36 with the cups 40 thereon is introduced into the lower container 14. The unit consisting of the upper container 13, the pipe lengths 28 and the cover 31 is then placed on the cylindrical shell 30 of the lower container 14 in such a manner that the lower end portions 29 of the pipe lengths 28 terminate over respective cups. The ball plug valves in the pipe lengths 28 are closed at that time.
In a mixing trough 18 which has been placed into the washbasin 16 the components of the desired composition are then mixed to form the composition used to make the casting molds. That mixing is effected by a sufficiently powerful stirrer 19, which is commercially available. When the composition has been formed it is poured into the upper container, whereafter the cover 21 is applied and the vacuum pump 15 is started. The vacuum is established in the two containers 13, 14 at the same time. Under the reduced pressure, the air which is contained in the composition is sucked upwardly so that the composition rises to an extent that depends on its viscosity. The composition will subside approximately to the initial level as soon as the air has been removed. That operation takes about 120 seconds. The ball plug valves are then opened one after the other so that all cups can be filled almost at the same time. As soon as a cup 40 has been completely filled the associated ball plug valve is closed. When conventional compositions, which contain gypsum as a binder, are employed, the filling time will amount to about 60 seconds. As soon as the cups 40 have been completely filled the vacuum pump is deenergized and air is admitted to both containers 13, 14. The upper container is then rinsed in the position shown in FIG. 6. When compositions having a relatively high viscosity are to be filled into cups, the vacuum in the upper container 13 is separately eliminated so that air may be admitted to that container during the filling operation and a pressure drop can be set up between the upper and lower containers. That pressure drop will assist the flow of the composition through the pipe sections 28. If the external mixing takes about two minutes, the total time until the filling has been completed may be less than five minutes so that the aqueous and solid phases of the slurry will not segregate from each other. Such segregation is often the cause of defects in the castings.
Again with reference to FIG. 3 the right-hand cup 40 contains a wax tree 59 and the composition has been poured from the outlet end portion 29 into the cup 40 around the wax tree 59 and has been allowed to solidify in the cup 40 to form a casting mold 60. The wax tree is then melted and the molten wax is poured out of the mold 60. | The apparatus comprises two containers, which are adapted to be connected to a vacuum pump. The upper container contains a rotationally symmetrical guiding body. A distributing space is defined by the shell of the upper container and the closed peripheral surface of the guiding body and extends from the cover of the upper container to pipe lengths, which terminate at their lower end over cups arranged in the lower container. As a result, the apparatus permits an economical making of molds in series and meets the requirements arising in practice regarding the batchwise processing of batches in quantities which vary within an extremely wide range. | 1 |
TECHNICAL FIELD
This invention is related to phosphors that emit ultraviolet (UV) radiation and lamps containing UV-emitting phosphors. More particularly, this invention is related to phosphors that emit UV radiation when stimulated by vacuum ultraviolet (VUV) radiation.
BACKGROUND OF THE INVENTION
The use of ultraviolet (UV) radiation for medical phototherapy is well established. In fact, UV therapy is now involved in the treatment of more than 40 types of skin diseases and disorders such as psoriasis, vitiligo and eczema. Phototherapy studies of UVB wavelengths between 260 nm and 320 nm have found that a narrow-band UVB emission centered at approximately 312 nm is most effective for phototherapy while at the same time limiting undesirable erythemal effects. Since the skin's erythemal (or sunburning sensitivity) is at its maximum at about 297 nm, a narrow-band emission at about 312 nm allows a patient to have longer treatment times before an erythemal response appears.
The Gd 3+6 P 7/2 --> 8 S transitions are ideal for 312 nm narrow-band emissions. However, f-f transitions of rare earths, being parity forbidden, are very weak and the use of a sensitizer is necessary to obtain a useful emission intensity. One of the first narrow-band UVB phosphors to be developed was sensitized with bismuth, e.g., (Gd 0.5 ,La 0.487 )B 3 O 6 :Bi 0.013 . On excitation by 254 nm radiation, this borate phosphor emits the characteristic radiation with a very narrow band centered on 312 nm. However, because of the toxicity of the bismuth sensitizer, other narrow-band UVB phosphors were developed, in particular YMgB 5 O 10 :Gd,Ce (U.S. Pat. Nos. 4,319,161 and 6,007,741), and YMgB 5 O 10 :Gd,Ce,Pr (U.S. patent application Ser. No. 10/907,349, filed Mar. 30, 2005).
For the most part, UV-emitting phosphors have been optimized for excitation by the 254 nm emission of the low-pressure mercury discharge used in conventional fluorescent lighting. However, because of environmental concerns, there is a growing need for mercury-free lighting technologies. One such technology is the xenon discharge lamp which produces radiation at about 172 nm in the vacuum ultraviolet (VUV) region of the electromagnetic spectrum. It would be advantageous to develop phosphors which are optimized for excitation in the VUV region and could be used in a Xe-discharge lamp for medical phototherapy.
SUMMARY OF THE INVENTION
Cerium-activated strontium magnesium aluminate, Sr(Al,Mg) 12 O 19 :Ce, is a commercial UVB-emitting phosphor used in suntan lamps as a minor component to increase the tanning efficiency of such lamps and reduce the time needed to obtain a tan of the desired level. This phosphor is excited by 254 nm radiation and has a broad band emission centered approximately at 307 nm.
The amount of Ce 3+ activator substituted for strontium on the Sr 2+ sites is counterbalanced by substituting a similar amount of Mg 2+ for aluminum on the Al 3+ sites leading approximately to charge balance. In addition to and beyond the benefit of charge balancing, the presence of an optimum Mg 2+ level in the phosphor lattice is thought to be necessary for maximum light output. Most of the rare earth 3+ ions have similar atomic and ionic radii, and it was thought that other rare earth 3+ ions could replace cerium in the phosphor lattice as in, for example, the quantum-splitting phosphor Sr(Al,Mg) 12 O 19 :Pr which is described in U.S. Pat. Nos. 5,571,451 and 6,613,248 and U.S. application Ser. No. 11/160,052, filed Jun. 7, 2005.
The inventors discovered that when strontium magnesium aluminate is activated with gadolinium a narrow-band UV line emission is observed at about 310 nm. This is a slightly lower wavelength than exhibited by the above-mentioned yttrium magnesium pentaborate phosphors, but it is still close to the optimal wavelength for medical phototherapy. The UV emission intensity of this phosphor is very weak under 254 nm excitation, however, under VUV excitation, the emission intensity is significantly greater than the commercial yttrium magnesium pentaborate phosphors. Thus, the phosphor of this invention may be used in a Xe-discharge lamp to provide a mercury-free lamp for medical phototherapy.
The composition of the gadolinium-activated strontium magnesium aluminate phosphor of this invention may be generally represented by the formula, Sr(Al,Mg) 12 O 19 :Gd. In a preferred embodiment, the phosphor may be represented by the formula, Sr 1−x Gd x Al 12−y Mg y O 19 , where x ranges from about 0.03 to about 0.15 and y ranges from greater than 0 to about 0.2. More preferably, y ranges from x−0.02 to x+0.02 for optimal charge balance. A more preferred value for x is about 0.07. It is possible to include additional coactivators such as Ce and Pr to increase the phosphor's sensitivity to 254 nm radiation. However, these coactivators tend to decrease the VUV-excited emission and are therefore less preferred.
In addition, the gadolinium-activated strontium magnesium aluminate phosphor can easily be prepared using dry blending and a single firing step, whereas the yttrium magnesium pentaborate phosphors are prepared through a more complicated process of precipitation and double firing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph comparing the UV emission of the phosphor of this invention with two yttrium magnesium pentaborate phosphors.
FIG. 2 is a cross-sectional illustration of a lamp containing the phosphor of this invention.
FIG. 3 is a graph of the relative intensity of the ultraviolet emission of the phosphor of this invention as a function of the amount of the gadolinium activator.
FIG. 4 is a graph of the excitation spectra of the phosphor of this invention compared with a yttrium magnesium borate phosphor.
DETAILED DESCRIPTION OF THE INVENTION
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims taken in conjunction with the above-described drawings.
FIG. 1 shows the VUV-excited emission spectra between 300 nm and 320 nm of a Sr(Al,Mg) 12 O 19 :Gd phosphor and two 312 nm line emitting phosphors, YMgB 5 O 10 :Gd, Ce and YMgB 5 O 10 :Gd, Ce, Pr. Under VUV-excitation, the Sr(Al,Mg) 12 O 19 :Gd phosphor of this invention exhibits a much more intense UV line emission in the region of interest for medical phototherapy.
FIG. 2 illustrates a type of VUV-excited device which is generally referred to as a dielectric barrier discharge lamp. The flat rectangular-shaped device is shown in cross section. The discharge vessel 10 is constructed of a transparent material such as glass and comprises a front plate 3 and a back plate 2 which are joined by frame 5 at the periphery of the plates. The discharge vessel 10 encloses discharge chamber 15 which contains a rare gas, typically xenon, or mixture of rare gases, and is used to generate a discharge which emits vacuum ultraviolet (VUV) radiation. A preferred discharge is a Xe-excimer discharge which emits VUV radiation at about 172 nm. The back plate 2 has multiple strip electrodes 6 which may serve as anodes and cathodes during operation. At least some of the electrodes 6 ′ are covered with a dielectric barrier layer 7 . Further examples of dielectric barrier discharge lamps are described in U.S. Pat. Nos. 6,566,810, 6,246,171 and 6,469,435.
A UV-emitting lamp may be formed by coating the inner surface of the top plate 3 and back plate 2 with a phosphor layer 11 that contains the UV-emitting phosphor of this invention. The UV-emitting phosphor converts at least some of the VUV radiation from the gas discharge into longer wavelength UV radiation. In a preferred embodiment, the lamp produces a narrow-band UV line emission at about 310 nm which may be used for medical phototherapy.
The Sr(Al,Mg) 12 O 19 :Gd phosphor may be prepared by thoroughly dry blending the appropriate metal oxides, hydroxides, carbonates, and halides, then firing the blended material in a reducing atmosphere, preferably 75% H 2 -25% N 2 , for a time and temperature sufficient to form the phosphor, preferably at least about 1.5 hours at a temperature between about 1500° C. and about 1600° C. The fired material may be sifted and further processed with water and/or chemical washing and milling steps before it is dried and sifted for lamp use. Chemical precipitation techniques may also be used to prepare a thorough mixture in lieu of dry blending.
EXAMPLES
Table 1 lists the reagents, their assays, their formula weights, and the quantities used for inventive samples 1-11. Each sample was formulated to contain 0.083 moles Mg/mole phosphor. Depending on the amount of activator, it may be necessary to adjust the amount of Mg in the formulation to obtain optimal charge compensation and brightness. Such adjustments are well within the capabilities of one skilled in the art in view of the present disclosure. In a preferred embodiment, the amount of magnesium in the phosphor ranges from greater than 0 to about 0.2 moles Mg/mole of phosphor.
The materials were weighed, added to a 500 ml plastic bottle, and then thoroughly blended on a paint shaker. The blended materials were then loaded into 100 ml alumina crucibles and fired for 2 hrs at 1550° C. in a continuous furnace under a reducing atmosphere of 75% H 2 /25% N 2 . The fired phosphors were then screened through a −60 mesh nylon screen and measured for their emission properties under VUV excitation.
TABLE 1
Sample
SrCO 3
SrF 2
Pr 4 O 7
MgO
Gd 2 O 3
CeO 2
Al(OH) 3
Assay
0.997
0.995
1.000
0.994
0.995
1.000
0.996
Formula
147.630
127.620
675.63
40.304
362.500
172.120
78.003
Wt. (g/mol)
1
19.26 g
7.95 g
0.34 g
0.67 g
1.09 g
0.34 g
186.70 g
2
18.67 g
7.95 g
0.34 g
0.67 g
1.82 g
0.34 g
186.70 g
3
18.97 g
7.95 g
0
0.67 g
1.82 g
0.34 g
186.70 g
4
18.08 g
7.95 g
0.34 g
0.67 g
2.55 g
0.34 g
186.70 g
5
18.97 g
7.95 g
0.34 g
0.67 g
1.82 g
0
186.70 g
6
18.37 g
7.95 g
0.17 g
0.67 g
2.55 g
0.17 g
186.70 g
7
17.49 g
7.95 g
0
0.67 g
4.01 g
0
186.70 g
8
16.30 g
7.95 g
0
0.67 g
5.46 g
0
186.70 g
9
18.08 g
7.95 g
0
0.67 g
3.28 g
0
186.70 g
10
19.26 g
7.95 g
0
0.67 g
1.82 g
0
186.70 g
11
18.67 g
7.95 g
0
0.67 g
2.55 g
0
186.70 g
The UV line emissions of the samples were measured with a Perkin-Elmer LS-50B model spectrophotometer, which had been modified with a nitrogen-purged sample chamber and fitted with a Xe lamp for vacuum ultraviolet excitation. The excitation source is a commercially available xenon excimer lamp (XeCM-L from Resonance, Ltd., Barrie, Ontario, Canada) used to illuminate powder plaques while excluding air from the VUV beam path. This particular lamp has a very intense sharp Xe emission line at 147 nm and a broad, much less intense Xe excimer band emission at about 172 nm. Table 2 gives the formulated amounts of the activators in samples 1-11 in moles of activator/mole of phosphor and the resulting relative integrated intensities of their UV line emission between 305-315 nm. Two yttrium magnesium borate phosphors were also measured as controls. The integrated intensities are given relative to Control 1.
TABLE 2
Sample
Gd
Ce
Pr
Rel. Intensity
Control 1-
NA
NA
NA
100%
YMgB 5 O 10 : Gd, Ce
Control 2-
NA
NA
NA
169%
YMgB 5 O 10 : Gd, Ce, Pr
1
0.03
0.01
0.01
148%
2
0.05
0.01
0.01
226%
3
0.05
0.01
0
236%
4
0.07
0.01
0.01
257%
5
0.05
0
0.01
292%
6
0.07
0.005
0.005
302%
7
0.11
0
0
335%
8
0.15
0
0.01
335%
9
0.09
0
0
350%
10
0.05
0
0
384%
11
0.07
0
0
437%
The amount of gadolinium that yielded the maximum emission intensity was approximately 0.07 moles Gd/mole phosphor, but all levels between 0.03 and 0.15 moles Gd/mole phosphor yielded a relatively good emission intensity. The addition of Ce and Pr coactivators tended to reduce the intensity of the UV line emission under VUV excitation. The effect of the amount of Gd activator alone on the emission intensity is shown in FIG. 3 which is a plot of the relative intensity for samples 7 and 9-11 (no coactivators).
The excitation spectrum of sample 11 is shown in FIG. 4 together with the excitation spectrum of a YMgB 5 O 10 :Gd,Ce,Pr phosphor. For sample 11, the intensity of the UV emission at 311 nm was observed while the excitation wavelength was varied. For the YMgB 5 O 10 :Gd,Ce,Pr phosphor, the intensity of the UV emission at 313 nm was used. In both cases, the intensity of the UV emission was normalized to the intensity of the excitation wavelength. It can be seen in FIG. 4 that the excitation maximum for the Sr(Al,Mg) 12 O 19 :Gd phosphor occurs at about 172 nm which makes it ideal for use with a Xe-excimer discharge. There is also significant excitation down to at least 140 nm making the phosphor useable with other VUV wavelengths. On the other side of the maximum, there is virtually no excitation of the phosphor above about 188 nm. Almost the opposite is true for the YMgB 5 O 10 :Gd,Ce,Pr phosphor. The level of excitation below about 180 nm is significantly less than the excitation at about 254 nm. This means that the yttrium magnesium borate phosphor would not be nearly as effective as the Sr(Al,Mg) 12 O 19 :Gd phosphor when used with a VUV source such as a Xe-excimer discharge.
While there have been shown and described what are present considered to be the preferred embodiments of the invention, 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. | A UV-emitting phosphor is described wherein the phosphor is excitable by vacuum ultraviolet radiation (VUV). The phosphor is a gadolinium-activated strontium magnesium aluminate which preferably has an excitation maximum at about 172 nm. The phosphor exhibits a narrow-band UV emission at about 310 nm which makes it useful for medical phototherapy applications. | 2 |
BRIEF SUMMARY OF THE INVENTION
During the manufacturing process of bipolar integrated circuits, the many semiconductor elements are generally isolated from each other by a process known as "junction isolation" in which a pocket of heavily-doped subepitaxial material is buried between the epitaxial layer and the common substrate material to form a current-blocking reverse-biased junction. The isolation is completed with "sidewall" junctions which intercept the lower junction. While junction isolation is both economical and effective under normal applications, there are conditions under which its inherent leakage currents and/or junction capacitances make it unacceptable, and in environments subject to intense ionizing radiation that may penetrate the casing of the integrated-circuit package, photocurrents may completely destroy isolation junctions. The radiation tolerance of MOS integrated circuits is also limited by primary and secondary photocurrents (a dose-rate effect) and, in addition, by the total-dose effect of electrical charge accumulation in associated dielectric materials and in oxide-semiconductor interface regions. For these reasons integrated-circuit devices are often fabricated with the many semiconductor elements separated from each other by a dielectric isolation in which a thin layer of dielectric material is formed between each single-crystal silicon pocket or island and a common polycrystalline silicon supporting layer. Most dielectric-isolation fabrication schemes also produce sidewall isolations which involve dielectric materials rather than p-n junctions. Such dielectric isolation offers significant advantages where speed, electrical isolation, and tolerance to ionizing radiation are important.
Formerly, the technological capacity for manufacturing dielectrically-isolated single-crystal silicon films on supporting layers has primarily included the so-called "single-poly", "double-poly", and "silicon-on-sapphire" processes. The first two processes lack the dimensional control necessary to define very thin silicon films and the incorporated sidewall isolations are relatively large thereby imposing an additional restriction on component density and speed. On the other hand, the silicon-on-sapphire process provides the precision dimensional control that is necessary and silicon films fabricated with this process can be made one micrometer or less in thickness with the uniformity of approximately 0.1 micrometers on a sapphire dielectric substrate. However, while the silicon-on-sapphire process was a considerable advance in the art, its use in the fabrication of many solid-state devices was limited by various properties of the sapphire material, such as its relatively low thermal conductivity, a mismatch in thermal properties at the silicon-sapphire interface, and poorly controlled process-induced and radiation-induced electrical charges within the structure. In addition, inherent limitations in the crystalline quality of the silicon film impose severe limitations on minority-carrier lifetime.
The disadvantages of the aforementioned single-poly, double-poly and silicon-on-sapphire processes are overcome by the present invention in which thin single-crystal epitaxial silicon films are formed on a polycrystalline silicon support layer and are separated therefrom by a thin dielectric isolation of either a thermally-deposited layer of silicon dioxide or a layer of silicon nitride, both of which may be selectively defined on the same chip during the disclosed process.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate a preferred embodiment of the invention:
FIG. 1 through FIG. 8 illustrate the various steps in the process of the fabrication of thin single-crystal silicon films dielectrically isolated by silicon dioxide and silicon nitride from a thick polycrystalline silicon substrate; and
FIG. 9 through FIG. 12 illustrate an alternate process which may replace the steps illustrated in FIG. 1 through FIG. 4.
DETAILED DESCRIPTION
In the following description, it is assumed that it is desired to fabricate a generalized integrated circuit including either bipolar and MOS circuit elements or "complementary" (both n- and p-channel) MOS circuit elements. In such applications, which might include ionizing-radiation exposure, the bipolar-element properties are improved or preserved by the dielectric isolation and excellent minority-carrier lifetime, while the MOS-element properties are improved (or preserved) by the dielectric isolation and the selection of supporting dielectric material. For example, it can prove most beneficial to fabricate n-channel devices in silicon nitride supported islands and p-channel devices in silicon dioxide supported islands. The benefit is achieved by selectively controlling "back-bias" and "back-channel" effects through different electrical charges (process-induced and/or radiation-induced) under differently supported devices.
The description of the preferred embodiment will cover the development of a dielectrically-isolated p-type silicon film although it is to be understood that the process is equally applicable for fabricating lightly doped n-type films. As illustrated in FIG. 1, the formation of p-type silicon films is started with a highly-doped n-type single-crystal silicon wafer 20 which, in the illustrated embodiment, has a <100> crystal orientation. After wafer 20 is cleaned, it is mounted in an epitaxial reactor and about three micrometers of silicon are removed by hydrochloric-acid vapor etching. A p-type epitaxial silicon film 22 is then grown to a thickness of approximately four micrometers on the wafer 20 by the thermal decomposition of silane at approximately 1,000° C in order to obtain an abrupt doping concentration at the n±p interface. As will be subsequently explained, the wafer 20 will eventually be removed by electrochemical etching and the sharp interface between wafer 20 and film 22 will result in a very thin p-type silicon film 22 of a uniform thickness that cannot be achieved by normal lapping and polishing methods of wafer thinning.
Upon the completion of the epitaxial growth of the p-type silicon film 22, a silicon dioxide film 24 is applied which has a thickness of between approximately 0.1 to 0.3 micrometers, preferably by thermal oxidation at approximately 1,000° C in an oxygen atmosphere.
As shown in FIG. 3, portions of the silicon dioxide film 24 that are to remain as dielectric isolation on the p-type silicon layer 22 are covered with a photoresist mask 26 and the remaining or exposed portions of the silicon dioxide are selectively removed to the surface of the film 22. The photoresist mask 26 is then removed and the entire surface is deposited with a film of silicon nitride 28 to a thickness approximating the thickness of the original silicon dioxide film 24 to produce the structure shown in FIG. 4.
The deposition of a thick layer of polycrystalline silicon on the insulator film then follows. Since this layer serves as a mechanical support for the thin film of single-crystal silicon, it should have adequate mechanical strength; therefore, as shown in FIG. 5, a polycrystalline silicon layer 30 having a thickness of approximately 250 micrometers is deposited at a relatively low temperature using dichlorosilane gas.
The original heavily-doped n-type silicon substrate wafer 20 is then removed by electrochemical etching. The entire wafer is inserted into an electrochemical etching bath which contains an electrolyte of five to seven percent hydrofluoric acid in deionized water which, under the conditions in the bath, readily attacks only the heavily-doped n-type silicon, and the wafer 20 is removed to the surface of the p-type film 22 as illustrated in FIG. 6.
The flat uniform silicon layer 22 is then hydrochloric-acid vapor thinned to the desired thickness. The wafer is then covered with a suitable masking material 32 and the p-type silicon is then anisotropically etched with a conventional material, such as potassium hydroxide to produce individual single-crystal silicon device islands 34, 36, 38 and 40, as illustrated in FIG. 7. (If the crystal wafer 20 and silicon film 22 were described in the preferred embodiment as having <111> crystal orientation, the sidewall isolation could be accomplished with local-oxidation techniques which require partial etching of the silicon film 22 in the sidewall regions for films exceeding approximately one micrometer in thickness.) Finally, a passivation layer 42 of silicon dioxide is applied by oxidizing the entire surface of the chip, as illustrated in FIG. 8. The chip now contains p-type epitaxial silicon semiconductor device islands separated from the polycrystalline silicon substrate 30 by a dielectric isolation of either a silicon dioxide layer 24 or silicon nitride layer 28. Selected islands may then be converted to n-type (or p-type if layer 22 were initially n-type) by ion-implantation or diffusion techniques, and the islands may then be processed into the desired circuit elements by conventional processes that form no part of the invention.
An alternate process which may replace the steps illustrated in FIG. 1 through FIG. 4 is illustrated in FIGS. 9 through 12. FIG. 9, which is identical to FIG. 1, illustrates a heavily-doped n-type single-crystal silicon substrate 20 supporting a p-type epitaxial silicon film 22. As illustrated in FIG. 10, the film 22 has been coated with a thin silicon nitride film 44. The silicon nitride film is then covered with a silicon dioxide film 46 and a photoresist mask 48 is used to selectively remove the silicon dioxide film 46, the remainder of which serves as a mask to define the silicon nitride film 44. As illustrated in FIG. 11, the silicon nitride film 44 is etched to the epitaxial film 22; this may be accomplished, for example, by hot phosphoric acid which readily attacks silicon nitride but which does not attack silicon dioxide. Upon completion of the etching of the silicon nitride, the chip is cleaned of all photoresist and silicon dioxide and is returned to a furnace for oxidation of the exposed areas of the silicon layer 22, as illustrated in FIG. 12; note that the oxidation which produces the silicon dioxide film 50 can have only a minor effect on the adjacent silicon nitride film 44. It will also be noted that FIG. 12 is essentially identical to FIG. 4 and, upon completion of the layer illustrated in FIG. 12, the process may be continued in accordance with the steps illustrated in FIGS. 5 through 8. | Thermoprocessing of integrated-circuit devices and ionizing radiation environments create electronic charges in dielectric isolation materials and in dielectric-semiconductor interface regions. These charges can produce serious alterations in the operating characteristics of the devices and integrated circuits. The deleterious effect of these charges may be greatly reduced by the disclosed process which produces a single-crystal silicon film dielectrically isolated from a polycrystalline silicon support by an underlying insulator of either silicon nitride or silicon dioxide, both of which may be grown by the process at selected locations on the same chip. | 8 |
FIELD OF THE INVENTION
This invention relates to interactive computer systems, and particularly to interactive computer systems for use with infants or disabled individuals.
BACKGROUND OF THE INVENTION
Severely disabled infants, such as infants with cerebral palsy (CP), frequently grow up to become passive children with limited or nonexistent speech, even when the infant possesses apparently normal cognitive skills. The following factors have been proposed to explain this passivity: limited oral motor control and a consequent diminished repertoire of speech sounds; limited ability to control its physical environment by manual manipulation of objects; and consequent limited opportunity to engage caregivers in mutually enjoyable interaction.
The incidence of infants with CP is estimated to be a least one per thousand live births. Some CP infants are likely to suffer from diminished control of the vocal tract and the respiratory system upon which speech depends. These physically impaired infants are commonly described by their parents as "quiet babies". Without a means by which a CP infant can vocalize, the cognitive and emotional development of the infant is at risk.
Babbling in infancy has been studied, and it has been found that an infant progresses through an identifiable sequence of developmental stages characterized by babbles of increasing syllabic structure and segmental contrastivity. The infant's progression through these babbling stages is assumed to be partly dependent on maturational changes in the configuration of the infant's vocal tract, and partly upon changes in motor control. Babbling has not been found to be closely related to cognitive level. Of particular interest is the finding that deaf infants use manual babbles, i.e., repetitive movements similar to the canonical babbles used by infants learning speech. This finding indicates that there is an innate capacity to practice the motor movements for babbling, regardless of whether the infant is learning to interact via speech, manual signing, or other form of non-vocal communication, such as device-assisted communication. Thus, babbling appears to be a form of exploration and rehearsal of the particular communication mode that the infant is learning which is necessary for later phonological development. Furthermore, feedback has been found to be important to an infant's progression through the various stages of babbling. For example, an infant is reinforced by the sound of his or her own voice.
The social reinforcement that the infant receives in the second half of its first year appears critical to the development of a vocalic repertoire, and to an understanding of the "rules of conversation" that must be developed to achieve meaningful communication with parents or other caregivers. By vocalizing and using manual gestures and changes of facial expression, infants can elicit responses from caregivers. By responding to such communicative initiatives, parents or other caregivers reinforce these activities. Physically disabled infants are unable to control the motor systems upon which speech is dependent, or the manual systems for playing with objects or making gestures. Due to motor impairment, they may also show little facial affect. Consequently, they lack the means for providing consistent signals to their parents or other caregivers that are available to normal infants. As a result, caregivers are unable to discern patterns of behavior to which they can attach meaning and respond accordingly. Ultimately, physically disabled infants are likely to grow up passive and with a diminished motivation to learn.
By exploring their environment, normal infants gradually develop the concept that an action brings about a consequence. The infant's early attempts at vocalization may be seen as an exploration of cause and effect using the vocal mechanism. Actions such as banging and shaking are developed and reinforced by interesting consequences. Also, toys such as rattles and noise-makers are designed to help the child in his or her explorations of cause and effect relationships. However, physically disabled infants are frequently limited in their ability to explore the environment and to vocalize, resulting in delayed or attenuated development.
SUMMARY OF THE INVENTION
A system is disclosed for use by an infant or a physically disabled individual that includes an input device with a plurality of actuator elements that are selectively responsive to gross physical movement of the individual; an audiovisual output device for providing feedback to the individual and for communicating messages to others near the system; and an adaptive control unit. The adaptive control unit transforms information provided by the input device into instructions to the audiovisual output device in accordance with a spatiotemporal pattern of activation of the actuator elements of the input device. In a preferred embodiment, the adaptive control unit also includes a test and measurement module for collecting statistical information based on patterns of activation of the input device. For example, by allowing an infant to use very early developing motor activity to activate various sound recordings, information can be obtained regarding the earliest age at which infants can be taught to understand cause and effect. The system of the invention is particularly suited to be operated by the earliest movements an infant can make, e.g., rolling, kicking, hitting, and other gross motor activities. Additionally, the input device can be fitted inside a crib or against a vertical surface that the infant can kick against.
The system can be used to help infants or physically impaired individuals communicate with others, such as parents or caregivers. It can also be used to learn cause and effect relationships, serving as both an educational aid and an amusement device. Additionally, it can promote normal development by facilitating the individual's exploration of a developmental sequence of babbling sounds, as well as providing a repertoire of simple spoken words, and thus also serves as a therapeutic aid by promoting normal physical, emotional, and cognitive development. In a preferred embodiment that includes a testing module, the system is useful as a research or diagnostic tool. In a further preferred embodiment, the system allows the individual to control various aspects of its environment. The system can also be used with normal infants to assist in their development or to test and measure developmental performance.
DESCRIPTION OF THE DRAWING
The invention will be more fully understood from the following detailed description, in conjunction with the accompanying figures, in which:
FIG. 1 is a schematic diagram of an embodiment of the system of the invention;
FIG. 2 is a sketch of the invention in use by an infant; and
FIGS. 3, 4, and 5 are representations of exemplary computer screen displays.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, the system of the invention includes an input device 10, including a plurality of actuator elements 12, such as microswitches, that are each selectively responsive to gross physical movement of an individual, such as an infant or CP patient. Each actuator element 12 is connected to an adaptive control unit 14 via a data interface line 16. The adaptive control unit 14 serves to transform information provided by the input device 10 into instructions to at least one audiovisual output device 18, such as a personal computer with digital sound playback unit and a graphic display, by relating activation of individual actuator elements 12 to corresponding outputs, such as a sequence of canonical baby babbles or words, as will be explained in further detail below. Each audiovisual output device 18 serves to provide feedback to the individual that activates the system of the invention using the input device 10, as well as serving to communicate messages from the individual to others.
The input device 10 in exemplary implementation is a NINTENDO POWERPAD which is a pad, 38.5" by 36.75" in size, placeable on a floor, and with twelve 9" by 9" actuation zones coupled to the switches included therein. Other possible input devices include a more sensitive blanket with an alternate switch distribution; a joystick; a rollerball; a computer mouse; a data-glove, such as one used with a so-called virtual reality apparatus; or any other device for sensing body movement and providing a signal indicative of such movement. Alternative output devices include any other sound synthesis or playback device, as well as any video synthesis or playback device, such as a VCR or a videodisc player.
When calibrating the system, or when using the system as a research or diagnostic tool, a test and measurement unit 20, which can be a module within the adaptive control unit 14, can be used for collecting and storing statistical information based on patterns of activation of the actuator elements of the input device 10. Also, an audiovisual recording unit, e.g., a video camera/recorder 22, can be controlled by the test and measurement unit 20 to record events associated with actuation of any of the actuator elements 12.
With reference to FIG. 2, in an exemplary embodiment of the system of the invention, referred to as a "baby babble blanket", the system includes a "blanket" 24, such as a NINTENDO POWER PAD, which serves as an input device. The blanket includes twelve large-area microswitch zones 26 that are sensitive to a range of pressures commonly applied by individuals ranging from infants to adults. For example, a nine month old infant weighing twenty pounds can activate any one of the microswitch zones 26.
The system also includes a personal computer 28, such as a MACINTOSH computer, which executes a commercially available software program called SOUND EDIT that works in conjunction with a MACRECORDER, both available from Farallon Computing, Berkeley, Calif. SOUND EDIT enables a user to digitize, record, and edit sounds, such as speech or music. MACRECORDER includes a microphone, or can be used in conjunction with a separate microphone 30 to digitally record babble sounds and simple words and phrases, and then store them on a nonvolatile storage medium, such as a magnetic disk, that is accessable to the computer for retrieval at a later time. More generally, any sound can be recorded and played back using MACRECORDER or similar apparatus.
The computer also serves as an adaptive control unit. Switch closure signals are received from the blanket via an interface 32, such as a GOLD BRICK, manufactured by Transfinite Systems Company, Inc., Cambridge Mass., and then a control program executed by the computer interprets a pattern or sequence of microswitch actuations and executes a prescribed output sequence. For example, the computer will play different digitized babbles, depending on which switch is activated. The babbles are based on audio recordings of vocalizations of a normally developing infant. The developmental sophistication of the babbles can be increased over time to allow an expansion of the infant's repertoire in a time to developmentally normal fashion. The infant can also activate switches sequentially to produce repetitive babbled strings, or canonical babbles, and eventually words and sentences.
The personal computer executes a control program, such as computer software written using HYPERCARD and THINK PASCAL, for example, that coordinates all input, output, and data collection activity. In particular, the software controls how each switch actuation results in communication with a caregiver or control of the infant's environment. The software must take into account the infant's position on the "blanket" input device 24. Only switch actuations that result from volitional activity are of interest, so the caregiver interprets any continuous switch actuation that persists for more than a particular period of time, e.g., one minute, as being the result of the baby resting his or her body on a microswitch 26 of the blanket 24, as opposed to a intentional communicative or manipulative act. Therefore, signals that originate from a microswitch 26 that is pressed for more than a specified time will be ignored.
Also, the caregiver monitors the frequency with which certain microswitches are actuated, and assigns the microswitches according to the observed frequency of actuation of each microswitch. For example, if an infant is placed on the blanket 24 in a position such that it rests primarily on the regions of the blanket 24 corresponding to microswitches 26E and 26H, the microswitches 26E and 26H remain actuated beyond a preset limit, and are therefore be disabled. In this position, the infant will tend to actuate the microswitches 26D and 26F more often than he or she will actuate the microswitch 26A, for example. The caregiver can also change the output associated with a microswitch if the frequency with which it is pressed changes. Furthermore, if the overall pattern of activation changes significantly, all previously disabled microswitches can be re-enabled. The caregiver then continues to monitor all of the microswitches 12 so that upon any prolonged actuation of a microswitch 12, the caregiver would disable that switch, as before.
It is important that involuntary movements not result in audiovisual feedback. In one embodiment, a caregiver or experimental supervisor disables any microswitches that are actuated due to involuntary movements.
The outputs associated with the microswitches 12 can be selected to promote a particular outcome, such as behavior modification, therapeutic action, amusement, communication, or control of the infant's immediate environment. For example, if it is desired that the infant kick its legs, more pleasing sounds or light displays, for example, can be associated with microswitches disposed near the infant's legs, so as to reinforce that behavior. Alternatively, uninteresting consequences can follow from the infant pressing any switch associated with undesirable movements. To promote speech development and facilitate communication with a caregiver, as discussed above, actuation of various microswitches 12 can result in well defined and consistent consequences, such as playback of digitally recorded babbles, or simple words and phrases, in accordance with the infant's developmental stage. Additionally, certain microswitches can be associated with pleasing sound effects, music, the mother's voice, or a pleasing colorful video or light display. This feature provides amusement, as well as an enjoyable way to experience cause and effect relationships, and also builds the infant's sense of self-efficacy. Further, a particular microswitch can be associated with one or more environmental controls, such as room temperature or lighting; the infant could also control the location of various items in the room, such as the placement of a mobile. Of course, the function of each microswitch can also be assigned by a human supervisor based on observation of the infant's activity.
Examples of the various patterns and sequences of microswitch activation include any two microswitches pressed simultaneously, such as 26D and 26F of FIG. 2 which could be so pressed if the infant were lying on its back and moving each arm downward. Three rapid taps of microswitch 26J with the infant's foot could activate a fan directed toward the infant. Alternatively, slow alternating actuations of microswitches 26G and 26I might activate a blue light bulb over the baby, to which a caregiver would respond by bestowing food or attention upon the infant. Those skilled in the art will recognize that there are a prodigious variety of combinations and sequences of inputs, each of which can be associated with one or more of a virtually unlimited set of possible outcomes. Also, the control software that implements the adaptive control technique herein disclosed can be executed in a variety of higher or lower level computing languages, and thus in no way depends upon being implemented using a HYPERCARD or PASCAL program. Furthermore, any and all sounds can be recorded and reproduced using analog as well as digital sound equipment.
In a preferred embodiment of the system of the invention, a test and measurement module 20 records and quantifies the type and number of switch activations over time. It also is cooperative with an audiovisual recording unit, such as a video camera/recorder 22, which records the interactions of the infant or patient with its mother or caregiver. The video camera/recorder 22 is activated whenever a microswitch is actuated, and is turned off after a set interval of time transpires, e.g., five minutes, since the last microswitch activation event. Alternatively, the camera/recorder 22 can be activated by a sonic activation device, incorporated within the camera/recorder 22, for example, which is responsive to sounds produced by the audiovisual output device 18. Thus, an infant's own vocalizations and movements can be recorded, as well as its parent's spoken or non-verbal response. The video camera/recorder 22 is reactivated upon any subsequent microswitch use.
The test and measurement module 20 can be used to evaluate the effectiveness of a particular set audiovisual outputs of the device 18, or the particular way spatiotemporal input patterns of activation of the microswitches are associated with particular audiovisual outputs. First, spatiotemporal input patterns generated by the baby, without generating any associated audiovisual outputs, are recorded by the module 20. Next, the system is configured such that spatiotemporal input patterns cause audiovisual outputs to be generated in response to the input patterns, and the resulting microswitch activation activity is recorded by the module 20. Last, the system is reconfigured so that audiovisual outputs are no longer generated in response to microswitch actuation. In an effective system configuration, associating audiovisual output with spatiotemporal input patterns will increase the frequency with which the microswitches are actuated.
Referring to FIGS. 3, 4, and 5, an exemplary HYPERCARD program is represented by the three screen displays entitled CONFIGURATION, PLAYBACK, AND DATA ANALYSIS. FIG. 3 shows the CONFIGURATION screen which includes a representation 30 of an embodiment of the blanket 24 having twelve microswitches 26. Box icons 32 represent microswitches 26 that have been disabled, as will be further explained below. The remaining microswitches 26 are in an enabled state, and are accordingly displayed as a plurality of icons 33 each consisting of a number within a circle. FIG. 3 shows a configuration of the microswitches 26 having two central switches 32 disabled to provide an infant an area within which to lie.
The CONFIGURATION screen of FIG. 3 includes a further plurality of icons 34-48. A user can select a function associated with an icon by actuating a button on a mouse input device (not shown) when a cursor directed by the mouse is superimposed on the icon, the mouse input device being commonly found as standard equipment with, for example, a MACINTOSH computer.
When the `Enable` icon 34 is selected, the user is prompted to select a microswitch to enable. Upon actuation of the mouse button, a square icon 32 becomes a numbered circle icon 33, thereby signifying that the microswitch associated with the numbered circular icon 33 has become enabled. Selecting a circular icon 33 after selecting the `Enable` icon 34 will have no effect.
When the `Disable` icon 36 is selected, the user is prompted to select a microswitch to disable. Upon actuation of the mouse button, a numbered circle icon 33 becomes a square icon 32, thereby signifying that the microswitch associated with the square icon 32 has become disabled. Selecting a square icon 32 after selecting the `Disable` icon 36 will have no effect.
Selecting the `Assign Sound` icon 38 prompts the user to choose a sound from a list of sounds displayed in a standard "pop-up" window (not shown), for example, to be assigned to the selected circular icon 33.
By selecting the `View Bindings` icon 40, a list of the sound associated with each microswitch is presented in a pop-up window. Also, selecting any circular 33 or square 32 icon will show the name of the sound resource that is associated with that icon.
Selection of the `Sound Tools` icon 42 provides a list of available sound resources and options, such as `rename`, which renames a sound, `delete`, which deletes a sound, and `play`, which plays a sound to the user.
To move to the PLAYBACK screen of FIG. 4, or to the DATA ANALYSIS screen of FIG. 5, either the `Playback` icon 44 or the `Data Analysis` icon 46 is selected, respectively.
Referring to FIG. 4, when the PLAYBACK screen is displayed, selection of any enabled icon 33 causes is associated sound to be played to the user. The user can adjust the volume of the sound by selecting a volume button 48 of the `Volume` icon 50. To move to the CONFIGURATION screen of FIG. 3, or to the DATA ANALYSIS screen of FIG. 5, either the `Configure` icon 52 or the `Data Analysis` icon 46 is selected, respectively.
With reference to FIG. 5, selection of the `File:` icon 54 shows the user the name of a data file in which data representative of spatiotemporal patterns of activation of the microswitches is to be stored. The `Record` icon 56 opens a data file, and allows the user to input a file name to replace a default file name. The `Stop` icon 58 closes the data file opened with the `Record` icon. The `Pause` icon 60 suspends storage of data, while leaving the data file open for further storage of data. Selecting the `Graphs` icon 62 graphically displays the data stored in the data file. `Printout` serves to print a paper copy of the data stored in the data file. To move to the CONFIGURATION screen of FIG. 3, or to the PLAYBACK screen of FIG. 4, either the `Playback` icon 44 or the `Data Analysis` icon 46 is selected, respectively.
Other modifications and implementations will occur to those skilled in the art without departing from the spirit and the scope of the invention as claimed. Accordingly, the above description is not intended to limit the invention except as indicated in the following claims. | A system for helping infants or physically impaired individuals to communicate with others, such as parents or caregivers, to learn cause and effect relationships, to control a surrounding environment, and to promote normal development by facilitating the individual's exploration of a developmental sequence of sounds and a repertoire of simple spoken words. The system includes an input device with a plurality of actuator elements that are selectively responsive to gross physical movement of the individual, an audiovisual output device for providing feedback to the individual and emitting communicated messages to others, and an adaptive control unit for transforming information provided by the input device into instructions for use by the audiovisual output device. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed to Provisional Application 61/145,528, filed Jan. 17, 2009.
FIELD OF THE INVENTION
[0002] This invention relates to bottled water products, and more particularly to a nutritionally enhanced drink.
BACKGROUND OF THE INVENTION
[0003] Additives are commonly sold in combination with bottled water. Currently marketed examples include energy, or health, drinks, where the additive is provided in solution form. Other examples include a medication where the bottled water is supplied simply as a convenience for washing down a pill or a capsule.
[0004] In particular instances involving nutritional supplements, however, it is useful to supply the supplement in solid dosage form, similar to the medication example. Doing so improves the shelf stability of a natural active ingredient, and particularly one of a biological derivation, which might otherwise degrade or lose potency over time when in dissolution.
[0005] In contrast with the medication circumstance, however, the water is not just a convenience for administering the dosage. It is also a measured amount of ingredient required for the best metabolic results. Therefore, the means for combining the two components into a single package is an important aspect of the product put-up.
[0006] The bottle closure typically provides such means in the prior art. For example, in U.S. Patent Application 2003/0000910 to Jang, a cap to a water bottle contains a compartment for the dosage. The compartment is closed with a separate cap, which may be attached by a hinge. Such a device does not selectively dispense a dosage, however.
[0007] U.S. Pat. No. 3,866,797 to Palomo discloses a dispensing cap for a pill bottle, but two hands are required for manipulating it. Furthermore, the device would not be compatible with a screw-threaded neck finish, such as that typically found on stock water bottles. U.S. Pat. No. 6,112,942 to Deacon teaches a single-hand dispensing mode using a roller-type mechanism, but Deacon, as in the other references above, does not provide a safety feature for the prevention of tampering.
[0008] The prior art is missing a dispensing cap capable of single-handed operation which protects its solid dosage contents both from handling damage and from tampering.
SUMMARY OF THE INVENTION
[0009] In view of the above-mentioned unfulfilled needs, the present invention embodies, but is not limited by, the following objects and advantages:
[0010] A first objective of the present invention is to provide a solid dosage preparation together with a bottle of water.
[0011] A second objective of the present invention is to provide the solid dosage preparation in a dispenser package which selectively dispenses the preparation with one-handed convenience.
[0012] A third objective of the present invention is to utilize a stock, or commodity, bottle for the water.
[0013] A fourth objective of the present invention is to provide protection with respect to light degradation and handling damage for the solid dosage preparation.
[0014] A fifth objective of the present invention is to render both the water and the solid dosage preparation secure from tampering.
[0015] In a preferred embodiment of the present invention, an enhanced water product combined with a safety feature comprises a water bottle containing water and having a neck finish operable with a closure. A closure sealingly fitted to the neck finish has a compartment within to protectively house a solid dosage preparation. A means for selectively and single-handedly dispensing the solid dosage preparation from the compartment, and an integrated means for providing an indication of tampering should pre-purchase access to the compartment be attempted, are provided thereto.
[0016] In a particularly preferred embodiment, the means for selectively and single-handedly dispensing comprises a rotatable means for opening the compartment to expose a selected solid dosage preparation. The rotatable means for opening comprises an axis and a roller having opposing sides and a cavity there between. The roller comprises a means for pivoting about the axis. The cavity contains the selected solid dosage preparation. The means for pivoting comprises a pair of coaxial hinge pins protruding from the opposing sides of the roller. The hinge pins are received by a pair of cradles attached to the closure in flanking positions to the compartment wherein the roller is pivotally fixtured.
[0017] In another particularly preferred embodiment, the integrated means for providing an indication of tampering comprises a break-away feature frangibly attached to at least one of the hinge pins. The break-away feature has a sufficient extent of structure to bring it into rotational interference with an adjacent structure by any slight rotational movement of the roller. The interference causes the feature to break away. The integrated means for providing an indication of tampering further comprises at least one of the cradles having at least one flexible arm. The flexible arm has a ledge and the corresponding hinge pin has a detent. The ledge and detent are interpositionally disposed when the hinge pin is seated in the cradle. Such interposition prevents the unseating of the hinge pin in any translational direction. At the same time, the combination of the interposition and the flexible arm urges rotation of the roller when an unseating force is applied, the rotation thereof causing a separation of the break-away feature. In this manner, any translational or rotational force, which is to say, any force applied, will cause an indication thereof.
[0018] As this is not intended to be an exhaustive recitation, other embodiments may be learned from practicing the invention or may otherwise become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
[0019] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood through the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0020] FIG. 1 is a perspective partial view of the closure on the bottle of the invention, illustrating the roller in a closed position and the break-away feature in-tact;
[0021] FIG. 2 is a perspective partial view of the closure on the bottle of the invention, illustrating the roller in an open position with the break-away feature separated;
[0022] FIG. 3 is an exploded view of the invention in perspective;
[0023] FIG. 4 is an elevation view of the closure without the roller;
[0024] FIG. 5 is a perspective view of the roller and break-away feature;
[0025] FIG. 6 is a perspective view of the closure with the roller in the closed position;
[0026] FIG. 7 is a section view of FIG. 6 along the lines 7 - 7 , illustrating the solid dosage form nested in the cavity;
[0027] FIG. 8 is another section view of FIG. 6 along the lines 8 - 8 , illustrating the interposition of the ledge and detent features; and
[0028] FIG. 9 is a perspective bottom view of the closure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] FIG. 3 best shows the major components of an enhanced water product 1 . Water bottle 10 is capped by closure 20 . Closure 20 has a means for selectively and single-handedly dispensing 30 a solid dosage preparation 22 housed in a compartment 21 of closure 20 . Water bottle 10 , containing water, can be sealingly closed by means of screw threads 23 of closure 20 ( FIG. 9 ) and neck finish 11 .
[0030] The means for selectively and single-handedly dispensing 30 is best shown in FIGS. 1 and 2 . FIG. 1 illustrates a rotatable means for opening 31 in a closed position. FIG. 2 shows the rotatable means for opening 31 in an open position. The rotatable means for opening 31 can be rotated about axis 32 by means of a single finger of a single hand clutching water bottle 10 .
[0031] In a preferred embodiment, the rotatable means for opening 31 of the means for selectively and single-handedly dispensing 30 is roller 33 . Roller 33 has opposing sides 34 and a cavity 35 there between. Cavity 35 contains solid dosage preparation 22 and dispenses the same when rotated to an open position (see also FIG. 7 , showing the nested components). Cavity 35 is scalable, and can be sized to accommodate one, or a plurality, of solid dosage preparations, such as tablets, capsules, caplets, or some volumetric measure of a powder or granulation. The size of cavity 35 is to be determined by the quantity of, or the volume of, the solid dosage preparations constituting a single administration. Compartment 21 may contain one or a plurality of administrations. In the case of a plurality of administrations, it can be seen that roller 33 can selectively dispense an appropriate amount.
[0032] Roller 33 has a means for pivoting 36 , as best shown in FIGS. 6 and 8 . In a preferred embodiment, the means for pivoting 36 comprises hinge pins 37 and cradles 38 . Hinge pins 37 are aligned coaxially and protrude from the two opposing sides 34 of roller 33 . Hinge pins 37 are received in cradles 38 , which flank the compartment 21 such that roller 33 is rotatably suspended in compartment 21 . Each cradle 38 has a saddle into which a corresponding hinge pin 37 is seated, the saddle having upright arcuate arms ( FIG. 4 ). At least one of the arms is a flexible arm 44 , which permits the hinge pin 37 to bypass over-arching structure and securely seat. In this manner, roller 33 can be assembled to closure 20 by simply pressing against roller 33 to force pins 37 in to cradles 38 . This is best done in a closed position with the solid dosage preparation 22 inserted, as the discussion below will make evident.
[0033] Enhanced water product 1 further comprises an integrated means for providing indication of tampering 40 , as best shown in FIGS. 4 and 5 . The means for providing indication of tampering 40 comprises a break-away feature 41 which is frangibly attached to a pivoting member 42 . Break-away feature 41 has an extended structure which is in close proximity to the top surface of closure 20 . The top surface and the extended structure are substantially parallel when roller 33 is assembled to closure 20 in a closed position. Any attempt to rotate the pivoting member 42 will cause the break-away feature to separate, as shown in FIG. 2 . In a preferred embodiment, the pivoting member 42 is at least one of hinge pins 37 . Break-away feature 41 is frangibly attached to hinge pin 37 by a filament 47 .
[0034] The means for providing indication of tampering 40 further comprises a means for inhibiting any non-pivoting movement 43 of roller 33 . The means for inhibiting any non-pivoting movement 43 effectively assures that the roller 33 cannot be disassembled, as in reversing the manner in which it was previously assembled, from the closure 20 without indication of the action thereof; in other words, any translational motion resulting in the exposure of the solid dosage preparation 22 , in addition to any rotational motion to dispense, must bear witness.
[0035] In a preferred embodiment, the means for inhibiting any non-pivoting movement 43 is comprised of a ledge 45 on the flexible arm 44 and a detent 46 on the corresponding hinge pin 37 . The ledge 45 and the detent 46 are interpositionally disposed when hinge pin 37 is seated in cradle 38 in the closed position of roller 33 . In such a position, and in no other, the break-away feature 41 is substantially hovering above the top surface of closure 20 , as best shown in FIG. 6 . Once seated, any attempt to move roller 33 in the only translational direction having freedom of movement, that is to say, upwardly, will bring ledge 45 into contact with detent 46 at a radial position offset from axis 32 . The moment thereby created by the interposition of ledge 45 and detent 46 will cause a rotational response by roller 33 , bringing break-away feature 41 into contact with closure 20 and fracturing filament 47 .
[0036] The interposition of ledge 45 and detent 46 serves a secondary purpose, as well, by registering the angular position of roller 33 . Only one rotational freedom of movement is permitted by the interfering structure, that of the direction tending toward the separation of ledge 45 and detent 46 . Rotation in that direction, however, requires flexing flexible arm 44 in order for the hinge pin 37 to bypass ledge 45 with its intrusion into the circumferential path. Flexible arm 44 in the interposition posture thereby biases roller 33 to a discrete closed position.
[0037] Water bottle 10 can be formed by known methods in a variety of thermoplastic materials. In the preferred embodiment, the bottle is blow-molded from polyethylene terephthalate (PETE), which is a clear resin of the polyester family. Similarly, production methods and materials for the closure 20 and the roller 33 can be selected from those well known by practitioners in the art. In the preferred embodiment, closure 20 is injection molded from one, or a combination of, polypropylene (PP) or polyethylene (PE), both of which are commodity resins generically known as polyolefin's. It is preferred that roller 33 be injection molded from a resin which lacks the property of toughness, such as non-impact grade polystyrene (PS) or polyethylene (PE). It is also preferred that the bottle 10 come from a stock-supply scenario, where high-volume tooling in continuous production can keep costs to a minimum. It is an advantage of the present invention to allow use of such a non-specialized component for the packaging of water. Solid dosage preparation 22 can be granulated, compressed, or comminuted in accordance with known methods, typically in the domain of pharmaceuticals.
[0038] While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. For example: (i) Instead of threading, the closure may snap over a lip on the neck finish; (ii) The compartment may be provided on a separate part which is combinable with the closure to capture the roller there between, thereby eliminating the need for the ledge and detent. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | A solid dosage preparation is provided with a bottle of water. The solid dosage preparation is housed in a compartment of a closure applied to the bottle of water. The solid dosage preparation is capable of being dispensed in a single-handed manipulation of a roller-like chamber. The roller-like chamber is provided with a means for indicating any tampering of the enclosed solid dosage preparation, which is maintained in a protective environment between the chamber and the compartment. | 1 |
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a coupler and, more particularly, to a coupler that provides a pin connection and which can be used to mount a blade to grass mowing equipment, for example.
In grass mowing equipment, and especially large grass mowing equipment, for example the mowing equipment often used along highways, the loss of a mower blade while the equipment is being operated is dangerous. Therefore, it is important for the blade to be mounted to the rotating hub of the mower by a bolt that has the proper capacity.
Accordingly, there is a need to assure that the proper bolt or coupler is being used, especially in situations when failure of the connection using the bolt or coupler could expose someone to risk of injury.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides an improved coupler that reduces the risk of the wrong coupler being used in a connection that can be subject to large loads and hence high stresses.
In one form of the invention, a coupler includes a shaft and an enlarged head formed on the end of the shaft. The head includes a journal for contacting and rotating in an annular bearing surface of a component to thereby form a pin connection with the component and further a plurality of projecting fins that project from the journal along axes generally parallel to the longitudinal axis of the shaft and which are radially spaced around the journal.
In one aspect, the shaft comprises a round cylindrical shaft. In other aspects, the shaft may have a multi-sided cylindrical shaft, such as a square, hexagonal or pentagonal sided cylindrical shaft.
In other aspects, the coupler includes two, three, four, five or six fins. In a further aspect, the shaft includes a key for cooperating with a keyway in the component.
According to yet other aspects, the journal has an annular outer surface, with each of the fins having an outer surface that is contiguous with the annular outer surface of the journal and lies in the same curved space as the curved surface of the annular outer surface of the journal.
According to a further aspect, when the coupler is mounted to the component, the fins are folded to thereby form outwardly projecting shoulders, which project outwardly from the curved surface of the annular outer surface of the journal.
In another form of the invention, a blade assembly includes a blade with a mounting opening and a coupler mounted in the opening. The coupler includes a shaft and an enlarged head formed on the end of the shaft. The head includes a journal, which has a greater transverse dimension than the shaft. The shaft is extended through the mounting opening with the journal located in the mounting opening and bearing on the annular bearing surface of the blade provided by the mounting opening. The journal is capture in the mounting opening by the enlarged head, which is positioned on one side of the blade, and by a plurality of outwardly extending shoulders formed at the terminal end of the journal which project radially outward from the annular surface of the journal and which are located on the other side of the blade.
In one aspect, the shoulders comprise folded members projecting from the journal.
In other aspects, the journal may include two, three, four, five or six shoulders.
In other aspects, the shaft includes a threaded portion for receiving a nut and for connecting the blade to mower equipment.
In another form of the invention, a method of mounting a coupler, which has a shaft and an enlarged head and a plurality of longitudinally extending fins that extend from the head along axes generally parallel to the longitudinal axis of the shaft, to a component, which has a mounting opening with a bearing surface, includes extending the shaft through the mounting opening wherein the fins project through the mounting opening. The fins are then folded to form a plurality of shoulders wherein the head is positioned on one side of the component and the shoulders are positioned on the other side of the component to thereby mount the coupler to the component.
A method of forming a coupler includes a forming a shaft, forming an enlarged head one end of the shaft, and forming a plurality of fins on the head that extend along axes generally parallel to the longitudinal axis of the shaft, wherein the fins are formed by cold forming a portion of the head.
These and other objects, advantages, purposes, and features of the invention will become more apparent from the study of the following description taken in conjunction with the drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a coupler design of the present invention;
FIG. 2 is a top plan view of the coupler of FIG. 1 ;
FIG. 3 is a bottom plan view of the coupler of FIG. 1 ;
FIG. 4 is another side elevation view of the coupler of FIG. 1 ;
FIG. 5 is a front elevation view of the coupler of FIG. 1 ;
FIG. 5A is a side partial fragmentary view of the coupler of the present invention mounted in a blade;
FIG. 5B is a top plan view of the blade and coupler of FIG. 5A shown mounted to a piece of equipment;
FIG. 5C is an enlarged detail view of area VC of FIG. 5A ;
FIG. 6 is a front elevation view of another embodiment of the coupler design of the present invention;
FIG. 7 is a top plan view of FIG. 6 ;
FIG. 8 is a bottom plan view of the coupler of FIG. 6 ;
FIG. 9 is a front elevation view of another design of the coupler of the present invention, which is substantially identical to the rear elevation view of the coupler;
FIG. 10 is a top plan view of the coupler of FIG. 9 ;
FIG. 11 is a bottom plan view of the coupler of FIG. 9 ;
FIG. 12 is a front elevation view of another embodiment of a coupler design of the present invention;
FIG. 13 is a bottom plan view of the coupler of FIG. 12 ;
FIG. 14 is a left side elevation view of the coupler of FIG. 13 ;
FIG. 15 is a front elevation view of another embodiment of a coupler of the present invention;
FIG. 16 is a bottom plan view of the coupler of FIG. 15 ;
FIGS. 17-21 illustrate the steps of forming the coupler of the present invention; and
FIG. 22 is a partial fragmentary bottom plan view of the coupler of FIG. 21 in its final form.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , the numeral 10 generally designates a coupler of the present invention. As will be more fully described below, coupler 10 is adapted to be mounted to a component, such as a blade of a mower, for mounting the component to, for example, a piece of equipment E ( FIG. 5B ) in a manner to limit the removal of the coupler. Suitable mowing equipment includes residential mowing equipment or commercial mowing equipment, including for example, any of the Toro or John Deere mowing equipment. Coupler 10 has particular application high load applications where it is important to assure that the correct coupler has been used to mount the component to the equipment.
Referring to FIGS. 1-5 , coupler 10 comprises a bolt and includes a shaft 12 and an enlarged head 14 . Head 14 is formed on one end of the shaft and includes a downwardly extending annular collar 16 , which forms a shoulder. As will be more fully described below in reference to FIGS. 5A-5C , shoulder 16 provides a journal for coupler 10 when mounted to a component.
As best seen in FIGS. 1 , 4 , and 5 , projecting downwardly from shoulder 16 (as viewed in FIGS. 1 , 4 , and 5 ) are a plurality of fins 18 . As will be more fully described in reference to the method of making coupler 10 , fins 18 may be formed from a portion of the material that forms shoulder 16 . In the illustrated embodiment, coupler 10 includes three fins, which are generally equally, spaced around the shaft. Each fin has tapered sides starting at the juncture with the shoulder 16 and which terminate at a distal end 18 a . In the illustrated embodiment, distal ends 18 a are generally flat and form edges between the respective angled sides 18 b and 18 c ; however, it should be appreciated that the shape and number of the fins may be varied.
Further, in the illustrated embodiment, shaft 12 comprises a round cylindrical shaft, but it should be understood from the alternate embodiments described below, the shaft's shape may be varied.
Referring to FIGS. 1 and 3 - 5 , shaft 12 may include a key 20 , which may be formed form the material forming shaft 12 . When forming key 20 , a localized planar surface 22 is created on shaft 20 on either side of the key. Key 20 may comprise a number of different shapes, but in the illustrated embodiment comprises an elongate body 24 ( FIG. 5 ) with a generally central recess 26 that extends longitudinally along the longitudinal axis of elongate body 24 . As best seen from FIG. 3 , recess 26 is generally centrally located in body 24 and, further, is formed between arcuate surfaces 26 a and 26 b , which are formed when the material from shaft 12 is removed and compressed to thereby form the key.
Referring to FIGS. 5A-5C , coupler 10 is particularly suitable for use in mounting a blade 30 to a grass mower, for example. As best seen in FIG. 5A , blade 30 includes a mounting opening 32 in which coupler 10 is inserted and, further, placed such that annular member 16 is located in opening 32 to provide a journal or bearing contact with the blade. Once shaft 12 is inserted through the mounting opening, and shoulder 16 is positioned in mounting opening 32 , fins 18 project outwardly from the blade on the other side of the mounting opening from enlarged head 14 . The fins are then folded to form a shoulder 34 as best seen in FIG. 5C . Referring to FIG. 5B , when fins 18 are folded, shoulders 34 are arranged radially around the longitudinal axis of bolt 10 and provide a three point contact between the coupler and blade 30 in the direction of the longitudinal axis of coupler 10 .
In this manner, when coupler 10 is mounted to blade 30 , coupler 10 cannot be removed without removal of the shoulders.
For example, for a coupler with nominal diameter of 1 inch, shoulders 34 may be configured to have a minimum lateral dimension as measured along lateral axes 10 a of coupler 10 of about 0.06 inches and may fall in the range of about 0.06 to 2.0 inches, depending on the size of the coupler. It should be understood that these dimensions are given as examples only and the dimensions may vary depending application and material used.
Referring to FIG. 6 , the numeral 110 generally designates another embodiment of the coupler of the present invention. Coupler 110 is similar to coupler 10 and includes a shaft 112 and an enlarged head 114 . In the illustrated embodiment and as best seen in FIG. 8 , shaft 112 comprises a square shaft with each of the respective fins 118 generally aligned with a respective side 112 a of the shaft. In the illustrated embodiment, therefore, coupler 10 includes four fins, one associated with each side of the shaft. The remaining details of coupler 110 are similar to the details of coupler 10 . Therefore, for further details of coupler 110 , reference is made to coupler 10 .
It should be understood that the number of fins may be varied. For example, referring to FIGS. 9-11 , coupler 210 , which is similar to coupler 110 , includes a pair of fins 218 , which are generally aligned with opposed sides 212 a of shaft 212 , which is a square shaft similar to shaft 112 . As noted above, the shape of the shaft may be varied.
Referring to coupler 310 , FIGS. 12 and 13 includes a hexagonal-sided shaft 312 , with a fin 318 associated with each side 312 a of shaft 312 . As noted above, the number of fins may be modified though it is preferred to have a balanced arrangement. For example, two or three fins may be used provided they are spaced generally evenly around the center axis of the coupler.
Referring to FIG. 15 , coupler 410 includes a shaft 412 with a pentagon-shaped shaft 412 . As best seen in FIG. 16 , in order to provide a balanced support system, coupler 410 includes five fins 418 , with each fin associated with a side 412 a of coupler 412 in a similar manner described in reference to the previous embodiments.
Referring to FIGS. 17-22 , coupler 10 is formed from bar stock, for example of carbon steel. The shaft portion of coupler 10 is formed by extrusion of the bar stock into the desired cross-section. For example, in the illustrated steps, the lower portion is extruded into a circular shaft. The upper portion of the bar stock is then formed, such as by cold forging (upsetted), into the enlarged head 14 and shoulder 16 . A portion of the shoulder is then cold forged into fins 18 , which provides a uniform grain flow and which does not significantly, if at all, impact the structural strength of the shoulder region. Similarly, key 20 is cold forged from a portion of the shaft mass. Again, the mass that is removed from the shaft to form the key does not significantly, if at all, impact the structural strength of the shaft.
The lower end of the lower portion of the shaft is then threaded for receiving a nut for securing the coupler to the desired surface.
For example, for a 1 inch nominal diameter coupler, the height of enlarged head 14 may be approximately ½ inch with an outer diameter of approximately 2.47 inches to 2.530 inches. The height of the shoulder 16 may fall in the range of 0.53 to 0.545 inches with an outer diameter (OD) of 1.488 to 1.498. The overall length of the shoulder at the center of each fin may fall in a range of 0.1 inch to 0.085 inches. The key, for example, may have a height in a range of 0.72 inches to 0.82 inches with its center located below the terminal edge of the collar in a range of about 0.38 inches to 0.5 inches.
As described above, when coupler 10 is mounted to the component, for example blade 30 , fins 18 are compressed and folded to form shoulders 34 with a minimum width as measured from the outer circumference of shoulder 16 of about 0.06 inches. For example, the height of the shoulder may be approximately 0.03 inches. It should be understood that the foregoing dimensions are provided merely as exemplary dimensions only and are not intended to limit the scope of the invention.
Accordingly, the present invention provides a coupler that may be mounted and secured to a component, which may be particularly useful when used in high load applications when the coupler specifications must be controlled to assure the safe operation of the component.
While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the invention which is defined by the claims which follow as interpreted under the principles of patent law including the doctrine of equivalents. | A coupler comprising a shaft, an enlarged head, a proximal end of the shaft, and a journal for contacting and rotating in an annular bearing surface of a component for forming a pin connection with the component. In addition, the coupler includes a plurality of projecting fins projecting from the journal along axes generally parallel to the longitudinal axis of the shaft and are radially spaced around the journal. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a process for the treatment of waste paper, sometimes referred to herein as with the exclusion of biocides and the total exclusion of chlorine compounds as well as with the virtual avoidance of hydrogen peroxide and/or peracetic acid, which also yields a recycled base tissue and optionally, to a tissue product that is suited for final consumption and that has a total germ count of less than 1000 CFU/g (colony-forming units per gram); the invention also relates to a device to carry out this process as well as to recycled base tissue paper and optionally, a tissue product that is suited for final consumption and that has a surface germ count of less than 20 CFU/dm 2 and a total germ count of less than 1000 CFU/g as a product. The above-mentioned germ counts are determined in a manner similar to DIN 54378 (surface germ count) and in a manner similar to DIN 54379 (total germ count).
The expression “with the exclusion of biocides,” which is used in conjunction with the process according to the invention, refers to biocide quantities that are present in small quantities, preferably in quantities of less than 0.01% by weight relative to the recycled base tissue or to the tissue product that is suited for final consumption.
Moreover, in this context, it should also be pointed out that the clear water that is used within the scope of the process according to the invention (for example, as a temperature-control medium in the papermaking machine, as shown in FIG. 1) is circulated and purified by means of a circulating-water treatment system (Sedifloat); right from the start, this water only has concentrations of biocide substances that lie below the detection limit of less than 0.1 ppm, since its HPLC analysis was negative. The DCM extract that was examined did not reveal any biocide either. As is known, in the above-mentioned circulating-water treatment system, the fine substances and fillers are separated almost quantitatively from the water and thus the treated water is used again for dilution purposes.
The article in the PTS Manuscript Volume 19/95, titled Microbiocides in Papermaking, Hygienic Aspects of the Use of Various Grades of Old Paper, by U. H{umlaut over (oo)}tmann, gives a general overview as to which starting materials, for example, a fiber raw material recovered from mixed household garbage, from mixed old paper, from industrial waste or mixed old paper or from raw material obtained from collections within the scope of Germany's Dual System can be used for waste paper processes. This general overview, however, does not provide any information that could anticipate the process according to the invention as claimed.
German Patent No. 26 07 703 relates to a process for the production of sanitized recycled paper made of waste containing paper, whereby a fraction—consisting essentially of paper fragments or a mixture of paper and plastic fragments which are retained by a screen having a mesh size of at least 20 mm—is separated from the waste in a generally known manner and is then subjected to a brief thermal treatment, whereby the fragments are heated to a temperature ranging from about 100° C. to 130° C. [212° F. to 266° F.], whereupon the fragments, optionally after separation of the plastic fraction, are compacted while a temperature of at least 100° C. [212° F.] is maintained, and the compacted fragments are kept at a temperature of about 100° C. to 110° C. [212° F. to 230° F.] for at least 24 hours at the appertaining temperature limit. The heat treatment is carried out by means of IR heat, that is to say, dry heat. This process is based on the objective of producing recycled paper that, in contrast to conventional processes, is no longer laden with a bacteria content in the order of magnitude of 10 9 heterotrophic colony-forming bacteria per gram of product and with an unknown amount of mold and mildew as well as with thermophilic organisms that not only pose a threat to the health of the operating personnel but that also lead to annoying odor and slime problems in the return water system of the papermaking machines. According to this process, the bacteria content is reduced to about 10 2 bacteria per gram of weighed-in material.
However, this state of the art does not suggest the subject matter of the present invention as claimed, that is to say, working in a medium containing water or in moist heat, nor does it give any indication that, by means of this process, the spores of the bacteria or fungi are to be activated before the germination.
European Preliminary Published Application No. 0,514,864 relates to a process for the treatment of secondary pulp comprising cellulose fibers and tacky contaminants that is made of old paper, whereby the pulp is brought into contact with a gas containing oxygen without added alkali under such conditions in terms of temperature and oxygen partial pressure and for such a period of time that the stickiness of the tacky contaminants is diminished, thus reducing problems involving operating conditions and relating to the product quality during the further processing of the cellulose fibers into the recycled paper product. This contacting procedure is preferably carried out at a temperature between 60° C. and 130° C. [140° F and 266° F.] at an oxygen partial pressure ranging from 34.5 to 3,100 kPa.
The outcome of this process is, on the one hand, a product with a low percentage of old paper that already has a suitable strength for special application purposes and, on the other hand, a product with a high proportion of recycled paper that can be used, for example, for newspapers, diapers, tissues, writing paper and printing paper. This state of the art is based on the objective of providing a treatment process of the type mentioned above for secondary pulps. This state of the art, however, makes no mention of the production of a recycled paper that is produced so as to be essentially free of biocides and that, as a result of this process, has a surface germ count of less than 20 CFU/dm 2 .
European Patent Specification No. 0,394,734 relates to a process for the sterilization of objects, preferably packaging material, using a gaseous sterilization means. However, this publication does snot give any indication of parallels to the treatment process according to the invention which functions without the use of biocides and which leads to a low bacterial load in the product of the process.
German Patent No. 3,001,862 relates to a process for the production of raw material for paper production using old paper, whereby old paper from trash is already treated with a disinfectant gaseous means when it is sorted out from the trash and only subsequently is the old paper treated, especially by means of dissolution and defiberization, for purposes of paper production. Ozone or chlorine are preferably used as the disinfectant or biocide. This neither anticipates nor suggests the process according to the invention, since this process of the state of the art—in contrast to the process according to the invention—is a dry process that makes use of disinfectants.
German Preliminary Published Application No. 2,214,786 relates to a process for the destruction of files and spent packaging tubes made of paper or paperboard, whereby the material to be disintegrated is first mechanically shredded and the shredded product is then compacted for purposes of volume reduction, whereby the shredded product is moistened before the compacting step. Preferably, ink-degrading as well as bactericidal substances and optionally binders are added to the water. Another subject matter of this state of the art is a suitable device to carry out the above-mentioned process. This state of the art is based on the objective of creating a process and a device of the above-mentioned type with which the shredded material can be compacted very tightly and also kept in this compacted form so that further treatment is facilitated. This does not suggest the process according to the invention whose objective is rather to provide a process for the preparation of old paper without the use of biocides so as to manufacture paper that is largely free of spore-forming microorganisms and that has a low total germ count.
U.S. Pat. No. 5,324,432 relates to a process to inhibit filamentous growing bacteria in water streams from industrial processes, whereby a protease enzyme is added to the water streams together with a biocide in such a quantity that the components interact to kill the bacteria. Process water types used in the pulp and paper mill industry are preferably used as the process water. This state of the art is based on the objective of lowering the bacterial load in industrial process water streams by adding a biocide as well as an enzyme. In particular, this makes it possible to markedly reduce the bacterium Sphaerotilus natans. However, this state of the art does not suggest the subject matter of the present invention as claimed, namely, the creation of a treatment process for old paper without the use of biocides that yields a process product with a very low germ count.
World Patent No. 92/18638 relates to a process for the hydrolysis of water-insoluble esters in the presence of a special lipase, whereby they are converted at an acidic pH value in the presence of an aluminum salt. Preferably, the above-mentioned ester hydrolysis process is used during a pulping or papermaking process. This state of the art is based on the objective of increasing the hydrolysis rate of esters in the presence of lipases by adding chemicals. This does not suggest the subject matter of the present invention as claimed, namely, the creation of a treatment process for old paper that yields a process product with a very low germ count.
German Patent No. 3,741,583 relates to a process to destroy microbes that cause precipitates, form slime and/or impair the quality of food-grade paper or paperboard, said process being used in the production water of papermaking plants, whereby a lytic enzyme with glucanase and protease activity that destroys the microbe cell walls is added to the production water in the papermaking plant. Using this process and the enzyme preparation, the growth of Aspergillus niger—a mold that is commonly found in the paper industry—is reduced, and so is the growth of Bacillus subtilis and yeast sp.1696. This, however, neither anticipates nor suggests the process according to the invention, since this state of the art describes a completely different objective.
The publication by T. Yoda, M. Tsutoma and M. Osamu, Production of Paper Fibers from Community Waste, in the Conference Report titled “Recycling”, Berlin 1979, pages 1299 to 1304, relates to a process to recover paper fibers by means of a wet process to treat the product, which is contaminated with Coli bacteria in the order of magnitude of 10 6 germs per gram of material; by using hypochlorites, the number of these Coli bacteria can be reduced to 10 3 germs per gram of material. The material obtained from the sterilization and simultaneous bleaching with hypochlorite is made of initial materials such as newspaper and magazine paper, corrugated cardboard and writing paper or white paperboard, and it can be further processed into a fibrous material that could be used for the middle and bottom layers of white paperboard and corrugated cardboard together with other fibers; conceivably, this fibrous material could also be used for writing paper and toilet paper of a lesser grade. However, this process neither anticipates nor suggests how to arrive at the process according to the invention in question.
The article in the journal Paper, dated Jun. 10, 1985, no. 10, vol. 203, pages 23 to 29, describes a processing of fibers at a number of Austrian and German companies in the paper industry. As representative examples, a description is given of recycling at the Austrian company Neupack by means of a thermal treatment of the old-paper starting material at 90° C. [194° F.] as well as at the German company FS Karton with a steam treatment unit at a temperature of 140° C. [284° F.] that kills all bacteria, although no mention is made of bacterial spores. Aside from this isolated information, the state of the art does not give any information that would suggest the process according to the invention. In particular, it is not stated that the temperature increase is used specifically to induce spore germination, as is done in the process according to the invention.
The monograph titled “Possibilities for the use of fiber material from household garbage in paper and paperboard manufacture” by H. Stark, Vol. 2, Berlin, Germany, pages 1145 to 1152, relates to laboratory experiments as well as to a large-scale study with old paper from trash for the production of a low-grade, coated gray paperboard with a substance of 350 g/m 2 . Within the scope of this process, after the material has been deckered to 30%, it is dispersed at about 95° C. [203° F.], as a result of which it has been shown that the germ count is reduced by more than 99%; thus, the finished paperboard only contains germs in the order of magnitude of between 160 and 85 germs per gram of paperboard. These general statements, which did not include the production of tissue paper, do not suggest the process according to the invention since in the latter process, substantially lower germ counts are obtained without using an additional biocide.
The publication titled “Research into the hygienic qualities of paper recovered by mechanical sorting of municipal waste” by H. W. Kindler, published in Recycling World Congress 1, Basel, Switzerland, 1978, Paper 2/4, relates to a treatment process of the Escher Wyss company in which paper fibers from an old-paper starting material are used for recycling. The process of fiber production consists of the steps of dissolving old-paper particles in a pulper, adding fresh water and a screen press effluent, followed by a treatment—for example, in an intermediate tank—in a cleaning device, a defiberizer, a central cleaning unit, a vibration frame and the dewatering on a double mesh net, heating the crumbly material up to 90° C. [194° F.], using steam at a temperature of 162° C. [323.6° F.] a heating spiral in order to plasticize the dirt particles and reduce the bacteria fraction, followed by a screening of the fibers in a disperser and a discharge of the material to a papermaking plant at 45° C. [113° F.]. However, this sequence of steps neither anticipates nor suggests the process according to the invention, in particular, no indication is given as to whether the bacteria fraction, and especially the fraction of microorganisms capable of spore formation, can be reduced to germ counts of less than 100 colony-forming units per gram of product.
An article by J. M. Clément in the 1993 yearbook of the Papermakers Conference describes the new JMC process, which makes use of a decontamination procedure to remove contaminants such as glues and hot melts. However, this article does not state that no biocides are used during the treatment of the old paper or that, at the same time, a product with only a low germ count is obtained.
The article by G. W. Gove and J. J. McKeown in Tappi, the issue of November 1975, Vol. 58, page 121 gives an overview of disposal practices in old-paper processing. However, this general article does not indicate what approach would be taken within the scope of processing old paper in order to obtain a process product that is largely free of sporeforming microorganisms without the use of biocides.
The article by S. J. Poock in Tappi Journal, August 1985, page 78 ff. relates to microbial contamination when starch is used during paper manufacture. In this context, special mention should be made of the fact that biocides should be used in this case. Thus, this state of the art neither anticipates nor suggests not using any biocides while nevertheless obtaining a process product that is extremely low in germs within the scope of a process for the treatment of old paper.
The article by W. Salzburger et al. titled “The Cell'link concept for optimizing the use of chemicals in the deinking process”, published in the Weekly for Paper Manufacture, Vol. 13, 1996, page 592 ff., describes a new process that achieves an optimal utilization of the deinking chemicals peroxide, sodium hydroxide solution and water glass. This translates into a targeted savings on chemical that has an influence on the degree of whiteness and the residual peroxide content of the deinked recycled material. This, however, neither anticipates nor suggests using biocides, chlorine compounds, hydrogen peroxide and/or peracetic acid in order to obtain a largely germ-free process product within the scope of a process for the treatment of old paper.
In addition to the usual vegetative forms of life of microorganisms, the old-paper starting product contains spores (permanent forms) of sporulating microorganisms.
SUMMARY OF THE INVENTION
The present invention is based on the objective of providing a treatment of old paper without the use of biocides and chlorine compounds as well as with the virtual avoidance of hydrogen peroxide and/or peracetic acid, whereby the paper is largely free of sporeforming microorganisms. In addition to shredding and cleaning, the old-paper treatment according to the invention also encompasses a minimization of the microbial contamination of the old paper used.
SUMMARY
Accordingly, the present invention provides a process for the treatment of waste paper containing spores of sporulating microorganisms, without the use of biocides and chlorine compounds as well as with the virtual avoidance of hydrogen peroxide and peracetic acid, including the following process steps: treating the waste paper starting material in an environment containing water in order to activate the microorganism spores, germinating the spores, further processing the material in at least one separation stage at temperatures above room temperature, hot dispersing the further processed material in a water vapor atmosphere at a pressure greater than atmospheric pressure, subjecting the dispersed material to a temperature-controlled treatment and processing into a largely spore-free recycled pulp, and from that into a largely spore free base tissue with a total germ count of less than 1000 CFU/g and a surface germ count of less than 20 CFU/dm 2 .
Thus, the present invention relates to a process for the treatment of old paper without the use of biocides and chlorine compounds and—with the virtual avoidance of hydrogen peroxide and/or peracetic acid—for the production of a recycled base tissue with a total germ count that is lower than 1000 CFU/g and a surface germ count of less than 20 CFU/dm 2 , comprising the following process steps:
the treatment of the pre-sorted and/or unsorted, optionally pre-shredded, old-paper starting material in an environment containing water in order to activate the micro-organism spores,
the induction of germination of the spores,
the germination of the spores,
the further processing of the old-paper starting material containing germinated spores, preferably in at least one sorting stage in a generally known manner at temperatures between 20° C. and 70° C. [68° F. and 158° F.], optionally comprising
pre-sorting,
flotation,
fine sorting,
washing and deckering while returning the separated and de-pulped clear water, all the way to the dissolving stage, followed by
a dispersion (hot treatment) of the paper starting material to be further processed in a water vapor atmosphere at atmospheric overpressure, a subsequent temperature-controlled treatment and
a subsequent substance dilution using papermaking machine return water and
processing in a generally known manner into a virtually spore-free recycled pulp and from this, into a virtually spore-free recycled base tissue or a tissue product that is suited for final consumption. The above-mentioned temperature-controlled treatment should generally take at least 120 minutes.
According to a preferred embodiment of the treatment process according to the invention, a thermal treatment, a treatment by means of ultrasound, a treatment by means of ultraviolet light or a suitable enzymatic or chemical treatment serves as the spore-activating treatment.
In another preferred embodiment of the process according to the invention, an old-paper starting material dispersed in water is used as the environment containing water for the old-paper starting material.
In another preferred embodiment, the residual moisture of the old-paper starting material is 5% to 15% by weight, preferably 7% to 13% by weight, and especially 9% to 10% by weight. The term residual moisture as defined by the invention is the percentage of water present in the old-paper starting material.
Moreover, commonly employed auxiliaries and additives such as up to 2% by weight of sodium hydroxide, up to 3% by weight of water glass, deinking auxiliaries such as soaps, enzymes or surfactants in amounts of up to 2% by weight as well as commonly employed complexing agents in amounts of up to 2% by weight, each relative to the air-dry starting material, can be added to this old-paper starting material that is dispersed in water. “Air-dry starting material” definition: see DIN 6730 1996-05.
In another preferred embodiment, the subsequent germination of the spores takes place over a period of 60 to 120 minutes, preferably 70 to 100 minutes, at temperatures of 20° C. to 70° C. [68° F. to 158° F.], preferably 30° C. to 60° C. [86° F. to 1400F]. Here the pulp consistency is 1% to 10% by weight, preferably 3% to 5% by weight.
According to another preferred embodiment of the treatment process according to the invention, the subsequent dispersion is carried out in a water vapor atmosphere above atmospheric pressure, preferably at a pressure of 0.1 to 4 bar, especially 1.2 to 1.6 bar. Here, the pulp consistency is 15% to 50% by weight, preferably 25% to 35% by weight.
According to another preferred embodiment, the dispersion is carried out at temperatures of 100° C. to 140° C. [212° F. to 284° F.], preferably at 110° C. to 130° C. [230° F. to 266° F.], especially at about 121° C. [249.8° F.], for a period of time that is sufficient to kill off the germinated microorganisms in the mixture.
According to another preferred embodiment of the treatment process according to the invention for old paper, subsequent to the dispersion, a thermal (temperature-controlled) treatment is carried out for a period of time of at least 120 to 240 minutes, preferably 150 to 180 minutes. Here the pulp consistency is 5% to 16% by weight, preferably 10% to 14% by weight. With this thermal treatment, the temperatures normally used are about 50° C. to 90° C. [122° F. to 194° F.], preferably 60° C. to 85° C. [140° F. to 185° F.], and especially 70° C. to 80° C. [158° F. to 176° F.].
The above-mentioned sporulating microorganisms are preferably spores of algae, fungi and/or bacteria which differ from the usual vegetative life forms of microorganisms in that they form endospores. The frequently occurring vegetative cells are normally Pseudomonas of various species; these are usually present in the old-paper starting material in an amount of 10 5 to 10 7 CFU/g. Moreover, species of bacillus are commonly found in old-paper starting materials, and they are present in bacterial counts between 10 3 and 10 4 CFU/g. The total bacterial count is, of course, higher by several powers of ten. Due to the formation of highly heat-resistant spores, these bacteria survive the passage through the dry segment of the process according to the state of the art, for example, through a tissue or papermaking machine. Furthermore, mold spores are also found in old-paper starting materials, although they only add to the microbiological load if the production takes place in a neutral or slightly acidic pH range. In addition, yeast with germ counts between 10 4 and 10 8 CFU/g are found in individual cases, and finally, there are also anaerobic micro-organisms such as sulfate reducers in some systems. Last but not least, in some cases, it is also possible for anaerobic spore-forming bacteria such as, for example, Clostridia, to grow in anaerobic zones.
According to another preferred embodiment, the old-paper starting material used has already been pre-sorted according to the individual components and selected from low-grade, medium-grade or high-grade paper as well as kraft paper as defined in European Standard EN 643.
Low-grade paper, as defined in the above-mentioned standard and as can be used according to the invention, refers to originally mixed old paper, mixed old paper and cardboard (unsorted), sorted mixed old paper and cardboard, paperboard cuttings, retail store old paper, corrugated cardboard, corrugated cardboard chips (new), illustrated magazines, illustrated brochures without glued spines, newspapers and brochures (mixed), newspapers and brochures without glued spines (mixed), brochures and magazines (mixed) as well as shredded office paper (mixed).
Medium-grade paper, as defined in the above-mentioned standard and as can be used according to the invention, refers to old newspapers, magazines, over-issues, sections of multi-layer paperboard with a white layer, chips in mixed colors, magazine chips, magazine chips (free of glued spines), colored folders, books without covers (wood-free), books, heavy stock, white carbonless paper, colored carbonless paper, bleached coated polyethylene paperboard, polyethylene-coated paperboard as well as office paper containing wood throughout.
High-grade paper, as defined in the above-mentioned standard and as can be used according to the invention, refers to pastel mixed printed chips, bright colored mixed printed chips (wood-free), printed cards (mixed colors), non-compacted printed wood-free white office paper, punch cards (chamois colored), white files (mixed), white files (wood-free), white continuous-feed forms (wood-free), white continuous-feed forms (wood-free, non-dyeing), white multi-layer paperboard with imprint, white multi-layer paperboard (not printed), white newsprint, white magazine printing paper, coated paper (white, containing wood), coated paper (white, wood-free), white chips containing wood, white chips (mixed) white chips (wood-free) as well as white chips (wood-free, not coated).
Kraft paper, as defined in the above-mentioned standard and as can be used according to the invention, refers to brown corrugated cardboard, kraft corrugated cardboard II, kraft corrugated cardboard I, kraft paper bags (used), kraft paper bags (used, clean), kraft paper (used) as well as kraft paper (new). Any mixtures of the above-mentioned components of each group can be used according to the invention.
According to another preferred embodiment, the processing of the old-paper starting material passes through the intermediate stage of a largely spore-free recycled pulp to the largely spore-free recycled base tissue in a generally known manner, and then, likewise in a generally known manner through a further process, for example, that yields the corresponding tissue paper products, preferably in the form of single-layer or multi-layer folded products and/or rolled products, for example, toilet paper, kitchen paper towels, napkins, paper tissues, cosmetic wipes, paper towels, cleaning wipes and cloths.
Another subject matter of the present invention is a device to carry out the above-mentioned treatment process for old paper, comprising essentially a dissolving aggregate, optionally a vat or a dump chest, other commonly employed sorting stages in the form of a pre-sorting unit, a flotation unit, a fine-sorting unit, a washing unit as well as a deckering device, followed by a pressure dispersion device (hot-treatment stage), temperature-control device and further processing devices such as, for example, holding basins or towers and drying units to form the recycled pulp or recycled fibrous material in flat or bale form.
Moreover, there can also be machines for additional material cleaning and bleaching in the old-paper treatment installation. The order in which these machines are set up and operated can vary, depending on the required material and quality properties.
Another subject matter of the present invention is a tissue paper product in the form of base tissue paper or as a ready-to-use tissue product that is suitable for consumption, with a total germ count of less than 1000 CFU/g and a surface germ count of less than 20 CFU/dm 2 , which can be obtained by means of the processes described above.
This is done in a generally known manner in that the recycled pulps are fed, for example, either directly to an installation for base tissue paper production or else are dewatered, stored temporarily in flat or bale form, for example, by drying to a 10% residual moisture content and subsequently conveyed to a base tissue paper production installation consisting of a so-called constant section and the actual base tissue production machine, for example, a conventional “Yankee machine” or a TAD (Through Air Drying) tissue machine.
In a hygiene paper processing unit located downstream from the base tissue production, a tissue product that is suited for the above-mentioned final use is then manufactured in that one or more single-layer or multi-layer feed roll(s) of the base tissue paper is/are processed on either automatic folding or roller machines to make the tissue final product. It goes without saying that no auxiliaries that would increase the germ counts in the finished tissue product are used within the scope of the further processing. Special attention should be paid to this when glue, lotions or other components are used that could conceivably be susceptible to microbial contamination.
Biocide as defined in the present invention refers to commonly employed environmental chemicals, especially environmental chemicals used in the paper industry, that are utilized to control harmful, minute organisms, especially microorganisms. The primary effect of many biocides is selective for individual groups of microorganisms, but often such biocides such as, for example, DDT—which belongs to the organic chlorine compounds—can also accumulate via the food chain in other species that do not belong to the actual target groups, thus posing a chronic or acute risk to other groups of a community of living creatures. Biocides typically used in the paper industry are, for example, sodium chloride, sodium peroxide, sodium hydrogen sulfite, 1,4-bis-(bromoacetoxy)butene, tetramethylthiuram disulfide, 3,5-dimethyl-tetrahydro-1,3,5-thiadiazine-2-thione, bromo-hydroxyacetophenone, disodium cyanodithioimido carbonate, potassium-N-methyldithio carbamate, N-(2-p-chlorobenzoylethyl)-hexaminium chloride, methylene bis-thiocyanate, potassium-N-hydroxymethyl-N′-methyl dithiocarbamate, sodium-2-mercaptobenzo-thiazole, sodium hexafluorosilicate, 2-oxo-2-(4-hydroxy-phenyl)-acetohydroxim acid chloride, N-[α-(1-nitroethyl)benzyl]-ethylene diamine, 2-bromo-2-nitropropanediol-(1,3), aqueous solution of p-hydroxybenzoic acid ester (methyl-, ethyl- and n-propylester of p-hydroxybenzoic acid as well as its sodium salts) in hydrogen peroxide (35% by weight), mixtures of 5-chloro-2-methyl-4-isothiazolinon-3-one and 2-methyl-4-isothiazoline, mixtures of tris-(hydroxymethyl)-nitromethane from 5-chloro-2-methyl-4-isothiazolinon-3-one and 2-methyl-4-isothiazoline, a mixture of N,N′-dihydroxymethylene urea and 1,6-dihydroxy-2,5-dioxahexane and 5-chloro-2-methyl-4-isothiazolinon-3-one and 2-methyl-4-isothiazo-linon-3-one, 2,2-dibromo-3-nitrilopropionamide, a mixture of phenyl-(2-chloro-2-cyanovinyl)-sulfone and phenyl-(1,2-dichloro-2-cyanovinyl)-sulfone and 2-phenyl-sulfonylpropionitrile, 1,2-benzisothiazoline-3-one and mixtures of the preceding products, sorbic acid, p-hydroxybenzoic acid ethyl- and/or -propylester, formic acid, benzoic acid, adduct from 70% benzyl alcohol and 30% formaldehyde.
The term chlorine compounds refers to inorganic as well as organic chemicals that either contain chlorine or else split off chlorine and that are commonly employed especially in the paper industry. These are, for instance, alkali hypochloride, earth alkali hypochloride, chlorine and chlorine dioxide.
The present invention is explained in greater detail below with reference to embodiments in the form of drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a detailed old-paper starting material process according to the invention,
FIG. 2 shows the essential process steps of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In a typical process sequence of the treatment process according to the invention as shown in FIG. 1, first of all, the pre-sorted old-paper starting product 1 is fed into a dissolving and sorting drum 2 , for example, an Ahlström drum, and treated there together with a flotation agent, optionally in the presence of a base, such as sodium hydroxide, for a period of time of about 10 to 60 minutes, preferably 20 to 25 minutes, at temperatures of 20° C. to 70° C. [68° F. to 158° F.], preferably 45° C. to 60° C. [113° F. to 140° F.].
Then the product treated in this manner is transferred to a vat 3 that can have typical pulp residence times of, for example, 20 to 60 minutes at temperatures of 20° C. to 70° C. [68° F. to 158° F.], preferably 30° C. to 50° C. [86° F. to 122° F.].
This is followed by a cleaning stage by means of centricleaners, for example, in a thick stock cleaner 4 , in which particles that are specifically heavier than the fibers, for instance, paper clips and staples, are separated out.
The further processing according to the invention as a result of the pretreatment of the paper starting material containing germinated spores is preferably carried out as follows:
After the centricleaners 4 , the starting product enters a perforated sorting device 5 where unwanted components are separated out through perforated or slotted metal plates. Then the product is transferred to a vat, for example, a deflaking vat 6 , which serves as the tank. Subsequently, the starting product is optionally fed through a deflaker 7 where any fiber bundles are dissolved and printing inks and coating chips, etc., are ground up. Then comes the flotation in the flotation apparatus 8 , here printing ink flotation, for a period of 6 minutes at a temperature of 45° C. [113° F.]. Afterwards the starting product goes into a vat, for example, a flotation pulp vat 9 , with a residence time of 2 to 4 minutes and it is then further treated for a time of 1 to 2 minutes at a temperature of 40° C. to 45° C. [104° F. to 113° F.] in a cleaner 10 . This is followed by further separation in a slotted sorting device 11 at a residence time of 1 to 2 minutes. Then the starting product is taken to a combined washing 12 and deckering stage 13 + 14 consisting of either a washing device 12 , for example, a disk save-all, or of the Variosplit, whereby the usual residence time is 1 to 5 minutes.
Subsequent to these treatment steps that can be used as an alternative, the product is transferred to a standpipe 13 with a deckering pump—in this case, a middle consistency pump (MC pump). This conveys the starting product into a screen belt press 14 , whereby this treatment takes from 3 to 5 minutes.
Then comes the pressure treatment with a residence time of 2 to 8 minutes, whereby the temperature is raised to 110° C. to 130° C. [230° F. to 266° F.]. In the heating spiral and subsequent dispersion device 15 , this pressure treatment is carried out at 0.75 to 1.8 bar during the time that the pulp needs to pass from the inlet of the heating spiral to the outlet of the standpipe 16 after the pressure dispersion 15 . The pulp consistency in the heating spiral and in the disperser is 15% to 50% by weight, preferably 25% to 35% by weight.
At the disperser outlet, water from the papermaking machine is now used for dilution. The product treated in this manner is then transferred via a standpipe 16 and the MC pump into a stacker 17 , consisting of a stacking tower and a vat, where the treated product remains for a period of 120 to 240 minutes at a temperature of 60° C. to 80° C. [140° F. to 176° F.], preferably 70° C. to 80° C. [158° F. to 176° F.], and at a pulp consistency of 8% to 16%, preferably 10% to 14%, and subsequently for an additional period of 10 to 30 minutes at a temperature of 40° C. to 45° C. [104° F. to 113° F.] in a mixing vat located down-stream. This residence of the product at an elevated temperature is referred to as the temperature-controlled treatment.
Then the product thus treated leaves the mixing vat as so-called recycled pulp 18 and is subsequently further processed in a generally known manner into recycled base tissue 25 and in a likewise generally known manner into recycled tissue paper products for the final use 27 .
Beside this main product line, pre-sorting waste 19 is generated in stages 2 , 4 and 5 and this is removed from the process. Moreover, in stages 8 , 10 , 11 and 12 , additional undesired by-products are formed that are collected in a vat, here a slurry vat 22 , and discharged out of the process via the wastewater treatment installation 23 .
In the process according to the invention, the old-paper starting material is placed onto a conveyor belt in bales or in loose form and loosened up by a bale breaker, for example, configured as rotating screws and additional conveyor belts, for example, the weighing belt, and subsequently conveyed to the next drum.
Here, the old-paper starting material first reaches the dissolving drum with a residual moisture of about 9% and is mixed with heated return water from the circulation cleaning system of the old-paper treatment. The water is at a temperature of 45° C. to 60° C. [113° F. to 140° F.]. Through rotation of the drum, paddle-like baffles on the drum walls lift up the old-paper mixture which is then defibrated by the impact energy. Additional baffles that prevent a rapid flow through the dissolving zone ensure a defined dissolving duration. In the second part of the drum, with the addition of dilution water, the so-called screen part, all pieces that are smaller than 7 mm are rinsed out through the drum perforation. Particles that cannot pass through this perforation due to their shape are removed from the process. In this process section, the work is normally done at temperatures of 20° C. to 70° C. [68° F. to 158° F.], preferably 50° C. to 60° C. [122° F. to 140° F.], with a residence time of 10 to 40 minutes, preferably at least 20 to 25 minutes. The pulp consistency in the dissolving section is normally 5% to 40%, preferably 15% to 20%, and the pulp consistency in the further screen section is 2% to 8%, preferably 3.5% to 4.5%. The pH value is usually set at 5 to 12, preferably 7 to 8.
Spores that are present are activated in the dissolving drum, that is to say, by raising the temperature to the indicated values, conditions are created that induce the germination process of the microbial spores and allow a subsequent, largely quantitative, washing out. In order to ensure these processes, the length of the dissolving drum was increased. Conventional dissolving drums have a residence time of 15 to 20 minutes. As a result of the lengthened version of the drum used in the process according to the invention, the dissolving time is prolonged to 20 or 25 minutes. As an alternative, a pulper or pulp dissolver can be used, as long as it guarantees the necessary residence time at the temperature needed to induce the germination.
Subsequently, the old-paper starting material reaches a vat or the dump chest that is equipped with an agitator so as to homogenize the pulp suspension and keep it in motion in order to prevent the settling of pulp, along with the formation of anaerobic zones and thus the growth or multiplication of anaerobic bacteria. Moreover, the activated spores are induced to enter a germination or sprouting phase. Process parameters typically employed for this purpose are temperatures of 20° C. to 70° C. [68° F. to 158° F.], preferably 30° C. to 50° C. [86° F. to 122° F.], especially 45° C. [113° F.]. The typical pulp consistency is 2% to 6%, preferably 3% to 4%. Appropriate residence times are 20 to 60 minutes, preferably 25 to 45 minutes. The pH value should lie between 6 and 8, preferably around the neutral range, depending on the types of microorganisms and microorganism spores present.
This is followed by a number of cleaning and sorting stages in which unwanted components such as particles that are specifically heavier than the fiber, printing ink particles, particles that are specifically lighter than the fiber, fine particles and fillers as well as flat and cubic particles are removed from the old-paper fiber material by means of a screen barrier with a typical mesh size of 1.0 to 2.4 mm and a typical slot width of 0.1 to 0.3 mm. These steps are normally referred to as pre-sorting, flotation, cleaning, fine-sorting, washing and deckering. The filtrate generated during the deckering is fed through a relief flotation stage into a super cell device where solids are separated from the water so that the water cleaned in this manner can be returned to the process. Typical process parameters used during these cleaning stages are temperatures ranging from 30° C. to 50° C. [86° F. to 122° F.], preferably 40° C. to 45° C. [104° F. to 113° F.]. The pulp consistency after the sorting is approximately 0.5% to 3%, preferably about 1% by weight, and the pulp consistency after the deckering rises to values ranging from 20% to 40%, preferably 35% by weight. Typical pulp passage times for these process stages lie in the range from 10 to 30 minutes, preferably about 20 minutes. The pH value of the reaction mixture is set at values of 5 to 10, preferably 6.5 to 8. While passing through the above-mentioned cleaning stages, the germinated and sprouting spores are especially sensitive to mechanical influences (shear stress). As a result, the cell walls can be destroyed and the bacteria can be destroyed. Aerophilic bacteria that are present can also attach themselves to the air bubbles formed in the flotation stage and are removed from the process together with the flotation foam. Over the course of the washing step, bacteria can also be rinsed out together with the washing water; the next time the circulation system is cleaned, they remain in the sediment or in the flotate, and will thus have been removed from the treatment process for old paper according to the invention.
After this cleaning, pressurized hot dispersion is carried out, whereby so-called dirt specks outside of the visibility range are ground up and residues of sticky impurities are deactivated; finally, the grinding process strengthens the fiber material. Typical process parameters of this pressurized hot dispersion are heating spiral temperatures ranging from 100° C. to 140° C. [212° F. to 284° F.], but preferably at least 110° C. to 130° C. [230° F. to 266° F.], with a typical residence time in the heating spiral of 2 to 8 minutes, but preferably about 7 minutes. The temperature between the grinding blocks should lie between 115° C. and 130° C. [239° F. and 266° F.], preferably about 121° C. [249.8° F.]. The mechanical intrinsic energy exerted on the pulp should be about 40 to 80 kWh/ton of air-dry pulp, preferably about 60 kWh/ton of air-dry pulp.
The pulp consistency lies in the range from 20% to 40% dry weight, but preferably at least 30% dry weight. The pressurized hot dispersion is preferably carried out in a device consisting of the heating spiral of the kind sold, for example, by the Andritz Sprout Bauer Company of Vienna, Austria under the designation “Sprout Bauer pressurized dispersion unit”. In the above-mentioned pressurized hot dispersion, the high temperatures and the overpressure kill the remaining spores that have not already germinated as well as the already germinated spores or any microorganisms present or remaining in vegetative form.
This pressurized hot dispersion is followed by storage (under temperature-control) of the old-paper fibers which are now present in a pulp consistency of 5% to 15% by weight, preferably at about 10% by weight, at temperatures of 60° C. to 80° C. [140° F. to 176° F.], preferably in the range between 70° C. and 80° C. [158° F. and 176° F.], for an adequately long time, in order to kill off any intact vegetative bacteria that might still remain, that is to say, usually for a residence time of at least 100 minutes, preferably 2 to 4 hours, and especially about 3 hours.
The present invention will now be explained in greater detail with reference to embodiments. The surface colony count is determined in a manner similar to German standard DIN 54378, taking into account the special circumstances of tissue paper in that the number of colonies is determined that are found after an incubation time of 3 days at a temperature of 25° C. [77° F.], expressed in terms of a surface area of 100 cm 2 of the paper to be examined. DIN 54378 provides for a determination of the number of molds, but for the determination in the case of tissue paper, it can also be used in conjunction with other micro-organisms according to the list of abbreviations given below.
For this purpose, the prepared samples are placed onto Petri dishes on poured-out culture medium and covered with sterile, liquid culture medium and incubated. At the end of the incubation period, the colonies are counted and expressed in terms of a test surface area of 100 cm 2 .
The following equipment was used for this purpose: an incubator that can be set at a temperature of 25° C. [77° F.]±1° C. [1.8° F.], a steam sterilizer for an operating pressure of up to about 3.5 bar, and a sterilization temperature up to 134° C. [273.2° F.]. This is set up in such a way that a temperature of 120° C. [248° F.]±2° C. [3.6° F.] can be maintained; the equipment used includes disposable Petri dishes with a diameter of 97 mm, scissors made of stainless steel, a template measuring 50 mm×50 mm, 2 pairs of tweezers, a Dispensette, a Bunsen burner, a clean-room workplace, a heatable magnetic agitator, a 500 ml laboratory bottle with a threaded neck as well as analytical scales.
The testing agents—in addition to freshly distilled water—were a casein peptone/soy meal peptone agar that is sold by the Merck Company under the designation Caso-Agar under Item No. 5458. A total of 40 grams of this agar is added per liter of water, this is heated to 25° C. [77° F.] and subsequently sterilized at 121° C. [249.8° F.] for 15 minutes. In order to prepare the samples, about 40 layers of the paper to be tested are cut out and subsequently taken to the clean-room workplace.
The actual test is performed in that, first of all, the Dispensette is sterilized at 121° C. [249.8° F.] for 15 minutes or else, in the case of serial analyses, it is sufficient to sterilize the tweezers and scissors as well as the templates by holding them over a flame. Then, at a temperature of 48° C. [118.4° F.]±2° C. [3.6° F.] and using a Dispensette, 10 ml of the sterile culture medium are poured into a Petri dish. Immediately after that, a layer of the paper, which has already been cut into a square (5 cm×5 cm), is placed into the culture medium. After the culture medium solidifies again, another 10 ml are added. The ready Petri dishes are then placed into the incubator for 15 minutes with the cover facing downwards, which prevents condensation water from dripping onto the cultures. The subsequent incubation of the cultures takes place over the course of 3 days at 25° C. [77° F.]±1° C. [1.8° F.]. The evaluation is done after 3 days by counting the colonies that can be found on the top layer of the culture medium. The test report indicates the date of the sampling, the grade of the paper, the paper production and roll number as well as the surface colony count per 100 cm 2 .
The total colony count is determined in a manner similar to German standard DIN 54379, and serves here to determine the total colony count on tissue paper and other substances. Moreover, this determination can also be used to check the efficacy of bactericidal and fungicidal additives.
The term total colony count refers to the number of cronies that are found after an incubation time of 3 days at a temperature of 25° C. [77° F.]±1° C. [1.8° F.], expressed in terms of 1 gram of the air-dry sample. For this purpose, the sample is placed into a sterile test tube and shaken 30 times with a Ringer solution. Part of the fiber material suspension is transferred to a Petri dish, mixed with nutrient agar and incubated. The number of colonies is determined at the end of the incubation time in the incubator. The arithmetic mean value from two determinations per sample is expressed in terms of 1 gram of air-dry sample and given as the total colony count.
As was the case for the determination of the surface colony count, the equipment used includes an incubator, a steam sterilizer, disposable Petri dishes, scissors, tweezers, a Dispensette, Bunsen burner, a clean-room workplace, a heatable magnetic agitator, laboratory bottles, analytical scales and, in addition, disposable measuring pipettes with a 0.1 ml graduation as well as disposable polyethylene tubes with a 12-mm plug closure.
The testing agents used are identical to those used for determining the surface colony count and, in addition, a Ringer solution of 8.5 g/l of sodium chloride (available from the Merck Company under Item No. 841) together with 1 g/l of peptone (available from the Merck Company, made from peptically digested meat, Item No. 7224). Subsequently, the solution is sterilized at 121° C. [249.8° F.] for 15 minutes.
Sample preparation and execution are done in such a way that square pieces having a side length of about 15 mm are cut from the sample pieces using sterile scissors. The samples must not be touched with the fingers. For each test, at least 2 samples of about 1.5 grams each have to be cut, 1.0 gram of the paper to be tested is weighed into a sterile test tube under sterile conditions. Then it is mixed with 10 ml of Ringer solution and shaken 30 times. When the sample is removed, it is necessary to ensure that any fibers that may have settled are completely swirled up with the sterile pipette used for the removal. The basic suspension thus obtained is the starting point of further dilutions. Since only 30 to 300 bacteria can be counted out on a plate with accuracy, the basic suspension has to be diluted in the case of higher germ counts, while the amount placed into the test tube has to be increased in case of lower germ counts. The actual test is carried out by sterilizing the tweezers, scissors and Dispensette for 15 minutes at 121° C. [249.8° F.]. Then 1 ml of the basic suspension is placed into a Petri dish and mixed with 10 ml of nutrient agar at a temperature of 48° C. [118.4° F.]±2° C. [3.6° F.]. In order to mix the nutrient agar uniformly with the basic suspension, the Petri dish is closed with the cover and carefully moved in a figure-eight, that is to say, not in a circular motion. The dishes are placed horizontally until the mixture has solidified. The filled Petri dishes are incubated for 3 days at 25° C. [77° F.]±1° C. [1.8° F.]. The plates have to be placed into the incubator in such a way that the cover is facing downwards.
The evaluation is done after 3 days by taking the samples out of the incubator, counting all of the colonies that are present and expressing these results as 1 gram of air-dry sample. In doing so, it is necessary to painstakingly make sure that fibers are not mistaken for colonies. The test report that is to be subsequently drawn up indicates the date of the sampling, the quality of the paper, the paper production and roll number as well as the total colony count, expressed in terms of 1 gram of air-dry material as well as the appertaining dilution factor.
The determination of the aerobic and anaerobic spore count is done by transferring 5 ml of a slurry into an empty test container and then left for 10 minutes in a water bath at 80° C. [176° F.]. This procedure brings about a growth activation of the bacteria spores, whereas all of the other vegetative cells die off.
This is followed by a ten-fold dilution series in which 1 ml of each dilution is transferred into a Petri dish. TGE agar is added to determine the aerobic spores and the agar plates are incubated anaerobically for 3 days at 30° C. [86° F.]. Reinforced Clostridia Agar (RCA) is used for the anaerobic spores and the agar plates are incubated anaerobically for 2 days at 37° C. [98.6° F.].
The old-paper treatment process according to the invention was studied with several different arrangements (Tests 1 through 6) within the spectrum of the critical process steps in order to ascertain its effectiveness in reducing the number of bacteria. In this context, Test 1 was carried out under the following production conditions: the temperature in the dispersion 15 was 110° C. to 112° C. [230° F. to 233.6° F.], the residence time in the heating spiral was 7 minutes at a temperature of 110° C. to 112° C. [230° F. to 233.6° F.], the level in the stacking tower 17 was 70% to 71%, thus resulting in a mean residence time of the pulp of 150 minutes at 75° C. [167° F.]±0° C. [0° F].
Test 2 was conducted at an elevated temperature (121° C. [249.8° F.]) in the dispersion 15 , the residence time in the heating spiral was 7 minutes at a temperature of 121° C. [249.8° F.], the level in the stacking tower 17 was 47% to 58%, thus resulting in a mean residence time of the pulp of 120 minutes at 79° C. to 81° C. [174.2° F. to 177.8° F.].
Test 3 was carried out again at an elevated temperature (121° C. [249.8° F.]) in the dispersion 15 , but the residence time in the heating spiral at a temperature of 121° C. [249.8° F.] was lowered from 7 minutes to 3.5 minutes, the level in the stacking tower 17 was 77% to 82%, thus resulting in a mean residence time of the pulp of 165 minutes at 78° C. to 81° C. [172.4° F. to 177.8° F.].
Test 4 was once again carried out at an elevated temperature (121° C. [249.8° F.]) in the dispersion 15 , the residence time in the heating spiral was 7 minutes at a temperature of 121° C. [249.8° F.], the level in the stacking tower 17 was markedly lowered and was 33% to 39%, thus resulting in a mean residence time of the pulp of 90 minutes at 75° C. to 77° C. [167° F. to 170.6° F.].
In comparison to the standard, Test 5 employed a tower temperature (90° C. [194° F.]) in the dispersion 15 , the residence time in the heating spiral was 6 minutes at a temperature of 90° C. [194° F.], the level in the stacking tower 17 was 59% to 68%, thus resulting in a mean residence time of the pulp of 135 minutes at 62° C. to 63° C. [143.6° F. to 145.4° F.].
In comparison to the standard, Test 6 once again employed a lower temperature (90° C. [194° F.]) in the dispersion 15 , the residence time in the heating spiral was 6 minutes at a temperature of 90° C. [194° F.], the level in the stacking tower 17 was 69% to 85%, thus resulting in a mean residence time of the pulp of 150 minutes at 50° C. to 61° C. [122° F. to 141.8° F.].
The temperature in the dissolving aggregate, namely, the Ahlström drum 2 , was set at a constant temperature of 50° C. [122° F.] for all of the tests T1 through T6. If the temperature falls below this value, the result is non-synchronous and incomplete germination. This is based on the current knowledge on this subject.
Furthermore, as described in the process according to the invention, biocides were not used.
During the test runs, aseptic samples were taken at staggered time intervals downstream from the dissolving aggregate 2 , upstream from the dispersion 15 , downstream from the stacking tower 17 and from the finished final product, and these samples were examined according to DIN 54379—Determination of the total germ count in paper, paperboard and cardboard—for their germ counts of aerobic bacteria, spores of aerobic bacteria, spores of anaerobic bacterial, fungi and yeast.
In all of the tests, the number of colony-forming units for anaerobic spores and for yeast was less than 10 in the pulp and less than 100 in the finished paper, that is to say, below the detection limit for the determination according to DIN 54379.
The further results of these tests are compiled in Tables 1 through 6. For a better understanding of the tables, it should be pointed out that, according to the above-mentioned standard, germ counts of less than 10 per gram or milliliter of pulp or less than 100 per gram of finished product are no longer detected. This means that no colonies of micro-organisms were visible on the cultured plates.
The abbreviations used in Tables 1 trough 6 have the meanings given below:
A. spp.
Aspergillus spp.
B. c.
Bacillus cereus var.
B. ci.
Bacillus circulans
B. l.
Bacillus licheniformis
B. m.
Bacillus megaterium
B. p.
Bacillus pumilis
B. s
Bacillus subtilis
B. sp.
Bacillus sphaericus
E. spp.
Enterobacterium spp.
G. spp.
Geotichium spp.
M. spp.
Mucor spp.
Ma. spp.
Mariannea spp.
N. spp.
Neurospora spp.
S. spp.
Sphingomonas spp.
P. spp.
Penicillium spp.
T. spp.
Trichoderma spp.
n.d.
not determined
CFU
colony-forming units = number of germs
T1 through T6
Tests 1 through 6
TABLE 1
Content of aerobic bacteria in CFU/g (total colony count) during Tests T1 through T6
Aerobic bacterial (CFU per ml or g) Test No. and type of organisms
Sampling site
T1
type
T2
type
T3
type
T4
type
T5
type
T6
type
After dissolving
6 · 10 6
S. spp.
21.5 · 10 6
S. spp.
22.5 · 10 6
S. spp.
5 · 10 6
S. spp.
5.2 · 10 6
S. spp.
5.5 · 10 6
S. spp.
aggregate
11.5 · 10 1
B. s.
5 · 10 3
B. sp.
5 · 10 3
B. s.
1 · 10 2
B. c.
After double-screen
11.5 · 10 6
S. spp.
31.5 · 10 6
S. spp.
35 · 10 6
S. spp.
4.5 · 10 6
S. spp.
60 · 10 6
S. spp.
6.8 · 10 6
Sp. spp.
press (=before
1.3 · 10 2
B. s.
E. spp.
1 · 10 2
B. p.
E. spp.
pressure dispersion)
After the disperser
1.5 · 10 4
S. spp.
3 · 10 4
S. spp.
8 · 10 3
S. spp.
3.5 · 10 4
S. spp.
3 · 10 5
S. spp.
5 · 10 4
S. spp.
5 · 10 2
B. s.
30
B. sp.
After the stacking
1.2 · 10 4
S. spp.
1 · 10 4
S. spp.
2.5 · 10 2
S. spp.
4 · 10 2
B. sp.
2.1 · 10 6
S. spp.
2.5 · 10 3
S. spp.
tower
40
B. sp.
20
B. c.
In the paper
<100
n.d.
<100
n.d.
<100
n.d.
5 · 10 2
B. sp.
2.1 · 10 4
B. sp.
2 · 10 4
B. sp.
B. s.
B. s.
B.s.
B. l.
B. ci.
TABLE 2
Content of aerobic bacterial spores in CFU/g (total colony count) during Tests T1 through T6
Aerobic bacterial spores (CFU per ml or g) Test no. and type of organisms
Sampling site
T1
type
T2
type
T3
type
T4
type
T5
type
T6
type
After dissolving
4 · 10 3
B. s.
7 · 10 2
B. s.
8 · 10 2
B. s.
2.5 · 10 2
B. s.
3.5 · 10 2
B. l.
2.3 · 10 2
B. s.
aggregate
B. c.
B. l.
B. c.
B. s.
After double-screen press
2.5 · 10 3
B. s.
3 · 10 2
B. s.
8 · 10 2
B. s.
1.4 · 10 2
B. s.
3.5 · 10 2
B. sp.
1 · 10 2
B. s.
(=before pressure
B. l.
B. c.
B. c.
B. s.
B. p.
dispersion)
B. sp.
After the disperser
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
6.5 · 10 2
B. s.
3 · 10 2
B. s.
B. sp.
B. p.
After the stacking tower
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
9.5 · 10 2
B. s.
7.5 · 10 2
B. s.
B. sp.
B. p.
B. l.
B. sp.
B. c.
B. m.
In the paper
<100
n.d.
<100
n.d.
<100
n.d.
<100
n.d.
7 · 10 2
B. s.
2.6 · 10 3
B. sp.
B. sp.
B. m.
B. l.
TABLE 3
Content of fungi in CFU/g (total colony count) during Tests T1 through T6
Fungi (CFU per ml or g) Test no. and type of organisms
Sampling site
T1
type
T2
type
T3
type
T4
type
T5
type
T6
type
After dissolving
1.3 · 10 3
A. spp.
2 · 10 3
G. spp.
3.5 · 10 3
G. spp.
10.5 · 10 2
A. spp.
8 · 10 2
G. spp.
2.5 · 10 3
A. spp.
aggregate
G. spp.
M. spp.
M. spp.
G. spp.
N. spp.
G. spp.
M. spp.
P. spp.
P. spp.
M. spp.
P. spp.
M. spp.
P. spp.
T. spp.
Ma. spp.
Ma. spp.
T. spp.
P. spp.
P. spp.
T. spp.
T. spp.
After double-
3 · 10 2
A. spp.
2 · 10 3
G. spp.
6.5 · 10 3
G. spp.
6 · 10 2
A. spp.
1.6 · 10 3
A. spp.
1.35 · 10 3
A. spp.
screen press
G. spp.
M. spp.
M. spp.
G. spp.
G. spp.
G. spp.
(=before pressure
M. spp.
P. spp.
P. spp.
M. spp.
M. spp.
M. spp.
dispersion)
P. spp.
T. spp.
P. spp.
P. spp.
Ma. Spp.
T. spp.
T. spp.
T. spp.
N. spp.
P. spp.
T. spp.
After the
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
disperser
After the stacking
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
<10
n.d.
tower
In the paper
<100
n.d.
<100
n.d.
<100
n.d.
<100
n.d.
<100
n.d.
<100
n.d.
TABLE 4.1
CFU reduction of aerobic bacteria during Tests T1 through T6
Aerobic bacteria Test no. and CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
Sampling site
T1 (%)
T2 (%)
T3 (%)
T4 (%)
T5 (%)
T6 (%)
After double-screen press
0
0
0
0
0
0
(=before pressure
dispersion)
After the disperser
99.8695
99.9047
99.9771
99.2222
99.50
99.2569
After the stacking tower
99.9895
99.9683
99.9993
99.9911
96.50
99.9623
In the paper
99.9991 (b)
99.9997 (b)
99.9997 (b)
99.9888
99.965
99.4118
(a) assumed operand: 9 CFU
(b) assumed operand: 99 CFU
TABLE 4.2
CFU reduction of aerobic bacterial spores during Tests T1 through T6
Aerobic spores Test no. and CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
Sampling site
T1 (%)
T2 (%)
T3 (%)
T4 (%)
T5 (%)
T6 (%)
After the dissolving
0
0
0
0
0
0
aggregate
After double-screen press
37.5
57.143
0
0
0
0
(=before pressure
dispersion)
After the disperser
99.795 (a)
98.714 (a)
98.075 (a)
44.0 (a)
−85.71 (*)
−30.43 (*)
After the stacking tower
99.795 (a)
98.714 (a)
98.75 (a)
44.0 (a)
−171.43 (*)
−226.08 (*)
In the paper
97.525 (b)
85.857 (b)
87.625 (b)
60.4 (b)
−100 (*)
1030.435 (*)
(a) assumed operand: 9 CFU
(b) assumed operand: 99 CFU
(*) a minus sign means growth instead of reduction
TABLE 4.3
CFU reduction of fungi during Tests T1 through T6
Fungi Test no. and CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
CFU reduction
Sampling site
T1 (%)
T2 (%)
T3 (%)
T4 (%)
T5 (%)
T6 (%)
After the dissolving
0
0
0
0
0
0
aggregate
After double-sereen press
76.923
85.0
−85.714 (*)
−474.26 (*)
−100.0 (*)
46.0
(=before pressure
dispersion)
After the disperser (a)
99.308
99.55
99.743
91.43
98.875
99.64
After the stacking tower
99.308
99.55
99.743
91.43
98.875
99.64
(a)
In the paper (b)
92.385
95.05
97.171
5.714
87.625
96.04
(a) assumed operand: 9 CFU
(b) assumed operand: 99 CFU
(*) a minus sign means growth instead of reduction
The following Table 5 provides an overview of the values for the surface and total germ counts for the above-mentioned recycled tissue obtained in the Tests T1 through T6.
TABLE 5
Surface germ count and total germ count
of the recycled base tissue
Surface germ count
Total germ count
T1
0.8
220
T2
1.3
860
T3
2.5
890
T4
8.57
5100
T5
43
16,600
T6
38
17,070
In a dissolving drum made by the Ahlström Company, the dispersion was carried out employing the following technical characteristic data and process parameters in the process according to the invention described above in FIG. 1 or FIG. 2 during Tests 1 through 6, using an old-paper starting material 1 consisting of mixtures having the grades as described above in the process according to the invention. The dissolving temperature was 50° C. [122° F.], the pulp consistency in the dissolving section was 14% to 16%, the pulp consistency in the screen section was 3.5% to 4.5% and the passage time was 20 to 25 minutes.
The next drum vat, made by the Ahlström Company, had the following parameters: a temperature of 50° C. [122° F.], a pulp consistency of 3.5% to 4.5% and a pH value in the neutral range. The residence time was 5 minutes.
In the subsequent old-paper dump chest 3, the temperature was 45° C. to 50° C. [113° F. to 122° F.], and the residence time was 33 minutes.
The subsequent cleaning stages, which were described above, made use of thick stock cleaners 4 (made by the Voith/Sulzer Company) and this was followed by a three-stage pre-sorting unit 5 (made by the Voith/Sulzer Company) with a maximum throughput quantity of 670 oven-dry tons per 24 hours, followed by deflakers 7 (made by the Voith/Sulzer Company) with a maximum throughput quantity of 800 oven-dry tons per 24 hours, followed by a two-stage flotation unit 8 consisting of 6+2 cells (made by the Voith/Sulzer Company) with a maximum throughput quantity of 357 oven-dry tons per 24 hours—followed by a four-stage cleaner 10 (made by the Voith/Sulzer Company) with a maximum throughput quantity of 415 oven-dry tons per 24 hours, followed by a three-stage slot sorting unit 11 (made by the Voith/Sulzer Company) with a maximum throughput quantity of 311 oven-dry tons per 24 hours, followed by a washing stage that is in a disk save-all unit 12 (made by the MFA Company) with a maximum throughput quantity of 125 oven-dry tons per 24 hours and a washer 12 (made by the Voith/Sulzer Company), with a maximum throughput quantity of 215 oven-dry tons per 24 hours followed by a screen belt press (made by the MFA Company) that functions as a deckering device, whereby the process parameters used were a temperature of 45° C. [113° F.], a pulp consistency after the sorting of about 1%, a pulp consistency after the deckering of about 33%, at a neutral pH range and a pulp passage time totaling 20 minutes.
The pressure dispersion unit 15 , made of up two elements, consists of a heating spiral (made by the Sprout Company) and a connected disperser (made by the Sprout Company), whereby the following process parameters are used: a temperature in the heating spiral of at least 110° C. to 130° C. [230° F. to 266° F.], a residence time in the heating spiral of 7 minutes, a temperature between the grinding plates of 121° C. [249.8° F.], a mechanical intrinsic energy exerted on the pulp of about 60 kWh/ton of air-dry pulp, a pulp consistency of at least 30% dry weight at an overpressure of 0.5 to 0.7 bar and a steam consumption of approximately 0.5 tons of steam per ton of oven-dry pulp.
In the last step, the so-called stacking tower 17 , which has a volume of about 400 m 3 , the product fed in is kept at temperatures of about 80° C. [176° F.] at a pulp consistency of 10% for at least 2 hours. The product made in this manner (recycled pulp) 18 was made into a spore-free recycled base tissue with a substance of 18 to 20.2 g/m 2 . This recycled base tissue 25 was then analyzed for the total germ count, surface germ count, number of aerobic bacteria, spores of aerobic bacteria, spores of anaerobic bacteria, fungi and yeast. | The disclosure relates to a process for the treatment of old paper without the use of biocides and chlorine compounds as well as with the virtual avoidance of hydrogen peroxide and/or peracetic acid with a total germ count of less than 1000 CFU/g and/or a surface germ count of less than 20 CFU/dm 2 , comprising the following process steps: a treatment of the pre-sorted, optionally pre-shredded, old-paper starting material in an environment containing water in order to activate the microorganism spores, a germination of the spores, a further processing of the old-paper starting material containing germinated spores, preferably in at least one separation stage in a generally known manner at temperatures above room temperature (20° C. to 70° C. [68° F. to 158° F.]), optionally comprising pre-sorting, flotation, fine-sorting, washing and deckering, while returning the separated and de-pulped clear water, all the way to the dissolving stage, followed by hot dispersion of the further processed paper starting material in a water vapor atmosphere at atmospheric overpressure, temperature-controlled treatment and processing in a generally known manner into a largely spore-free recycled pulp, from that into a largely spore-free recycled base tissue and from that into a tissue product suited for final consumption; it also relates to the recycled base tissue or tissue product thus obtained and to a device for the execution of the process. | 3 |
RELATED APPLICATIONS
The present invention was first described in Disclosure Document Registration 502,395 filed on Dec. 17, 2001 under 35 U.S.C. §122 and 37 C.F.R. §1.14. There are no previously filed, nor currently any co-pending applications, anywhere in the world.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an insect screen, more particularly, an insect screen attached to a lawn chair and provided with an opening for the passage of various items.
2. Description of the Related Art
A great number of people around the world enjoy fishing. Whether fishing for food or for the sport of it, the calmness and serenity of the sport coupled with the excitement of landing “the big one” makes fishing a popular pastime. Much fishing takes place from a chair on the banks of a river or lake. While this type of fishing has many advantages, one disadvantage that must be dealt with is that of flying insects such as mosquitoes, flies, gnats and the like. Area foggers, bug lights, candles and the like provide some relief, but they are not totally effective and may negatively affect the environment. Also, if one should move their chair, the repellent system is difficult or impossible to move. Another solution is that of a spray-on insect repellant. However, many people do not like the feel or smell of such sprays. These sprays also require repeated application, especially if the user is sweating or gets wet.
The present invention is aimed at a screen and cover attachable to a lawn chair, thereby preventing annoyance from insects while fishing or other outdoor activities. The present invention is a dome-shaped screen coupled to a support member. The support member may include a connector, such as rope or a hook and loop material strap, for securing the support member to a lawn chair. The present invention includes an entrance and an opening for passing items into and out of the screen and cover. The present invention may be reinforced with a sufficiently rigid band that maintains the structure of the screen.
A search of the prior art did not disclose any patents that read directly on the claims of the instant invention; however, the following references were considered related.
U.S. Pat. No. 5,797,650 issued in the name of Gonzalez, Jr. et al., describes a sunshade attachment for a chair.
U.S. Pat. No. 5,320,405 issued in the name of Foster et al., describes a sunshade attachment for a chair.
U.S. Pat. No. 5,203,363 issued in the name of Kidwell et al., describes a portable canopy attachment.
U.S. Pat. No. 5,135,281 issued in the name of Pappalardo, describes a sunshade attachment for a chair.
U.S. Pat. No. 5,096,257 issued in the name of Clark, describes an adjustable sunshade apparatus for a recreational chair.
U.S. Pat. No. 4,643,479 issued in the name of Servi, describes a wheelchair shade or canopy means.
U.S. Pat. No. 3,404,915 issued in the name of de Souza Filho, describes a combination beach chair and cot.
U.S. Pat. No. 900,572 issued in the name of Morton, describes a sunshade attachment for a chair.
Consequently, there exists a continuous need for new product ideas and enhancements for existing products in the insect screen industry.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a screen and cover attachable to a lawn chair.
It is a feature of the present invention to provide a lawn chair screen and cover that combines inexpensive and long-lasting components completely integrated to provide a convenient means for enjoying outdoor activities without the annoyance or interference of insects.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes an entrance for entering and exiting the device.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes an opening for allowing penetration by a fishing rod, a hunting rifle or other items that might be passed from inside to outside or vice versa.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes a support member that may be collapsed thereby providing a convenient means for storage or transportation.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes reinforcing bands for maintaining the structural integrity of the screen.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes a second opening capable of accommodating a second fisher or hunter.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes a padded compartment for allowing a user to rest.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes an outside canopy, thereby allowing other users to shade themselves.
It is yet another feature of the present invention to provide a lawn chair screen and cover that includes a cooling and/or heating system.
Briefly described according to one embodiment of the present invention, the lawn chair screen and cover, provides an enclosure system for lawn or folding chairs to protect the occupant from flying insects. Designed specifically for use with lawn or folding chairs, the invention is made of fabric mesh and supported by a frame structure that connects to the chair by rope, hook and loop fasteners or clamps. The fabric mesh extends all around the chair, thus allowing the user full visibility and air flow through the invention. The sloped front of the invention provides a door closed by a zipper. An opening is also ideal for allowing a fishing rod to extend through, thus allowing the user to comfortably fish while being shielded from flying insects such as mosquitoes, flies, gnats and the like. The use of the lawn chair screen and cover allows outdoor enthusiasts the ability to sit and relax in a chair without being annoyed or bitten by flying insects.
An advantage of the present invention is that it is specifically adapted for personal use because of the light weight components and the use of inexpensive materials, making the present invention cost affordable and easy to assemble and disassemble.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a side view of a lawn chair screen and cover;
FIG. 2 is a side view of a support member, having lockable and collapsible hinges, and depicting the upper, middle and lower portions in a collapsed manner;
FIG. 3-A is an exploded perspective view of the upper portion and the middle portion connected by an impingement pin placed through an aperture in the upper and middle portions of the support member;
FIG. 3-B is an exploded perspective of an alternative embodiment of the impingement means, depicting the upper portion and middle portion connected by threaded members;
FIG. 4-A is a perspective view of a connector depicted as hook and loop material;
FIG. 4-B is a perspective view of a connector depicted button snaps;
FIG. 4-C is a perspective view of a connector depicted rope or string;
FIG. 4-D is a perspective view of a connector depicted as a C-shaped connector with ribs that is snapped onto and around the frame of a lawn chair;
FIG. 5 is a top view of the mesh-lattice screen depicting the diameters of the lattice d 1 and d 2 in which the lattice diameters are preferably less than 0.50 millimeters;
FIG. 6 is a front view of the opening in the screen illustrating the two rectangular panels filled with foam and the integral relationship between the panels forming the slit for passing items from the outside to the inside;
FIG. 7 is a side view of the lawn chair screen and cover depicting an alternative embodiment illustrating two openings and an entrance positioned between the two openings;
FIG. 8 is a perspective view of the alternative embodiment depicted in FIG. 7 , illustrating a fisher using a rod and reel through the opening to fish;
FIG. 9 is a side view of an alternative embodiment of FIG. 1 in which a padded compartment with enclosure and a cooling and/or heating system are included to provide added comfort to a user; and
FIG. 10 is a perspective view of another alternative embodiment of FIG. 1 in which an outside canopy is included, having a cover and two legs, for providing shade to those that may not want to stay inside the lawn chair screen and cover.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within the Figures.
1. Detailed Description of the Figures
Referring now to FIG. 1 , a lawn chair screen and cover 10 is shown, according to the present invention, and includes a linearly elongated vertical support member 12 , wherein the support member 12 includes an upper portion 14 supporting the apex of a mesh-lattice screen 16 , a middle portion 18 , and a lower portion 20 coupled to a lawn chair 22 by a connector 28 . The lawn chair screen and cover 10 further includes an entrance 26 , for entering and exiting the lawn chair screen and cover 10 , and an opening 24 so as to allow passage of various items through the lawn chair screen and cover 10 , such as fishing rods, hunting weapons, food or other similar items. The lawn chair screen and cover 10 is a dome-shaped device.
Referring now to FIG. 1 and FIG. 2 , the support member 12 includes an upper portion 14 coupled to a middle portion 16 by a first impingement means 30 , and the middle portion 18 coupled to a lower portion 20 by a second impingement means 32 . The first and second impingement means 30 and 32 allow the support member 12 to foldably collapse into a compacted component, thereby providing easy disassembly, storage and transportation. Preferably, the upper portion 14 and middle portion 18 are each approximately three to four feet in length, while the lower portion 20 is no shorter than three and one-half feet in length. The length combinations described provide a unitary support member 12 which may vary from nine and one-half feet to eleven and one-half in height. At least one and one-half feet of the lower portion 20 is buried within the ground, either driven like a stake or cork-screwed into the ground, thereby providing a lawn chair screen and cover 10 that has an apex height of at least eight feet and may extend as tall as ten feet. The lower portion 20 includes a connector 28 for securing the support member 12 to the lawn chair 22 . The connector 28 may be a hook and loop material strap 66 , a button snap strap 68 , a rope 70 , or a C-shaped connector 72 (as shown in FIG. 4-A through FIG. 4-D ). The C-shaped connector 72 with a pair of opposable gripping ribs 74 for sliding around and coupling to the upper back 76 of a lawn chair 22 . The first and second impingement means 30 and 32 may be locking and collapsible hinges 60 ( FIG. 2 ), pins 62 ( FIG. 3-A ), or threaded members 64 ( FIG. 3-B ) coupled to one another. Preferably, the support member 12 is manufactured from a flexibly-durable, lightweight material, such as plastic, so as to provide structural support for the screen 16 while providing easy of assembly, disassembly, transportation and storage.
Referring now to FIG. 5 , the mesh-lattice screen 16 is a tightly woven mesh-lattice pattern with a diameter “d 1 ” or “d 2 ” that is 0.50 millimeters or less, thereby preventing the usual size of insects from penetrating the lawn chair screen and cover 10 . However, the mesh-lattice pattern allows for the fresh circulation of air through the lawn chair screen and cover 10 . Preferably, the mesh-lattice screen 16 is manufactured from nylon or other similar material capable of withstanding repeated assembly and disassembly and general use associated with such an item.
Referring again to FIG. 1 , a protective hoop 34 lies along the curvilinear plane of the mesh-lattice screen 16 and radially extending from the apex of the screen 16 . The protective hoop 34 is attached to the screen 16 by hook and loop material, button snaps, tie downs or another securing mechanism and may be attached to or removed from the screen 16 depending upon the environment desired by the user. For instance, the protective hoop 34 might be attached to the screen 16 so as to provide protection from rain or snow. Conversely, the protective hoop 34 might be removed from the screen 16 so as to provide a sunbather protection from the insects while allowing sunlight to penetrate the screen 16 . The protective hoop 34 might include reflective material so as to combat the ultraviolet and heat generating rays emitted by the sun.
The entrance 26 is positioned along the circumference of, and in the same curvilinear plane as the screen 16 , providing a convenient means for entering and exiting the lawn chair screen and cover 10 . The entrance 26 extends from the lower lip of the screen 16 and up to a point approximately four feet high along the circumference of the screen 16 , although a variation of the height is foreseeable. The entrance 26 avoids the inefficient necessity of entering and exiting the lawn chair screen and cover 10 by way of raising the lowest lip of the screen 16 , and then hoping that the lawn chair screen and cover 10 remains secured and/or standing. Preferably, the entrance 26 is opened or closed by a zipper 36 , although it is foreseeable that other closure means 36 may be employed, such as button snaps or hook and loop fasteners.
A plurality of support bands 58 are included which radiate from the apex of the screen 16 and extending to the lowest lip of the screen 16 . The bands 58 act to provide further structural reinforcement to the lawn chair screen and cover 10 .
Referring to FIG. 1 and FIG. 6 , the opening 24 is positioned along the circumference of, and in the same curvilinear plane as the lawn chair screen and cover 10 , thereby providing a convenient means for passing items through the lawn chair screen and cover 10 without having to physically pass the items through the entrance 22 . The opening 24 extends from near the apex of the dome to near the lip of the screen 16 , and is approximately six feet in length and approximately six to twelve inches wide. The opening 24 has two rectangular panels 38 and 40 , in which the first and second panels 38 and 40 extend along the curvilinear length of the opening 24 . The first and second panels 38 and 40 are filled with a soft material, such as foam, to provide structural support to the first and second panels 38 and 40 while also providing the flexibility desired for passing items into and out of the lawn chair screen and cover 10 . The first and second panels 38 and 40 are integral along respective lengths so as to provide a resilient slit 42 in which the slit 42 completely seals around and envelopes an item passed through or when unused. Thus, the opening 24 allows a fisher to cast a rod either within or outside the lawn chair screen and cover 10 , pass the handle of the rod/reel through the opening 24 and patiently wait for a strike. When the line is struck, the opening 24 allows a fisher to pull on the rod/reel either up or down the length of the opening 24 , and ultimately, pull the fish into the lawn chair screen and cover 10 . Preferably, the opening 24 is positioned at least eighteen inches up and away from the lowest lip of the screen 16 so as to ensure optimum convenience for passing a fishing rod or other similar item through the lawn chair screen and cover 10 . However, it is also foreseeable that people other than fishers may find use for the lawn chair screen and cover 10 , such as hunters, and may pass a hunting rifle or any number of items from person to person without having to do so through the entrance 26 or underneath the lowest lip of the screen 16 . Preferably, the opening 24 is opened or closed by a zipper 36 , although it is foreseeable that other closure means may be employed, such as button snaps or hook and loop material.
Referring now to FIG. 7 and FIG. 8 , an alternative embodiment is shown in which two openings 24 are included with the lawn chair screen and cover 10 so as to provide adaptability for accommodating two fishers or hunters. The two openings 24 have the same construction and arrangement as described for the lawn chair screen and cover 10 having one opening 24 .
Referring now to FIG. 9 , another alternative embodiment is shown in which the lawn chair screen and cover 10 includes a compartment 44 for providing a place for a user to lie down or rest. The compartment 44 includes a padded base 46 and an enclosure 48 .
FIG. 9 also shows yet another alternative embodiment of the lawn chair screen and cover 10 which includes a cooling and/or heating system 78 . The cooling and/or heating system 78 may include a fan or a water misting device for cooling and generated heat distributed by a fan. The fan, as shown in FIG. 9 , preferably lies in the same curvilinear plane as the mesh-lattice screen 16 and is operated through electricity generated from an automobile or a generator. The cooling and/or heating system 78 adds further comfort and convenience to the user of the lawn chair screen and cover 10 .
Referring now to FIG. 10 , another alternative embodiment is shown in which the lawn chair screen and cover 10 includes an adjustable canopy 50 which attaches along the outside of the screen 16 . The canopy 50 includes two exterior support members (first exterior support member) 52 and (second exterior support member) 54 and a protective cover 56 . The canopy 50 is envisioned as adaptable in allowing those that wish to remain outside the lawn chair screen and cover 10 to do so in a shaded area. The canopy 50 is adaptable to shade from one to four people comfortably.
2. Operation of the Preferred Embodiment
A user will unfold or the support member 12 about the impingement means 30 and 32 , resulting in a unitary support member 12 at least nine and one-half feet in length. A user will then drive the pointed end of the lower portion 20 into the ground, either by force or by cork-screwing the lower portion 20 into the ground. The user will then place a plurality of stakes 78 around the lower lip of the screen 16 to secure the screen 16 to the ground. A user will then attach the lower portion 20 or middle portion 18 to the lawn chair 22 via a connector 28 . A user may then pass a fishing rod (or hunting rifle) through the opening 24 and begin fishing (or hunting). While fishing, if a struggle ensues between the fisher and the fish, the fisher may raise or lower the rod within the opening 24 .
To disassemble the lawn chair screen and cover 10 , the user will pull up the stakes 78 and collapse (or disconnect) the support member 12 . The user may then compact the lawn chair screen and cover 10 so as to fit within a traveling bag, case or within a compacted area of an automobile.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents. Therefore, the scope of the invention is to be limited only by the following claims. | The lawn chair screen and cover is an enclosure system for lawn or folding chairs to protect the occupant from flying insects. The lawn chair screen and cover is made of fabric mesh and supported by a frame structure that may connect to the chair by rope, hook and loop fasteners or clamps. The fabric mesh extends around the chair, thus allowing the user full visibility and air flow through the lawn chair screen and cover. The sloped front of the invention provides a door closed by a zipper. An opening is ideal for allowing a fishing rod to extend through, thus allowing the user to comfortably fish while being shielded from flying insects such as mosquitoes, flies, gnats and the like. The use of the lawn chair screen and cover allows outdoor enthusiasts the ability to sit and relax in a chair without being annoyed or bitten by flying insects. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 60/556,997, filed Mar. 26, 2004. The aforementioned provisional application is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The current invention is in the field of home improvement and home construction and more particularly, relates to a cover or housing system which may be integrated with a pull down stairway. The present invention addresses certain problems associated with access to an upper floor using a pull down stairway. In a further aspect, the present invention provides an improved method of access to and exit from an upper room such as an attic using an installed folding stairway.
There are various inventions that cover, insulate, or attempt to seal the opening above a pull down stairway. Pull down stairways are notorious for their inefficiency with loss of warm air and moisture up through the stairway access. Previous devices made of foam or fiberglass enclosures must be manually removed when access is needed and re-positioned manually while climbing back down the stairway or standing on a ladder. Other devices attempt to reduce the infiltration of warm air, but lack the insulation R-value recommended by the building industry. Other inventions are designed as trap door devices, but still require manual intervention.
The preferred embodiments of the present invention address air, moisture and dust infiltration and thermal loss associated with access through an upper floor opening using a folding or pull down stairway while also providing a handrail, positioned to be grasped by a user when the pull down stairway is deployed for assisting the user when entering and leaving the upper floor opening.
SUMMARY OF THE INVENTION
According to the invention, the integrated housing system is physically attached to and is activated by the up and down motion of the separately installed pull down stairway.
In one aspect of the invention, an integrated system activated by the action of a pull down stairway is provided. One or more handrails are deployed making it easy to enter and exit the stairway opening without the need to manually intervene in removing the housing box above the opening. The deployment of the one or more handrails is accomplished when the stairway is pulled down for use. In the preferred embodiments a pair of handrails are deployed, positioned on opposite sides of the upper floor opening; the handrail being pivotally connected to the cover such that in a closed position the handrail extends above the cover.
In another aspect, a highly insulated housing above the pull down stairway is provided that reduces the heat loss of the enclosed access into an upper space that may or may not be heated.
In yet another aspect, a sealed housing over the closed pull down stairway is provided that reduces the passage of warm air and moisture from rising into an upper room that may or may not be heated.
It still another aspect, a housing over the closed pull down stairway is provided that reduces the infiltration of dirt and debris from entering the living space below the pull down stairway opening.
In operation, as the pull down stairway assembly is deployed in a downward direction for use, the integrated housing above the stairway moves away from the access opening. Likewise, when the pull down stairway assembly is returned to its stored position, the housing returns to the closed position and seals the access opening. Unlike prior art stairway covers, additional manual intervention is not required to remove the cover from the opening in the floor above once the stairway has been deployed for use and/or to return the cover to the closed position when the pull down stairway is returned to the stored position.
In certain embodiments, the present invention is embodied in a sliding or rolling configuration wherein the housing rolls back and away from the access opening. In certain other embodiments, the present invention is embodied in a hinged configuration wherein the housing rises or pivots up and away from the access opening.
The activation is accomplished by one or more arms attached to a stairway rail and by one or more adjustable push pull sleeves connected to the one or more arms and a housing extension. The push pull sleeves differ in the two configurations, as described in the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings, wherein like reference numerals are used for like or analogous components throughout the several views, are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
FIG. 1 is a perspective view of the integrated housing system of the sliding configuration and in the opened position.
FIG. 2 shows a side view of the air convection seals at the front and back housing panels of the sliding cover configuration in the closed position. The side view also shows the handrail arm and push pull sleeve in the up and closed position. The rollers at the bottom edge of the side panels are shown.
FIG. 3 is a perspective view of the activated insulated housing of the hinged configuration held in the raised or open position by the handrail arms and the push pull sleeves.
FIG. 4 is a side view of the activated hinged housing held in the closed position by the handrails and push pull rod attachments.
FIG. 5 is the left half cross-sectional view from the head of the folded stairway showing the activation apparatus of the integrated housing system in the closed position.
FIG. 6 shows the position of the air, moisture and dirt seal attached to the lower edge of the arm catcher and the sides and the back panels of the hinged popup housing configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The primary components of the current invention are shown in the perspective views of FIGS. 1 and 3 . A housing box or cover 1 is provided to selectively cover an opening in a building floor 5 which is accessible via a pull down stairway 7 . In a preferred embodiment, the housing box or cover 1 is fitted with insulation, which may be provided in a number of ways. For example, an insulating material may be provided on one or more exterior surfaces of the cover 1 and/or within the interior compartment defined by the housing box 1 . Alternatively, the insulating material may encased within the cover shell or the cover 1 may otherwise be formed of a thermally insulating material. The runners 3 in FIG. 1 are attached to the upper floor 5 and are used for guiding the housing box 1 in the sliding configuration of the invention. The two curved arms 6 are pivotally attached to push pull sleeves 8 and function as actuators when the stairway 7 is in motion. The curved arms 6 also preferably act as handrails when the stairway 7 and housing box 1 are fully deployed. The push pull sleeves 8 each hold a respective one of the arms 6 in place for use as handrail when the cover 1 is in the open position as shown in FIG. 1 . The push pull sleeves 8 cooperate with the handrails 6 and act as a component of the activator mechanism in moving the housing box 1 to the closed position as shown in FIG. 2 .
A riser 10 provides for passage and positioning of the arms 6 when the cover 1 is in the closed position. The handrail posts 11 in FIGS. 3 and 4 are fastened to the upper floor 5 by the post flanges 15 shown in FIG. 3 . In FIG. 2 , gasket or seal material 12 is attached under the arm catcher 30 and rear close stop 22 for reducing air and moisture infiltration into the upper room. The gasket material 12 in FIG. 3 is applied under the housing side panels 18 that meet the floor. In FIG. 1 , the gasket material 12 is applied along the lower outside portion of the housing side panels 18 overlaying and sealing the outside of the runners 3 . Sliding members 31 such as rollers, glides, or the like, appear in FIG. 2 and may be provided for reducing friction and thus the effort required to effect the sliding movement of the cover. Finally, the hinge 2 in FIG. 4 at the rear panel 4 of the housing 1 is used for the pivot location in raising the housing box 1 .
The construction of the housing member consists of a preferably lightweight box, which may be made of durable wood, plastic, or other suitable material, and may be molded or monolithically formed, or may comprise panels bonded or fastened on its connecting edges. The arms 6 shown in FIGS. 1 and 3 may be made of a plastic, preferably a dimensionally stable plastic composite, wood, treated wood, metal or metal alloy such as steel, or the like. The push pull sleeves 8 and 8 A include a channel or groove for receiving the handrail ends and may created, for example, from rigid tubing. Sleeves 8 A may have an adjustment rod 9 for length. The handrail posts 11 may be fabricated from metal or metal alloy, wood, or plastic material with a receptacle 14 to accept the upper end of the arms 6 . The height of handrail posts 11 and receptacle 14 is preferably adjustable. A flange 15 at the base of the post 11 is provided for securing the post to the upper floor 5 .
In operation, the housing box 1 shown in FIGS. 1 and 3 moves away from the stairway opening 17 as the pull down stairway 7 is moved in the downward direction when deploying for use. Conversely, as the pull down stairway 7 is raised toward its stored position, the housing box 1 moves back into the closed position, thereby sealing the living space below from thermal loss, moisture loss, air convection and dust infiltration.
Previous solutions require manual intervention to remove a cover from the access opening and to return the cover to its proper position.
In operating the present invention, no change in the operating procedure of the pull down stairway 7 is required.
A method for installing the housing apparatus of the present is described below. It will be recognized that the cover system of the present invention may be installed on an existing pull down stairway installation, or, may readily adapted for use with a new pull down stairway construction. The runners 3 shown in FIG. 1 are fastened parallel to each other such that both runners are positioned equally on either side of the access opening 17 and aligned with the head of the stairway opening. With the stairway 7 in the down or open position as shown in FIGS. 1 and 3 , the two arms 6 are fastened to the stair rails 20 . With the stairway 7 in the closed position as shown in FIGS. 2 and 4 , the riser 10 is fastened to the head of the stairway flush with the upper floor 5 . The arms 6 may be adjusted for fit into the riser grooves and the fasteners that hold the lower portion of the arms 6 to the side rails 20 of the stairway 7 are tightened.
A boot 24 shown in FIGS. 2 and 4 is used to surround and clamp the lower portion of the arm 6 to the upper stairway rail 20 using bolt fasteners.
With the stairway fully open for the sliding configuration as shown in FIG. 1 , the arms 6 are positioned into the sleeves 8 . The cross member 32 is added between the two arms 6 and sleeve joints. The sleeves 8 are attached to the housing extension 16 . The legs 25 which are attached to the arms 6 are adjusted to fit firmly onto the upper floor 5 .
With the stairway fully open for the hinged configuration shown in FIG. 3 , the handrail posts 11 are positioned onto the upper floor just below the upper ends of the deployed arms 6 . The height of the post receptacles 14 at the top of the posts is adjusted to cradle the upper end of the activating arms 6 . The posts 11 are fastened to the upper floor 5 with the post base flanges 15 . The cross member 32 A is added between the two arms 6 and sleeve joints. The sleeves 8 A and adjustment rods 9 are attached to the housing extension 16 A.
With the stairway 7 in the closed position, the housing box 1 with gasket seals 12 is fit over the access opening 17 with a snug fit around the head of the stairway 7 , riser 10 and arms 6 . For the sliding configuration in FIG. 2 , the push pull sleeves 8 are attached to the arms 6 . For the hinged configuration in FIG. 4 , attach the sleeves 8 A with push pull rods 9 to the extensions 16 A. The length of the adjustment rods 9 is adjusted such that the front housing panel 13 fits snugly over the riser 10 at the head of the stairway with the arms 6 cradled in the notches at the top of the installed riser 10 . For the hinged configuration, the hinge 2 is attached at the rear portion of the cover 1 , as shown in FIG. 4 . For the sliding configuration, the rear close stop 22 is attached as shown in FIG. 2 . Insulation may be attached to the housing top 19 , sides 18 , front panel 13 , and/or rear panel 4 .
In operation, the two configurations shown in FIGS. 1 and 3 differ in the method of opening the stairway access 17 .
For the sliding configuration shown in FIG. 1 , the push pull sleeves 8 meet the housing extensions 16 attached to the sides 18 of the housing box 1 . The adjustable extension brace 26 is attached to the housing extension 16 and the side 18 of the housing box 1 . The extension brace 26 controls the position of the housing extension 16 , the arms 6 and the housing 1 . The extension brace 26 is adjusted with the housing box 1 in the closed position and the notches in the arm catcher 30 firmly around the arms 6 near the upper floor 5 . With the adjustable braces 26 firmly in place, open the housing system and fasten the rear open stop 23 to the upper floor 5 as shown in FIG. 1 .
For the hinged configuration shown in FIG. 3 , the push pull sleeves 8 A and adjustment rods 9 are attached to the extensions 16 A placed near the back of the housing sides 18 to give the proper moment arm force in relation to the hinge 2 location. The position and alignment of the apparatus in FIG. 5 involves the stairway 7 , the arms 6 , the push pull rods sleeves 8 A, and the extension 16 A. The hinged configuration demands less floor space, which may be an advantage in certain situations.
Optionally, the arms 6 may be constructed in two components for packaging and shipping. During installation, the arms are joined as shown in FIG. 1 and FIG. 3 . Likewise, the runners 3 shown in FIG. 1 may, optionally, be constructed in multiple sections for packaging and shipping. During installation the runners 3 are joined into contiguous segments for guiding the housing box 1 . Exemplary positions of the joint for the handrails 6 appear in FIGS. 1 and 3 . Preferably the positions of the joints between the members are selected such that the parts will fit within the interior enclosure defined by the housing box 1 . In this manner, the individual components for constructing the apparatus of the present invention may be provided disassembled or partially disassembled as a kit. In a preferred kit embodiment, the housing box or cover 1 serves as packaging container and/or shipping box for the kit.
The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. | An integrated insulated housing system with handrails and a system of seals for a pull down stairway opening is provided. The integrated housing system reduces air convection, moisture loss and dirt infiltration. The insulation of the housing system reduces heat loss. Handrails as part of the system are deployed by the action of the pull down stairway. No manual intervention is required. As the stairway is pulled down for use, the integrated housing above moves away from the access opening. Simultaneously, the two integrated handrails move into a stable position on the upper floor and to either side of the stairway. As the stairway is returned up to its closed position, the connected insulated housing moves back into position sealing the access opening. | 4 |
This is a continuation of application U.S. Ser. No. 07/829,878, filed Jan. 3, 1992, which was abandoned upon the filing hereof.
FIELD OF THE INVENTION
Novel perfluorinated sulfonyl monomers and polymers and membranes made therefrom are provided.
BACKGROUND OF THE INVENTION
Electrochemical processing involves the interaction of electrical and chemical reactions to produce a wide variety of products, separations, and processes. Included among the more significant industries that employ electrochemical processing are the plating industry, the chloro-soda industry, hydrogen-oxygen fuel cells, waste water treatments, and the plethora of industries employing electrochemical membranes, hollow fibers and tubes. Electrochemical processes are used to produce products such as aluminum, deuterium, fluorine, platinum, and sorbitol, to name only a few.
Electrochemical processes are used to convert chemical energy into electrical energy in electrolytic fuel cells, such as batteries. Electrolytic cells usually employ membranes that are permeable to one type of ion but impermeable to the other. Recently, DuPont has developed a perfluorosulfonic membrane known as "Nafion". Nafion membranes have the chemical and thermal stability of Teflon tetrafluoroethylene resins but are very hydrophilic. Unlike Teflon, which is one of the most hydrophobic substances known, Nafion absorbs water rapidly even at room temperature. Their high chemical stabilities and high water absorption rates have made Nafion membranes a unique, long-life separator in electrochemical and chemical processing.
Nafion is a polyperfluorosulfonic acid resin. Membranes made from Nafion resins were a revolutionary development in the field of electrochemistry. The resin and its membranes, especially the composite membrane of polyperfluorosulfonic acid and polyperfluorocarboxylic acid, have been broadly used in all industries where electrochemical membranes are employed.
In the 1950's, chemists began focussing on fluorocarbon polymers having extraordinary chemical stabilities and the mechanical and electrical properties of polytetrafluoroethylene (PTFE) but that were also melt-fabricable like the polyethylenes and polyamides. The rearrangement of hexafluoropropylene epoxide (HFPO) led to the production of perfluoropropionyl fluoride, which is then reacted with more HFPO to produce a dimer which, on heating with sodium carbonate, yields perfluoropropyl vinyl ether (PPVE). PPVE has been copolymerized with tetrafluoroethylene (TFE) to provide a thermoplastic with the chemical stability and mechanical properties closely approaching those of PTFE.
Chemists then discovered the remarkable properties of an ionomer resin which was an acid salt of an ethylene and methacrylic acid copolymer. These ionomers were sold under the trademark "SURLYN". Researchers also began to search for fluorocarbon resin ionomers having acid groups with greater thermal stability than carboxyls in order to find ionomers capable of withstanding the high processing temperatures required for fabricating fluorocarbon plastics.
Then, in the late 1970's, a Bronsted acid of nitrogen was synthesized for the purpose of extending the number of possibilities of xenon-nitrogen bonds. From that research, a class of superacids with considerable promise in electrochemical applications emerged. The superacid developed was a perfluorinated sulfonyl nitrogen acid having the formula (CF 3 SO 2 ) 2 NH.
(CF 3 SO 2 ) 2 NH is more than two orders of magnitude stronger in acidity than nitric acid in acetic acid solvent (dissociation constant of 10.2 vs.7.8). The phase acidity of these compounds show that they far exceed the inherent acidity of other acids such as CF 3 SO 2 OH, FSO 3 H, and HI.
Electrochemical studies have shown that these acids exhibit favorable properties on low surface area and high surface area electrodes employed in practical fuel cells. The compounds greatly improve the output of the typical fuel cell. Electrolytes and fuel cells employing these materials dictate that the fluoropolymers be extremely stable. Presently, Nafion and Dow 560 are the current ionomers of choice in fuel cell applications.
To produce a Nafion polymer, a cyclic sultone is rearranged to a linear form and reacted with HFPO to produce a sulfonyl fluoride, which is then reacted with sodium carbonate to yield a sulfonyl fluoride vinyl ether (PFSEPVE). PFSEPVE is then polymerized with TFE to give a perfluorocarbon sulfonyl fluoride copolymer that can be fabricated into a membrane and other various articles. This polymer has the chemical formula: ##STR3##
The sulfonyl copolymer can be completely saponified with hot caustic to give a sodium salt which can then be converted with an acid to an acid polymer resin form. The salt and free acid forms of the polymer resin are essentially infusible.
Nafion polymers may be fabricated into various forms, including membranes, diaphragms, tubing, laminates, and filaments. These products are shaped as desired by melt fabricating the sulfonyl fluoride copolymer, followed by saponifying and exchanging. In this manner, the Nafion products can be made free of pin holes, which is a necessity for membrane processes.
Nafion membranes have been used in electrolytic fuel cells, electrodialysis processes, including dialysis of brackish water and electrolysis of brine, chrome plating, and other applications. In electrochemical cells, Nafion membranes separate the cell into two compartments and serve as a wettable, ionically conductive, perm selective barrier. In dialysis, Nafion membranes serve as a wettable, perm selective reactor.
Nafion membranes are permeable to positively charged ions (cations) but are impermeable to negatively charged ions (anions). By tailoring the polymer structure and employing special techniques for fabricating and reinforcing the membrane, Nafion membranes combine good selectivity with low resistance, high physical strength and long service life.
The membrane processes employing Nafion membranes are advantageous from an energy standpoint over evaporative and crystallization processes. Processes using these membranes allow separation of dissolved materials from one another or from a solvent with no phase change. Membrane processes do not require the added energy required for vaporization or crystallization. Because energy costs represent a substantial and increasing percentage of the total cost for most separation operations, membrane processes offer significant energy savings. In addition, electrochemical membrane processes offer possible solutions to ecological problems, particularly in the plating industry. Potential pollutants in the plating industry are converted into valuable products by electropurifying and electrooxidzing a process stream to make the stream constituents suitable for reuse.
Nafion membranes, however, suffer from the inability to retain sufficient water to maintain proton conductivity above 80° C. New monomers which form superior polymeric membranes and offer greater flexibility in the design of membranes are currently being sought.
The present invention, which incorporates the ##STR4## acid groups into a perfluorocarhon polymer, can be used to create new and novel polyfluorocarhon electrolytes for improved use in fuel cells and other applications.
Various fluorocarbon compositions having sulfonyl groupings are known in the art. For example, U.S. Pat. No. 3,050,556 to Tiers relates to a mono-chloro-substituted long chain alkanesulfonyl fluoride having the general formula Cl(CHR-CH 2 ) n SO 2 F where R is an alkyl radical of from 6 to 16 carbons and n is an integer of from 1 to 2. U.S. Pat. No. 3,301,893 to Putnam et al. also relates to various fluorocarhon ethers having the general formula: ##STR5## where R f is a radical selected from fluorine and perfluoroalkyl radicals having from 1 to 10 carbons, X is a radical selected from fluorine, trifluoromethyl radicals and mixtures thereof, Y is a radical selected from fluorine, amino, hydroxyl and --OMe radicals where Me is a radical selected from ammonium radicals, alkali metals and other monovalent metals, and where n represents a number from 0 to 12. U.S. Pat. No. 3,849,243 to Grot relates to laminates of fluorinated polymers containing pendant side chains having sulfonyl groups where a majority of the sulfonyl group of one surface is in the --(SO 2 NH) m Q form where Q is H, a cation of an alkali metal, or a cation of an alkaline earth metal or combination thereof, and m is the valance of Q, while the sulfonyl groups of the other surface are in the --SO 2 M form wherein M is a halogen atom. One monomer used in making the polymers of the invention disclosed therein has the generic formula CF 2 =CFR f SO 2 F wherein R f is a bifunctional perfluorinated radical comprising 1 to 8 carbons.
Other patents and applications, such as U.S. Pat. Nos. 4,578,512 to Ezell et al., 4,337,211 to Ezell et al., 4,734,474 to Hamada et al., 4,554,112 to Ezell et al., 4,474,400 to Krespan, German Patent No. 1959142 to Abitz et al. and EPO Publication Nos. 0062323 of Darling and 0062324 of Krespan et al., show various perfluorinated monomer compounds and polymers resulting therefrom.
Although various perfluorinated monomers containing sulfonyl groups are known, the particular features of the present invention are absent from the art. The prior art is generally deficient in affording a non-oxy perfluorinated superacid monomer for producing an ionomer membrane having the characteristics and flexibility of the presently claimed invention. The present invention overcomes the shortcomings of the prior art in that the monomers disclosed herein and polymers made therefrom result in higher chemical stabilities and physical flexibilities than the Nafion polymers while providing all the desired characteristics of a Nafion polymer.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide novel fluorinated monomers and polymers made therefrom.
It is another object of the present invention to provide novel fluorinated monomers containing sulfonyl groups and polymers made therefrom.
It is a further object of the present invention to provide novel fluorinated superacid monomers and polymers made therefrom.
It is further another object of the present invention to provide nitrogen acid monomers and polymers produced therefrom.
It is another object of the present invention to provide electrochemical membranes produced from ionomers of fluorinated polymers containing sulfonyl and nitrogen acid groups.
Still another object of the present invention is to provide fluorinated monomers and their corresponding derivative salts wherein the monomers have superacid characteristics and are capable of forming electrolytic membranes for use in fuel cells.
Generally speaking, the present invention is directed to novel perfluoronated superacid monomers containing sulfonyl groups and polymers produced therefrom. The polymers produced according to the present invention are useful as new polyelectrolytes applicable in fuel cell apparati and other applications that currently employ Nafion polymers.
Broadly speaking, the present invention is directed to fluorinated monomers having the general formula: ##STR6## wherein X=CH or N 2=H, K, Na, or Group I or II metal
R f =one or more fluorocarbon groups including fluorocarbon ethers and/or sulfonyl groups and/or perfluoronon-oxy acid groups ##EQU1## Examples of specific monomers that fall within the scope of the present invention include: ##STR7##
The monomers may be polymerized with other various monomers including tetrafluoroethylene (TFE) and tetraethylethylene (TEE), to provide copolymers useful for making various products, including electrolytic fuel cell membranes.
DESCRIPTION OF PREFERRED EMBODIMENTS
Novel fluorinated monomers which may be polymerized to form new polymers for use in various applications, including as solid polymer electrolytes electrochemical membranes, are provided. The polymers formed from the monomers described herein may be used to form chemically stable perfluorosulfonic membranes used in electrocells for electrochemical production of inorganics and organics. Polymers made from the inventive monomers can be used to replace Nafion and Dow 560 membranes currently being used as electrolytes in fuel cells and other applications. The inventive monomers have the general formula: ##STR8## wherein X=CH or N 2=H, K, Na, or Group I or II metal
R f =one or more fluorocarbon groups including fluorocarbon ethers and/or sulfonyl groups and/or perfluoronon-oxy acid groups ##EQU2##
Monomers having the above-referenced formula are superacids of carbon or nitrogen and may be synthesized through two basic synthetic routes, both employing perfluoroalkylsulfonyl fluorides. The parent member of the carbon superacid is (CF 3 SO 2 ) 2 CH 2 and the parent member for the nitrogen super acid is (CF 3 SO 2 ) 2 NH. The reaction routes for the nitrogen and carbon acid parent members are shown below. ##STR9## wherein Me is methyl and HMDS is hexamethyldisilazane.
Through the synthesis routes described herein, specific monomers of having the general formula above can be produced including the following: ##STR10##
It should be understood that the present invention is not limited to the specific monomers described herein, and that any monomer having the general formula described fall within the scope of the present invention. Synthesis routes of the five specific monomers identified above are merely exemplary so as to enable one of ordinary skill to make the superacid monomers of the present invention. Likewise, synthesis of the copolymers described hereinbelow are merely exemplary of the copolymers that come within the scope of this invention.
The present invention may be better understood by reference to the following examples. The process of producing each of the monomers in Examples 1-5 is described in terms of producing each progressing intermediate compound. Where appropriate, a reaction sequence is shown in diagram form to indicate the progression of intermediates to final monomer product.
EXAMPLE 1
Sodium N-trifluoromethylsulfonyl 2-[(1-pentafluoro- 2-propenyloxy) tetrafluoroethylene] sulfonamide (CF 2 =CFCF 2 OCF 2 CF 2 SO 2 NHSO 2 CF 3 ) monomer having the general formula above, was produced according to the following method.
Perfluoroallyl fluorosulfate (CF 2 =CFCF 2 OSO 2 F) was prepared according to the method of U.S. Pat. No. 4,235,804 to Krespan except that the molar ratio of perfluoropropene, sulfur trioxide and boron trifluoride used was 2.5:1:0.2 instead of 1.6:1:0.007. 24 g of sulfur trioxide, 4 g of boron trifluoride and 112 g of hexafluoropropene were vacuum-transferred into a 350-ml pressure reactor and agitated at 25° C. for 3 days. The mixture was then fractionated in high vacuum through-traps at -70° C. and -196° C.
Fluorosulfonyl difluoroacetyl fluoride was produced by modifying England's method disclosed in England, D. C., Dietrich, M. A. and Lindsey, R.V.J. Am. Chem. Soc., (1960), 82, 6181 (which is incorporated in full by reference thereto) as follows. 53 g of sulfur trioxide and 73 g of tetrafluoroethylene were transferred into a 350-ml pressure reactor. The mixture was then warmed to 80° C. and agitated for one week. The products were fractionated in high vacuum through traps cooled to -90, -110 and -196° C.
To produce 2-[(1-Pentafluoro-2-propenyloxy) tetrafluoroethylene] sulfonyl fluoride (CF 2 =CFCF 2 O-CF 2 CF 2 SO 2 F), a suspension of 5.8 g of potassium fluoride in 100 ml of tetraglyme was stirred for 10 min at 25° C. 0.1 mole of fluorosulfonyl difluoroacetyl fluoride was then vacuum-transferred into the same flask and stirred at 25° C. for 30 minutes. 0.1 mole of perfluoroallyl fluorosulfate was then vacuum-transferred to the flask and stirred at 25° C. for 2 hours. The mixture was distilled in high vacuum through a trap at a -196° C. The product was then redistilled at 100 torr.
2-[(2,3-dichloropentafluoroproxyl) tetrafluoroethylene] sulfonyl fluoride (CF 2 ClCFClCF 2 OCF 2 CF 2 SO 2 F) was produced by transferring 6 millimoles of chlorine into a 250-ml flask containing 1.65 g of 2-[(1-pentafluoro-2-pro-penyloxy) tetrafluoro ethylene] sulfonyl fluoride and stirring at 25° C. for 11 hours. The mixture was then fractionated at high vacuum through traps cooled to -70° C. and -196° C.
Sodium N-trifluoromethylsulfonyl 2-[(2,3-dichloro pentafluoropropoxy)-tetrafluoroethylene] sulfonamide (CF 2 ClCFClCF 2 OCF 2 CF 2 SO 2 NNaSO 2 CF 3 ) was produced by vacuum-transferring 5.4 g of 2-[(2,3-dichloropenta fluoropropoxyl)tetrafluoro-ethylene] sulfonyl fluoride and 10 ml of acetonitrile into a 50-ml flask containing 3 g of CF 3 SO 2 NNaSiMe 3 , and stirring at 75° C. under reflux for 2 days. The volatile materials were then removed under vacuum to give the sodium salt.
Finally, the salt form of the monomer of this example, sodium N-trifluoromethyl sulfonyl 2-[(1-penta-fluoro-2-propenyloxy) tetrafluoroethylene] sulfonamide (CF 2 =CFCF 2 OCF 2 CF 2 SO 2 NNaSO 2 CF 3 ), was produced by stirring a suspension of 9 g of activated zinc dust in 20 ml of pure acetic anhydride while 21.7 g of sodium N-trifluoromethylsulfonyl 2-[(2,3-dichloro pentafluoropropoxy) tetrafluoroethylene] sulfonamide was added under nitrogen atmosphere. The mixture was stirred at 80° C. under reflux for 3 hours and then filtered. The filtrate was then distilled in a high vacuum and the resulting solid product was dried under vacuum for several days.
N-trifluoromethylsulfonyl 2-[(1-pentafluoro-2-pro-penyloxy) tetrafluoroethylene] sulfonamide (CF 2 =CFCF 2 OCF 2 CF 2 SO 2 NHSO 2 CF 3 ) was produced by acidifying the monomer produced above. 16 ml of 60% sulfuric acid and 1.5 g of sodium N-trifluoromethylsulfonyl 2-[(1-pentafluoro-2-propenyl-oxy) tetrafluoroethylene] sulfonamide were added to a 50-ml flask. The mixture was stirred at 25° C. for one hour until it separated into two liquid phases. The bottom liquid layer was removed and distilled in high vacuum to obtain the acid form of the monomer.
The following represents the reaction diagram for producing sodium N-trifluoromethylsulfonyl 2-[(1-pentafluoro-2-propenyloxy) tetrafluoroethylene] sulfonamide (CF 2 =CFCF 2 OCF 2 CF 2 SO 2 NHSO 2 CF 3 ) monomer: ##STR11##
EXAMPLE 2
The monomer of this example, having the general formula above and the specific formula, ##STR12## was prepared according to the following method.
Sulfur trioxide was melted in a 70° C. oil bath. After conversion to liquid, it was cooled to room temperature and then transferred into a 500-ml round bottom flask easily connectable to a vacuum line. The vessel was evacuated after cooling in liquid nitrogen. 61 g of SO 3 and 80 g of C 2 F 4 were transferred by vacuum into a 200-ml stainless metal reactor at liquid nitrogen temperature. The reactor was shaken for 4 days at 40°-60° C. after which the products were transferred into a liquid nitrogen-cooled trap. The trap was opened and maintained at room temperature (protected with a CaCl 2 dry tube) to evaporate the dissolved C 2 F 4 and other gaseous products.
The product formed above was purified by adding it to a 250-ml three-necked round bottom flask equipped with a dropping funnel, distillation condenser, receiver, reflux condenser and stir bar. The flask was cooled in an ice-water bath. 2-ml of dry triethylamine was dropped slowly from the dropping funnel into the flask to create a vigorous reaction, changing the colorless liquid to a red color. Stirring was continued at room temperature for 1 hour and purified ##STR13## was distilled out.
15 g of CsF (fused powder) and 150 ml of tetraglyme (dried with sodium) were added into a 1000-ml round bottom vessel equipped with a Kontes Valve and stir bar. The vessel was attached to a vacuum line and cooled in liquid nitrogen. 120 g of ##STR14## was transferred into the vessel through the vacuum line. The mixture was slowly returned to room temperature to avoid a vigorous thermopositive. The mixture was then stirred at room temperature for 1 hour and cooled in a -10° C. to -20° C. bath. 210 g of hexafluoropropylene oxide was continuously introduced into the vessel at between 750 and 400 torr and the mixture was vigorously stirred for 18 hours. The product was then distilled and two fractions were collected. The first fraction was pure n=0 and the second fraction was 14:66:16 mixture of n=0, 1, and 2, respectively. The second fraction obtained was ##STR15##
An apparatus for producing the pyrolytic decarboxylation of the carbonyl fluoride in fraction number 2 above was then constructed. 160 g of powdered sodium carbonate and 160 g of glass beads were mixed and packed into a column (50 cm long and 2.5 cm inner diameter). The fillings were supported by glass wool at the bottom of the column and covered with a glass wool on the top. A tape heater was tied tightly around the entire column. The pyrolysis temperature was measured by a thermocouple. A screw valve-controlled dropping funnel was fitted on top of the column through which a constant nitrogen flow (dried by P 2 O 5 ) was introduced. At the bottom of the column, a two-necked receiver vessel was fitted and cooled in an ice-water bath. Another neck was protected with a condenser to prevent escape of the product. The column was preheated at 300° C. for 8 hours, and then maintained at 210° C. to 225° C. for pyrolysis.
The distillate (fraction number 2) prepared above was dropped slowly through the funnel into the column during 4 hours. The material was evaporated and brought through the column by nitrogen flow and pyrolized to obtain ##STR16##
The double bond formed was then chlorinated. 48 g of vinyl ether was added to a 1000-ml round bottom reaction vessel equipped with glass-Teflon Kontes Valve and stir bar and containing the above pyrolized product. The vessel was attached to a vacuum line and cooled with liquid nitrogen. 100 bar (10.4 bar=1 mmol) of chlorine was introduced and condensed in the vessel. The Kontes Valve was closed and the reaction mixture was stirred at room temperature for 24 hours. Excess chlorine was removed by condensing it through the vacuum line into a trap. The chlorinated product, ##STR17##
To produce the monomer and its precursors, 9 g of CF 3 SO 2 N(Na)SiMe 3 and 20 g of the chlorinated product produced above were stirred in a mixed solvent of 50 ml acetonitrile (dried with CaH 2 and P 2 O 5 ) and 50 ml 1,4-dioxane (dried with sodium) under dry nitrogen at about 80° C. to 90° C. for 12 hours and then at 70° C. overnight. Solvents were removed at 70° C. under reduced pressure. The residue was dried at equivalent conditions for 8 hours.
100 ml of solid acetic anhydride and 20 g of zinc dust were added. The solution was stirred in a 80° C.-90° C. oil bath and under dry nitrogen for 12 hours and then at 70° C. overnight. Acetic anhydride was removed under vacuum at 60° C. 50 ml of 98% sulfuric acid was added. The solid slowly changed to a viscous liquid which was the crude monomer, ##STR18## which was further purified by vacuum distillation.
The end product is a perfluorovinyl ether with a ##STR19## functional group. It is a stable monomer and can be stored at low temperatures for a long period of time. The results of copolymerization with TFE indicate that it is an active copolymerization monomer and provides ##STR20## at equivalent weights as low as 1000 (n less than 6).
Unlike the Nafion resin, this novel perfluoro copolymer is soluble in dimethylformamide. It can be processed by casting to form the corresponding membrane.
The following represents the reaction diagram for producing the monomer of this example: ##STR21##
EXAMPLE 3
Two perfluoromonomers (CF 2 =CFCF 2 CF 2 SO 2 F and CF 2 =CFCF 2 SO 2 N(H)SO 2 CF 3 ) containing the sulfonyl fluoride moiety and non-oxy superacid group were synthesized in high yield according to the method described in this example.
Sodium 3,4-Dichloro-perfluorobutane sulfinate (ClCF 2 CFClCF 2 CF 2 SO 2 Na) was prepared by stirring 100 g Na 2 S 2 O 4 , 82 g NaHCO 3 , 250 ml H 2 O, and 150 ml CH 3 CN in a 1000-ml three-necked flask provided with a dropping funnel, an efficient reflux condenser and a magnetic stirrer. 100 g of 1,2-dichloro-4-iodo-perfluorobutane was added drop by drop through a 100-ml dropping funnel into the reaction mixture during one hour at 40° C. while stirring magnetically under nitrogen atmosphere. The mixture was stirred for 15 hours at 40° C., then distilled to remove CH 3 CN and extracted with 300 ml of ethyl acetate. The mixture was washed three times with 160 ml of sodium chloride-saturated water to remove all of the inorganic compounds. Ethyl acetate and water were evaporated under high vacuum to give dry solid product.
3,4-Dichloro-perfluorobutanesulfonyl chloride (ClCF 2 CFClCF 2 CF 2 SO 2 Cl) was prepared by placing 80 g of the sodium 3,4-Dichloroperfluorobutane sulfinate produced above (dissolved in 250 ml H 2 O) in a 1000-ml three-necked flask provided with a magnetic stirrer, gas inlet tube and reflux condenser, the upper end of which was connected to a washing bottle filled with concentrated NaOH/water solution. Chlorine gas was bubbled through the solution, with occasional ice-water bath cooling, for 30 minutes. The product was washed with an aqueous solution of NaHCO 3 , and dried over molecule sieves. Distillation at normal pressure yielded the liquid product.
3,4-Dichloro-perfluorobutanesulfonyl fluoride (ClCF 2 CFClCF 2 CF 2 SO 2 F) was then produced by one of two methods. In the first, a 1000-ml three-necked flask, provided with a magnetic stirrer, a reflux condenser, the upper end of which was connected to a drying tube, was filled with 250 ml dry cyclic sulfolane, 100 g activated potassium fluoride, and 100 g of 3,4-Dichloro-perfluorobutanesulfonyl chloride produced above. The product was distilled under high vacuum and cooled in a liquid nitrogen trap. Distillation under normal pressure yielded liquid product.
In the second method for producing 3,4-Dichloro-perfluorobutanesulfonylfluoride (ClCF 2 CFClCF 2 CF 2 SO 2 F), a three-necked flask provided with magnetic stirrer, a reflux condenser, the upper end of which was connected to a drying tube, was filled with 150 ml of very dry CH 3 CN, 11.6 g activated potassium fluoride and 14.8 g of distilled 3,4-dichloro-perfluorobutanesulfonyl chloride produced above. The reaction mixture was stirred under a dry nitrogen atmosphere at room temperature for three days. The product was distilled to yield the product. Finally, the sulfonyl fluoride monomer, perfluoro-butene-3-sulfonyl fluoride (CF 2 =CFCF 2 CF 2 SO 2 F) was prepared by adding 200 ml dry 1,4-dioxane, 25 g of zinc powder and 23 g of the 3,4-dichloroperfluoro-butane sulfonyl fluoride produced above into a 500-ml three-necked flask, fitted with a magnetic stirrer and a reflux condenser, the upper end of which was connected to a trap cooled to -70° C. The reaction mixture was heated and stirred at 90° C. under nitrogen atmosphere for 10 hours. The product was distilled under vacuum and trapped in cooled liquid nitrogen. The crude product was washed by water to remove 1,4-dioxane, separated from water, dried over molecule sieves, and distilled to yield the intermediate.
Sodium perfluoromethylsulfonyl perfluoro-3,4-dichlorobutanesulfonyl imide intermediate (ClCF 2 CFClCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 ) for producing the non-oxy superacid of this example was prepared as follows. First, CF 3 SO 2 NNa(SiMe 3 ), was prepared according to the method described in J. Foropoulos, Jr., D. D. DesMarteau, Inorganic Chemistry (1984) 23, 3720, which is incorporated in full by reference. Next, 100 ml of very dry CH 3 CN, 21 g of CF 3 SO 2 -NNa(SiMe 3 ) and 29 g of 3,4-dichloroperfluorobutane sulfonyl fluoride prepared as described above were placed in a 500-ml three-necked flask fitted with a magnetic stirrer and reflux condenser, the upper end of which was connected to a drying tube. The reaction mixture was heated at 80° C. with magnetic stirring for 4 days. The solvents and FSiMe 3 evaporated under high vacuum and the product was recrystallized in a small volume of water.
Perfluoromethylsulfonyl perfluoro-3,4-dichlorobutenesulfonyl imide (CLCF 2 CFClCF 2 CF 2 SO 2 N(H)SO 2 CF 3 ) was prepared as follows. 0.5g of the sodium perfluromethyl sulfonyl perfluoro-3,4-dichlorobutane sulfonyl imide prepared above was dissolved in 4 ml H 2 SO 4 (98%) and sublimed at 120° C. and high vacuum to yield the liquid product.
The sodium salt of the acid monomer, sodium perfluoromethyl sulfonyl perfluorobutene-3-sulfonyl imide (CF 2 =CFCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 ) was then produced. 40 g of the sodium perfluoromethyl sulfonyl perfluoro-3,4-dichlorobutane sulfonyl imide, 150-ml of absolute ethanol, and 15 g of zinc powder were placed in a 500-ml three-necked flask, fitted with a reflux condenser and a magnetic stirrer. With magnetic stirring, the reaction mixture was heated at 80° C. under nitrogen atmosphere for 2.5 hours. The mixture was filtered to remove excess zinc and evaporated under high vacuum to yield solid product.
The salt form of the monomer was then converted into its acid form, perfluoromethylsulfonyl perfluoro-butene-3-sulfonyl imide (CF 2 =CFCF 2 CF 2 SO 2 NHSO 2 CF 3 ). 37 g of sodium perfluoromethyl sulfonyl perfluorobutene-3-sulfonyl imide was dissolved in 70 ml of concentrated HCl (36%). NaCl deposits were removed by filtration. The layers were separated by distillation under reduced pressure, yielding the acid form of the monomer of this example.
The reaction mechanisms for the preparation of the specific monomers of this example are as follows: ##STR22##
EXAMPLE 4
Bis[(trifluoromethyl) sulfonyl]-3 -propenylmethane potassium salt (CF 3 SO 2 ) 2 C(K)CH 2 CH=CH 2 ) was prepared according to the procedure described hereinbelow. To initially produce bis[(trifluoromethyl) sulfonyl] methane potassium salt ((CF 3 SO 2 ) 2 CHK), 11.2 g of bis[(trifluoromethyl)] methane (CF 3 SO 2 ) 2 CH 2 ) was combined with 100 ml of acetone and 6.9 g of potassium carbonate in a 250-ml flask. The mixture was stirred under reflux for 4 hours and filtered. After filtration of the hot mixture, the filtrate was distilled under reduced pressure and the product was dried at 100° C. in high vacuum for one day.
Next, bis[(trifluoromethyl)sulfonyl]methane potassium magnesium chloride salt ((CF 2 SO 2 ) 2 CLMgCl) was prepared by adding 20 ml of dry THF and 9 g of the bis[(trifluoromethyl)sulfonyl]methane potassium salt prepared above to a 100-ml two-necked flask. After the mixture turned clear, 11.5 ml of 3M MeMgCl was gradually added to the mixture at 20° C. After methane production ceased, the reaction was allowed to run in a closed system for one day. The product was not isolated from THF but was used directly for further reaction.
Perfluoroallyl fluorosulfate (CF 2 =CFCF 2 OSO 2 F) was then produced by adding 24 g of sulfur trioxide, 4 g of boron trifluoride and 112 g of hexafluoropropylene to a 310-ml stainless-steel pressure reactor by vacuum line. The pressure reactor was warmed to 20° C. and shaken for 3 days. The reaction mixture was fractionated through traps of -70° and -196° C. in high vacuum and the product was trapped in the -70° C. trap.
Perfluoroallyl iodide (CF 2 CFCF 2 I) was prepared by transferring 8.5 g of dry potassium iodide, 20 ml of tetraglyme and 42.5 millimoles of perfluoroallyl fluorosulfate by vacuum line to a 100-ml flask. The mixture was warmed to 20° C. and stirred for 12 hours in a dark room. The mixture was then fractionated through -100° C. and -196° C. traps, with the product being collected in the -100° C. trap.
Bis[(trifluoromethyl)sulfonyl]-t-1-perfluoro propenyl methane potassium salt was prepared by transferring 28.3 millimoles of the bis[(trifluoromethyl) sulfonyl]methane potassium magnesium chloride prepared above, 30 ml of THF and 8.5 g of the perfluoroallyl iodide prepared above by vacuum line to a 100-ml flask. The mixture was warmed to 20° C. and stirred for 3 days in a dark room. The mixture was filtered and distilled. The residue was dissolved into water and the present intermediate was extracted with ethyl ether from the aqueous solution several times. The ethyl ether solution was collected, dried with CaCl 2 and distilled.
Next, 4,4-bis[(trifluoromethyl)sulfonyl]-1-butene was prepared by adding 3 ml of allyl bromide to 31.3 millimoles of the bis[(trifluoromethyl)sulfonyl] methane potassium magnesium chloride in 35 ml of THF. The mixture was stirred at 70° C. under reflux for 8 hours. After removal of solvent by distillation under reduced pressure, 50 ml of 3N hydrochloric acid was added to the residue and the aqueous solution was extracted with ethyl ether. The ethyl ether solution was dried with anhydrous MgSO 4 . The ethyl ether was removed from the solution and the product was distilled at 0.02 torr.
Finally, the monomer of the present example (bis[(trifluoromethyl)sulfonyl]-3-propenylmethane potassium salt) was produced by stirring a solution of 9 g of 4,4-bis[(trifluoromethyl)sulfonyl]-1-butene in 60 ml of acetone and adding 4.6 g of potassium carbonate. The mixture was stirred at 60° C. under reflux for 4 hours, then filtered and distilled. The residue was dried at 100° C. in high vacuum for one day to yield the monomer product.
EXAMPLE 5
The monomer of this example, ##STR23## was prepared according to the method described hereinbelow. Initially, CF 3 SO 2 NNaSO 2 CF 2 CF 2 CF 2 SO 2 F was produced by transferring, in a dry box, 23.4 g of CF 2 SO 2 NNaSiMe 3 to a 500-ml one-necked flask with a stir bar. 70g of FSO 2 (CF 2 ) 4 SO 2 F and 300 ml of acetonitrile were added to the flask under nitrogen atmosphere. The mixture was stirred with reflux at 85° C. under nitrogen atmosphere for 2 days. Acetonitrile and unreacted (FSO 2 CF 2 CF 2 ) 2 were removed by high vacuum evaporation and the residue was dried under high vacuum at 80° C. for 12 hours to give an intermediate product.
CF 3 SO 2 NNaSO 2 CF 2 CF 2 CF 2 CF 2 SO 2 NHNa was prepared next. A 500-ml three-necked flask was fitted with a nitrogen and NH 3 gas inlet, mechanical stir rod, and gas outlet connected to a oil trap. The flask was cooled to -196° C. and nitrogen gas was passed through the flask until 200 ml of liquid NH 3 had been added. 44 g of dry CF 2 SO NNaSO 2 (CF 2 ) 4 SO 2 F was added to the flask under nitrogen atmosphere. The temperature of the mixture was raised to -70° C. and the mixture was stirred under nitrogen atmosphere for 2 hours. The temperature of the mixture was raised to 20° C. and nitrogen gas was passed through the flask to remove NH 3 gas. 9.2 g of sodium methoxide and 200 ml of methanol were added to the flask and the mixture was stirred at 50° C. for one day. After filtration, methanol was removed from the filtrate by rotatory evaporation. The residue was dried under high vacuum at 80° C. for one day to yield the intermediate product.
Next, CF 3 SO 2 NNaSO 2 CF 2 CF 2 CF 2 CF 2 SO 2 NNaSiMe 3 was prepared by transferring 40 g of the CF 3 SO 2 NNaSO 2 (CF 2 ) 4 SO 2 NHNa to 500-ml one-neck flask containing a stir bar. 200 ml of HMDS (hexamethyldisilazane) and 150 ml of acetonitrile were added to the flask and the mixture was stirred under reflux at 110° C. under nitrogen atmosphere for one day. Acetonitrile and HMDS were removed by high vacuum distillation. The residue was dried under high vacuum at 80° C. for one day to obtain the product.
To obtain the chlorinated product, CF 2 ClCFClOCF 2 CF(CF 3 )O(CF 2 ) 2 SO 2 NNaSO 2 (CF 2 ) 4 SO 2 NNaSO 2 CF 3 , 45 grams of the CF 3 SO 2 NNaSO 2 (CF 2 ) 4 SO 2 NNa SiMe 3 produced as above was transferred to a 500-ml one-neck flask. 200 ml acetonitrile and 41.4 g CF 2 ClCFClOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 F was then added to the flask under nitrogen atmosphere. The mixture was stirred under reflux at 85° C. under nitrogen atmosphere for 2 days. Acetonitrile and unreacted reactant were removed by high vacuum evaporation. The residue was dried under high vacuum at 80° C. for one day to yield a chlorinated product.
To finally produce the monomer of this example, CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 NHSO 2 (CF 2 ) 4 SO 2 NHSO 2 CF 3 , 10 g of CF 2 ClCFClOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 NNaSO 2 (CF 2 ) 4 SO 2 NNaSO 2 CF 3 , 5 g of activated zinc powder and 50 ml of acetic anhydride were stirred together in a 200-ml flask at 80° C. for 8 hours. After filtration, acetic anhydride was removed by high vacuum evaporation and the solid residue was dried under high vacuum at 90° C. for 12 hours. The residue was acidified with 100 ml of 3M hydrochloric acid. Extraction of the solution with ethyl ether and evaporation of ether from the ether layer yielded crude monomer which was then sublimed at 100° C. for purification.
The reaction mechanism for producing the monomer of this example is as follows: ##STR24##
EXAMPLE 6
As previously explained, the novel monomers of the present invention may be polymerized and copolymerized according to the teachings herein. One exemplary copolymer which is described in this example is the copolymer of CF 2 =CFCF 2 OCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 and C 2 F 4 (TTF). This copolymer is produced by diluting 10 g of CF 2 =CFCF 2 OCF 2 CF 2 SO 2 NNaSO 2 CF 3 to 100 ml with distilled water and adding a portion of this solution to a 100-ml beaker. 0.1 g of NaHSO 3 , 0.1 g of Na 2 S 2 O 8 , 0.5 g of Na 2 HPO 4 ×7H 2 O, and 0.3 g of C 7 F 15 CO 2 Na were then added and the mixture was diluted to 40 ml with distilled water. To remove O 2 gas in the solution, N 2 gas was bubbled through the solution for 5 minutes. The solution was poured into a funnel connected to a 50-ml autoclave which had been evacuated and the solution was drawn into the autoclave. The mixture was stirred at 450 rpm while C 2 F 4 was added at 75 psi and the rate of the copolymerization was monitored. Once a 80 psi total pressure drop of C 2 F 4 was achieved in the autoclave, the copolymerization reaction was stopped and the solution was removed from the autoclave and added to a beaker. 20 ml of concentrated hydrochloric acid was added to the beaker and the mixture was left for 12 hours. After filtration, the precipitate was washed with ether and deionized water and dried under high vacuum at 100° C. for one day. The solid was washed with deionized water until the wash water was neutral. The solid was dried under high vacuum at 100° C. for one day. NMR analysis showed that --[(CF 2 CF 2 ) n CF 2 CF] x --CF 2 OCF 2 CF 2 SO 2 NHSO 2 CF 3 was produced.
EXAMPLE 8
In this example, CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 NNaSO 2 (CF 2 ) 4 SO 2 NNaSO 2 F 3 was copolymerized with C 2 F 4 . In dry box, CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 NNaSO 2 (CF 2 ) 4 SO 2 NNaSO 2 CF 3 was added to a 100-ml beaker. 5 ml of distilled water was added in addition to sufficient NaHCO 3 saturated aqueous solution to neutralize the acidic solution. 0.1 g of NaHSO 3 , 0.1 g of Na 2 S 2 O 8 , 0.3 g of C 7 F 15 CO 2 Na and 0.5 g of Na 2 HPO 4 ×7H 2 O were added to the solution along with distilled water. N 2 gas was bubbled through the solution for 5 minutes to remove O 2 gas. The solution was added through the funnel connected to a 50-ml autoclave which had been evacuated. The mixture was stirred at 450 rpm and 25° C. and C 2 F 4 was added at 75 psi. After at total pressure drop of 80 psi of C 2 F 4 in the autoclave was reached, the copolymerization reaction was stopped and C 2 F 4 gas was vented. 40 ml of ethanol and 20 ml concentrated hydrochloric acid were added to the solution and the mixture stood for 12 hours. After filtration, the precipitate was washed with ether several times and heated under high vacuum at 80° C. for 12 hours. The solid was washed with deionized water until the wash water was neutral. The solid was then dried under high vacuum at 80° C. for one day. NMR analysis showed that ##STR25## was produced.
EXAMPLE 9
Various other copolymers were produced as described in Examples 9-12 and ionomer membranes made from therefrom were produced as described in Examples 13 and 14. A 40 ml solution of distilled water, 0.3 g of C 7 F 15 CO 2 Na, 0.1 g of Na 2 S 2 O 8 , 0.1 g of NaHSO 3 , 0.50 g of Na 2 HPO 4 ×7H 2 O and 0.55 g of were drawn into a an evacuated autoclave (50 ml volume). The solution was stirred at 30° C. and between 70 and 75 psi pressure of TFE was maintained for 6 hours. 40 ml of ethanol and hydrochloric acid were added with stirring. The precipitated copolymer was washed with ethyl ether and redistilled water and then dried.
EXAMPLE 10
40 ml of distilled water, 0.30 g of C 7 F 15 CO 2 Na, 0.10 g of Na 2 S 2 O 8 , 0.10 g of NaHSO 3 , 0.50 g of Na 2 HPO 4 ×7H 2 O and 1.0 g of CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF2 2 SO 2 N(Na)SO 2 CF 3 were polymerized in the same manner as in Example 9.
EXAMPLE 11
300 ml of water, 2.1 g of C 7 F 15 CO 2 Na, 3.5 g of Na 2 HPO 4 ×7H 2 , 0.7 g of Na 2 S 2 O 8 , 0.7 g of NaHSO 3 and 5.0 g of CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 were absorbed into a 450-ml evacuated autoclave. The solution was stirred at 20° C. and between 70 and 75 psi pressure of TFE for 10 hours. 200 ml of ethanol and 150 ml of hydrochloric acid were then added. The precipitated copolymer was washed with ethyl ether and redistilled water and then dried.
EXAMPLE 12
300 ml of water, 2.1 g of C 7 F 15 CO 2 Na, 3.5 g of Na 2 HPO 4 ×7H 2 ), 0.7 g of Na 2 S 2 O 8 , 0.7 g of NaHSO 3 and 7.5 g of CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(Na)SO 2 CF3 were copolymerized with TFE in the same manner as in Example 11.
EXAMPLE 13
2.0 g of the acid form of a copolymer of TFE and CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 was swelled in 40 ml of DMF. The mixture was blended to form a polymer solution and filtered to remove air bubbles. The polymer solution was poured into a leveled dish and the solvent was evaporated in a vacuum oven at about 90° to 100° C. and 600 mm Hg pressure. An ionomer membrane exhibiting the desired characteristics described hereinabove was formed at the bottom of the dish.
EXAMPLE 14
2.0 g of the acid form of a copolymer of TFE and CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(Na)SO 2 CF 3 was swelled in 40 ml of DMF. The mixture was blended to form a polymer solution. After filtration and removal of air bubbles, the polymer solution was poured into a dish having a Teflon PFA cloth at the bottom. The solvent was evaporated according to the method described in Example 13. A reinforced copolymer electrochemical membrane exhibiting the desired characteristics described hereinabove was formed at the bottom of the dish. | Novel perfluorinated sulfonyl monomers and polymers and membranes made therefrom are provided. The fluorocarbon monomers have the general formula: ##STR1## wherein X is CH or N, I is H, K, Na, or a Group I or II metal, R f is one or more fluorocarbon group, including fluorocarbon ethers and/or sulfonyl groups and/or perfluoro-non-oxy acid groups, R f , is C n F 2n+1 (n=0,1,2, . . .), Y is C n F 2n+1 (n=0,1,2, . . .) and m is 0 or 1. The monomers are made from the non-oxy superacid groups ##STR2## Copolymers of the above monomers with other monomeric material such as tetrafluoroethylene are also provided. These copolymers may then be cast into ionomer membranes and other structures for use in electrochemical processing. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of co-pending U.S. provisional patent application Ser. No. 62/046,400, filed Sep. 5, 2014 (Attorney Docket No. APPM/22327USL), which is herein incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the present disclosure generally relate to an inject insert for use in semiconductor processing equipment.
[0004] 2. Description of the Related Art
[0005] Some processes for fabricating semiconductor devices, for example rapid thermal processing, epitaxial deposition, chemical vapor deposition, physical vapor deposition, electron-beam curing, are performed at elevated temperatures. Usually substrates being processed are heated to a desired temperature in a processing chamber by one or more heat sources. The one or more heat source is typically mounted outside the chamber body so that the energy generated by the heat source radiates upon the substrate positioned within the chamber body.
[0006] Processing gases are usually supplied to the chamber from a gas inlet, and are kept flowing in the chamber by a pumping system connected to chamber. Gas distribution in a conventional chamber is not uniform across the chamber. For example, gas distribution near the gas inlet is different from gas distribution near the pumping port, and gas distribution near the edge region is different from gas distribution near the center region.
[0007] Further, some chambers may include multiple flow zones having different process gases or gas flow rates which feed into a single channel defined within the gas inlet. As a result of the “crosstalk” between the multiple flow zones feeding into a single gas inlet, attempts to tune the gas flow distribution within the processing chamber by varying the type of gas or gas flow rate in the different flow zones have unpredictable tuning results.
[0008] Additionally, in operation, localized zones of cyclically flowing gas, known as “recirculation cells,” often form within the channels of inject inserts used in conventional gas manifolds. Recirculation cells result in degraded uniformity of the gas flow distribution within the processing chamber, which results in strong variations in epitaxially-grown films.
[0009] Continuous rotation has been previously employed in an attempt to resolve some of the above non-uniformity issues. In theory, continuous rotation delivers a majority of the substrate to a variety of flow zones such that flow zone non-uniformity is minimized. Although, continuous rotation of the substrate may reduce the non-uniformity of gas distribution, the rotation alone may not be enough as the requirement for uniformity increases. The foregoing problems attributable to conventional gas inlets are amplified when the flow rate of the process gas is increased, which is desirable to increase the throughput of the CVD device.
[0010] Therefore, there is a need for a thermal reactor with improved gas flow distribution.
SUMMARY
[0011] Embodiments disclosed herein include an inject insert for use in a semiconductor processing chamber. In one embodiment, an inject insert can include a monolithic body with an inner connecting surface and an exterior surface to connect with a gas delivering device; a plurality of inject ports formed through the monolithic body, each forming an opening in the interior connecting surface and the exterior surface, and a plurality of inject inlets, each of the plurality of inject inlets being connected with at least one of the plurality of inject ports. The plurality of inject ports can create at least a first zone with a first number of inject ports of the plurality of inject ports; a second zone with a second number of inject ports of the plurality of inject ports, the second number of inject ports being different from the first number of inject ports; and a third zone with a third number of inject ports of the plurality of inject ports, the third number of inject ports being different from the first number of inject ports and the second number of inject ports.
[0012] In another embodiment, an inject insert can include a monolithic body with an inner connecting surface to connect with a liner body and an exterior surface to connect with a gas delivering device; a plurality of inject ports formed through the monolithic body, each forming an opening in the interior connecting surface and the exterior surface, the plurality of inject ports creating at least; and a plurality of inject inlets, each of the plurality of inject inlets being connected with at least one of the plurality of inject ports, wherein at least a first inlet of the plurality of inject inlets comprises a first width, the first width being greater than an average width.
[0013] In another embodiment, a liner assembly can include a liner body comprising an upper liner portion and a lower liner portion, the liner body having a plurality of liner ports formed therein; and an inject insert, the inject insert having a monolithic body with a substantially planar upper surface; a substantially planar lower surface; a curved inner connecting surface to connect with the liner body; an exterior surface to connect with a gas delivering device; and a plurality of inject ports formed therethrough, the plurality of inject ports creating at least a first zone with a first number of passages; a second zone with a second number of passages, the second number of passages being different from the first number of passages; and a third zone with a third number of passages, the third number of passages being different from the first number of passages and the second number of passages; and a plurality of inject inlets connected with at least one of the plurality of inject ports, wherein each of the plurality of inject ports fluidly connect with at least one of the plurality of liner ports through the plurality of inject inlets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, 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 disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
[0015] FIG. 1 is a schematic, cross sectional view of a process chamber according to embodiments described herein.
[0016] FIG. 2A depicts a schematic diagram of an inject insert in accordance with some embodiments.
[0017] FIG. 2B is a side view of an inject insert according to some embodiments.
[0018] FIG. 3 is a cut away overhead view of an inject insert and gas line combination, according to some embodiments.
[0019] FIG. 4 is a side view of a multi-tier inject insert, according to some embodiments.
[0020] To facilitate understanding, identical reference numerals have been used, wherever possible, to designate identical elements that are common to the Figures. Additionally, elements of one embodiment may be advantageously adapted for utilization in other embodiments described herein.
DETAILED DESCRIPTION
[0021] Embodiments disclosed herein describe a liner for use in semiconductor process systems. The inject insert connects with and incorporates at least 6 zones to allow for greater flow control.
[0022] A variety of CVD chambers may be modified to incorporate the embodiments described herein. In one embodiment, the CVD chamber to be modified is the CVD chamber of the EPI CENTURA® CVD System, available from Applied Materials, Inc., of Santa Clara, Calif. The CENTURA® system is a fully automated semiconductor fabrication system, employing a single wafer, multi-chamber, modular design, which accommodates a wide variety of wafer sizes. In addition to the CVD chamber, the multiple chambers may include a pre-clean chamber, a wafer orienter chamber, a cooldown chamber, and a loadlock chamber. The CVD chamber presented herein is shown in schematic in FIG. 1 is one embodiment and is not intended to be limiting of all possible embodiments. It is envisioned that other CVD chambers can be used in accordance with embodiments described herein, including chambers from other manufacturers.
[0023] FIG. 1 is a cross sectional view of a processing chamber 100 according to one embodiment. The processing chamber 100 comprises a chamber body 102 , support systems 104 , and a chamber controller 106 . The chamber body 102 includes an upper portion 112 and a lower portion 114 . The upper portion 112 includes the area within the chamber body 102 between the upper dome 116 and the substrate 125 . The lower portion 114 includes the area within the chamber body 102 between a lower dome 130 and the bottom of the substrate 125 . Deposition processes generally occur on the upper surface of the substrate 125 within the upper portion 112 . The substrate 125 is supported by support posts 121 disposed beneath the substrate 125 . The substrate 125 may be any substrate used in the art for epitaxial deposition, such as a silicon or germanium containing substrate. Further, the substrate may be of varying sizes, such as a 300 mm diameter substrate or a 450 mm diameter substrate.
[0024] An upper liner 118 is disposed within the upper portion 112 and is adapted to prevent undesired deposition onto chamber components. The upper liner 118 is positioned adjacent to a ring 123 within the upper portion 112 . The processing chamber 100 includes a plurality of heat sources, such as lamps 135 , which are adapted to provide thermal energy to components positioned within the processing chamber 100 . For example, the lamps 135 may be adapted to provide thermal energy to the substrate 125 and the ring 123 . The lower dome 130 may be formed from an optically transparent material, such as quartz, to facilitate the passage of thermal radiation therethrough.
[0025] The chamber body 102 includes an inlet 120 and an exhaust port 122 formed therein. The inlet 120 may be adapted to provide a process gas 150 therethrough into the upper portion 112 of the chamber body 102 , while an exhaust port 122 may be adapted to exhaust a process gas 150 from the upper portion 112 . In such a manner, the process gas 150 may flow parallel to the upper surface of the substrate 125 . Thermal decomposition of the process gas 150 onto the substrate 125 to form an epitaxial layer on the substrate 125 is facilitated by the lamps 135 .
[0026] A substrate support assembly 132 is positioned in the lower portion 114 of the chamber body 102 . The substrate support 132 is illustrated supporting a substrate 125 in a processing position. The substrate support assembly 132 includes a plurality of support pins 121 and a plurality of lift pins 133 . The lift pins 133 are vertically actuatable and are adapted to contact the underside of the substrate 125 to lift the substrate 125 from a processing position (as shown) to a substrate removal position. The components of the substrate lift assembly 132 can be fabricated from quartz, silicon carbide, graphite coated with silicon carbide or other suitable materials.
[0027] The ring 123 can be removably disposed on a lower liner 140 that is coupled to the chamber body 102 . The ring 123 can be disposed around the internal volume of the chamber body 102 and circumscribes the substrate 125 while the substrate 125 is in a processing position. The ring 123 can be formed from a thermally-stable material such as silicon carbide, quartz or graphite coated with silicon carbide. The ring 123 , in combination with the position of the substrate 125 , can separate the volume of the upper potion 112 . The ring 123 can provide proper gas flow through the upper portion 112 when the substrate 125 is positioned level with the ring 123 . The separate volume of the upper portion 112 enhances deposition uniformity by controlling the flow of process gas as the process gas is provided to the processing chamber 100 .
[0028] The support system 104 includes components used to execute and monitor pre-determined processes, such as the growth of epitaxial films in the processing chamber 100 . The support system 104 includes one or more of gas panels, gas distribution conduits, power supplies, and process control instruments. A chamber controller 106 is coupled to the support system 104 and is adapted to control the processing chamber 100 and support system 104 . The chamber controller 106 includes a central processing unit (CPU), a memory, and support circuits. Instructions resident in chamber controller 106 may be executed to control the operation of the processing chamber 100 . Processing chamber 100 is adapted to perform one or more film formation or deposition processes therein. For example, a silicon carbide epitaxial growth process may be performed within processing chamber 100 . It is contemplated that other processes may be performed within processing chamber 100 .
[0029] FIGS. 2A and 2B depict a liner 200 with an inject insert 220 according to embodiments described herein. FIG. 2A depicts a top view of the inject insert 220 in connection with the liner assembly 200 . FIG. 2B depicts a side view of the inject insert 220 . The liner assembly 200 includes a liner body 202 with an inner surface 204 and an outer surface 206 . The inner surface 204 forms the boundaries of a process region (not shown). A plurality of liner inlets 208 , which are depicted as dashed line circles, are formed through the inner surface 204 and outer surface 206 of the liner body 202 . The inject insert 220 , shown here with two inject inserts 220 , is fluidly connected with the plurality of liner inlets 208 . Gas supplied from a gas supply source (not shown) is introduced into the process region 206 through the inject insert 220 and then through the plurality of liner inlets 208 , whereby the plurality of liner inlets 208 can deliver one or more individual gas flows. The inject insert 220 , plurality of liner inlets 208 or both may be configured to provide individual gas flows with varied parameters, such as velocity, density, or composition. The plurality of liner inlets 208 are configured to direct the process gas in a generally radially inward direction, with the gas being delivered to a central area of the process region 206 . Each of the plurality of gas inlets 208 and the inject insert 220 may be used, individually or in combination, to adjust one or more parameters, such as velocity, density, direction and location, of the gas from the gas supply source.
[0030] The inject insert 220 can be formed from a single piece of metal, ceramic or otherwise inert composition, such as aluminum or quartz. The inject insert 220 can have a substantially planar upper surface 222 and a substantially planar lower surface 224 . The inject insert 220 can have a number of inject ports 226 formed therein. The end portions of the inject insert 220 are shown here, with the middle portions omitted for simplicity. In this embodiment, the inject insert 220 is depicted as having seven (7) inject ports 226 . The inject ports 226 may be of any shape or size, such that the flow rate, flow velocity and other flow parameters may be controlled. Further, multiple inject ports 226 may connect with any number of the plurality of liner ports 208 . In one embodiment, a single port of the plurality of ports 208 is served by more than one of the inject ports 226 . In another embodiment, a multiple ports of the plurality of ports 208 is served by a single port of the inject ports 226 . The inject insert 220 has a connecting surface 228 . The connecting surface 228 may have a surface curvature such that the inject ports 226 penetrating through the inject insert 220 are fluidly sealed to the plurality of liner ports 208 . The inject insert 220 may have an exterior surface 230 . The exterior surface 230 may be configured to connect to one or more gas lines 301 or other gas delivering device.
[0031] The inject ports 226 and the liner ports 208 create at least a first zone, a second zone and a third zone. The first zone has a first number of passages. The second zone has a second number of passages, the second number of passages being different from the first number of passages. The third zone has a third number of passages, the third number of passages being different from the first number of passages and the second number of passages. Larger substrates, due to their increased surface area, require tighter control of process parameters. Thus, by increasing the number of zones, the area that is controlled by a single zone is decreased allowing for finer tuning of process parameters.
[0032] FIG. 3 depicts a cutaway overhead view of an inject insert 300 , according to one embodiment. The inject insert 300 may have the same or a similar composition to the inject insert 220 described with reference to FIGS. 2A and 2B . The inject insert 300 has a plurality of inject ports 326 formed therein, such as seven inject ports 326 . As shown with relation to inject insert 220 , the end portions of the inject insert 300 are shown here, with the middle portions omitted for simplicity. The inject insert 300 can have one or more multi-connect gas lines, shown here as first multi-connect gas line 302 , second multi-connect gas line 304 and third multi-connect gas line 306 . The multi-connect gas lines 302 , 304 and 306 are in connection with more than one of the plurality of inject ports 326 (also referred to as the connected ports).
[0033] The multi connect gas lines 302 , 304 and 306 can deliver either different gases or gases under differing conditions. In one embodiment, the first multi connect gas line 302 delivers a first gas to the connected ports, the second multi connect gas line 304 delivers a second gas to the connected ports and the third multi connect gas line 302 delivers a third gas to the connected ports. The first gas, the second gas and the third gas can be different gases from one another. In another embodiment, the first multi connect gas line 302 delivers a gas to the connected ports at a first pressure and/or a first temperature, the second multi connect gas line 304 delivers a gas to the connected ports at a second pressure and/or a second temperature, and the third multi connect gas line 302 delivers a gas to the connected ports at a third pressure and/or a third temperature. The first pressure, second pressure and the third pressure may be different from one another. As well, the first temperature, second temperature and the third temperature may be different from one another. Further any number of inject ports 326 may be connected to any number of multi-connect gas lines. In further embodiments, the one or more gas lines 301 and/or the multi-connect gas lines 302 , 304 and 306 may connect with the same inject port 326 .
[0034] Though one or more of the inject ports 326 are shown as connected through the one or more gas lines 301 and the multi-connect gas lines 302 , 304 and 306 , the inject ports 326 may be interconnected within the inject insert 300 such that one or more of the multi-connect gas lines 302 , 304 and 306 is unnecessary. In this case, a group of the inject ports 326 can branch internally to the inject insert 300 , shown by a branch 330 , such that the group of the inject ports 326 receive gas from a single gas line 301 .
[0035] The inject insert 300 can further include a plurality of inject inlets, shown here as inject inlets 308 a - 308 j. The inject inlets 308 a - 308 j may be approximately equally spaced and positioned in the inject insert 300 . The inject inlets 308 a - 308 j may have a varying width such that the inject inlet 308 a - 308 j delivers a differing volume of gas at a proportionally changed velocity. When delivering gas through two inject ports 326 at a standard pressure, an increased width is expected to deliver gas to the process region at a decreased velocity but higher volume than a standard width. Under the same conditions as above, a decreased width is expected to deliver gas to the process region at an increased velocity but lower volume than a standard width.
[0036] Shown here, inject inlet 308 a has a width 312 a which is increased as compared to the width 312 c of the inject port 326 . Further, the inject inlet 308 a has a graded increase, creating the appearance of a cone. Shown here, the increase of the width 312 a of the inject inlet 308 a results from a graded increase of 5 degrees from a center line 310 , as noted by the dashed line extending outward from the related inject port 326 . The graded increase may be more or less than 5 degrees. Further, a graded increase is not necessary for the formation of an increased in the width 312 a In one embodiment, the width 312 a is simply increased at a point prior to the inject inlet 308 a forming a slightly larger cylinder in the inject port 326 (not shown).
[0037] Though the center line 310 is only described with reference to the inject port 326 , it is understood that all bisymmetrical objects or formations as described herein have a center line. Further, though the center line 310 is only shown with relationship to inject inlet 308 a, it is understood that each of the inject inlets 308 a - 308 g have a related center line 310 which bisects each of the respective inject ports 326 .
[0038] In another example, the inject inlet 308 b has a width 312 b which is decreased as compared to the standard width 312 c of the inject ports 326 . As above, the inject inlet 308 b has a graded decrease, creating the appearance of an inverted cone. Shown here, the decreased width 312 b of the inject inlet 308 b is formed from a graded decrease of 5 degrees from the center line 310 , as noted by the dashed line extending inward from the related inject port 326 . The graded decrease may be more or less than 5 degrees.
[0039] Though the increased width 312 a, the decreased width 312 b, and the related graded increase and decrease are shown as symmetrical to the center line 310 , this is not intended to be limiting of embodiments described herein. A change in size and shape can be created with full freedom of position and rotation such that the gas can be delivered in any direction and at any angle desired by the end user. Further, the liner inlets 208 of FIG. 2A and 2B may have a design which either compliments or replicates the designs described with reference to inject inlets 308 a - 308 g.
[0040] FIG. 4 depicts a side view of a multi-tier inject insert 400 , according to one embodiment. The multi-tier inject insert 400 , shown here with two rows of inject ports 426 , can have more than one row of inject ports 426 such that gas can be delivered to the process region more uniformly. As shown with relation to inject insert 220 , the end portions of the inject insert 400 are shown here, with the middle portions omitted for simplicity. The multi-tier inject insert 400 can have a substantially planar upper surface 422 and a substantially planar lower surface 424 . The multi-tier inject insert 400 can have a number of inject ports 426 formed therein per row. In this embodiment, the multi-tier inject insert 400 is depicted as having fourteen (14) inject ports 426 . In this embodiment, the number or shape of each of the inject ports 426 used in each of the corresponding rows may be of varying shapes, sizes and positions.
[0041] Further, multiple inject ports 426 may connect with any number of the plurality of inject inlets (not shown). The inject inlets described with reference to FIG. 4 are substantially similar to the inject inlets 308 described with reference to FIG. 3 . The multi-tier inject insert 400 has a connecting surface 428 . The connecting surface 428 may have a surface curvature such that the inject ports 426 penetrating through the multi-tier inject insert 400 are fluidly sealed to the upper liner 118 and the lower liner (not shown). The multi-tier inject insert 400 has an exterior surface 430 which may be configured to connect to a gas line as described in FIG. 3 .
[0042] Tight control of both chemistry and gas flow is required for current and next generation semiconductor devices. Using the embodiments described above, control of both of the delivery of gas to the inject ports and flow of the gas from the inject ports through the inject inlets can be increased, leading to an increased control of process parameters for a majority of the substrate. Increased control of process parameters, including control of the velocity of the gases delivered to the chamber and the subsequent zone formation, will lead to improved epitaxial deposition and reduced product waste among other benefits.
[0043] While the foregoing is directed to embodiments of the disclosed devices, methods and systems, other and further embodiments of the disclosed devices, methods and systems may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | Embodiments of the present invention provide a liner assembly including an inject insert. The inject insert enables tenability of flow parameters, such as velocity, density, direction and spatial location, across a substrate being processed. The processing gas across the substrate being processed may be specially tailored for individual processes with a liner assembly according to embodiment of the present invention. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an improved touchpad for use in home audio/video system control, distribution and automation.
[0003] 2. Description of Related Art
[0004] Keypads are used in homes for control of home systems such as audio/video (A/V), heating, ventilation and air conditioning (HVAC), security, etc. A typical keypad is hard wired for power and control, and is mounted on the wall with fixed hard buttons for input and a display for feedback. As functionality, feedback and portability of such devices increases, so does the price.
[0005] Current keypads offer a fixed level of control. Keypad configurations range from a greater number of small buttons with a greater degree of control or a lesser number of large buttons with a more limited degree of control. Keypads with a greater number of keys are often difficult to operate and are labeled by small text that is difficult to read, especially when not back-lit. Conventional keypads generally do not have the flexibility to add or delete buttons as needed.
[0006] Displays on conventional keypads are often difficult to read because of low resolution and low contrast ratios. Some conventional keypads offer only very limited feedback in the form of light emitting diodes (LEDs). Alternatively, some keypads utilize more flexible and customizable liquid crystal display (LCD) panels. However, LCD panels are expensive to manufacture and typically have a contrast ratio of only about 80. In addition, most keypad LCDs have an off-axis viewing angle limitation of about 45 degrees or less.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes these drawbacks of the prior art and provides a touchpad with multiple, easily-selectable levels of control and changeable and customizable overlays. The touchpad has an organic light emitting diode (OLED) display with a superior contrast ratio and no viewing angle limitations. The result is a unique touchpad display that is attractive and readable from any angle.
[0008] Accordingly, one embodiment of the invention is an interactive touchpad. A touchscreen defines active areas responsive to contact. An overlay template is provided and is removably coupled to the touchscreen to define input and control buttons corresponding to the active areas of the touchscreen. A display is also provided in the interactive touchpad for providing feedback in response to contact with the touchscreen. The touchpad is further provided at least one additional overlay template removably couplable to the touchscreen and interchangeable with the overlay template removably coupled to the touchscreen. The at least one additional overlay template defines input and control buttons corresponding to the active areas of the touchscreen, wherein the input and control buttons defined by the at least one additional overlay template are different from the input and control buttons of the overlay template such that the overlay template and the at least one additional overlay template correspond to different levels of touchscreen functionality. The touchscreen is a resistive touchscreen comprising a glass panel and a polyester film or a capacitive touchscreen comprising two glass panels. The touchscreen has a hinged connection to the touchpad and is pivotable to an open position to permit insertion and removal of the overlay template. The display is an organic light emitting diode (OLED) having approximately 160 degrees of usable viewing angle and a contrast ratio of approximately 200. The touchscreen and the overlay template define a feedback area where feedback is provided by the display. The touchpad has a dimension compatible with mounting in a double gang junction box. The touchpad further comprises a trim ring surrounding the touchscreen, the trim ring defining a dam to prevent moisture intrusion into the space between the overlay and the touchscreen.
[0009] In another embodiment of the present invention, an interactive touchpad includes a touchscreen defines active areas responsive to contact. A display provides feedback in response to contact with the touchscreen. A backlight is provided and a light sensor for detecting an ambient light level and adjusting the intensity of the backlight in response is provided. The light sensor sets a maximum brightness value of the ambient room light when the light sensor is first activated and sets a minimum brightness value according to a predetermined offset value of the maximum brightness value. The interactive touchpad further includes a faceplate surrounding the touchscreen and the display, wherein the light sensor is provided behind a hole in the faceplate. An overlay is removably coupled to the touchscreen. At least one additional overlay is removably couplable to the touchscreen and is interchangeable with the overlay removably coupled to the touchscreen.
[0010] In yet another embodiment of the present invention, an interactive touchpad includes a touchscreen defining active areas response to contact and a display for providing feedback in response to contact with the touchscreen. An IR sensor and dual function IR sensor circuit provides a normal mode that produces a high gain IR signal and a learning mode that provides a low gain IR signal. The interactive touchpad can be programmed via a remote control device during the learning mode. An overlay is removably coupled to the touchscreen and the IR sensor is provided behind the overlay. The IR sensor operating in normal mode can receive a signal from up to 30 feet away from the IR sensor. The signal received by the IR sensor during the learning mode is amplified by a first amplification stage and then passed through a high impedance buffer and a high pass filter in the dual function IR sensor
[0011] Other features and advantages of the invention will be apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, various features of embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 a is a front view of a touchpad according to the present invention with a basic overlay template.
[0013] FIG. 1 b is a front view of a touchpad according to the present invention with a moderate overlay template.
[0014] FIG. 1 c is a front view of a touchpad according to the present invention with an advanced overlay template.
[0015] FIG. 2 is a block diagram of a dual function IR sensor circuit according to the present invention.
[0016] FIG. 3 is a disassembled perspective view showing components of a touchpad according to the present invention.
[0017] FIG. 4 is a perspective view of a touchpad of the present invention with a trim ring opened.
[0018] FIG. 5 is a perspective view of a trim ring having a trim ring moisture dam according to the present invention.
[0019] FIG. 6 is a section view showing the orientation of the trim ring dam relative to the touchpad.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Introduction
[0021] A film interactive touchpad (“FIT”) 10 according to the present invention is illustrated in FIGS. 1 a - 1 c and can be used in the control of home systems. Touchpad 10 is a double-gang, in-wall system controller that uses a touch overlay in lieu of hard buttons to perform all functions normally associated with a keypad. Source and system control icons and functions are printed on interchangeable backlit film transparencies or overlays. Icon and function names on the overlays correspond to active “hot spots” that issue a control command and give audible and/or visual feedback/confirmation to the user when pressed.
[0022] Multiple IR commands or sequences can be issued from a single press of any button on any template. An organic light emitting diode (OLED) provides source, system and programming feedback to the user. Programming is accomplished with software through a direct link from a computer to a USB or mini-USB download port 52 on the front of the unit, as well as from received IR commands and switch 56 .
[0023] The overlays or transparencies are easily installed and available in a wide variety of configurations and various graphical themes to match any functional requirements and/or room decor. Three levels of complexity are available to customize each touchpad, from basic functionality to advanced system control.
[0024] Film interactive touchpad 10 utilizes a resistance touchscreen having a polyester plastic film suspended over a glass panel, which is placed over a changeable backlit overlay. A capacitive touchscreen may also be utilized. Depressing the polyester film with a finger allows the film to touch the glass panel underneath, generating a location signal that is read by the electronics. Each button location (“hot spot”) is assigned an IR or RS-232 command that controls sources such as A/V equipment, home theater, HVAC systems, shades, lighting systems, security systems, fireplaces, etc. Each touchpad is custom-programmed to perform exactly the functions required for each individual home, room and/or system.
[0025] Detailed Description
[0026] FIGS. 1 a - 1 c illustrate a film interactive touchpad 10 according to the present invention. In the embodiment described herein, three levels of functionality or complexity are available and are easily selectable by a switch or button 56 ( FIG. 4 ) without the requirement of a computer to reprogram the pad. However, it should be understood that three levels is merely exemplary, and that more or less than three levels of functionality could be provided and is within the scope of this invention.
[0027] FIG. 1 a shows a touchpad 10 overlaid with a template for basic functionality; FIG. 1 b shows a touchpad 10 overlaid with a template for moderate functionality; and FIG. 1 c shows a touchpad 10 overlaid with a template for advanced functionality. Touchpad 10 comprises an organic light emitting diode (OLED) 15 and backlight 12 , above which is a changeable overlay 14 with defined buttons for input and control. A touchscreen 40 comprising a polyester film and a glass panel is above overlay 14 (see FIG. 3 ) and defines active areas or “hot spots”. OLED display 15 and overlay 14 are surrounded and contained within a faceplate 18 .
[0028] Depressing the polyester film with a finger allows the film to touch the glass panel underneath, generating a location signal that is read by electronics within touchpad 10 . An audible “click” or other sound may be generated to confirm the button press, and may be accompanied by a visual indication as well. Each button location (“hot spot”) is assigned an IR or RS-232 command that controls sources such as A/V equipment, HVAC systems, shades, lighting systems, security systems, fireplaces, etc. Each touchpad is custom-programmed to perform exactly the functions required for each individual home, room and/or system. Any button press may generate virtually unlimited IR command sequences.
[0029] OLED display 15 is self illuminating and has 160 degrees of usable viewing angle. In one embodiment, OLED 15 is a 4-line, 1.2″ color OLED having a contrast ratio of approximately 200. Overlay 14 is back-lit by backlight 12 and is made of a material that provides superior clarity and readability. In one embodiment, overlay 14 is made of a marketing sign material such as duratrans/duraclear, which also has 160 degrees of usable viewing angle. The combination of these two components provides a bright, clear, high-contrast and very readable device with no limits on viewing angle.
[0030] The provision of basic ( FIG. 1 a ), moderate ( FIG. 1 b ) and advanced ( FIG. 1 c ) levels of functionality provides the flexibility of changing the functionality by changing the overlay 14 without any requirement to reprogram touchpad 10 . Some users may want just a basic configuration, with only enough buttons to get to their favorite music or show, while other users will want an advanced configuration with complete systems control. In one embodiment, the basic configuration has 13 buttons; the moderate configuration has 17 buttons; and the advanced configuration has 25 buttons. By contrast, while an LCD panel of the prior art can be programmed to any level of functionality, they are expensive and the reprogramming must be done by a computer in communication with the keypad.
[0031] A touchscreen in combination with an overlay allows a user to create different looks and button combinations just by changing the overlay. For example, with 36 different overlays, multiplied by the three levels of overlays, and seven colors and two styles of faceplates, almost 1600 unique touchpads can be created to fit any user's taste, without the need for a computer to reprogram the device, although a computer may still do so.
[0032] The overlays can be custom designed, i.e., a user can select his/her own background for the overlay. For instance, a user could provide a digital file containing the background (vacation, family photos, sporting event photos, etc.), along with an indication of the function level (basic, moderate, advanced) and the style of button. In this manner, each room of a home could have a custom overlay selected and designed by the user.
[0033] The OLED display area of touchpad 10 includes a feedback area OLED 15 ( FIG. 1 c ) that provides feedback information depending on the function currently selected or the operation being performed. For example, feedback area 15 may indicate the name and/or graphic of a source (i.e. satellite, cable, game, tuner, etc.), system status, etc. Feedback area 15 may have virtually limitless indicators, depending on the type of system and controls provided by touchpad 10 . The OLED color options may match the motif and color palette of the overlay.
[0034] Touchpad 10 includes an infrared (IR) sensor that is used both to teach touchpad 10 IR commands as well as for normal IR control of touchpad 10 by a remote control device. Normal operation with a remote can be 30 feet or more from keypad 10 . To accomplish this, touchpad 10 incorporates a dual function IR sensor circuit 20 ( FIG. 2 ).
[0035] Each signal received by IR receiver or sensor 22 is amplified by a first amplification stage 24 . When touchpad 10 is in a normal operation mode (i.e., when the remote may be 30 or more feet away), the signal is also amplified by a second amplification stage 26 and a third amplification stage 28 to provide a high gain IR signal for source control. By contrast, when keypad 10 is in learning mode, the remote will typically be less than one foot away and such amplification is not needed and may corrupt the signal. So, in a learning mode, the signal is not amplified again but is instead fed to a high impedance buffer 30 and a high pass filter 32 to provide a low gain IR signal for the learning mode. A learning mode in the IR sensor 22 is particularly useful in allowing the touchpad to be programmed via the remote such that a computer is not required to program touchpad 10 and allows the remote to carry out the programming.
[0036] The IR sensor is behind the touch screen, overlay, diffuser, backlight and reflector to provide an IR sensor that is invisible to the user and that allows control buttons to be on top of the IR sensor. The placement of the IR sensor results in superior appearance and more space for control buttons. FIG. 3 is a disassembled view illustrating the various components of touchpad 10 , including faceplate 18 , touchscreen 40 , overlay 14 , diffuser 42 , backlight 12 , and other components.
[0037] It is important that the entire assembly of touchpad 10 fit into a standard electrical junction box, such as a “double gang” box. Generally speaking, such boxes are limited in room, which in turn limits the display on the user interface. LCD panels are very small for this reason. Many conventional keypads are not able to fit into a double gang box. However, some embodiments of the present invention may provide a larger active touch area in a smaller package that fits into a double gang box.
[0038] The changeable overlay design of the present invention is provided with a trim ring 50 having a trim ring dam 51 that keeps moisture out of the assembly and prevents moisture from wicking into the space between the overlay and touch screen. Trim ring 50 is illustrated in FIG. 4 surrounding touch screen 40 and overlay 14 , and is depicted in isolation and with a better view of dam 51 in FIG. 5 . As shown, trim ring 50 is hinged to faceplate 18 and defines a hinged glass door that may be pivoted up and opened to allow for easy insertion and removal of an overlay.
[0039] Also shown in FIG. 4 is a USB or mini-USB download port 52 , a light sensor 54 and a switch 56 for setting the keypad to one of the three levels corresponding to the selected overlay. Light sensor 54 may be a brightness-adjusting light sensor that senses the ambient light level in the room and adjusts backlighting intensity accordingly. A small hole is provided in faceplate 18 for light to pass through onto the light sensor 54 . When light sensor 54 is first activated, a reading of the ambient room light is taken and is set as a maximum brightness value or full backlight. Then, a fixed offset value is used to determine a minimum brightness based on the maximum brightness value. In this manner, the light sensor 54 can properly determine and adjust the backlight for different colored faceplates that would otherwise produce inaccurate backlight conditions. For example, when a black faceplate is provided instead of a white faceplate, this feature causes the light sensor behind the faceplate to sense a bright room as dark and dimming the backlight. FIG. 6 is an exploded view showing that trim ring dam 51 nests within back light groove 58 to keep out water or moisture traveling a path along face plate 18 .
[0040] Touchpad 10 may have various system interconnects and ports, such as an RJ45 for system interconnection, a system IR output and a local component IR control output. The local component IR output or emitter may be used, for example, to control devices such as TV or DVD players located in the same room as the touchpad. An IR input terminals for connection of an external IR sensor to the touchpad is provided. Typically, a plasma-friendly IR sensor (such as, for example, an ELAN IRS8EP is placed near a TV, or an auxiliary sensor is placed in an area more convenient than the location of the touchpad. A sense port or motion sensor may be provided to provide such automated actions as system power on, drapes closed, lights dimmed, etc.
[0041] Touchpad 10 is easily programmable via software such as ELAN VIA! TOOLS®. In one embodiment, a standard USB to mini-USB cable is attached between mini-USB port 52 and a user's PC. The connection between a PC and one touchpad may be used to sequentially program all other touchpads in the system. The programming software may include functionality, for example, enabling a user to add a keypad to a system; to select a motif and a level of functionality; to select and name A/V input sources and icons; program buttons and macros; enable and disable particular features; “auto” populate system IR commands; and transfer commands from one keypad or system to another.
[0042] The embodiments of the present invention are not limited to an OLED display and can be used with an LCD, LED or other display type. Furthermore, the embodiments of the present invention are not limited to a resistive touch screen including a polyester film and glass panel.
[0043] The particular embodiments of the invention described in this document should be considered illustrative, rather than restrictive. Modification to the described embodiments may be made without departing from the spirit of the invention as defined by the following claims. | A film interactive touchpad for control of home systems. A touchscreen defined by a glass panel and polyester film defines active areas responsive to contact. Multiple, customizable and interchangeable templates correspond with multiple levels of functionality and define input and control buttons corresponding to active areas of the touchpad. A display such as an organic light emitting diode (OLED) provides interactive, color feedback. The touchscreen has a hinged connection to the touchpad and is pivotable to an open position to permit insertion and removal of the overlay templates, and is surrounded by a trim ring dam to prevent moisture intrusion. A light sensor is provided for detecting the ambient light level and adjusting the intensity of a backlight for faceplates of any color. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/619,165 filed on Apr. 2, 2012, entitled “Bone Bag.” The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to pet treat supports and weighted supports. More specifically, the present invention pertains to a weighted support for a pet treat, whereby at least one treat or chew toy article is supported along a surface in stationary position for at least one pet to consume the article therefrom.
[0004] Many domestic pets enjoy chew toys and other tough treats that require long-term chewing and gnawing in order to completely consume or gain access to the consumable portion thereof. The chewing provides an activity for the pet that allows the pet to direct its energy toward the given toy or treat, displacing boredom and preventing the pet from otherwise chewing on household items like shoes and furniture. For most pets, the chewing and gnawing activity is both soothing and therapeutic, as the pet can entertain itself while it wears down the article exterior to gain access to the article interior, which is generally a consumable product. Chew toys such as bones, rawhide, and rubberized articles provide a means to support an interior quantity of food for the pet or have an inherently tough exterior that requires extensive gnawing to consume. The act of chewing gnawing relieves anxiety for the pet, provides a source of entertainment, and keeps the pet occupied for extended periods of time.
[0005] Certain pets must be monitored during these chewing activities to ensure the pet does not choke on the chewing article, and to make sure the pet does not hide a partially eaten article within the house or bury it outside. If the pet likes to chew in seclusion, the pet may run away with the article and make the ability of an owner to watch the chewing activity quite difficult. Holding the article while the animal is chewing another end is not a feasible option, as the pet will likely pry it away from its owner or even injure the owner by accidentally biting or scraping his or her fingers.
[0006] To address this known issue in the art, the present invention provides a weighted pet chew article support that includes a means to secure at least one chew article thereto and prevent the pet from readily relocating the article. The device comprises a weighted structure having a strap means for connecting to a bone or chew toy. A multiple strap harness is also disclosed for simultaneously securing a plurality of treats to the structure for use by multiple pets. The structure itself is a resilient bag comprised of a repairable construction that surrounds a quantity of high density material to give weight to the device. Below the weighted bag may include a high friction base that prevents sliding along wood and other slick indoor surfaces while deployed. Overall it is desired to provide a chewable article support and weighted base for an animal, and particularly a dog, to enjoy the article in place.
[0007] 2. Description of the Prior Art
[0008] Devices have been disclosed in the prior art that relate to pet chew toy supports. These include devices that have been patented and published in patent application publications, and generally relate to weighted articles having mechanical connectors to an elevated chew toy for a pet to consume or chew. The following is a list of devices deemed most relevant to the present disclosure, which are herein described for the purposes of highlighting and differentiating the unique aspects of the present invention, and further highlighting the drawbacks existing in the prior art.
[0009] Specifically, U.S. Pat. No. 6,672,253 to Viola discloses a flying disk toy having a rope attachment for recreational use with a pet. The device comprises a gyroflier disk toy having a rope secured therethrough and tied into a knot at both ends for the pet to chew and grasp the assembly. The circular gyroflier can be thrown for the pet to chase, or the pet can use the knots as chew toys for singular enjoyment. The device, while providing a chew toy for a pet, does not pertain to the main object of the present invention, notably the use of a weighted support for maintaining the position of a supported treat while a pet consumes the treat in place. The structure and the intent of the Viola device diverge from that of the present invention.
[0010] U.S. Patent Application Publication No. 2003/0172879 to Bader discloses a chew toy holding apparatus comprising a base platform and an adjustable attachment for a pet chew toy that allows the assembly to grasp and position a chew toy in relationship to the base. The attachment can swivel and pivot to position the chew toy in the most advantageous position for the pet to chew a toy or consume an edible chew article such as a bone. While demonstrating a similar purpose and intent as compared to the present invention, the present invention discloses a non-mechanical attachment to a pet toy or treat, while also offering the capability to support multiple toys at once for more than one pet to enjoy.
[0011] U.S. Patent Application Publication No. 2003/0205206 to Natale discloses a dog bone or chew toy holder having a weighted base and a vertically disposed rod for securing the bone or toy to the distal end thereof. The rod end includes a threaded connection while the toy or bone includes a tapped hole for securing the two articles together. The base is a cylindrical structure having a concrete filler material, maintaining the position of the base while the toy or bone is engaged by the pet. In a similar fashion as the Bader device, the Natale device describes a pet toy or treat holder having a mechanical connection to the pet article. The present invention provides a treat support device having similar purpose; however the elements of present invention diverge from that of the Natale device.
[0012] Finally, U.S. Patent Application Publication No. 2009/0217885 to Peter discloses a pet treat holder device that comprises a first and second member that clamp together about a pet treat and support the treat therebetween. The members include a coupling therebetween to draw the member together around the pet treat, while one of the members includes a cavity or recess to receive a portion of the treat to improve the grip of the clamp thereof and reduce the clamp member distance when engaging the coupling therebetween. The Peter device discloses a bone or pet treat clamp that is adapted to hold the treat to facilitate access to the consumable portions thereto and prevent ingestion of wrapping or non-ingestible portions thereof by the pet. The present invention pertains to a weighted base for supporting at least one pet treat, wherein several embodiments are disclosed for supporting at least one treat and maintaining its position as the pet consumes the treat.
[0013] The present invention provides a weighted chew article support for a pet to gnaw or consume the article while being prevented from relocating the article during the activity. The device comprises a weighted bag having a strap connector along its upper surface for securing to the chew article, or optionally connecting to a harness that supports a plurality of chew articles for multiple pet use. It is submitted that the present invention substantially diverges in design elements from the prior art, and consequently it is clear that there is a need in the art for an improvement to existing devices. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
[0014] In view of the foregoing disadvantages inherent in the known types of weighted pet article supports now present in the prior art, the present invention provides a new pet chew article support that can be utilized for providing convenience for the user when securing at least one pet chew article in place while the pet engages and chews the article.
[0015] It is therefore an object of the present invention to provide a new and improved weighted chew article support device that has all of the advantages of the prior art and none of the disadvantages.
[0016] It is another object of the present invention to provide a weighted chew article support device that comprises a resilient and weighted structure supporting a pet chew toy or pet treat along its upper portion, whereby a pet can consume or gnaw on the article within a given area, while the weight resists the pet moving the article from a location chosen by an owner.
[0017] Another object of the present invention is to provide a weighted chew article support device that utilizes a strap securement for the pet treat and a means to prevent sliding of the pet treat while grasped by the strap securement, supporting the treat in an open and accessible manner while preventing the pet from removing the treat from the strap securement.
[0018] Yet another object of the present invention is to provide a weighted chew article support device that comprises a weighted, repairable and resilient sack of dense material to position a pet treat or chew toy in a static and accessible position, while also providing a lowermost surface that prevents sliding of the assembly along smooth surfaces.
[0019] Another object of the present invention is to provide a weighted chew article support device that provides a multiple chew article support device, whereby more than one chew article is supported and secured to the weighted support for enjoyment by more than one pet at a time.
[0020] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0021] Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
[0022] FIG. 1 shows an overhead perspective view of the present invention attaching to a pet chew article, whereby its strap attachment means is in an open position.
[0023] FIG. 2 shows a perspective side view of the present invention in a working state along with a cut-away view of the cross section of the support device.
[0024] FIG. 3 shows an exploded view of an embodiment of present invention connecting to a weighted and non-slip base surface.
[0025] FIG. 4 shows a perspective view of an embodiment of the present invention, wherein a multi-chew article support means is provided.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the pet chew article support device. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for supporting at least one chew article for a pet to gnaw or consume, while preventing the pet from relocating the assembly during deployment. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
[0027] Referring now to FIG. 1 , there is shown a perspective view of the pet chew article support of the present invention being deployed in conjunction with a dog bone 20 pet chew article. The article support comprises a weighted and compressible sack 10 having an outer sidewall 15 and an internal volume filled with a dense material that weighs down the assembly and prevents a pet from moving the assembly once positioned on a surface. Ideally the internal material is a granular material such as sand, which allows for compression of the sack. Alternatively, the dense material may be a combination of granular material and an internal weight that is positioned within the granular medium. Finally, it is contemplated that a solid material may fill the interior volume of the same to provide the necessary weight for support of the pet chew article. The support secures to a pet treat or chew toy article 20 and prevents the pet from readily picking up the article 20 and relocating it within the house or outside of a residence. In this way, a pet and its chew article can be readily located, while its position can be controlled while the pet engages a chew article. This provides pet owners with a convenient way to monitor a pet in one location while eating, preventing the pet from hiding partially consumed articles, and further for providing a means to locate the pet within a given area for unmonitored occupation of the pet's attention.
[0028] Along the upper portion of the weighted article is a pet article strap attachment means comprising a first and second elongated strap 12 . Each strap secures at one end to the upper portion of the weighted sack 10 , while the strap second end 11 is meant to overlap the body section 21 a pet treat article 20 . The straps 12 overlap one another and secure over the chew article 20 , whereby the two straps secure to one another using a strap connector elements to prevent separation. The connector elements are preferably hook and loop fastener strips 14 that secure each strap to one another for removable connection therebetween. Along the interior surface of each strap 12 is a length of elastomeric, tacky, or silicon strip 13 , which prevents the body 21 of the chew article 20 from sliding within the enclosed straps, and further prevents the pet from pulling the article 20 through the straps 12 by its ends 22 . When secured, the pet chew article 20 is also largely exposed, whereby its ends 22 can be chewed, gnawed, or consumed by the pet while the assembly remains in position and the weighted support prevents ready relocation of the chew article 20 . Preventing the pet from pulling the article 20 through the straps 12 is of primary importance for the overall effectiveness of the assembly. The large exposed regions of the chew article 20 allow easy purchase by the pet within its mouth, therefore the use of the interior strip 13 is imperative to counteract any pulling force along the length of the chew article body 21
[0029] Referring now to FIG. 2 , there is shown a second perspective view of the present invention, this time in a working state and with a cut-away view of the structure of the weighted sack 10 . When deployed, the straps 12 provide a means to secure a chew toy or treat 20 to the weighted structure of the device, whereby a pet can freely chew and consume the article 20 without causing damage to the structure sidewalls 12 . The sidewalls 12 are preferably comprised of a toughened, weather-proof fabric material layer 16 having an interior moisture barrier layer 17 thereunder. The fabric material is one that can be chewed upon without readily being compromised, while after a deployed period, the fabric can be patched or sewn together if holes are created. The moisture barrier 17 prevents moisture and pet saliva from entering into the interior of the sack and coagulating or clumping the fill material.
[0030] Within the interior of the sidewalls 12 is a high density material 18 that fills the open interior of the sack 10 and provides the structure with its weight and sidewalls stiffness. This fill material is preferably a sand or similar granular material, while the sack interior volume is filled to an extent that the walls 12 are not overly tensioned so as to prevent a structure that can rupture if the pet clinches the sidewalls 12 of the sack. At the same time, the fill material 18 must consume a sufficient amount of the interior volume of the sack to weigh down the chew article 20 and prevent the sidewalls 12 from folding onto themselves. This condition makes it too easy for a pet to obtain purchase of the sidewalls with their jaws and relocate the assembly. When deployed, the weight of the sack 10 prevents relocating of the chew article 20 , while the straps 12 secure the chew article body 21 to their first end connection 19 along the upper portion of the weighted sack.
[0031] Referring now to FIG. 3 , there is shown an exploded view of an embodiment of the present invention that includes a non-slip base 40 . The base 40 is one that prevents the weighted sack 10 from sliding along smooth surfaces 50 , such as linoleum, tile, and hardwood flooring while a pet engages a chew article 20 attached thereto. The base 40 connects to the underside of the weighted sack 10 by way of a permanent (sewn) connection, or preferably using a removable strap connection (shown in FIG. 3 ). The base 40 itself may be a thin, non-slip structure having a high friction underside surface 43 , or alternatively the base may be comprised of a weighted structure itself having a thickness and a non-slip underside surface 43 . The weighted base 40 embodiment adds to the overall weight of the assembly, furthering the goal of retaining the chew article 20 location once thereattached.
[0032] In a preferred embodiment, the base is optional and removably attachable to lower portion of the weighted sack 10 . In one embodiment, a lowermost strap 31 secures through a loop or bridge element 41 along the upper surface 42 of the base 40 . The strap 31 includes a strip of hook and loop fastening material that mates to a complimentary strip 32 along the lower portion of the sack 10 . This strap connection means 30 provides a removable connection with the base, allowing the fabric sack 10 to be removed therefrom if the user wishes to wash or repair the fabric sack 10 independently of the base 40 .
[0033] Referring now to FIG. 4 , there is shown an overhead perspective view of an alternate embodiment of the pet chew article support of the present invention. In this embodiment, the chew article strap securement 12 supports a multi-chew article support device about its base 60 . Extending from the base 60 while secured by the straps 12 of the weighted sack 10 are a plurality of elongated tethers 61 that extend away from the sack 10 and provide their own, independent chew article strap connector element 62 . In this way, the distal ends of each tether 61 attached to a chew article 20 and allow multiple pets to engage a chew article of their own in one centralized location. The weight of the sack 10 prevents the pets from relocating the entire assembly, while the optional base 40 can further prevent sliding along slick surfaces 50 . It is contemplated that many tethers may be deployed, whereby each tether 61 is secured to the base element 60 that is secured within the strap connector of the weighted sack 10 . The base element 60 is preferably an elongated structure that the straps 12 can encircle and secure therearound.
[0034] In an alternate embodiment of the multiple pet chew article support and the present invention, the tethers 61 may originate directly from the upper portion of the weighted sack 10 , as opposed to being supported by the chew article straps 12 . This embodiment is adapted for multiple pet use, and is only a contemplated variation of the preferred layout, wherein the multi-article support is removable connected to the sack 10 and is an accessory thereto.
[0035] When pet owners give their pets a chew article such as a bone or chew toy, they have to supervise the pet to make sure the pet doesn't choke. This can be an unwanted task for the owner, as many pets like to run away with the article and enjoy it or hide it elsewhere. This can create a mess both inside and outside of the home, where partially consumed or lost chew articles can attract pests, become rotten, or simply clutter interior and exterior spaces. As an alternative to allowing the pet to freely obtain and run away with the chew article, owners can attempt to hold the bone or chew toy with one end and let the pet chew on the other end. However, this arrangement poses a risk of being accidentally bitten, as some pets are more aggressive than others and may not understand. Further still, this does not solve the problem of providing a chew toy that can occupy the pet by itself and relief the owner of supervisory duties.
[0036] The present invention attempts to solve this known problem and provide a solution that offers owners flexibility, while also offering a product that is of low cost and low complexity. The device provides pet owners with a convenient way to hold pet chew articles for their pets and to prevent the articles from being repositioned or lost while the pet is engaging the article. The device comprises a sack filled with dense material, whereby the chew article is securely fastened thereto. Embodiments herein disclosed include a means to prevent the device from sliding along support surfaces and a means for supporting a plurality of extended chew articles in connection with the weighted sack, along with the chosen fill material to provide weight to the assembly. Pet owners can easily keep an eye on their pets while the pets are chewing on the articles, making sure the dogs don't choke or hurt themselves. Further still, owners can place a chew article in a desired location to occupy a pet for a given amount of time, relieving the owner of any duties to supervise or locate the pet or its chew article.
[0037] It is submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0038] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A weighted pet chew article support device is provided having a weighted structure that is designed to keep a pet within a given area while consuming or gnawing on the treat or chew toy. The device comprises a weighted member having sidewalls, a base, and an upper surface that supports a treat attachment strap. The strap wraps around a pet treat and includes a length of elastomeric material therein to prevent the treat from sliding while grasped by the strap. The base of the weighted member may comprise a non-sliding surface for use on slick floors. The weighted member itself is a resilient sack of lined material that can be readily repaired if the pet gnaws thereon. Further provided is a multi-treat attachment system that includes a plurality of elongated members attaching to the uppermost strap for securing more than one treat therewith. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This filing claims the benefit of, and priority from U.S. provisional application 61/497,260 filed Jun. 15, 2011, the contents of which are incorporated by reference herein in their entirety.
TECHNICAL FIELD
The present disclosure relates generally to a fabric construction, and more particularly, to a fabric construction adapted for use in applications such as a cleaning wipe or fluid acquisition layer in a diaper. The fabric construction is formed by stitch-bonding and has a contoured creped surface. A method for forming such materials is also provided.
BACKGROUND OF THE DISCLOSURE
Hand wipe products have recently gained popularity as a mechanism for cleaning and disinfecting surfaces. Such wipe products typically incorporate a nonwoven sheet which is saturated with a cleaning and sanitizing solution. By way of example only, such wipe products are available at many grocery stores for use by customers to clean the surfaces of grocery carts and baskets before use. Such wipe products are also sold for home use.
In existing wipe products the sheet material acts primarily as a carrier for the cleaning or disinfecting solution and must have sufficient thickness to avoid tearing during use. Flat or textured non-woven sheets have been used successfully, but such nonwoven sheets must have a relatively substantial weight to avoid falling apart during use. Thus, relatively substantial quantities of fiber are required to form such sheets. The use of additional fiber has the undesired consequence of making the sheets relatively bulky thereby making packaging more difficult. Additional fiber also increases the cost of the final wipe product. Pre-existing wipe products also tend to lack significant surface texture. Thus, scouring ability is relatively limited.
Diapers are well known for use in containing urine and bowel discharge. Modern diapers typically have a layered structure in which a user contact surface layer characterized by low moisture retention is disposed in overlying relation to a highly absorbent fiber layer which acts to lock expelled fluid in place. One or more intermediate wicking layers may be disposed between the user contact surface layer and the fluid absorption layer. In general, it is desirable to move fluid away from the user's skin as quickly as possible. However, there may be some delay in achieving full absorption of fluid into the absorbent layer. This may slow down the rate of fluid removal from the user's skin surface.
In light of the above, there is a continuing need for an improved wipe product which may act as a carrier for disinfecting solution and which has a scouring surface adapted to promote aggressive cleaning without failure. There is also a continuing need for an improved diaper construction which facilitates efficient removal of fluid from a user's skin surface.
SUMMARY OF THE DISCLOSURE
The present disclosure provides advantages and alternatives over the prior art by providing a stitch-bonded fabric construction in which broadly spaced parallel linear stitch lines are applied through a very low weight spun bonded substrate or the like to stabilize the substrate in the machine direction. Texture is imparted by applying significant overfeed conditions to the stitching substrate thereby causing a substantial bunching of the substrate at the stitching position. The resulting product has an arrangement of alternating ridges and valleys running predominantly in the cross-machine direction. The linear stitch lines define lateral sides of crater-like depressions between adjacent ridges. The stabilizing linear stitch lines lock in the puckered texture. The fabric construction may be saturated with a sanitizing or cleaning solution if desired. The substantially inelastic character of the linear stitch lines acts to lock in the textured construction.
In accordance with one exemplary aspect, the present disclosure provides a cleaning wipe of stitch-bonded construction. The wipe includes a stitching substrate of fibrous nonwoven material having a mass per unit area of not more than about 30 grams per square meter. A plurality of stitching yarns are disposed in stitched relation through the stitching substrate in a pattern of substantially parallel linear stitch lines extending in the machine direction across the stitching substrate. The linear stitch lines are spaced apart from one another by a significant distance. The stitching substrate is delivered to the stitching position at a substantial surplus such that it bunches and is consolidated during stitching. The stitching substrate is delivered to the stitch-forming position with at least 25% overfeed (i.e. surplus) relative to the rate of discharge from the take-up rolls such that one meter of stitching substrate yields no more than about 0.75 meters of stitched product. The surplus stitching substrate forms an arrangement of surface ridges running predominantly in the cross-machine direction with valleys disposed between the surface ridges. The stabilizing linear stitch lines lock in the texture-imparting ridges and valleys and define lateral sides of crater-like depressions between adjacent ridges. A disinfecting and/or cleaning solution may at least partially saturate the cleaning wipe.
In accordance with another exemplary aspect, the present disclosure provides a stitch-bonded fluid acquisition layer for a diaper disposed at an intermediate position between the user contact layer and the highly absorbent fluid retention layer. The fluid acquisition layer is highly permeable and includes a stitching substrate of fibrous nonwoven material having a mass per unit area of not more than about 30 grams per square meter. A plurality of stitching yarns are disposed in stitched relation through the stitching substrate in a pattern of substantially parallel linear stitch lines extending in the machine direction across the stitching substrate. The linear stitch lines are spaced apart from one another by a significant distance. The stitching substrate is delivered to the stitching position at a substantial surplus such that it bunches and is consolidated during stitching. The stitching substrate is delivered to the stitch-forming position with at least 25% overfeed (i.e. surplus) relative to the rate of discharge from the take-up rolls such that one meter of stitching substrate yields no more than about 0.75 meters of stitched product. The surplus stitching substrate forms an arrangement of surface ridges running predominantly in the cross-machine direction with valleys disposed between the surface ridges. The stabilizing linear stitch lines lock in the texture-imparting ridges and valleys and define lateral sides of crater-like depressions between adjacent ridges. The highly textured fluid acquisition layer collects and holds fluid in the crater-like depressions for dissipation into an underlying fluid absorption layer. This is believed to improve the efficiency of fluid removal from the user's skin surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and which constitute a part of this specification illustrate exemplary constructions and procedures in accordance with the present disclosure and, together with the general description of the disclosure given above and the detailed description set forth below, serve to explain the principles of the disclosure wherein:
FIG. 1 illustrates schematically a single bar stitch bonding system and take-up for forming a stitch-bonded fabric construction of creped character according to the present disclosure by stitching a pattern of parallel stabilizing stitch lines yarns running in the machine direction through a light-weight substrate material delivered at a substantial overfeed condition;
FIG. 2 illustrates one potential stitch pattern.
FIG. 3 is a scanned image of an exemplary creped material formed by the system of FIG. 1 illustrating stabilizing yarns running in parallel stitch lines along the machine direction retaining the substrate in a pattern of crater-like depressions bounded by cross-machine ridges and machine-direction stabilizing yarns; and
FIG. 4 is a schematic cross-section of one exemplary layered diaper construction incorporating the stitch-bonded creped material of the present disclosure as a fluid acquisition layer.
Before the exemplary embodiments are explained in detail, it is to be understood that the invention is in no way limited in its application or construction to the details and the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and being practiced or being carried out in various ways. It is intended that the present disclosure shall extend to all alternatives and modifications as may embrace the general principles of the invention within the full and true spirit and scope thereof. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of terms such as “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the drawings, wherein to the extent possible like reference numerals are used to designate like elements in the various views. In FIG. 1 , a so called single bar stitch-bonding process is illustrated schematically. In the illustrated exemplary practice, one or more plies of a substrate material 30 of fibrous nonwoven construction such as a spunbonded fleece or the like is conveyed to a stitch-forming position in the direction indicated by the arrows. By way of example only, the substrate material 30 may be a spunbonded polyester or polypropylene fleece having a mass per unit area of about 5 to about 30 grams per square meter and more preferably about 12-16 grams per square meter. However, other materials with higher or lower weights may also be used. While FIG. 1 illustrates the use of a single ply of substrate material, it is also contemplated that multiple plies also may be used if desired.
As will be appreciated by those of skill in the art, during the stitch-bonding process a needle 34 (shown in greatly exaggerated dimension) pierces the substrate material 30 and engages stitching yarns 36 delivered into position by the yarn guide such that the stitching yarns are captured within a hook portion of the needle 34 . By way of example only, and not limitation, the stitching yarns 36 may be multifilament polyester yarns or the like having a linear density in the range of about 20 to 150 denier, although heavier or lighter yarns may be used if desired. One potentially preferred yarn is a 40 denier, 12 filament fully oriented polyester, although other yarns may be used if desired. As the needle is reciprocated downwardly, a closing element such as a closing wire which moves relative to the needle 34 closes the hook portion to hold the stitching yarns therein. With the hook portion closed, the captured stitching yarns are pulled through the interior of an immediately preceding yarn loop disposed around the shank of the needle 34 at a position below the substrate material 30 . As the captured stitching yarns are pulled through the interior of the preceding yarn loop a stitch is formed which is knocked off of the needle 34 . As the needle 34 is raised back through the substrate material 30 , the hook portion is reopened and a new yarn loop moves out of the hook portion and is held around the shank of the needle 34 for acceptance of captured yarns and formation of a subsequent stitch during the next down stroke. As this process is repeated multiple times at multiple needles 34 , a resultant stitch-bonded fabric 38 is thus produced. In this regard, while only a single needle 34 is shown engaging a single stitching yarn 36 , in actual practice, multiple needles 34 are disposed in spaced-apart, side by side relation across the width of the substrate material 30 to each engage a stitching yarn 36 in a manner as will be well understood to those of skill in the art.
In practice, the substrate material 30 may be held down on either side of each needle 34 by a low profile hold down sinker 40 . According to one exemplary practice, in order to impart functional tear lines across the fabric, the stitch-bonded fabric 38 may be periodically subjected to localized melt fusion and/or perforation at a station 44 downstream from the needling position. As will be appreciated, the application of a melt fusion line and/or localized perforation line defines a stress concentrator to facilitate controlled tearing during use. That is, the material will have sufficient strength to permit rolling but application of a shear force along the perforation line will cause controlled tearing.
In accordance with the preferred practice, the substrate material is delivered to the needling position at a substantial overfeed condition of greater than about 25% and more preferably, about 40% or higher and most preferably about 50% or higher. In one potentially desirable construction illustrated in FIG. 2 , the substrate material 30 is delivered at about 60% overfeed. In this regard, it is to be understood that the term “overfeed” refers to the percentage difference between a defined linear distance of substrate material 30 fed into the stitching position and the resultant linear distance of stitch-bonded fabric 38 collected by the take-up roll. This ratio may be adjusted by varying the rate of substrate delivery relative to the rate of stitched fabric take-up. By way of example, in the event that one meter of substrate material 30 is delivered to the stitching position and is consolidated to 0.4 meters of stitch-bonded fabric following take-up, the overfeed is 60%. Likewise, in the event that one meter of substrate material 30 is delivered to the stitching position and is consolidated to 0.7 meters of stitch-bonded fabric 38 following take-up, the overfeed is 30%.
As best seen in FIG. 3 , the presence of excess substrate material 30 causes the substrate to bunch up and pucker at the needling position and to form a pattern of alternating raised ridges and depressed valleys of alluvial character oriented with major length dimensions predominantly in the cross-machine direction. Normally, bunching and puckering is considered a defect and is avoided if possible. As shown, the stitching yarns 36 are stitched into relatively widely spaced parallel linear stitch lines 50 which run in the machine direction (i.e. the direction of travel of the substrate material 30 . These linear stitch lines 50 act to lock in the puckered character of the substrate material 30 . In this regard, the linear stitch lines 50 act to compress the ridges at the location of contact and define lateral sides to crater-like depressions of substantial depth between adjacent ridges. In the stitch-bonded fabric 38 , the crater-like depressions on one side cooperatively define the ridges on the opposite side.
As will be appreciated, each of the linear stitch lines 50 is formed by an individual reciprocating needle 34 (only one shown) with a row of such needles extending in adjacent relation to one another across the width of the substrate material 30 substantially transverse to the direction of movement of the substrate material 30 . The so called gauge or needle density in the cross machine direction maybe adjusted as desired. By way of example only, and not limitation, it is contemplated that the gauge may be in the range of about 7 to 28 needles per inch and will more preferably be about 12 to 16 needles per inch and will most preferably be about 14 needles per inch. However, higher and lower needle densities may likewise be used if desired. By way of example only, and not limitation, it is contemplated that the stitch bonding machine may be set to apply about 10 to 16 stitches per inch and most preferably about 12 stitches per inch along each stitch line 50 in the machine direction (also known as courses per inch or CPI).
By way of example only, and not limitation, the stitch lines 50 may be formed by stitching the yarns 36 through the substrate material 30 in a pattern of parallel, spaced apart chain stitches extending along the machine direction in a partially threaded arrangement. By way of example, an exemplary stitch pattern notation for the linear stitch lines may be (1-0,0-1//). The distance between the linear stitch lines 50 is preferably at least about 3 mm and will more preferably be in the range of about 5 mm to about 12 mm although greater or lesser spacing distances may be used. In the illustrated exemplary construction of FIG. 2 , the stitching yarns 36 are threaded in a so called “1 miss 4” pattern with every fifth needle being engaged. Of course, other partial threading arrangements such as “1 miss 2”, “1 miss 3”, “1 miss 5”, “1 miss 6” etc. may be used if desired. It has been found that in at least some instances leaving the unthreaded intermediate needles in place may be beneficial in promoting processing in the desired overfeed condition. Perforation by these unthreaded needles continues to occur such that small needle holes are produced through the substrate material across the width of the stitch-bonded fabric 38 between the individual stitch lines 50 . These needle holes are oriented in linear relation to one another and to the individual stitches in the stitch lines across the width of the stitch-bonded fabric 38 .
The stitch-bonded material and resulting products according to the present disclosure are characterized by relatively limited stretch in the machine direction due to the presence of the linear stitch lines. In this regard, the stretch before failure in the machine direction is preferably less than 20% and is more preferably less than 10%. The absence of substantial machine direction stretch is believed to promote maintaining the presence of the texture-imparting ridges and valleys across the surface during use.
As noted previously, in one application, the stitch bonded constructions described may be used as a cleaning wipe. If desired, such cleaning wipes may be saturated with a disinfecting or cleaning solution by techniques such as spraying, immersion or the like as will be known to those of skill in the art and packaged as rolls with periodic tear lines to permit withdrawal and use for cleaning and disinfecting purposes. The presence of the ridges and valleys provides a textured scrubbing surface to facilitate the cleaning function.
In another application, the stitch-bonded fabric 38 such as illustrated in FIG. 2 may be used as a relatively light-weight fluid acquisition layer in a diaper disposed in overlying relation to a highly absorbent fluid retention layer. By way of example only, and not limitation, FIG. 4 illustrates one exemplary layered arrangement 70 for a diaper. The layered arrangement 70 includes a user contact layer 72 of highly permeable, non-absorptive character which is adapted to pass fluid while remaining relatively dry. An optional fibrous wicking layer 74 of generally hydrophobic character may be disposed below the user contact layer 72 to facilitate moving fluid away from the user. A fluid acquisition layer 76 formed by the stitch-bonded fabric 38 of creped construction as described may be disposed at an intermediate position below the user contact layer 72 and above a highly absorbent fluid retention layer 78 . An optional, fluid barrier layer 80 may be disposed at a position behind the fluid retention layer 78 . Of course, any number of additional layers may be introduced between any of the layers if desired.
In operation, the fluid acquisition layer is not highly absorptive but may act to hold a relatively large volume of fluid in a readily releasable manner for delivery to the underlying fluid retention layer 78 . In particular, it is contemplated that the fluid will pool in the available craters across the surface of the fluid acquisition layer 76 . It thus acts as a reservoir for collecting and holding fluid away from a user until it can be absorbed within the fluid retention layer 78 .
Of course, variations and modifications of the foregoing are within the scope of the present disclosure. Thus, it is to be understood that the disclosure disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. The embodiments described herein explain the best modes known for practicing the disclosure and will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art. | A stitch-bonded fabric construction in which broadly spaced parallel linear stitch lines are applied through a very low weight fibrous substrate to stabilize the substrate in the machine direction. Texture is imparted by applying significant overfeed conditions to the stitching substrate thereby causing a substantial bunching of the substrate at the stitching position. The resulting product has an arrangement of alternating ridges and valleys running predominantly in the cross-machine direction. The stabilizing linear stitch lines lock in the puckered texture. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates generally to the field of electrical contacts and more specifically to methods for the fabrication of electrical contacts.
BACKGROUND OF THE INVENTION
[0002] Existing electrical contact designs include interposers constructed from elastomeric material and interposers constructed from balls of wire. Both of these solutions have limitations inherent in their design. Current elastomeric materials are unable to sustain adequate contact spring force over time and temperature and have a small range of working heights. Interposers constructed from balls of wire are fragile, prone to unravel, often require costly inspection, and provide a limited amount of contact travel.
SUMMARY OF THE INVENTION
[0003] A method for the fabrication of electrical contacts using metal forming, masking, etching, and soldering techniques is presented. The method produces a plurality of specialized electrical contacts, capable of use in an interposer, or other device, including non-permanent or permanent electrical connections providing contact wipe, soft spring rates, durability, and significant amounts of travel.
[0004] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of an embodiment of a printed circuit board comprising a quantity of through-plated vias according to the present invention.
[0006] [0006]FIG. 2 is a perspective view of an embodiment of a metal sheet comprising a quantity of domes according to the present invention.
[0007] [0007]FIG. 3 is a perspective view of the metal sheet of FIG. 2 after masking and etching of the sheet to create a quantity of electrical contacts according to the present invention.
[0008] [0008]FIG. 4 is a perspective view of the structure created by soldering the metal sheet of FIG. 3 to the printed circuit board of FIG. 1 according to the present invention.
[0009] [0009]FIG. 5 is a perspective view of the structure of FIG. 4 after the connections between the individual electrical contacts have been etched away according to the present invention.
[0010] [0010]FIG. 6 is a perspective view of the structure of FIG. 5 after the electrical contacts have been plated according to the present invention.
[0011] [0011]FIG. 7 is a flowchart of a method for the creation of electrical contacts according to the present invention.
[0012] [0012]FIG. 8 is a flowchart of a method for the creation of an interposer comprising micro-spiders according to the present invention.
[0013] [0013]FIG. 9 is a flowchart of a method for the creation of an interposer comprising micro-spiders and ball grid array (BGA) balls according to the present invention.
[0014] [0014]FIG. 10 is a flowchart of a method for the creation of micro-spiders according to the present invention.
[0015] [0015]FIG. 11 is a perspective view of an embodiment of a three-legged micro-spider according to the present invention.
[0016] [0016]FIG. 12 is a perspective view of embodiment of a plurality of three-legged micro-spiders on a substrate according to the present invention.
[0017] [0017]FIG. 13 is a cross-sectional view of an embodiment of the present invention illustrating micro-spiders constructed on a first side of a substrate and ball grid array (BGA) balls constructed on a second side of a substrate.
DETAILED DESCRIPTION
[0018] [0018]FIG. 1 is a perspective view of an embodiment of a printed circuit board (PCB) comprising a quantity of through-plated vias 106 , according to the present invention. In an example embodiment of the present invention a printed circuit board substrate 100 is plated with copper on both sides of the substrate and the copper is etched leaving areas of copper 104 , surrounding each of the holes 102 , on opposite sides of the substrate from each other. While the areas of copper 104 in this embodiment are somewhat elliptical in shape, other shapes of the areas of copper 104 will work equally well within the scope of the present invention. For example, in some embodiments of the present invention, the area of copper 104 may be circular, square, rectangular, or other, more complex, shapes. While copper is a preferred metal, other example embodiments of the present invention may use other materials for the plating. The substrate 100 may comprise a wide variety of materials, with fiberglass as a common choice of material. Holes 102 are then drilled through the center of each area of copper 104 . The barrel of the holes are then through-plated to connect the corresponding areas of copper 104 on opposite sides of the substrate 100 thereby forming an array of through-plated vias 106 . This drilled and plated PCB may be created by any standard PCB manufacturing system, and will be as the substrate for a plurality of specialized electrical contacts referred herein to as micro-spider contacts. A PCB with these micro-spider contacts may be used as an interposer in an electronic system.
[0019] [0019]FIG. 2 is a perspective view of an embodiment of a metal sheet comprising a quantity of domes according to the present invention. A metal sheet 200 is processed such that it comprises a plurality of small domes 202 . The metal sheet 200 may be copper or other conductive metals as needed for any particular implementation of the present invention. The size of the domes 202 may also be varied as needed for any particular implementation of the present invention. In an example embodiment of the present invention, the domes 202 in the metal sheet 200 have a one-to-one correspondence with the through-plated holes 102 on the PCB substrate 100 , however other embodiments of the present invention need not maintain this one-to-one correspondence.
[0020] [0020]FIG. 3 is a perspective view of the metal sheet of FIG. 2 after masking and etching of the sheet 200 to create a quantity of micro-spiders, each on their own footing 304 , according to the present invention. After the metal sheet 200 has been masked and etched, micro-spiders 300 , footings 304 , and connectors 302 between individual footings 304 remain forming an etched metal sheet 310 . Note that while FIG. 3 shows a regular array of micro-spiders 300 , there is no need for the plurality of micro-spiders 300 to form a regular array, instead they may be formed only in locations where needed and longer connectors 302 used to connect the plurality of micro-spiders 300 .
[0021] [0021]FIG. 4 is a perspective view of an embodiment of the structure created by soldering the metal sheet of FIG. 3 to the printed circuit board of FIG. 1 according to the present invention. The etched metal sheet 310 is soldered to the PCB structure of FIG. 1, thereby forming an array of plated-through vias 106 covered by a corresponding array of micro-spiders 300 . The solder may be silk-screened onto the array of through-plated vias 106 to cover just the exposed metal areas 104 where it is desired that the micro-spiders 300 make electrical contact. At this point in the process the individual micro-spiders 300 are physically and electrically connected to the individual areas of metal plating 104 surrounding their corresponding via hole 102 in the PCB substrate 100 .
[0022] [0022]FIG. 5 is a perspective view of the structure of FIG. 4 after the connections between the individual micro-spiders have been etched away according to the present invention. At this point in the process, all of the micro-spiders 300 have been separated from each other physically and electrically by etching away all of the connectors 302 between the individual micro-spiders 300 . Note that in some implementations of the present invention, it may be desired to have a plurality of micro-spiders 300 physically and electrically connected to each other at the completion of the interposer. In that case, the masking and etching of the PCB substrate 100 and the thin metal sheet 200 may be designed to leave larger areas of metal 104 surrounding the PCB vias 102 such that a plurality of vias are electrically connected, and corresponding areas of the thin metal sheet 200 may be left un-etched for later soldering to the array of through-plated vias 106 . Such an alternate embodiment of the present invention may be useful for power supply connections that commonly require a large amount of current-carrying capability.
[0023] [0023]FIG. 6 is a perspective view of the structure of FIG. 5 after the micro-spiders have been plated according to the present invention. In an example embodiment of the present invention, the micro-spiders 300 may be plated with nickel and gold, improving their durability and conductivity, and thereby forming an array of plated micro-spiders 600 .
[0024] [0024]FIG. 7 is a flowchart of a method for the creation of micro-spiders 300 according to the present invention. In a step 702 , a PCB substrate 100 is plated, etched, and drilled to produce a plurality of through-plated vias 106 in the substrate 100 . In a step 704 , a quantity of domes are created in a first metal sheet 200 . In an example embodiment of the present invention, the first metal sheet 200 may be copper. In a step 706 , a first mask layer is created over the first metal sheet 200 . In a step 708 , the first metal sheet 200 is completely etched away in areas not protected by the mask, producing a quantity of micro-spiders 300 , footings 304 , and connectors 302 . In a step 710 , after the mask layer is cleaned off, the first metal sheet 200 comprising a quantity of micro-spiders 300 is soldered to the plurality of through-plated vias 106 in the substrate 100 . In a step 712 , a second mask layer is created over the first metal sheet 200 . In a step 714 , all of the areas of the first metal sheet 200 that are not protected by the second mask layer are completely removed by etching. In a preferred embodiment of the present invention, the connectors 302 are left unprotected by the second mask layer and removed in the etching step. In a step 716 , the quantity of micro-spiders 300 is metal plated.
[0025] Some methods of applying and patterning the first mask layer may have difficulties is creating an adequate mask layer over an irregular surface such as that resulting from step 704 (creating a quantity of domes in a metal sheet). Further, some photolithography systems may have difficulties in patterning a mask layer over an irregular surface, particularly with the sides of the domes. When using masking systems that are unable to create an adequate mask layer over an irregular surface, it may be necessary to perform the steps of the present invention in a different order than that shown in FIG. 7. For these reasons, in some example embodiments of the present invention, it may be beneficial to perform the step 706 of creating a first mask layer over the first metal sheet before the step 704 of creating a quantity of domes in the first metal sheet.
[0026] [0026]FIG. 8 is a flowchart of a method for the creation of an interposer comprising micro-spiders according to the present invention. The method for the creation of an interposer including micro-spiders shown in this example embodiment of the present invention includes the steps of the method shown in FIG. 7, with the addition of steps to preferably create an additional quantity of micro-spiders on the opposite side of the printed circuit board substrate. As explained in connection with FIG. 7, in a step 716 , the quantity of micro-spiders 300 is metal plated. In a step 802 , a quantity of domes is created in a second metal sheet 200 . This step 802 may occur concurrently with step 702 , if desired. In a step 804 , a third mask layer is created over the second metal sheet 200 . This step 804 may occur concurrently with step 706 , if desired. In a step 806 , the second metal sheet 200 is completely etched away in areas not protected by the third mask, producing a quantity of micro-spiders 300 . This step 806 may occur concurrently with step 708 , if desired. In a step 808 , after the third mask layer is cleaned off, the second metal sheet 200 including a quantity of micro-spiders 300 is soldered to the plurality of through-plated vias 106 . This step 808 may occur concurrently with step 710 , if desired. In a step 810 , a fourth mask layer is created over the second metal sheet 200 . This step 810 may occur concurrently with step 712 , if desired. In a step 812 , all of the areas of the second metal sheet 200 that are not protected by the fourth mask layer are completely removed by etching. This step 812 , may occur concurrently with step 714 , if desired. In a step 814 , the second quantity of micro-spiders 300 is metal plated. This step 814 , may occur concurrently with step 716 , if desired. Once again, in some embodiments of the present invention, it may be desirable to create the mask layers over the thin metal sheets before forming the domes in the thin metal sheets. This example embodiment (FIG. 8) of the present invention may be used to create a dual micro-spider interposer for use between a printed circuit board and a circuit module, such as an application-specific integrated circuit (ASIC) package, or a multi-chip module. The dual micro-spider interposer is easy to remove from the printed circuit board without costly rework of the board. This allows for quick and easy changes of the circuit module, including changes in the field, if needed.
[0027] [0027]FIG. 9 is a flowchart of a method for the creation of an interposer comprising micro-spiders and ball grid array (BGA) balls according to the present invention. The method for the creation of an interposer including micro-spiders and BGA balls shown in this example embodiment of the present invention includes the steps of the method shown in FIG. 7, with the addition of steps to preferably create a quantity of BGA balls on the opposite side of the printed circuit board substrate. As explained in connection with FIG. 7, in a step 716 , the quantity of micro-spiders 300 is metal plated. In a step 902 , ball grid array (BGA) balls are attached to the side of the substrate opposite from the micro-spiders. Once again, in some embodiments of the present invention, it may be desirable to create the mask layers over the thin metal sheets before forming the domes in the thin metal sheets. By creating an interposer comprising micro-spiders on one side and BGA balls on the other, thinner gold may be used on a printed circuit board that the BGA side of the interposer attaches to. This enables the use of standard BGA attachment processes to attach the interposer to the printed circuit board. While this implementation of the present invention (FIG. 9) enables less expensive plating on the printed circuit board, the removeability of the dual micro-spider interposer (FIG. 8) allows for easier re-work than the micro-spider BGA interposer.
[0028] [0028]FIG. 10 is a flowchart of a method for the creation of micro-spiders in accordance with the present invention. In an example embodiment of the present invention similar to the method of FIG. 7, a metal sheet is etched into a micro-spider configuration before the micro-spiders are domed. This method allows for masking and etching of the metal sheet before dome formation, eliminating the difficulties of masking and etching a domed surface. In a step 702 , a PCB substrate 100 is plated, etched, and drilled to produce a plurality of through-plated vias 106 . In a step 706 , a first mask layer is created over a first metal sheet 200 . In a step 708 , the first metal sheet 200 is completely etched away in areas not protected by the mask, producing a quantity of micro-spiders 300 , footings 304 , and connectors 302 . In a step 1000 , a substantially incompressible material is deposited between the legs of the micro-spiders etched into the metal sheet. The substantially incompressible material is used to keep the legs of the micro spider from improperly bending during the step 704 of forming domes. It may comprise a material such as plaster of paris, and one example embodiment of the present invention uses a silk-screening process for applying the material. Next, in a step 704 , a quantity of domes are created in the first metal sheet 200 . In a step 1002 , the substantially incompressible material is removed from between the legs of the micro-spiders. Depending on the material used, the substantially incompressible material may be removed by dissolution or other equivalent processes. In a step 710 , after the mask layer is cleaned off, the first metal sheet 200 including a quantity of micro-spiders 300 is soldered to the plurality of through-plated vias 106 . In a step 712 , a second mask layer is created over the first metal sheet 200 . In a step 714 , all of the areas of the first metal sheet 200 that are not protected by the second mask layer are completely removed by etching. In a step 716 , the quantity of micro-spiders 300 is metal plated.
[0029] [0029]FIG. 11 is a perspective view of an embodiment of a three-legged micro-spider according to the present invention. A three-legged micro-spider 100 is shown connected to the area of metal 104 surrounding a through-plated hole 102 in a substrate 100 .
[0030] [0030]FIG. 12 is a perspective view of a plurality of an embodiment of three-legged micro-spiders 1100 on a substrate 100 in accordance with the present invention. While this figure shows a regular array of micro-spiders 1100 , other embodiments of the present invention may use an irregular array of micro-spiders 1100 as desired by the intended use of the plurality of micro-spiders 1100 . Further, micro-spiders may be constructed with any number of legs (greater than one) as desired by an intended use, within the scope of the present invention.
[0031] In a specific example embodiment of the present invention, micro-spiders 300 are preferably constructed on a first side of the substrate 100 and ball grid array balls 1000 are preferably constructed on a second side of the substrate 100 , creating an interposer for use in non-permanently attaching electronic devices such as a multi-chip module (MCM) to a circuit board. FIG. 13 is a cross-sectional view of such an embodiment. The example embodiment of the present invention shown in FIG. 13 illustrates a plurality of micro-spiders 300 constructed on a first side of a substrate and ball grid array (BGA) balls 1300 constructed on a second side of a substrate 100 , connected together by through-plated holes 102 surrounded by areas of metal 104 contacting the micro-spiders 300 . This example embodiment of the present invention may be employed as an interposer for use in non-permanently attaching electronic devices such as a MCM to a circuit board, while the interposer is attached to the circuit board by the BGA balls 1300 . The example embodiment of the present invention may be fabricated using the process described in connection with FIG. 9.
[0032] The resulting micro-spiders are described further in a U.S. patent application, Ser. No. ______, “Electrical Contact”, filed concurrently with the present application, and incorporated herein by reference. Another method for the fabrication of micro-spiders is described further in a U.S. patent application, Ser. No. ______, “Method for the Fabrication of Electrical Contacts”, filed concurrently with the present application, and incorporated herein by reference. | A method for the fabrication of electrical contacts using metal forming, masking, etching, and soldering techniques is presented. The method produces a plurality of specialized electrical contacts, capable of use in an interposer, or other device, including non-permanent or permanent electrical connections providing contact wipe, soft spring rates, durability, and significant amounts of travel. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 61/901,536 filed 8 Nov. 2013, which is incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure is directed to systems and methods for managing and optimizing patient care and experience in an inpatient hospital setting in general and to the evaluation of patients, the managing and optimizing of patient and asset movements, and the coordination and quality of medical care in an inpatient hospital setting specifically.
BACKGROUND
[0003] Optimal medical care of a patient in a healthcare facility, such as a hospital, necessitates timely evaluation, testing and treatment. This is especially important in situations requiring emergent or urgent care. Currently, through various systems, patients admitted to a medical care facility are evaluated and tested to determine and deliver the best course of treatment. However, due to the number of patients seeking treatment at medical care facilities, especially during periods of high volume, such as flu season or following a disaster or other mass casualty incident, the large patient influx can result in situations where more critical patients are not treated in a timely fashion, either because they have been improperly categorized or the assets for treatment are unavailable because of allocation to less critical patients. Delays and/or mis-categorizations of a patient's status are often due to several factors, which may include a lack of granularity of patient evaluation, a lack of central control that can monitor and control patients and their movement as well as the status and availability of assets within a care facility.
[0004] Accordingly, a need exists for a system and method to evaluate better patients in need of medical care, monitor the availability and scheduling of assets and facilities, enhance communications and perform real-time or near-real-time evaluation of patients' needs and asset availability. Further, a need exists for a system and method that minimizes delay in diagnosis and maximizes efficiency, effectiveness, quality, and satisfaction of care. Such a system should also minimize delay in treatment with a goal of maximizing efficiency, effectiveness, quality, and satisfaction of care.
SUMMARY
[0005] Using novel and elaborate evaluation methodology, prioritization of patient needs for diagnostic testing and treatment procedures is established. Real-time locating system technology allows accurate identification of location and direction of movement of human and nonhuman resources in space and time. Computer assignment of sequence, timing, and location of testing and treatment is performed for the entire cohort of patients and/or disaster victims according to priority. Real-time inputs from examination, testing and treatment venues to a master processing center provide situational awareness information for just-in-time allocation of human and nonhuman assets. Real-time outputs from the master processing center provide direction for just-in-time delivery of human and nonhuman assets to testing and treatment venues. Under continuous human supervision, the automated system of the present disclosure manages multiple patients and/or disaster victims in the most efficient and effective manner to maximize efficiency, effectiveness, quality, and satisfaction of care.
[0006] In an embodiment a system for managing treatment of a plurality of patients in a facility is disclosed. The system comprising: an input device for inputting a status of the plurality of patients; a processor for determining a treatment priority for the plurality of patients based on the input; assigning, via the processor, the treatment priority to each of the plurality of patients; generating, via the processor, a treatment plan for each of the plurality of patients; and a real time locating system for monitoring and tracking equipment and personnel within the facility; allocating, via the real time locating system, equipment and personnel to implement the treatment plan for each of the plurality of patients; and implementing, via the processor, for the plurality of patients, based on the assigned treatment priority and the allocating of equipment and personnel, the treatment plan.
[0007] In an alternative embodiment, the system status is a health status determined by a multilevel assessment. In a further embodiment of the system, the status is updated a plurality of times during the treatment plan. In a further embodiment of the system, the status update is based on a test run on one of the plurality of patients. In a further embodiment of the system, a testing system, is utilized, wherein the testing system maintains the status of the plurality of patients. In still another embodiment, the system comprises a plurality of testing venues to collect the status of the plurality of patients and to provide the collected information to a testing system or the processor. In another embodiment, the allocating of equipment and personnel to implement the treatment plan for each of the plurality of patients is controlled by the processor.
[0008] In an embodiment, a system for treating a plurality of patients comprising a master processing center; an examination venue; and a real time locating system is disclosed. Wherein data from the examination venue, and the real time locating system is provided to the master processing system, and wherein the master processing center determines a treatment plan for the plurality of patients based on the data.
[0009] In an alternative embodiment of the system, the examination venue is selected from at least one of the following; a testing venue, a treatment venue and an evaluation and care venue. In another embodiment, the testing venue is selected from at least one of the following: a general laboratory, a non-invasive cardiology laboratories, a vascular laboratory, an electroencephalography laboratory, a cardiac catheterization laboratory, a diagnostic cardiac electrophysiology laboratory, a gastrointestinal endoscopy laboratory, a pulmonary function laboratory, a bronchoscopy laboratory, a hematology laboratory, an endocrinology laboratory, a peripheral angiography laboratory, a diagnostic radiology laboratory, a magnetic resonance imaging facilities, a computerized tomography facility, a positron emission tomography facility, a radiography facility, and a ultrasound facility.
[0010] In another embodiment, the examination venue is selected from at least one of the following: an examination room, a general or specialized treatment room, a procedure room, a surgical suites, an operating room, a bronchoscopy procedure suite, an endoscopy procedure suite, a cardiac procedure suites, and an interventional radiology suite.
[0011] In an embodiment, a method, implemented on a processor and a communications network, for managing the treatment of a plurality of patients in a facility is described. The method includes inputting to the processor, via an input device, a status of the plurality of patients; determining, via the processor, based on the inputting, a treatment priority for the plurality of patients; assigning the treatment priority to each of the plurality of patients; selecting, via the processor, a treatment plan for each of the plurality of patients; tracking equipment and personnel within the facility via a real time locating system located at the facility; allocating the equipment and personnel to implement the treatment plan.
[0012] In another embodiment, the method comprises testing the patients in an examination venue, and outputting a test result to be used as input for the processor. In another embodiment of the method, the examination venue is selected from at least one of the following; a testing venue, a treatment venue and an evaluation and care venue. In another embodiment the treatment plan is based on the test result. In another embodiment the method comprises a second testing and an update to the treatment plan based on a second test result.
[0013] In still another embodiment the method comprises routing equipment and personnel, via the processor, based on the treatment priority and the treatment plan assigned for each of the plurality of patients. In still another embodiment the routing is at least one of the following: a unidirectional flow routing, a bi-directional routing, and a hub and spoke routing. In still another embodiment the routing of the plurality of patients to the examination venues is based on input from the real time locating system. In still another embodiment the processor determines a shortest distance and a just-in-time transportation route.
[0014] In an embodiment, utilizing state-of-the-art medical knowledge and new and refined systems and methods to estimate degree of injury and/or illness and need for testing and/or treatment, a computer system determines priority order of patients and/or disaster victims for diagnostic and therapeutic procedures. Alternatively and/or additionally, input of information from hospital resources identifies the appropriate sequence, timing, and location of testing and procedures. In another embodiment, real-time-locating-systems technology determines the closest location of available assets i.e., personnel, equipment and supplies and, communicates via electronic messaging, texting, voice command, paging, loudspeaker or any other communications medium, and guides transport and delivery of both patients and assets in the most time-and-distance-efficient manner. In an embodiment, just-in-time delivery minimizes both need for additional inventory of personnel and assets and reduces dwell times during which clinical decompensation may occur. In an embodiment, the primary goal is to manage patients and/or disaster victims in a fashion that maximizes efficiency, effectiveness, quality, and satisfaction of care. Such maximizations results in important and valuable benefit during conditions of routine inpatient clinical volume. Furthermore, such maximizations are of even greater importance and value during periods of high-volume patient surge such as in the aftermath of disasters and other health emergencies.
[0015] Hardware, software, and/or firmware capable of collecting, processing and storing in various readable mediums, information from multiple sources, including but not limited to, sensors information, database information, location service information, tracking service information, patient information, mobile data, RFID information, IR sensors, ultra sound sensors and any other pertinent hospital data inputs may be employed to implement the present disclosure. The information may be processed according to a predetermined and updateable set of rules and instructions. The information may be stored and/or distributed locally or over a wired or wireless network to identified recipients. The information may be processed locally or may be processed from a central location where it may be monitored or unmonitored. The information may be gathered from a single source or from multiple sources.
[0016] In an embodiment, information is collected from and/or conveyed to a Real-Time-Locating-System that may be capable of identifying the location, type, quantity and direction of movement of inanimate objects, such as medical test equipment, gurneys, wheel chairs, beds, carts, or any other mobile equipment, as well as animate objects, such as patients, technicians, clinicians, doctors, nurses, administrators, or any other medical or administrative personnel involved in managing and/or treating patients or customers. Real-time-locating may be performed in multiple dimensions, such as identified object or person, space and time. Receivers may be located throughout entire facilities or portion of a facility, such as throughout clinical and critical portions of a health care institution. In such a way, staff may be assisted in locating both animate and inanimate objects and resources. Similarly, staff may be tracked and located and directed in a timely and efficient manner. Access to such information may be displayed on heads-up displays, tablets, personal computers, PDAs, smartphones, computers, monitors, or any other display interface. These displays may be located at central locations within the institution such as master processing center or control center, administrative offices, nurses stations, admissions area, intensive care, inpatient units, various testing and treatment locations including, among others, laboratories, imaging centers, surgical suites, etc. Similarly, displays may be portable and carried by staff and/or other designated individuals.
[0017] The system and method disclosed herein requires the involvement of appropriately trained staff. Trained staff, with appropriate level of training and experience, will have to participate in the planning, training, and implementation of the disclosed systems and methods because critical medical decisions and treatment plans need to be implemented.
[0018] Similarly flow of patients and equipment must be managed in order to prevent grid lock and to allow for increased capacity at the various locations governed by the system such as imaging centers, treatment rooms, surgical suites, and others. In an embodiment, a unidirectional flow model is utilized to ensure that equipment and patients not end up moving in opposite directions causing flow problems and also to facilitate increase in capacity through forward flow of the patients through the institution allowing new patient entry and processing in the locations vacated by the prior patient. Other flow models, such as bi-directional, hub and spoke, central dispatch, etc. may be utilized as well without departing from the spirit of the invention. In an embodiment, movement is under complete control of the master processing center and may be completely automated. Additionally and/or alternatively, flow may be managed by personnel monitoring and directing the movements of people and other assets within the facility.
[0019] In an embodiment, multilevel and multifactorial triage information is used to evaluate assessment and reassessment of individuals and is provided as inputs into the system to provide up-to-date and real-time characterization of clinical status. This information, as well as other evaluation information may be gathered from patient surveys, interviews, clinical evaluations and assessments and may be input directly into the system utilizing a wired, or wireless data input device, a manual input or any other system that is capable of collecting and inputting data into a system such as the one disclosed.
[0020] The multilevel and multifactorial triage information may use standard triage evaluation techniques or may use enhanced techniques. In an embodiment, enhanced triage evaluation techniques are used. The enhanced techniques require ratings and evaluations of the severity of the illness or injury that are more granular classifications of magnitude and extent of illness, organ system dysfunction, and/or pathophysiologic derangements. In an embodiment, the severity of illness or injury is ranked in a multilevel format by utilizing a detailed assessment of clinical findings. The multilevel format may include as few as three levels of assessment or as many as twenty with a range of 5-10 being preferred. Additionally and/or alternatively, in an embodiment, intensity of illness may be characterized based on a granular delineation of the total amount of disease that needs to be attended to within the stay at the facility and may incorporate not only the severity of illness but also the amount, complexity, and time for services to be rendered to the patient and/or disaster victim. In an embodiment, risk of mortality is used as part of the evaluation. Risk of mortality may include measurements that utilize granular classifications of the likelihood that a patient will succumb to illness or injury during the stay at the facility.
[0021] In an embodiment, urgency of illness information is another system input that may be utilized to evaluate and manage patient flow. Urgency of illness information may be determined utilizing granular classifications of the optimal temporal time windows (immediate or other) for needed interventions to prevent further system failures, illness, disability, or death. In various embodiments, other system information inputs may include optimal and maximum time before treatment. This information may be used as a gauge for the appropriate time window within which treatments need to be rendered, should be rendered, and must be rendered. Thresholds, with alarms and reminders, such as a “not-to-exceed temporal failsafe limit” may be generated and presented to the system operator, treating doctors, or other responsible health-care professionals by the system to ensure that critical windows are not missed or exceeded.
[0022] Other information and inputs, such as prioritization of testing may be utilized to describe the hierarchy of need for specific testing for any given individual as well as relative needs for testing among individuals competing for available testing slots. This information may be generated by the system based on simple criteria such as who is most critical, or complex algorithms that determine patient criticality. Additionally, and/or alternatively, the system may rely on user input or a combination of user inputs, and system determinations to determine and implement prioritization decisions.
[0023] Similarly, prioritization of treatment may be based on a hierarchy of needs for specific treatments for a given individual as well as the relative needs for treatment among individuals competing for the same treatment slots. This hierarchy and its implementation may be generated by the system based on simple criteria such as who is in the most critical condition or it may be based on complex algorithms that determine patient criticality. Additionally, and or alternatively, the system may rely on user input or a combination of user inputs, and system determinations to determine and implement prioritization decisions.
[0024] In an embodiment, the system and method comprise a master processing center that acts as a central command, control and communication node and accepts inputs from various hospital-based resources, processes data, and provides direction through outputs to hospital-based resources. The master processing center may be co-located with the facility it serves. Additionally, and/or alternatively, it may be located remotely. In an embodiment, the master processing center or command center may serve more than one facility and may serve a network of related facilities. Facilities may be related geographically, by specialty, by owner or by any other affiliation or characteristic.
[0025] The master processing center may comprise a single computer or a network of computers that serve a portion or the entire system. The processing center may comprise a single display for indicating the status of a facility and the flow and control of the facility or it may comprise a number of displays for indicating various components or aspects or facilities within a larger facility or network. The master processing center may be manned or unmanned and may be connected to the facility it controls via a large scale network such as the internet or any other wired or wireless network. In an embodiment, the master processing center or control center is capable of receiving real-time input from hospital-based resources. In an embodiment, such resources may describe and/or summarize the information from hospital-based resources and assets to the master processing center. This information includes, but is not limited to sensor information, database information, location service information, tracking service information, patient information, mobile data, RFID information, IR sensors, ultra sound sensors patient data information, test result information, treatment result information, and any other pertinent hospital data inputs.
[0026] In an embodiment, data is processed in real time as well as being stored for later evaluation and simulations. In an embodiment, the real-time processing of data from the various hospital-based resources is utilized to analyze and control efficient and effective clinical and resource management by the control center or master processing center. In an embodiment, real-time output from hospital-based resources, such as sensor information, database information, location service information, tracking service information, patient information, mobile data, RFID information, IR sensors, ultra sound sensors patient data information, test result information, treatment result information, and any other pertinent hospital data inputs may be utilized for the efficient and effective communication of information from the control center to hospital-based resources, including, but not limited to, people and other assets. In an embodiment, the master processing center may utilize system algorithms fed by input data to determine the best treatment options as well as patient and asset flow. In an embodiment, a shortest time-distance algorithm may be utilized, based on the facility and its assets, to predict, model and describe the most efficient way to transport and move patients through the institution from a time and motion perspective. These determinations may include which patients to route to which testing area, what is the shortest route available, which lab has the most available resources, which care giver is available to transport the patient or the equipment, etc.
[0027] In an embodiment, just-in-time delivery is utilized in an effort to maximize efficiency. Just-in-time denotes the allocation of human and/or nonhuman resources and/or assets at, substantially at, or very near in time and location to where they are needed within the institution. Such planning and implementation minimizes wait times and the need for additional inventory and maximizes resource allocation to ensure that personnel and equipment is not under-utilized.
[0028] In an embodiment, the system may comprise automated processing of animate and inanimate assets to maximize patient care while minimizing need for human and nonhuman resources. The system may operate in an automated manner and may be fully automated or operate under direct human supervision. In an embodiment, the system requires human intervention before any patient critical decisions are reached. Non-critical decisions may be system driven, such as for example selecting which test venue and equipment to use for a particular patient. In an embodiment of the disclosed system, continuous performance improvement is driven by several factors including, but not limited to, the incorporation of best-practices medical evidence as it becomes available and by after-action follow-up of feedback from evaluation of both process and outcome metrics, by improvements in system algorithms, improvements in tracking capabilities, and other hardware and/or software improvements.
[0029] In an embodiment, the method and systems metrics related to success or failure may be quantified and/or measured by the central processing center or by a separate application. Such metrics may include the overall length of stay associated with a patient, the cost associated with the treatment and care of a patient, morbidity and mortality measures and statistics, functional status (i.e., the ability to perform specified activities), patient readmission rates, and patient satisfaction with care given.
[0030] In an embodiment, a patient or disaster victim or a plurality of patients or victims may present to a health care institution such as a hospital or urgent care facility. If special handling or decontamination is required, for example, as a result of a chemical spill or attack, the patients may undergo decontamination. Next, the master processing or command center determines the current facility capacity (overall and by specific unit) by determining available resources. Facility capacity should be known before patients or victims arrive and such information can be conveyed from the master processing center to emergency personnel to direct and/or reroute as necessary to other facilities.
[0031] As patients arrive at the facility, they may be assigned to one of a plurality of evaluation and care venues (“ECV1”) located throughout the facility. Patient admission information may be collected and may include demographics, insurance, next-of-kin, etc. and can be obtained from patients, if possible. As much information as possible is obtained from patients, patient contacts, and response personnel. The information is input into the system and stored in a patient database. The system may assign a specific patient ID number or other designation for each patient which then follows that patient throughout the facility. Patient ID information may be conveyed in many ways including but not limited to bar codes, QR codes, alphanumeric characters, ID bracelets, tags, RFID's or any other means of uniquely identifying a patient.
[0032] The patient then may undergo a multimodal assessment (“MA”) which may include a detailed evaluation of the severity, intensity, mortality risk, urgency, appropriate time to treatment, and a special needs assessment. All of this information is entered into the system via any known input device such as a tablet, PDA, direct input, voice recognition, etc and used by the system to evaluate and prioritize patients care. The evaluation can be done at the central control center by the processing system with oversight by trained personnel. The system may make a determination based on data input as to patient priority and applicable testing and/or treatment. The determination may be based on assigning a numerical score to each input and setting threshold levels or may be based on weighted averages, or any other method of ranking.
[0033] Based on the determination, an assignment of prioritizations is computed for testing to be conducted and/or treatment to be performed. Also based on the above, a re-evaluation of which treatment and/or evaluation venue, as appropriate, should be used and a clinical environment or need for different environment is determined. The master processing center continuously monitors the respective capacity of each venue and performs an assessment for the availability of each next venue (ECV2) if necessary.
[0034] In an embodiment, the master processing center determines equipment prioritization at a facility and coordinates a patient priority hierarchy based on available resources evaluating facilities and patient priority. In an embodiment, a testing prioritization module at the master processing center identifies patient priority hierarchy and schedules testing. In an embodiment, the system determines the necessity of sequential versus non-sequential testing based in part on the patient and/or the availability of resources. If it is determined that testing of a particular patient is warranted, then notifications may be autonomously transmitted to both transport personnel (TRP), equipment personnel (EP) and testing facilities, regarding the need for and location of transportation modality, equipment, and just-in-time delivery of patients and/or assets. Further, testing personnel may be notified of the imminent arrival of a patient so as to prepare in advance of their arrival in order to facilitate and expedited the required testing. The respective testing venues convey real-time testing availability input from testing venues (TeV1, TeV2, etc.) to the master processing center to confirm availability. Based on this information, the master processing center can regulate and manage just-in-time delivery of human and/or nonhuman assets to appropriate available testing venues. In this way, patient waiting is minimized and equipment usage is maximized. Further, if facilities become available, the master processing center may update and reprioritize and/or redirect patients, transport personnel and/or equipment in a real-time manner. The process continues for all required diagnostic tests (DT1, DT2, etc.) as a patient works his/her way through the facility.
[0035] In an embodiment, venue capacity assessment may be performed in near real time or real time for all treatment venues (TrV1, TrV2, etc.) and data transmitted to the master processing center for updating of system parameters. Multilevel, multistage triage assessments continue to be performed at appropriate intervals and at multiple steps along the process. As new information is received, it may be input into the master processing center with a resulting recalibration of priority determinations.
[0036] In an embodiment, as the master processing center receives the information, it may assign just-in-time delivery of human and/or nonhuman assets to appropriate available treatment venues. Just-in-time delivery and just-in-time transportation is possible based on real-time tracking and real-time location of assets and personnel within the treatment facility. If assets are free, they may be utilized on an as-needed basis in a more efficient manner rather than standing idle because of scheduled time allocation or testing of a less critical patient. For example, a patient that needs an MRI can be transported to an available MRI machine just as it becomes available and precious treatment time is not wasted waiting for a machine to open up. In this manner, as assets and patients are treated through the facility, just-in-time delivery and just-in-time allocation ensure the shortest routes and the quickest most efficient use of resources.
[0037] The process continues for all required treatment procedures (TP1, TP2, etc.) as determined by the master processing center and based on re-evaluation of patients and venue as appropriate clinical environment or need for different environment arises.
[0038] In an embodiment, the master processing center continues to coordinate process of care through situational awareness from multi-focal inputs and through fine-tuning of patient status in priority hierarchy through multilevel and multistage triage, by coordination of care among all patients and/or disaster victims according to assignment of priority for testing and treatment, and by outputs to the institutional delivery system for just-in-time actions. The master processing center assigns final disposition for each patient and/or disaster victim. In an embodiment, the entire system is automated, but is supervised by trained medical personnel who may override or alter the master processing center decisions as medically necessary.
[0039] In an embodiment, the system further allows for after-action follow-up of all process and outcomes metrics to provide continuous feedback and ongoing system performance improvement via enhanced algorithms and changes to triage and patient treatment protocols.
[0040] In an embodiment, the Multimodal Assessment (“MA”) used in Multilevel and Multifactorial Triage may be used to determine patient priority assignment
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 depicts a schematic diagram of a patient care system in accordance with an embodiment of the present disclosure;
[0042] FIG. 2 depicts a diagram of the central coordination of inputs and outputs of a patient care system in accordance with an embodiment of the present disclosure;
[0043] FIGS. 3 a - b depict a Multilevel and Multifactorial Triage and Multimodal Assessment utilized in an embodiment of the present disclosure;
[0044] FIG. 4 depicts a flow diagram of the Triage and Multimodal Assessment utilized in an embodiment of the present disclosure;
[0045] FIG. 5 depicts the outputs from a master processing center utilizing in accordance with an embodiment of the present disclosure;
[0046] FIG. 6 depicts a general purpose computer that may be utilized in an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0047] The present disclosure is directed to systems and methods that rely on medical-evidence-based, real-time-locating-system-enabled, and computer-assisted inputs, processing and outputs to optimize the provisioning of medical care in an inpatient hospital setting. In an embodiment, the systems and methods are based on novel and granular assessments in real-time of the status of various elements of the inpatient care system, effective communication between numerous system nodes, and seamless coordination of multiple parallel processes.
[0048] FIG. 1 depicts system 10 comprised of master processing center (MPC) 100 , user devices 110 , equipment and locater sensors 115 , real-time locating system 120 , testing system 130 , network 140 , patient records or database 150 , and transceivers 160 . In an embodiment, system 10 enables the tracking and treatment of a patient 15 within a care facility. Patient 15 may be outfitted with user device such as handheld device 110 a or a patient tracker 110 b , transceivers 160 can locate and track patient 15 anywhere within the facility. The location of patient 15 and any associated equipment capable of being tracked, i.e., gurney, wheelchair, etc., may be conveyed to real-time locating system 120 . Master processing center 100 records patient information and communicates the information via network 140 to be stored in a patient database 150 . Triage and patient evaluation information may be entered via any user device 110 by medical personnel and communicated over network 140 to MPC 100 . In an embodiment, the MPC makes a determination on the testing required for patient 15 and conveys the information to real time location system (RTLS) 120 to schedule and route the proper transport equipment and personnel to transport patient 15 to the required testing venue for just-in-time testing. Once testing is complete, the information may be processed by testing system 130 and stored in the associated patient record in database 150 . The MPC may then reevaluate the protocol required to treat patient 15 and reallocate the required testing and facilities if necessary.
[0049] FIG. 2 depicts the central coordination of inputs and outputs of the MPC 100 with the various venues and components of a system in accordance with an embodiment. Master processing center 100 receives informational inputs from multimodal assessments 210 performed by medical personnel, locations and availability of transport personnel 220 , locations and availability of equipment and equipment personnel 230 , evaluation and care venues 240 , treatment venues 250 , and testing venues 260 .
[0050] Multimodal assessments 210 may be performed by medical personnel and may comprise patient evaluations based on severity, intensity, mortality risk, urgency and timing. The evaluation may be comprehensive and involve multi-input evaluations for each category or may be simpler such as a numerical rating scale. The multipoint evaluation information may then be entered into the system 10 via a user device 110 and conveyed to MPC 100 The multimodal assessment may be initially performed upon admittance of patient 15 but may also be performed after treatment or intermediate treatment of patient 15 to evaluate progress and next steps.
[0051] In an embodiment, inputs regarding transport personnel 220 may comprise locations and availability of transport personnel to MPC 100 . This information may be conveyed as part of a real-time tracking system which utilizes optical recognition, RFID sensors, IR sensors, ultra sound sensors or any other means of locating and monitoring personnel within the facility. Information on personnel may be conveyed via user devices 110 which may be a personal sensor or hand held device. The information may be conveyed to MPC 100 and real-time locating system 120 via transceivers 160 and network 140 . Transport personnel can be quickly and efficiently dispatched to the proper location to receive and transport patient 15 to a testing or treatment venue with minimal waiting and down time between patient interactions.
[0052] Similarly, equipment personnel 230 can be monitored and dispatched via MPC 100 and real time locating system 120 via transceivers 160 and network 140 . For example, a single x-ray technician in testing venue (1) who is not currently working with a patient can be sent to testing venue (2) with different x-ray equipment to perform a test rather than maintaining two technicians with one waiting idle.
[0053] Evaluation and care venues 240 may be utilized to initially or subsequently evaluate patients throughout the process. Information, such as patient assessment information may be collected and conveyed back to the MPC from each evaluation venue where the patient is evaluated and/or treated. Similarly, treatment venues 250 may be examination rooms, general or specialized treatment rooms, procedure rooms, surgical suites, operating rooms, bronchoscopy procedure suites, endoscopy procedure suites, cardiac procedure suites, interventional radiology suites, or any other types of treatment facilities the patient traverses. The information on treatment and patient status is conveyed to MPC 100 for continuous patient reevaluation and scheduling.
[0054] Testing venues 260 may comprise general laboratories, electrocardiography, stress testing, and other non-invasive cardiology laboratories, vascular laboratories, electroencephalography laboratories, cardiac catheterization laboratories, diagnostic cardiac electrophysiology laboratories, gastrointestinal endoscopy laboratories, pulmonary function laboratories, bronchoscopy laboratories, hematology laboratories, endocrinology laboratories, peripheral angiography laboratories, diagnostic radiology laboratories, magnetic resonance imaging facilities, computerized tomography facilities, positron emission tomography facilities, radiography facilities, ultrasound facilities, or any other types of testing facilities the patient traverses. The testing labs 260 may collect labs and data on patient 15 and process and convey that information to MPC 100 , and testing system 130 . The information may be processed and associated with patient records in database 150 and used to reevaluate the treatment for patient 15 by MPC 100 .
[0055] FIG. 3 a depicts the multilevel and multifactorial assessment and inputs that may be conveyed to MPC 100 in an embodiment of the present disclosure. As can be seen, a plurality of patients 300 - 1 to 300 - n may be evaluated using a multimodal evaluation 310 and assigned priority scores 320 for input top MPC 100 . In an embodiment, inputs from testing venues 260 are also provided to MPC 100 to aid in the evaluation and prioritization of patient treatments and patient control.
[0056] FIG. 3 b depicts the repetitive and repeated inputs and evaluations performed on patients as they move through the system. As seen in FIG. 3 b , each time patient inputs, whether in the form of direct inputs or inputs from testing or evaluation, are received and updated, evaluation and prioritization may take place within the MPC and/or by other evaluators who may reprioritizes patients 1 - n for follow up and/or additional testing.
[0057] FIG. 4 depicts flow of a patient through a facility utilizing the disclosed system. A patient is evaluated at the first evaluation and care venue (ECV). Initial evaluation and assessment includes care venue capacity evaluation as well as capability evaluation. Also during the initial evaluation, it is determined if there is sufficient testing and/or treatment capacity and equipment and personnel available to properly treat the incoming patient. If it is determined that there is sufficient capacity, the patient may be advanced to ECV 2 for further evaluation and or treatment. Diagnostic tests will be performed (DT1/DT2) and the patients reassessed and advanced to the next ECV center for additional evaluation. As will be understood by those skilled in the art, at each ECV, the master processing center determines treatment options and availability of personnel and equipment, as well as decision-making on just-in-time delivery and testing options to ensure coordinated treatment and movement throughout the facility.
[0058] The following abbreviations may be used with respect to FIG. 4 and/or other figures in the application. MPC—Master Processing Center; MA—Multimodal Assessment; ECV—Evaluation and Care Venues; TeV—Testing Venues; TrV—Treatment Venues; TRP—Transport Personnel (patient transport services); EP—Equipment Personnel (equipment retrieval and transport services); PT—Patient (PT1 is patient #1, etc.); RTLS—Real-Time-Locating-System; DT—Diagnostic Tests (performed at Testing Venues based upon best medical practices); and TP—Treatment Procedures (performed at Treatment Venues based upon best medical practices).
[0059] FIG. 5 depicts the outputs from the MPC utilizing shortest time/distance and just-in-time delivery and return options. As seen, the MPC 100 communicates computer-directed RTLS-guided outputs to the closest available transporter 510 or transporter dispatch. The transporter may be contacted via a handheld device 110 such as a pager, smart phone, display screen, or PDA, and directed to pick up transport equipment and/or medical equipment 520 . Next, the transporter may be directed to transport the highest priority patient 530 via the shortest and quickest distance to the testing venue or treatment venue 540 . Throughout the process, MPC 100 receives inputs from the transport operators regarding location and availability; from the equipment, testing, and treatment facilities regarding availability and operability; and from the various evaluation centers regarding patient evaluation to determine priority.
[0060] As will be understood by those skilled in the art, the systems and methods disclosed herein may be performed on a single computer or server over a single network or may be performed on a plurality of computers communicating via local or wide area networks. Communications may be via wired or wireless equipment and inputs and outputs may be received or transmitted via various wired or wireless formats without departing from the spirit of the invention.
[0061] FIG. 6 depicts a general computer architecture on which the present teaching can be implemented and has a functional block diagram illustration of a computer hardware platform that includes user interface elements. The computer may be a general-purpose computer or a special purpose computer. This computer 600 can be used to implement any steps of the method as described herein. It may be used to evaluate and prioritize patients and diagnostic and treatment plans, order tests, route personnel and equipment, and any other step or process that may be automated. Different steps can all be implemented on one or more computers such as computer 600 , via its hardware, software program, firmware, or a combination thereof. Although only one such computer is shown, for convenience, the methods disclosed herein may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load.
[0062] The computer 600 , for example, includes COM ports 602 connected to and from a network connected thereto to facilitate data communications. The computer 600 also includes a central processing unit (CPU) 604 , in the form of one or more processors, for executing program instructions. The exemplary computer platform includes an internal communication bus 606 , program storage and data storage of different forms, e.g., disk 608 , read only memory (ROM) 610 , or random access memory (RAM) 612 , for various data files to be processed and/or communicated by the computer, as well as possibly program instructions to be executed by the CPU. The computer 600 also includes an I/O component 614 , supporting input/output flows between the computer and other components therein such as user interface elements 616 . The computer 600 may also receive programming and data via network communications.
[0063] Hence, aspects of the method disclosed herein, as outlined above, may be embodied in programming. All or portions of the software may at times be communicated through a network such as the Internet or various other telecommunication networks.
[0064] Those skilled in the art will recognize that the present teachings are amenable to a variety of modifications and/or enhancements. For example, although the implementation of various steps may be performed manually, they may also be implemented as part of an automated process and carried out by a computer or other automation operation.
[0065] While the foregoing has described what are considered to be embodiments and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings. | The present methods and systems are directed to managing and optimizing patient care and experience in an inpatient hospital setting by coordinating the evaluation of patients, the managing and optimizing of patient and asset movements, and the quality of medical care especially during the period of a mass casualty event. | 6 |
CROSS RELATED APPLICATIONS
This application is a divisional of application Ser. No. 11/357,027 filed Feb. 21, 2006 now U.S. Pat. No. 7,472,855 and claims the benefit of provisional application Ser. No. 60/743,108, filed Jan. 9, 2006, both of which are incorporated by reference in their entirety.
This invention relates generally to refiners for removing contaminants from fiber materials, such as recycled or recovered paper and packaging materials. In particular, the present invention relates to refiner stator plates and especially to the outer row of teeth on the stator plates.
Refiner plates are used for imparting mechanical work on fibrous material. Refiner plates having teeth (in contrast to plates having bars) are typically used in refiners which serve to deflake, disperge or mix fibrous materials with or without addition of chemicals. The refiner plates disclosed herein are generally applicable to all toothed plates for dispergers specifically and refiners in general.
Disperging is primarily used in de-inking systems to recover used paper and board for reuse as raw material for producing new paper or board. Disperging is used to detach ink from fiber, disperse and reduce ink and dirt particles to a favorable size for downstream removal, and reduce particles to sizes below visible detection. The disperger is also used to break down stickies, coating particles and wax (collectively referred to as “particles”) that are often in the fibrous material fed to refiner. The particles are removed from the fibers by the disperger become entrained in a suspension of fibrous material and liquid flowing through the refiner, and are removed from the suspension as the particles float or are washed out of the suspension. In addition, the disperger may be used to mechanically treat fibers to retain or improve fiber strength and mix bleaching chemicals with fibrous pulp.
There are typically two types of mechanical dispergers used on recycled fibrous material: kneeders and rotating discs. This disclosure focuses on disc-typed disperger plates that have toothed refiner stator plates. Disc-type dispergers are similar to pulp and chip refiners. A refiner disc typically has mounted thereon an annular plate or an array of plate segments arranged as a circular disc. In a disc-type disperger, pulp is fed to the center of the refiner using a feed screw and moves peripherally through the disperging zone, which is a gap between the rotating (rotor) disk and stationary (stator) disk, and the pulp is ejected from the disperging zone at the periphery of the discs.
The general configuration of a disc-type disperger is two circular discs facing each other with one disc (rotor) being rotated at speeds usually up to 1800 ppm, and potentially higher speeds. The other disc is stationary (stator). Alternatively, both discs may rotate in opposite directions.
On the face of each disc is mounted a plate having teeth (also referred to as pyramids) mounted in tangential rows. A plate may be a single annular plate or an annular array of plate segments. Each row of teeth is typically at a common radius from the center of the disc. The rows of rotor and stator teeth interleave when the rotor and stator discs are opposite each other in the refiner or disperger. The rows of rotor and stator teeth intersect a plane in the disperging zone that is between the discs. Channels are formed between the interleaved rows of teeth. The channels define the disperging zone between the discs.
The fibrous pulp flows alternatively between rotor and stator teeth as the pulp moves through successive rows of rotor and stator teeth. The pulp moves from the center inlet of the disc to a peripheral outlet at the outer circumference of the discs. As fibers pass from rotor teeth to stator teeth and vice-versa, the fibers are impacted as the rows of rotor teeth rotate between rows of stator teeth. The clearance between rotor and stator teeth is typically on the order of 1 to 12 mm (millimeters). The fibers are not cut by the impacts of the teeth, but are severely and alternately flexed. The impacts received by the fiber break the ink and toner particles off of the fiber and into smaller particles, and break the stickie particles off of the fibers.
Two types of plates are commonly used in disc-type dispergers: (1) a pyramidal design (also referred to as a tooth design) having an intermeshing toothed pattern, and (2) a refiner bar design. A novel pyramidal tooth design has been developed for a refiner plate and is disclosed herein.
FIGS. 1 a , 1 b and 1 c show an exemplary pyramidal plate segment having a conventional tooth pattern. An enhanced exemplary pyramidal toothed plate segment is shown in commonly-owned U.S. Patent Application Publication No. 2005/0194482, entitled “Grooved Pyramid Disperger Plate.” For pyramidal plates, fiber stock is forced radially through small channels created between the teeth on opposite plates, as shown in FIG. 1 c . Pulp fibers experience high shear, e.g., impacts, in their passage through dispergers caused by intense fiber-to-fiber and fiber-to-plate friction.
With reference to FIGS. 1 a , 1 b and 1 c , the refiner or disperger 10 comprises disperger plates 14 , 15 which are each securable to the face of one of the opposing disperger discs 12 , 13 . The discs 12 , 13 , only portions of which are shown in FIG. 1 c , each have a center axis 19 about which they rotate, radii 32 and substantially circular peripheries.
A plate may or may not be segmented. A segmented plate is an annular array of plate segments typically mounted on a disperger disc. A non-segmented plate is a one-piece annular plate attached to a disperger disc. Plate segment 14 is for the rotor disc 12 and plate segment 15 is for the stator disc 13 . The rotor plate segments 14 are attached to the face of rotor disc 12 in an annular array to form a plate. The segments may be fastened to the disc by any convenient or conventional manner, such as by bolts (not shown) passing through bores 17 . The disperger plate segments 14 , 15 are arranged side-by-side to form plates attached to the face of the each disc 12 , 13 .
Each disperger plate segment 14 , 15 has an inner edge 22 towards the center 19 of its attached disc and an outer edge 24 near the periphery of its disc. Each plate segment 14 , 15 has, on its substrate face concentric rows 26 of pyramids or teeth 28 . The rotation of the rotor disc 12 and its plate segments 14 apply a centrifugal force to the refined material, e.g., fibers, that cause the material to move radially outward from the inner edge 22 to the outer edge 24 of the plates. The refined material predominantly move through the disperging zone channels 30 formed between adjacent teeth 28 of the opposing plate segments 14 , 15 . The refined material flows radially out from the disperging zone into a casing 31 of the refiner 10 .
The concentric rows 26 are each at a common radial distance (see radii 32 ) from the disc center 19 and arranged to intermesh so as to allow the rotor and stator teeth 28 to intersect the plane between the discs. Fiber passing from the center of the stator to the periphery of the discs receive impacts as the rotor teeth 28 pass close to the stator teeth 28 . The channel clearance between the rotor teeth 28 and the stator teeth 28 is on the order of 1 to 12 mm so that the fibers are not cut or pinched, but are severely and alternately flexed as they pass in the channels between the teeth on the rotor disc 12 and the teeth on the stator disc 13 . Flexing the fiber breaks the ink and toner particles on the fibers into smaller particles and breaks off the stickie particles on the fibers.
FIGS. 2 a and 2 b show a top view and a side cross-sectional view, respectively, of a standard tooth geometry 34 used in the outer row of a stator plate. The tooth 34 has a pyramidal design consisting of strait sides 36 that taper to the top 38 of the tooth. The sides of the standard tooth 28 are each substantially parallel to a radial 32 of the plate.
A primary role of the disperger plate is to transfer energy pulses (impacts) to the fibers during their passage through the channels between the discs. The widely accepted toothed plate typically includes the square pyramidal tooth geometry with variations in edge length and tooth placement to achieve desired results.
Refiner material passing between the discs can be accelerated to a high velocity due to the centrifugal forces imparted by the rotor disc. Some of the refiner material exits the discs 12 , 13 at a high velocity and are flung radially against the refiner casing 31 . The high velocity impacts of refiner material against the casing have caused abrasive wear and damaging cavitation to the casing. There is a long felt need for a means to reduce the wear and damage on refiner and disperger casing due and, particularly, to reduce the wear and damage caused by refiner material impacts against the casing.
BRIEF DESCRIPTION
This disclosure proposes a modified stator tooth geometry, such as an angled tooth, for the outermost row of a stator plate. The modified tooth geometry is intended to achieve a longer life of the casing by reducing impacts against the casing due to high velocity particles exiting the plates of the refiner.
A refiner stator plate has been developed having a plurality of concentric rows of teeth wherein an outer row is at or near an outer periphery of the plate segment. The teeth in the outer row include leading sidewalls, wherein the sidewalls are at an angle to radii of the plate segment. plate is preferably a stator plate for a disperger. The angle of the sidewalls of the outer row may be opposite to a direction of rotation of a rotor plate. The angle of the sidewalls is in a range of 10 to 60 degrees with respect to a radial, and preferably in a range of 15 to 45 degrees. The sidewalls may be planar, V-shaped having a straight radial inward surface and a slanted radial outward surface, or curved along their lengths.
Further, the angled sidewall of the teeth of the outer stator row are arranged to project normal (in other words, tangential) to a radial a distance at least equal to a gap between adjacent teeth of the outer stator row. In addition, the angled sidewall may include an angled wall portion and a radially aligned wall portion. Further, the outer row of teeth may have substantially perpendicular rear walls.
A refiner or disperger has been developed comprising a rotor disc including a rotor plate including concentric rows of rotor teeth; a stator disc arranged opposite to the rotor disc in a disperger, wherein the stator disc includes a stator plate, wherein the stator plate includes concentric rows of stator teeth intermeshing with the rotor teeth and an outer row of the stator teeth include sidewalls angled in opposition to the rotation of the rotor disc so as to deflect particles flowing between the teeth of the outer row.
A method of refining pulp material between opposing discs in a refiner has been developed, the method comprising: feeding the pulp material to an inlet of at least one of the discs; rotating one disc with respect to the other disc while pulp material is moved between the discs due to centrifugal force; refining the pulp material by subjecting the material to impacts caused by rows of teeth on the rotating disc intermeshing with rows of teeth on the other disc; deflecting the pulp material as the material flows through an outer row of teeth on the other disc, wherein the outer row of discs comprise teeth having a sidewall angled to deflect pulp material moving radially between the teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1( a ) and 1 ( b ) are a front view and cross-sectional sectional side view, respectively, of a toothed stator plate segment conventionally used in disc-type dispergers.
FIG. 1( c ) is a side cross-sectional view of a stator and rotor disperger plates and discs with channels therebetween.
FIGS. 2 a and 2 b are a top down view and a side perspective view, respectively, of a conventional tooth geometry for the outer teeth row of stator disperger plate.
FIGS. 3 a and 3 b are a top down view and a side perspective view, respectively, of an angled tooth for the outer row of a stator disperger plate, wherein the sidewalls of the tooth are each angled with respect to a radius of the disc.
FIGS. 4 a and 4 b are a front plan view and a side cross-sectional view, respectively, of a disperging stator plate segment utilizing the angled tooth geometry for the outer row of teeth.
FIG. 5 is a top down perspective view of an alternative angled tooth geometry for an outer row of a stator plate.
FIG. 6 is a top down perspective view of another alternative angled tooth geometry for an outer row of a stator plate.
DETAILED DESCRIPTION
A novel arrangement of teeth for a toothed refiner stator plate has been developed in which the outer peripheral row of teeth are angled to deflect refiner material, e.g., pulp, moving through the disperging zone. The deflection reduces the velocity of refiner material particles that would otherwise move along a radial line at a high speed from between the refiner discs and into the casing. This novel arrangement of outer row stator teeth may be applied to any type of toothed refiner plate and especially disc-type dispergers.
The outer row of stator teeth are angled to control the feed of the pulp exiting the disperging zone and out from between the discs. In particular, the leading sidewall of the stator teeth in the outer row of teeth are angled to slant the teeth so as to deflect particles moving along a substantially radial line between the outer row of stator teeth. Deflecting refiner material reduces the velocity of the exiting refiner material and minimizes the impact of the refiner material on the walls of the refiner casing.
The angled outer row of stator teeth prevent pulp from following a direct radial path from the last row of stator teeth and into the casing where high velocity pulp can damage the casing wall. The angle of the outer row of stator teeth and the length of the angled portion of these teeth are selected such that the refiner material, e.g. pulp, passing through the disperging zone is deflected by the angled sidewalls of the last row of stator teeth. The outer row teeth are slanted, at least along a portion of the teeth, such that the slanted portion of the teeth project tangentially a distance at least equal to the gap between adjacent teeth. The deflection prevents refiner materials from being flung at high velocity radially from the discs and into the refiner casing.
FIGS. 3 a and 3 b show a top view and a side perspective view, respectively, of an angled stator tooth 40 where the sides of the tooth are angled with respect to a radial 32 of the disc center. The stator tooth 40 is preferably positioned at the outer row of the stator plate. One or both of the sidewalls 42 of the tooth 40 form an angle 44 with respect to a radius 18 of the disc. Further, the sidewalls 42 taper towards the top 46 of the tooth. The base 48 of the tooth is at the substrate of the plate. The front wall 50 of the tooth faces radially inward and the rear wall 52 of the tooth faces radially outward. The front and rear faces may each be aligned substantially tangent to the row and plate. The front wall may slope towards the top of the tooth. The rear wall, preferably, is generally perpendicular to the substrate of the plate.
The slant (angle 44 ) of the outer row of stator teeth deflects refiner material as it passes through the outer row of stator teeth. The deflection is intended to slow the refiner material, pulp and entrained particles, as it leaves the channel between the disc and before the refiner material enters the casing of the disperger or refiner. By reducing the velocity of the refiner material, less damage is done to the casing as a result of refiner material hitting the casing.
FIGS. 4 a and 4 b are a font view and a side-cross-sectional view, respectively, of an exemplary stator plate 54 that is mounted on a disperger disc. The stator plate is opposite a rotor plate and a disperging zone is formed by the channels between the two opposing plates. The rotational direction (arrow 55 ) for the rotor plate is counter-clockwise (which appears clockwise from the view point of FIG. 4 a which shows a stator plate segment).
The stator disperger plate segment 54 includes rows 56 , 58 , 60 , 62 , 64 and 66 of teeth 68 . The inner teeth rows ( 56 , 58 , 60 , 62 and 64 ) may have a pyramidal shape such as shown in FIGS. 2 a and 2 b . The sidewalls of the inner rows of teeth may be aligned with a radius of the disc, or may be slanted with respect to the radius. Similarly, the rotor plate (not shown) may have rows of teeth that interleave with the row of stator teeth, when the plates are arranged in the refiner.
The outer row 66 of stator teeth 40 have sidewall angles that are angled either in the same direction as or opposite to the rotation 55 of the rotor. It should make no difference to casing protection whether the last row of stator teeth are slanted towards or against the rotational direction. Slanting the outer row of stator teeth in a direction opposite to direction places the teeth in a “holdback” position, and slanting the teeth in the same direction of rotation is a “feeding position.” Further, the sidewall angle of the teeth 40 may be between 10° to 60°, and preferably in a range of 15° to 45°, with respect to a radial of the plate and disc. The angle ( 44 in FIG. 3 a ) of the sidewalls of the last row 66 of stator teeth 40 is selected to deflect refiner material moving through the row and to allow the flow without too much obstruction.
The rear wall ( 52 in FIG. 3 b ) extends to the outer periphery 24 of the stator plate. The sidewall of the teeth 40 are extended as a result of the rear wall being substantially normal to the substrate 72 of the stator plate 54 . Extending the sidewalls provides additional sidewall area to deflect the refiner material. The length and angle of the sidewall should be sufficient such that a fast moving particle cannot move along a radial through the gap between the teeth without hitting the sidewall of a tooth. Accordingly, the projection of the width of the sidewall along a tangential direction should be at least as wide as the gap between the teeth of the last stator row.
The sidewalls on both sides of the outer row stator teeth 40 preferably form the same angles with respect to radii. The leading sidewall (facing the rotational direction of the rotor) deflects pulp. The trailing sidewall is on the opposite side of the tooth and faces a leading sidewall of an adjacent stator tooth. Maintaining the same angles on both sides of the teeth ensures that the gap between teeth remains constant along the length of the teeth. Accordingly, the leading and trailing sidewalls of the stator tooth are preferably symmetrical.
FIG. 5 shows a top down perspective view of an alterative tooth 70 for the last row of the stator plate. The alterative tooth has a double angled sidewall 72 that includes a radial sidewall section 78 and an angled wall section 80 . The radial sidewall section 78 is substantially aligned with a radial of the stator plate. The angled wall section 80 is offset from a radial by an angle 10 to 60 degrees and preferably between 15 to 45 degrees. The length and angle of the angled sidewall 80 are arranged to deflect all refined material moving along a radial and between teeth in the last row of stator teeth. In particular, the tangential projection 81 of the length of the sidewall 80 spans the width of the gap between adjacent teeth in the last stator row.
FIG. 6 shows a top down perspective view of another alterative tooth 84 for the last row of the stator plate. The alterative tooth has a curved sidewall 86 that starts as a substantially radial sidewall section 88 and progressively turns to an angled wall section 90 . The inward radial sidewall section 88 is substantially aligned with a radial of the stator plate. The length and curvature of sidewall 86 are arranged to deflect all refined material moving along a radial and between teeth in the last row of stator teeth. In particular, the tangential projection of the length of the sidewall 86 should span the width of the gap between adjacent teeth in the last stator row.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A refiner including: a rotor disc including a rotor plate including concentric rows of rotor teeth; a stator disc arranged opposite to the rotor disc, wherein the stator disc includes a stator plate; the stator plate includes concentric rows of stator teeth intermeshing with the rows of rotor teeth, and the rows of stator teeth include an outer row of stator teeth having leading sidewalls angled to deflect particles flowing between the teeth of the outer row. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to European patent application serial no. EP 11 400027.6 filed Apr. 11, 2011, the disclosure of which is incorporated in its entirety by reference herein.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention is related to a helicopter with a cycloidal rotor system with blades disposed at a tail boom with the features of the preamble of the claim 1 .
(2) Background Art
An empennage of a classical helicopter configuration features 1. a fixed horizontal stabilizer, 2. a fixed vertical fin and 3. a tail rotor.
1. The horizontal stabilizer provides static pitch attitude stability, by generating a negative lift and provides via the tail boom lever a velocity dependent positive pitch, in order to keep the fuselage in a more or less horizontal position minimizing the configuration drag but at the cost of positive lift. A first problem of this classical configuration is: Since the horizontal stabilizer incidence angle is fixed, its negative lift cannot be fully adjusted to the flight condition, keeping the fuselage in its minimum drag position. Finally, due to this problem the pilot is lacking one degree of control freedom to fully control fuselage and aircraft attitude. 2. The vertical fin provides yaw stability and generates in forward flight part or all of the antitorque for the main rotor. Again the vertical fin incidence is built in and thus fixed, resulting in a side force that cannot be freely adjusted and that is dependent on the forward flight speed of the helicopter. 3. The possibility to freely adjust said side force is provided by the tail rotor, providing all of the antitorque force in hover condition and almost no additional force in cruise. The side forces and the lift act in a vertical plane with a normal vector parallel to the tail boom. A second problem is the helicopter's limited maximum horizontal speed, since the main rotor has to provide the propulsive force. This propulsive force is naturally limited, since it depends on the rotor specific limitations in tilting the tip path plane forward.
The document U.S. Pat. No. 2,580,428 A discloses an aircraft with cycloidal propulsion units including respectively airfoil blades pivotally mounted along an essentially horizontal blade axis parallel to the hub axis and perpendicular to a longitudinal axis of the aircraft.
The document WO 2007106137 A1 discloses a cycloidal propulsion unit for controlling a thrust vector including a hub that rotates about a hub axis. Further, the unit includes an airfoil blade pivotally mounted on the hub along a blade axis parallel to the hub axis and perpendicular to a longitudinal axis of the aircraft. As a result, the blade may pivot about the blade axis while travelling along a blade path during rotation of the hub. The unit further includes a ring that rotates around a ring axis parallel to the hub axis. The ring is interconnected with the blade via a control rod. Also, a device is engaged with the ring to selectively position the ring axis relative to the hub axis. As a result of these structures, selective positioning of the ring axis provides control of the rotation of the blade about the blade axis as the blade travels along the blade path.
The document WO 2009109918 A2 discloses a cycloidal rotor system having airfoil blades travelling along a generally non-circular, elongated and, in most embodiments, dynamically variable orbit. Such non-circular orbit provides a greater period in each revolution and an optimized relative wind along the trajectory for each blade to efficiently maximize lift when orbits are elongated horizontally, or thrust/propulsion when orbits are vertically elongated. Most embodiments, in addition to having the computer system controlled actuators to dynamically vary the blade trajectory and the angle of attack, can also have the computer system controlled actuators for dynamically varying the spatial orientation of the blades; enabling their slanting motion upward/downward and/or back sweep/forward sweep positioning to produce and precisely control a variety of aerodynamic effects suited for providing optimum performance for various operating regimes, counter wind gusts and enable the craft to move sideways and to allow roll and yaw control of the aircraft. Thus a rotor is provided, which when used in a VTOL rotorcraft, will require lower engine power to match or exceed the operating performance of VTOL rotorcrafts equipped with prior art rotors, this rotor also offers increased efficiency and decreased required power when used for generating the propulsive force for various vehicles or used as a fan.
The document JP 2009051381 A discloses a cycloidal blade capable of generating an advancing force during forward flying and accelerating forward speed, said cycloidal blade being disposed at the rear end of a tail boom of a helicopter to generate a propulsive force F in one direction. The blade includes a rotating shaft which extends along a vertical shaft of the helicopter, a plurality of blades which extend along the vertical shaft of the helicopter and rotate together with the rotating shaft, and a pitch angle change mechanism which decreases a pitch angle of the blade passing the opposite side to the one direction by moving in a direction opposite to the one direction, and increases the pitch angle of the blade passing on the same side with the one direction.
The document DE 102007009951 B3 discloses an aircraft with a closed cylinder drivable around a transverse axis of the aircraft with a controllable number of revolutions for generation of lift and/or propulsion after the Magnus effect. A radial blower having adjustable driving power is assigned to each of the cylinders for generating air flow that flows transversely against the cylinder. A wing profile of the radial blower has rotor blades that are pivotable around an aligned axis parallel to a rotation axis where a rotor of the radial blower concentrically surrounds the cylinder with a distance.
The document U.S. Pat. No. 1,761,053 discloses an airplane with a semi-cylindrical housing open upward and with a rotatable plane operable in the housing.
The document DE102008015073 A1 discloses a helicopter with a main rotor arranged on a cabin, on which a rear rotor is fixed over a rear bracket at a distance from the cabin for torque balancing. The rear bracket is provided with units for aerodynamic support for torque balancing. The devices for aerodynamic support for the torque balancing comprise a high-lift flap on the side turned away from the main rotor rotating direction extending along the rear bracket for accelerating the flow of the discharged air passing through the area of main rotor.
The document U.S. Pat. No. 4,948,068 A discloses a no tail rotor system for a helicopter. The addition of vortex generators in the longitudinal slots or nozzles, which produce the circulation control portion of the system which combines with a jet thruster and fluid resource, replaces the tail rotor.
The common disadvantage of all of said rotor systems of the state of the art is a low lift to drag ratio, limiting the efficiency of the generation of a propulsive force.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a helicopter without the disadvantages of the state of the art.
A solution is provided with a helicopter with a cycloidal rotor system with the features of claim 1 . Preferred embodiments of the invention are presented in the subclaims.
According to the invention a helicopter is provided with at least one main rotor with an essentially vertical axis of rotation, a tail boom extending along a longitudinal axis essentially perpendicular with regard to said vertical axis of rotation and at least one anti-torque device. At least one cycloidal rotor is provided extending along said longitudinal axis of the tail boom said at least one cycloidal rotor having airfoil blades being rotated for anti-torque around said longitudinal axis of the helicopter the speed of said rotation being variable. The airfoil blades of said at least one cycloidal rotor are inclined relative to said longitudinal axis of the helicopter. Rotation creates aerodynamic effects at each of the airfoil blades that sum up to a lateral force resulting approximately in the middle of said at least one cycloidal rotor with some distance from the hub of the main rotor. The direction of rotation of said at least one cycloidal rotor and the inclination of each of the airfoil blades are tuned to create a lateral force with a suitable direction at said distance from the hub of the main rotor to provide anti torque to counter the operational torque of the main rotor. By varying the rotational speed of said at least one cycloidal rotor the lateral force is adapted to balance the operational torque of the main rotor for a controllable flight of the helicopter allowing for example at high forward speed of the helicopter to reduce the rotational speed of the cycloidal rotor as more anti torque may be contributed by a vertical tail thus allowing economy with regard to energy consumption of the inventive helicopter.
According to a preferred embodiment of the invention the inclination of each of the airfoil blades may be controlled relative to the longitudinal axis of the inventive helicopter to vary the direction of the force generated by the cycloidal rotor to allow as well yaw and pitch stabilization by means of said at least one cycloidal rotor allowing to replace the effect of any horizontal tail and thus allowing a more simple helicopter, said force being particularly directed to counteract the main rotor torque. The inventive helicopter with the cycloidal rotor allows for replacement of a classical tail rotor, any horizontal stabilizer and any vertical tail at the rear end of the tail boom of a helicopter and thus the inventive concept allows the provision of an improved helicopter with less structural elements.
Preferably said helicopter comprises as a second type of anti-torque means a rotating cylinder which extends inside said cycloidal rotor along said longitudinal axis of the tail boom and which is driven to produce a Magnus effect side force. The rotating cylinder extends from the fuselage towards a rear end of the tail boom of the inventive helicopter. According to a further advantage of the invention the rotating cylinder creates a force due to the down wash of the main rotor in a transversal direction to the tail boom. With a suitable rotational direction of the rotating cylinder relative to the rotational direction of the main rotor—mainly in hover flight—said force can principally be directed to counteract the effect of the main rotor torque to the inventive helicopter.
According to a preferred embodiment of the invention a three actuator combination drives the cycloidal rotor by means of a translational control plate with two translational degrees of freedom in a plane perpendicular to said longitudinal axis allowing said cycloidal rotor a thrust vector in any direction of a plane vertical to the longitudinal axis of the tail boom.
According to a further preferred embodiment of the invention a tail propeller is provided with a rotational axis in line with the tail boom to provide efficient thrust compounding for higher horizontal speed of the helicopter.
According to a further preferred embodiment of the invention said tail propeller is coupled to the tail boom by means of a gear box to adjust for different rotational speeds of cycloidal rotor and tail propeller.
According to a further preferred embodiment of the invention a periphery of the closed cylinder is provided with dimples and/or increased surface roughness for reduced drag in the downwash of the main rotor.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Preferred embodiments of the invention are presented in more detail with regard to the following description and reference to the attached drawings:
FIG. 1 shows a force diagram of a tail boom of a helicopter of the state of the art,
FIG. 2 shows a schematic view of a helicopter according to the invention,
FIG. 3 shows a force diagram for a cycloidal rotor and a rotational cylinder of the helicopter according to the invention,
FIGS. 4 and 5 each show a schematic view of a preferred embodiment of the helicopter according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to FIG. 1 an empennage 1 of a classical helicopter (not shown) comprises a fixed horizontal stabilizer 2 , a fixed vertical fin 3 and a tail rotor 4 . The horizontal stabilizer 2 generates a negative lift, the vertical fin 3 provides yaw stability and generates in forward flight part or all of the antitorque for the main rotor while the tail rotor 4 provides all of the antitorque force in hover condition and almost no additional force in cruise. ΣF indicates direction and amplitude of the resulting force at the empennage 1 said resulting force being principally directed vertical to a tail boom of said helicopter.
According to FIG. 2 the helicopter 10 has a fuselage 11 and is equipped with a main rotor 12 . A tail boom 13 with a longitudinal axis is fixed to the fuselage 11 . A cycloidal rotor 14 of individual blades 15 surrounds the tail boom 13 between the fuselage and its rear end 16 , said blades 15 being essentially parallel to the longitudinal axis of the tail boom 13 . The radius of the main rotor 12 extends beyond the entire length of any of the blades 15 . Consequently the blades 15 are within the downwash of the main rotor 12 in operation.
A three actuator combination (not shown) drives the cycloidal rotor 14 by means of a translational control plate (not shown) with two translational degrees of freedom in a plane perpendicular to said longitudinal axis. Said drive comprises an electric motor arranged at the periphery of the tail boom 13 and being drivingly connected to the cycloidal rotor 14 .
A tail propeller 17 is rotatable fixed to the tail boom 13 , said tail propeller 17 being coaxial with the cycloidal rotor 14 and having the same rotational speed. A gear box (not shown) is provided between cycloidal rotor 14 and tail propeller 17 to adjust for different rotational speeds of cycloidal rotor 14 and tail propeller 17 .
According to FIG. 3 corresponding features are referred to with the references of FIG. 1 , 2 . The tail boom 13 is surrounded by a closed rotating cylinder 18 being driven in a range of 1000-2000 rpm. The rotating cylinder 18 has a diameter range of 300-800 mm. The cycloidal rotor 14 is eccentrically arranged with respect to the rotating cylinder 18 . The cycloidal rotor 14 is driven to rotate in the same or a direction contrary to the rotational direction of the rotating cylinder 18 . The diameter of the cycloidal rotor 14 is always more than that of the rotating cylinder 18 and is in the range of 600-1600 mm. The cycloidal rotor 14 has five to fifteen blades 15 . Any force vector resulting from the blades 15 of the cycloidal rotor 14 is freely controllable by changing respectively the inclinations of the blades 15 with regard to their trajectories. The periphery of the rotating cylinder 18 is provided with dimples and/or increased surface roughness. The rotating cylinder 18 is driven by the electric motor arranged at the periphery of the tail boom 13 .
According to FIGS. 4 and 5 the cycloidal rotor 14 extends from the rear end 16 of the tail boom 13 towards the fuselage 11 covering approximately ⅓ to ⅔ of the length of the tail boom 13 with the radius of the main rotor 12 essentially extending along the entire length of the blades 15 . | The invention is related to a helicopter ( 10 ) comprising a main rotor ( 12 ), a cycloidal rotor ( 14 ) and a rotating cylinder ( 18 ). The rotating cylinder ( 18 ) extends along a longitudinal axis of a tail boom ( 13 ). The cycloidal rotor ( 14 ) extends at least partly along said same tail boom ( 13 ) and rotates outside the rotating cylinder ( 18 ). | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for cooling an electrical module arranged in a housing and, in particular, a base station of a mobile radio system or wireless subscriber line system.
In an electrically operated technical appliance, the lost power of components and modules through which current flows leads to a heating-up of the appliance. Since standard electrical components for technical appliances have only a limited admissible operating temperature range of, for example, up to 70° C., they are cooled by cooling devices. These cooling devices are, for example, fans which establish an air flow in the housing, flowing around or through the electrical components and modules, and which consequently bring about a discharge of the thermal output produced.
During operation of the technical appliances outside enclosed spaces or in adverse conditions within enclosed spaces, adequate protection from environmental influences, such as, for example, dirt particles and liquids, must be additionally provided along with heat discharge. In this respect, protective regulations in accordance with the specified IP classes must be observed in order to ensure longterm functioning of the technical appliances.
It is known from DE 19755944 to provide in an air inlet of a housing a membrane filter for a superficial filtering of dirt particles from inflowing cooling air and for separating out liquids. In comparison with a housing known, for example, from DE 19626778, with an air/air heat exchanger, which ensures complete separation of an internal cooling circuit from an external cooling circuit, adequate protection of the electrical components can be achieved for the aforementioned areas of use of the technical appliance with the corresponding protective regulations in a simple way by use of the membrane filter. At the same time, a temperature difference, required for the cooling, between the temperature of the ambient atmosphere and the temperature inside the housing is reduced.
A membrane filter of this type is based, for example, on a membrane filter known for use in articles of clothing by the designation Goretex, Sympatex, etc. The membrane of the filter includes a fine netting or knitted fabric of fibers, which permits a very small pore size. An example of a material which may be used for this is PTFE (polytetrafluoroethylene), also known by the name Teflon. The membrane is generally provided on a backing material, such as, for example, polyamide, in order to achieve a certain stability and resistance of the membrane filter.
In addition to the criteria with regard to protective regulations, EMC guidelines (EMC—Electromagnetic Compatibility) also must be satisfied, ensuring on the one hand protection of the electrical modules arranged in the housing of the technical appliance from electromagnetic influences from the surroundings of the appliance and, on the other hand, protection of the surroundings from electromagnetic radiation emanating from the electrical modules.
On account of the plastic material used, the membrane filter is permeable to electromagnetic radiation and consequently does not bring about adequate shielding. Additional shielding, for example by a wire netting arranged in front of the membrane filter, is therefore necessary to satisfy the EMC guidelines. However, it is disadvantageous to provide this additional wire netting as a further element of the housing of the technical appliance and, for example, it increases the overall dimensions of the housing. Furthermore, it makes maintenance and cleaning of the membrane filter more difficult.
U.S. Pat. No. 5,431,974 discloses a filter arrangement for electromagnetic shielding. The filter arrangement in this case includes an electrically conductive frame with at least one opening, a panel of porous electrically conductive material, a layer of electrically conductive adhesive and an electrically conductive gasket material. Preferably chosen as the porous panel is a synthetic polymer which has been made electrically conductive at the surface by electrochemical processes.
The present invention, therefore, is directed toward specifying an apparatus for cooling which, with known use of a membrane filter, permits adequate electromagnetic shielding without the specified disadvantages of the prior art.
SUMMARY OF THE INVENTION
The apparatus according to the present invention for cooling an electrical module arranged in a housing has at least one membrane filter, arranged in an air inlet of the housing in each case, for a superficial filtering of at least dirt particles from inflowing cooling air for cooling the electrical module and also at least one cooling device for establishing an air flow in the housing and for discharging the filtered cooling air, heated up from flowing through or around the module, out of the housing from at least one air outlet. The membrane filter is characterized by having a netting of an electrically conductive material for electromagnetically shielding the electrical module.
The configuration of the apparatus according to the present invention has the advantage that an integration of the electrically conductive netting achieves the effect of electromagnetic shielding without an additional shielding arrangement having to be provided. Furthermore, the advantageous properties of the membrane filter are not restricted. For example, simple cleaning of the filter without prior detachment of a shielding grating is possible. As a result, the housing of the technical appliance can be provided in a very compact form.
The apparatus according to the present invention can be used in technical appliances with at least one electrical module, such as, for example, base stations of a mobile radio system or wireless subscriber line system (access network systems), traffic control devices, power supply devices or switch cabinets for a control system of industrial machines. In the same way, the apparatus according to the present invention can be used, for example, in smaller electrical appliances, such as a portable or stationary home computer, or in electrical measuring instruments.
According to a first embodiment of the present invention, the membrane filter additionally separates out liquids at the surface, whereby use of the technical appliance is also possible outside enclosed spaces or under adverse ambient conditions.
According to a second embodiment, the membrane filter is provided in the form of a fine-pored membrane applied to a backing material. This configuration of the membrane filter advantageously permits individual adaptability of the backing material and/or the membrane to special conditions of use of the technical appliance. For example, a filter resistant to chemical substances, such as acids, can be used for technical appliances used in production.
According to a third embodiment, based on the second embodiment, the electrically conductive netting is woven into the backing material of the membrane filter. As a result, a firm bonding of the netting to the backing material is advantageously achieved, one of the effects being, for example, that the stability of the membrane filter is increased.
As an alternative to the third embodiment, the electrically conductive netting is applied to the backing material. This embodiment advantageously permits simple production of the membrane filter, the electrically conductive netting being applied to the membrane filter, for example, in an additional production step. A bonding between the netting and the backing material can be achieved, for example, by an adhesive bonding technique.
According to a further alternative embodiment, the electrically conductive netting is provided in the form of backing material for the membrane. By this embodiment, the electromagnetic shielding is advantageously integrated directly into the membrane filter, as a result of which there are no further working steps in the production of the membrane filter.
According to further alternative embodiments, the membrane may be made from a PTFE material known as Teflon or from an electrically conductive material. The PTFE material is already widely used, for example for water-impermeable items of clothing, and, based on its properties, can be flexibly adapted to a wide variety of requirements with regard to the pore size. If the membrane is produced from an electrically conductive material that has, for example, the same or comparable properties, it is advantageously possible to dispense with the additional electrically conductive netting.
According to a further embodiment, the electrically conductive material may be provided in the form of a metal, plastic or ceramic material. Plastic and ceramic materials, in particular, have advantageous properties in comparison with known metal materials; for example, with regard to the resistance to environmental influences, strength and processability.
According to a further embodiment of the present invention, the electrically conductive netting is electrically connected to the housing, the latter likewise being made at least partially from an electrically conductive material. Electrically conductive netting may be understood here according to the present invention as meaning an additional netting; a netting used as a backing material or a membrane of electrically conductive material. The connection to the housing brings about a grounding of the membrane filter, which alternatively also may be achieved via a separate grounded electrical connection.
According to a further configuration of the present invention, the effective surface area of the membrane filter is enlarged by a periodic folding, as a result of which clogging of the filter is advantageously reduced and the maintenance intervals are increased.
Furthermore, a membrane filter according to the present invention is advantageously additionally arranged at the air outlet of the housing. This configuration permits, for example, a reversal of the cooling air flow in the housing, in order to free the membrane filter at the air inlet of dirt particles, without dirt particles or liquids at the same time being able to pass through the air outlet into the housing.
According to a further embodiment, the cooling device includes a fan impeller driven by a motor. In this case, the motor speed, and consequently the throughput of the cooling air in the housing, for example, can be controlled in dependence on the temperature in the housing and/or on the temperature of the ambient atmosphere, with the advantageous result that a constant operating temperature of the electrical module and a constant temperature inside the housing are ensured, and consequently the service life of the electrical module is advantageously prolonged. Furthermore, the speed of the cooling device can be controlled, for example, in such a way that the admissible limiting temperatures of the electrical module are not quite exceeded. Consequently, the noise emission of the arrangement is minimized by the lowest possible speed of the cooling device.
The apparatus according to the present invention is suitable, in particular, for use in technical appliances, such as base stations or similar outdoor installations of a mobile radio system or wireless subscriber line system, and also in traffic control devices, radio relay devices, etc.
Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a base station of a mobile radio system with the apparatus according to the present invention for cooling electrical modules, in a front view.
FIG. 2 shows the apparatus according to the present invention in a side view.
FIGS. 3 a and 3 b show two ways in which the membrane filter according to the present invention can be provided, by way of example.
FIG. 4 shows a detailed representation of the membrane filter according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A prior-art technical appliance, such as, for example, a base station BTS of a mobile radio system or wireless subscriber line system, according to FIG. 1, includes a number of electrical modules BG. During the operation of the electrical appliance, the lost power of the individual electrical modules BG results in a heating-up effect, giving rise to the necessity for cooling in order not to exceed an admissible operating temperature of the modules.
The housing G, represented in a front view, of the electrical appliance has on the end face an air inlet LE with a membrane filter MB. The overall dimensions of the air inlet LE are set, for example, in such a way that cooling air flowing in through the membrane filter MB from the ambient atmosphere of the technical appliance can flow through the electrical modules BG in each case from below and, if appropriate, from the front. Consequently, it can bring about a cooling-down of the modules. The active surface area of the membrane filter MB, which may be larger than the air inlet LE, for example due to a fold formation, is dimensioned such that the pressure drop of the inflowing cooling air can be compensated by a cooling device, or an adequate amount of cooling air still can flow in despite a partial clogging of the membrane filter MB by dirt particles or liquid.
FIG. 2 presents the described technical appliance in a side view in order to illustrate, in more detail, the internal construction shown by way of example. On the left-hand side of the housing G, a frame R with the membrane filter MB is arranged in front of the air inlet LE. The additional frame R permits rapid removal of the membrane filter MB; for example, for maintenance and cleaning purposes or for replacement. At the same time, the frame R permits the described folding of the membrane filter MB. To restrict the overall dimensions of the technical appliance, the frame R also may be integrated into the housing G.
The membrane filter MB is designed in the form of a surface filter, which has the special advantageous property of separating out dirt particles and liquids from the ambient atmosphere already at the surface of the membrane, whereby, for example, sensitive electronic components or circuits in the modules BG are protected from environmental influences of this type. A membrane filter MB of this type is based, for example, on a membrane filter known by the designation Goretex, Sympatex, etc., for use in articles of clothing. The membrane of the filter includes a fine netting or a knitted fabric of fibers. A very small pore size prevents any ingress of dirt particles into the membrane and consequently clogging. Nevertheless, dirt particles can be deposited on the surface of the membrane, but can be removed in a simple way. In the same way, liquids cannot pass the membrane up to a specific pressure per unit area.
An example of a material used for the membrane is PTFE, also known by the name Teflon. The membrane is generally applied to a coarsely woven backing material, such as polyamide, in order to achieve high stability and resistance of the membrane filter MB.
A special design of the membrane filter MB allows protective regulations in accordance with the IP guidelines up to, for example, IP55 to be satisfied, thereby permitting use of the technical appliance outside enclosed spaces or under adverse ambient conditions, such as those which occur, for example, in industrial production. Special selection of the membrane filter material additionally allows individual adaptation to the actual ambient conditions, such as resistance to acids.
Known membrane filters MBR produced according to the prior art consist of materials described above which are permeable to electromagnetic waves. To satisfy EMC guidelines (EMC—Electromagnetic Compatibility), however, the housing G of the technical appliance must in the same way have an electromagnetic shielding in the region of the air inlet LE. This is generally achieved by a wire grating attached in front of the air inlet LE and electrically connected to the housing. According to the present invention, on the other hand, the electromagnetic shielding is achieved by a special configuration of the membrane filter MB, whereby, for example, the maintenance and cleaning of the membrane filter MB is simplified. The possible configurations are presented below in FIGS. 3 a and 3 b.
The cooling of the electrical modules BG by a direct flow of cooling air through the housing G has the advantage of a necessary temperature difference tending toward zero between the temperature of the ambient atmosphere or the temperature of the inflowing cooling air and the temperature inside the housing G, whereby the operation of the electrical modules BG is safeguarded even at a temperature of the ambient atmosphere of, for example, +70° C., which corresponds to the limiting temperature of the components reduced by the degree of internal heating-up.
A cooling device VE, which is arranged, for example, in the upper region of the rear housing wall, sucks in the air heated up as it flows through or around the electrical modules BG and discharges it to the ambient atmosphere through an air outlet LA. Used as cooling devices VE are, for example, one or more fans which produce an air flow. Cooling via natural convection is not adequate for reliable operation of the modules BG below the limiting temperature if a strong heating-up of the modules BG occurs due to a high internal lost power.
To control the temperature inside the housing G, the speed of the fan is automatically controlled. To acquire parameters for this control, temperature sensors which permanently determine the temperatures of the inflowing cooling air and the atmosphere inside the housing G may be provided; for example, in the region of the air inlet LE and at various points inside the housing G. In this automatic control, the throughput of the cooling air in the housing G is changed via the speed of the fan of the cooling device VE in order to obtain, for example, a constant temperature inside the housing G independently of the temperature of the ambient atmosphere. A constant operating temperature of the modules BG has positive effects; for example, on the service life of the electronic components and the high-performance circuits. In addition, constantly keeping the speed of the cooling device VE low, on condition that the limiting temperature of the components is not exceeded, makes it possible to minimize the noise emission of the technical appliance. Furthermore, the automatic control makes it possible to dispense with the operation of the cooling device VE initially during cold starting of the appliance, to heat up the modules BG quickly to the desired operating temperature, and to carry out further automatic control of the cooling device VE only once this operating temperature has been reached so as to maintain the operating temperature.
During maintenance of the technical appliance, it is possible, for example by a reversal of the direction of rotation or a change in the blade setting of the fan impeller of the cooling devices VE, for the air flow in the housing G to be reversed, whereby cooling air flows into the housing through the air outlet LA and is led out through the membrane filter MB. As this happens, dirt particles deposited on the surface of the membrane filter MB are dislodged, and a cleaning of the membrane filter MB is achieved. This cleaning operation also may be initiated, for example, by a permanent measuring process of the air throughput in dependence on the speed of the cooling arrangement VE, when it falls below a fixed value, the measured ratio indicating the degree of soiling of the membrane filter MB. In this case, a membrane filter MB is advantageously arranged in the air outlet LA, so that no dirt particles or liquid can get into the housing G even when the air flow is reversed.
Arranging the modules BG in such a way that they are spaced apart from one another makes it possible for a flow to take place through and/or around the modules BG. According to a known type of design, the modules BG include, for example, a module frame with electronic components and high-performance circuits located therein. The module frames are provided with ventilation slits, through which cooling air can reach the components and circuits. Within the scope of the present invention, modules BG are understood as also including all the electrical devices of a technical appliance. These are to include, for example, printed-circuit boards provided in a personal computer and also peripheral units, such as hard disks.
The arrangement of FIG. 2 has in the spaces between the individual modules BG and also below the lowermost and above the uppermost module BG air-directing devices which have the task of distributing cooling air flowing in through the membrane filter MB evenly over the base area of the respective module BG, so that a homogeneous flow through the entire module BG occurs. Furthermore, the air-directing devices may be used for the mutual electromagnetic shielding of the modules BG with regard to satisfying the EMC regulations.
FIGS. 3 a and 3 b each show a membrane filter MB according to the present invention in a sectional representation. A prior-art membrane filter MB includes a coarsely woven and stable backing material TM with a membrane MBR of a fine knitted fabric or filament applied thereto. According to the present invention, as shown in FIG. 3 a , a netting GT of an electrically conductive material is incorporated into the backing material TM. This conductive material may, for example, be woven in directly during the production of the backing material TM, and, in a way corresponding to FIGS. 1 and 4, produce a lattice-shaped structure referred to as Ripstock. The advantage of weaving-in is to be seen in the fact that the still very fine-pored surface prevents particles from becoming lodged on the netting and consequently clogging the membrane filter MB. A metal, plastic or ceramic is used as the electrically conductive material, it also being possible to take into consideration the use of all materials exhibiting the desired properties in the future. The electrically conductive netting GT is connected to a frame or grounded. This may take place by a connection of the netting GT to the housing, provided that the latter likewise consists at least partially of an electrically conductive material.
According to FIG. 3 b , the electrically conductive netting GT is applied to the carrier material TM and physically connected to it. Further variants according to the present invention of the construction of the membrane filter MB, according to which the backing material TM or the membrane MBR itself consists of an electrically conductive material, are not represented in the figures. In these latter configurations, it is possible to dispense with an additional electrically conductive netting, thereby further simplifying the construction and production of the membrane filter MB.
In FIG. 4, the membrane filter MB, arranged in a frame R, is shown with an electrically conductive netting GT. In an enlargement of a detail at the bottom, the structure of the membrane filter MB is presented in a plan view. The membrane MBR, including a knitted fabric of individual thin filaments and permitting a very small pore size, can be seen clearly. Arranged over the membrane MBR is the netting GT of electrically conductive material, with a relatively great distance between the individual members of the netting GT. The dimensioning of the netting takes place, for example, in such a way that, on the one hand, a smallest possible surface of the membrane filter MB is sealed by the netting GT and, on the other hand, adequate electromagnetic shielding and stability of the membrane filter MB are achieved. The structure of the electrically conductive netting GT indicated in FIGS. 1 and 4 is shown by way of example and can, within the scope of the present invention, also take the form of any of a large number of known further structures.
Although the present invention has been described with reference to specific embodiments, those of skill in the art will recognize that changes may be made thereto without departing from the spirit and scope of the invention as set forth in the hereafter appended claims. | An apparatus having at least one membrane filter for a superficial filtering of at least dirt particles from inflowing cooling air for cooling an electrical module and also at least one cooling device for establishing an air flow in the housing and for discharging the heated-up cooling air out of the housing from at least one air outlet, the membrane filter having a netting of an electrically conductive material for electromagnetically shielding the electrical module. | 8 |
TECHNICAL FIELD
The present invention relates in general to a system for analyzing drilling mud circulated through a borehole during drilling. More particularly, this invention involves a system for continuously sensing and recording the relative concentration of hydrocarbon gases associated with cutings carried by the drilling mud.
BACKGROUND ART
In drilling oil or gas wells, mud-laden fluid or "drilling mud" is typically circulated through the borehole to cool and lubricate the drill bit, and to remove cuttings from the hole. The drilling mud is pumped into the hole from a nearby surface pond or pit, and is returned to the pit to deposit the various cuttings carried by the mud before recirculation through the hole.
The drilling mud provides a means of communicating with the bottom of the hole and with the geological formations penetrated by the drill bit. By appropriate measurements at the surface, before the mud is returned to the pit, useful data such as the concentration of oil, gas, water or sulfur in the drilling mud and cuttings, rate of drilling penetration, etc. can be determined through mud analysis. Such data can then be correlated with drilling depth to provide a log of useful information.
Examination of drilling mud and the cuttings carried thereby is known as mud logging. Although batch samples of drilling mud can be collected and analyzed, it is preferable to conduct sampling on a continuous basis. Continuous sampling is generally faster and more accurate than batch sampling. The control and amount of information afforded by continuous mud logging is particularly desirable when drilling exploratory holes, for instance, or when the stratigraphy is complicated.
While mud logging systems have been developed heretofore, the systems of the prior art have tended to be complex, expensive and difficult to operate. Most if not all of the prior systems for logging drilling mud on a continuous basis have required the attention of at least one operator. For example, one system of the prior art is truck-mounted and operator-attended, and consumes a large amount of power. The drilling mud is sampled inside the truck, which is usually parked a substantial distance away from the borehole due to the various drilling equipment which must be located around the hole. By the time the drilling mud reaches the truck, it may have become stale by percolation of gases out of solution, thereby reducing reliability and accuracy of the sampling. In addition, the expense of operating and maintaining such mud logging systems has made it infeasible to drill some exploratory holes that otherwise might have been drilled.
A need has thus arisen for a simplified mud logging system for analyzing the hydrocarbon content of drilling mud on a continuous basis with very little operator attention, except to activate the system and change the disk of a chart recorder at periodic intervals.
SUMMARY OF THE INVENTION
The present invention comprises a mud logging system which overcomes the foregoing and other difficulties associated with the prior art. In accordance with the invention, there is provided a mud logging system of simplified and inexpensive construction. The system herein utilizes a clock-driven, chart recorder to log the relative concentrations of hydrocarbons detected in drilling and returning from the borehole over an extended period without operator attention.
More particularly, the mud logging system herein comprises a sampling chamber, a hydrocarbon sensor mounted in the sampling chamber, and a recorder connected to the sensor through appropriate circuitry. The sampling chamber is adapted for connection to the drilling mud return line between the borehole and mud pit. As the drilling mud flows through the sampling chamber, any hydrocarbon gases associated with the cuttings carried by the mud separate from the mud for detection by the sensor. The recorder provides a continuous log of the relative concentration of hydrocarbons in the drilling mud over a predetermined period, such as twenty four hours, for correlation with drilling depth to locate production zones.
BRIEF DESCRIPTION OF DRAWINGS
A more complete understanding of the invention can be had by reference to the following Detailed Description together with the accompanying Drawings, wherein:
FIG. 1 is a schematic diagram of a mud logging system incorporating the invention;
FIG. 2 is a side view (partially cutaway) of the sampling chamber of the system;
FIG. 3 is a schematic diagram of the sensor circuitry utilized in the invention;
FIG. 4 is a schematic diagram of the control circuitry utilized in the invention; and
FIG. 5 is an enlarged view of a portion of a chart recorded with the system.
DETAILED DESCRIPTION
Referring now to the Drawings, wherein like reference numerals designate like or corresponding parts throughout the views, and particularly referring to FIG. 1, there is shown a mud logging system 10 incorporating the invention. System 10 includes a flow or sampling chamber 12 connected via pipe 14 to the return line of a mud circulation system (not shown) for a borehole. Drilling mud and borehole cuttings carried thereby pass through chamber 12 before return to the mud pit, from which the drilling mud is continuously circulated through the borehole during drilling. Chamber 12 defines a separation chamber within which any hydrocarbons associated with the cuttings in the drilling mud can be detected by a sensor 16 mounted in the top of the chamber. A line 18 connects sensor 16 with a control panel 20 situated in the doghouse or at some other location remote from sampling chamber 12. Control panel 20 includes a power on/off switch 22, an on/off lamp 24, a voltmeter 26, and a warning lamp 28. Power for system 10 is provided by a cord 30 which includes a plug for connection to a 110 volt AC outlet. Control panel 20 is connected by line 32 to a recorder 34 which includes a clock-driven chart 36 and a movable pen 38. In the preferred construction, control panel 20 and recorder 34 are housed in a common case.
Recorder 34 is responsive to a voltage signal via the circuitry within control panel 20 in accordance with the relative concentration of hydrocarbons detected by sensor 16. As the drilling mud flows through sampling chamber 12, any hydrocarbons which percolate out of solution within the chamber are continuously detected by sensor 16 and charted on recorder 34, as will be more fully explained hereinafter.
FIG. 2 illustrates sensor 16 mounted in the top wall of sampling chamber 12. Any sampling chamber of suitable construction can be utilized with system 10; however, in accordance with the preferred embodiment, sampling chamber 12 corresponds to the chamber disclosed and claimed in copending application Ser. No. 115,002, filed Jan. 24, 1980, and assigned to Energy Detection Company. Chamber 12 is preferably generally triangular in longitudinal cross section, and generally rectangular in lateral cross section. The back wall of chamber 12 includes a fitting for connection to pipe 14, while the front wall of the chamber includes an outlet 40 with a hinged trap door 42 thereon located below the inlet. Drilling mud entering chamber 12 slides down the declined bottom wall of the chamber and through outlet 40 for return to the mud pit. Any gas associated with cuttings carried within the drilling mud is thus allowed to percolate out of solution and collect within the upper portion of sampling chamber 12 for detection by sensor 16.
The details of sensor 16 are best shown in FIG. 3. Sensor 16 comprises a conventional pass-through ionic sensor of the type utilized in smoke alarm systems. For example, the Figaro TGS-109 sensor has been found satisfactory for use as sensor 16. Sensor 16 is connected to a five pin plug 44 to which line 18 leading to control panel 20 is connected. Pins B and D of plug 44 are connected to the heated cathode 16a of sensor 16. Pins A and C of plug 44 are connected to the anode 16b of sensor 16. When a hydrogen-rich gas passes through the filament of sensor 16, the current flow from cathode 16a to anode 16b increases in accordance with the concentration of hydrogen in the gas to provide an indication of hydrocarbons.
Referring now to FIG. 4, there is shown the circuitry contained in control panel 20. Line 18, which is shown in FIG. 1, connects plug 44 on sampling chamber 12 to a five pin plug 46 on control panel 20. The pins of plug 44 are connected to their counterparts on plug 46. Pins A and C of plug 46 are connected to pin 6 of terminal board 48, while pin B of the plug is connected to pin 7 of the terminal board and pin D of the plug is connected to pin 8 of the terminal board. It will be understood that the pins located on either side of each of the numerals 1-8 on terminal board 48 are connected together, but have been shown as separate pins for purposes of clarity.
The two leads of AC power cord 30 are connected to pins 1 and 3 of terminal board 48, while on/off switch 22 and fuse 52 are wired in series between pins 1 and 2. The on/off lamp 24 together with a resistor 54 are wired in series between pins 2 and 3 of terminal board 48. When switch 22 is closed, lamp 24 is energized to indicate that system 10 is on.
A transformer 56 is provided for converting 110 volt alternating current to two levels of direct current for use by sensor 16 and recorder 34. The primary terminals 56a of transformer 56 are connected to pins 2 and 3 of terminal board 48.
Transformer 56 includes a first set of secondary terminals 56b for providing a relatively low direct current voltage to sensor 16, and a second set of secondary terminals 56c for providing a relatively higher direct current voltage to recorder 34. A pair of resistors 58 and 60 are connected in parallel between the upper lead of first secondary terminal 56b and pin 8. The lower lead of first secondary terminal 56b is connected to pin 7. Pins 7 and 8 of terminal board 48, of course, are connected to cathode 16a of sensor 16.
A diode 62 and resistor 64 are connected in series between the upper lead of the second set of secondary terminals 56c and ground. Another diode 66 is connected between the lower lead of the second set of secondary terminals 56c and the junction between diode 62 and resistor 64. A zener diode 68 is connected between ground and the center tap of terminals 56c, which is also connected to the lower lead of the first set of secondary terminals 56b. A variable resistor 74 is connected between the center tap of secondary terminals 56c and ground. A resistor 70 is connected between pin 4 and ground and a resistor 72 is connected between the wiper of variable resistor 74 and pin 4. The variable resistor 74 provides for adjustment of the current flow to sensor 16 to vary the temperature thereof. A resistor 76 is connected between pin 5 and ground. Variable resistor 78 and resistor 80 are connected in series between pins 5 and 6. Resistors 82 and 84 are connected in series between pin 6 and ground. Resistors 78-84 provide signal conditioning and adjustment for the sensor signal which is transmitted to recorder 34.
Looking now at the left side of FIG. 4, line 32 interconnecting control panel 20 and recorder 34 is comprised of five leads 86, 88, 90, 92 and 94. Leads 86 and 88 which carry the alternating current to power recorder 34 are connected to pins 2 and 3, respectively, of terminal board 48. Lead 90, which carries the negative reference voltage for the sensor signal to ride on, is connected to pin 4. Lead 92 connected to pin 5 carries the conditioned signal from sensor 16. Lead 94 is connected to an internal threshold detector within recorder 34, which applies a voltage to energize the warning lamp 28 when a predetermined threshold, as set by arm 95 (FIG. 1) on recorder 34. has been exceeded. Diode 96, resistor 98 and capacitor 100 comprise a relaxation oscillator network causing lamp 28 to flash when a voltage is applied to lead 94.
Referring now to FIG. 5 in conjunction with FIG. 1, recorder 34 is preferably a twenty four hour, clock-driven unit. Any suitable recorder can be utilized, such as the Model ET recorder available from Partlow Corporation of New Hartford, N.Y. FIG. 5 illustrates a portion of a mud log recorded on chart 36 of recorder 34. Between the times of 1:00 p.m. and 4:00 a.m., it will be noted that the tracing on chart 36 is relatively close to the center of the chart, thus indicating little or no hydrocarbons in the formations penetrated by the drill bit at that time. On the other hand, a high concentration of hydrocarbons would appear to be present in the particular formations traversed between the times of 5:30-6:30 a.m. and 7:30-8:30 a.m. as indicated by the large deflections in the tracing made by pen 38. In correlating the information on chart 36 with drilling depth, of course, it will be necessary to allow for the lag time required for the drilling mud to travel from the bottom of the borehole to sampling chamber 12.
In view of the foregoing, it will be apparent that the present invention comprises a new and improved mud logging system having several advantages over the prior art. The system herein features simplified construction and requires no operator attention other than to turn on and adjust the system, and to periodically change the chart of the recorder. With the system herein, it becomes economically feasible to drill and log some exploratory holes which would be too costly with the complicated systems of the prior art. Other advantages will be apparent to those skilled in the art.
Although particular embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the specific embodiments disclosed, but is intended to embrace any alternatives, equivalents, modifications, and rearrangements of elements as fall within the scope of the invention as defined by the following Claims. | A system (10) for continuously analyzing drilling mud circulating through a borehole comprises a sampling chamber (12) through which flows the return mud, a sensor (16) mounted in the sampling chamber for detecting hydrogen gas percolating out of the drilling mud and for producing a signal representative of the concentration of hydrogen, and a recorder (34) for recording the signal from the sensor over a period of time. Appropriate circuitry within a control panel (20) is connected between the sensor (16) and recorder (34). In the preferred embodiment of the invention, the recorder (34) comprises a clock driven disk recorder. | 4 |
RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 12/436,696, filed on May 6, 2009, which claims the benefit of U.S. Provisional Application No. 61/050,928, filed on May 6, 2008, the contents of which are incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure relates to mobilizing musculoskeletal structures, including injured musculoskeletal structures.
BACKGROUND
[0003] Casts, splints, bandages, and braces are used to stabilize, immobilize, or otherwise protect or support, musculoskeletal disorders such as traumatic injuries, e.g., fractures, deformities, and other problems of bones, joints, and connective tissues of the body (“injury sites”). Protecting and supporting the injury site can assist in reducing pain or discomfort, reducing inflammation, providing physical support, promoting healing, and protecting from further damage or injury. Supporting and protecting an injury site typically involves immobilizing the injury site. For example, one treatment for fractures of the bones of the toes (the phalanges) includes taping the injured toe to an adjacent toe to limit independent movement of the injured toe. Additionally or alternatively, a splint is sometimes attached to an injured toe in an attempt to immobilize and protect the injured toe.
SUMMARY
[0004] An injured musculoskeletal structure, such as a broken toe or finger bone, is also susceptible to painful and potentially damaging forces. Particularly, normal use of interconnected musculoskeletal structures can transfer forces to the injury site, potentially causing pain and inflammation, and potentially hindering healing of the injury. For example, when a person steps down on the foot, the metatarsals normally move down and forward in relation to the heel, and they also spread to the sides in relation to one another. Thus, mobilizing an injured musculoskeletal structure relative to a support device can allow natural movement of the injured musculoskeletal structure, and can reduce undesired transfer of forces to the injured musculoskeletal structure during healing.
[0005] In one general aspect, a device includes a shell member sized and shaped to juxtapose an injured digit of a limb during healing. The shell member has a digit-facing surface formed of a slippery material to mobilize the injured digit relative to the shell member. The device also includes means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure of the limb.
[0006] Some implementations may include one or more of the following features. The device includes an interface member disposed between the injured digit and the shell member to facilitate movement of the injured digit relative to the shell member. The means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure includes a slip-resistant body-facing surface juxtaposing the adjacent healthy musculoskeletal structure of the limb. The means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure includes a hook-and-loop fastener.
[0007] The shell member is formed as a shoe insole. The device includes an upstanding deflection member configured to at least partially cover an injured toe. The digit-facing surface includes an upper surface portion of the shell member on which a wearer's foot rests during use, and the means for limiting movement includes an upper surface portion of the shell member on which the wearer's heel or instep rests during use. The shell member defines a space in which the wearer's heel does not rest on the shell during use, and the means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure of the limb includes the space.
[0008] The device includes an interface member formed as a sock configured to cover a wearer's foot, and the sock is configured for sliding engagement with the digit-facing surface and substantially non-sliding engagement with the upper surface portion of the shell member on which the wearer's heel or instep rests.
[0009] The shell member defines an interior cavity configured to receive at least a portion of the injured digit, and the digit-facing surface includes an inner surface of the shell member. The device further includes an interface member including a splint or a sleeve. The device includes a deflection member configured to at least partially enclose the injured digit to protect the injured digit from damaging contact.
[0010] The device includes a shoe member that is configured to receive the shell member. The shoe member includes the means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure of the limb.
[0011] In another general aspect, a splint for supporting an injured musculoskeletal structure includes a rigid supportive shell configured to cradle an injured musculoskeletal structure. The supportive shell limits bending of the injured musculoskeletal structure in a first direction. An interface member is disposed between a portion of a wearer's body and at least a portion of the supportive shell to mobilize at least one of the injured musculoskeletal structure and a musculoskeletal structure adjacent to the injured musculoskeletal structure relative to the supportive shell.
[0012] In another general aspect, a process includes providing a device for mobilizing an injured musculoskeletal structure to slide relative to an orthotic member juxtaposing the injured musculoskeletal structure to support the injured musculoskeletal structure during healing.
[0013] In another general aspect, supporting an injured musculoskeletal structure during healing includes mobilizing the injured musculoskeletal structure to slide relative to an orthotic member juxtaposing the injured musculoskeletal structure.
[0014] Some implementations may include one or more of the following features. Supporting an injured musculoskeletal structure includes isolating the injured musculoskeletal structure from the orthotic member such that the orthotic member limits the transfer of a force to the injured musculoskeletal structure when moving with a body portion to which the orthotic member is attached. The method includes retaining the orthotic member to a healthy musculoskeletal structure during use, substantially limiting bending of the injured musculoskeletal structure in a first direction, or at least partially enclosing the injured musculoskeletal structure to protect against damaging contact.
[0015] In another general aspect, supporting an injured musculoskeletal structure includes placing an interface member on an exterior skin surface juxtaposing the injured musculoskeletal structure and placing a shell member in a position juxtaposing the injured musculoskeletal structure. The interface member facilitates sliding movement of the injured musculoskeletal structure and/or an adjacent musculoskeletal structure relative to the shell member during support.
[0016] In another general aspect, a device includes a shell member sized and shaped to juxtapose an injured toe during healing. The shell member includes a first, foot-facing surface portion formed of a slippery material to mobilize the injured toe relative to the first surface portion, and a second, foot-facing surface portion having a higher coefficient of friction than the first surface portion and arranged relative to the first surface portion to support a healthy musculoskeletal structure adjacent the injured toe and to limit sliding between the second surface and the healthy musculoskeletal structure.
[0017] In another general aspect, a device includes a shell member sized and shaped to juxtapose a foot sole at a location proximate an injured toe while not juxtaposing adjacent portions of the sole. The shell member includes a foot-facing surface formed of a slippery material to mobilize the injured toe relative to the foot-facing surface.
[0018] In another general aspect, a device includes a shell member sized and shaped to juxtapose an injured finger or thumb during healing. The shell member includes a first digit-facing surface portion formed from a slippery material to mobilize the injured finger or thumb relative to the first surface portion and a second surface portion configured to immobilize the shell member relative to healthy musculoskeletal structure adjacent the injured finger or thumb.
[0019] In another general aspect, a device includes a shell member sized and shaped to juxtapose an injured metacarpal structure during healing. The shell member includes a first surface portion configured to immobilize the shell member relative to the injured metacarpal structure and a second digit-facing surface portion formed from a slippery material to mobilize a finger or thumb adjacent the injured metacarpal structure relative to the second surface portion.
[0020] In one general aspect, a device includes a shell member sized and shaped to juxtapose an injured musculoskeletal structure of a limb during healing. The shell member has a surface configured to face the injured musculoskeletal structure and/or an adjacent musculoskeletal structure. The surface is formed of a slippery material to mobilize the injured musculoskeletal structure and/or the adjacent musculoskeletal structure relative to the shell member. The device also includes means for limiting movement of the shell member relative to an adjacent healthy musculoskeletal structure of the limb.
[0021] In some implementations, musculoskeletal structures adjacent to an injured musculoskeletal structure are mobilized. For example, other bones, skeletal muscles, cartilage, and/or tendons in the forefoot, in addition to the injured musculoskeletal structure, can be mobilized relative to a support device to limit painful and/or injurious forces from being transferred to an injured toe during standing or walking. In other implementations, the musculoskeletal structures adjacent to, and/or adjoining an injured musculoskeletal structure are mobilized instead of the injured musculoskeletal structure. Additionally, the mobilized adjacent and/or adjoining musculoskeletal structures include those structures distal to the injured musculoskeletal structure. For example, a healthy toe can be mobilized relative to a support device to protect a connected metatarsal bone or joint such that when the metatarsal bone pushes forward or outward against the toe during walking, the mobilized toe moves with the internal motion of the connected metatarsal bone. Mobilizing the toe minimizes resistance against such internal movements of the metatarsal bone, and reducing painful and/or injurious forces transferred to the injury site.
[0022] The details of various implementations set forth in the accompanying drawings and description. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a top view of an orthotic support device according to one implementation.
[0024] FIG. 2 is a perspective view of the orthotic support device shown in FIG. 1 , with the low friction liner removed.
[0025] FIG. 2A is a plan view of the low friction liner of the orthotic support device shown in FIG. 1 .
[0026] FIG. 3 is a side view of the orthotic support device shown in FIG. 1 with the low friction liner removed.
[0027] FIGS. 4 and 4A are diagrammatic views of socks according to two implementations.
[0028] FIG. 5 is a side view of an orthotic support device in which an open area of the shoe portion of the device is replaced by an enlarged protective area.
[0029] FIG. 6 is a partial cut-away side view of the orthotic support device of FIG. 1 in use with a toe splint.
[0030] FIG. 7 is an exploded view of another orthotic support device.
[0031] FIG. 8 is a perspective view of the orthotic support device of FIG. 7 in use.
[0032] FIG. 9 is an exploded view of another orthotic support device.
[0033] FIGS. 9A and 9B are perspective views of the orthotic support device of FIG. 9 .
[0034] FIG. 10 is an exploded view of another orthotic support device.
[0035] FIGS. 10A and 10B are perspective views of the orthotic support device of FIG. 10 in use.
[0036] FIG. 11 is an exploded view of another orthotic support device.
[0037] FIG. 11A is a perspective views of the orthotic support device of FIG. 11 in use.
[0038] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0039] An injured musculoskeletal structure is mobilized relative to a juxtaposing support device by a low friction interface provided where the support device contacts the injury site. For example, as will be discussed in further detail below, in the case of a toe fracture the support device provides a slippery surface located on a surface facing the injured toe such that a very low friction interface is provided between the injured toe and the support device. This allows the injured toe to move relative to the support device when pressure is applied to the foot, e.g., when the patient stands or walks, causing the metatarsal bones to spread and push forward in relation to the heel of the foot and in relation to the support device. Because the toe can slide over the slippery surface to accommodate these movements of the musculoskeletal structure of the foot, pressure and stress on the toe are reduced, thereby reducing pain and inflammation, and reducing the likelihood of further damage to the injured toe.
[0040] Referring to FIGS. 1-3 , a mobilizing support device 10 for supporting an injured foot, e.g., having a toe fracture, a deformed toe, or other musculoskeletal injury, includes a shoe portion 12 having an open area 14 surrounding the injury site. The open area 14 is arranged such that contact between the injured musculoskeletal structure of the foot and the shoe portion 12 is reduced or eliminated. Thus, during walking or standing, the shoe portion 12 does not contact the top, end, or sides of the injured musculoskeletal structure. The shoe portion 12 includes a sole 16 , an upper 18 , a lacing system 20 , and a toe cover 22 positioned adjacent the open area 14 to protect uninjured toes from impact with external objects.
[0041] In an alternative embodiment, shown in FIG. 5 , the open area 14 and toe cover 22 are replaced, at least in part, by an enlarged, protective area 23 . Protective area 23 has sufficient dimensions to provide clearance around the injured musculoskeletal structure. For example, the protective area 23 provides a clearance distance of from about 0.125″ to about 1.0″ around the top, end, and sides of the injured toe(s), and is formed of a material that is sufficiently stiff to provide a desired degree of protection to the toes from an impact from the front or above, e.g., an object being dropped on the foot. The protective area 23 can include perforations or other ventilation structure, and can be lined with a low friction material to provide a low friction sliding interface with the toes in case the toes contact the inner surface of the enlarged protective area 23 . Ideally, the open area or enlarged area is configured to allow the injury site to slide relative to the insole, as will be discussed further below, without contact of the upper part of the injured area with the device 10 .
[0042] The lacing system 20 holds in place a portion of the limb that is adjacent to the injury site, such as the heel, ankle, and/or calf, relative to the shoe portion 12 and allows adjustment of the size of the shoe, e.g., to accommodate swelling and to allow the wearer to easily don and remove the shoe. For example, the lacing system can retain musculoskeletal structures of the heel and/or ankle in generally slip-free communication with the upper 18 . The lacing system can be replaced by, and/or supplemented with, any suitable attachment device, for example hook and loop fastener strips such as those available commercially under the tradename Velcro®, or other adjustable straps. Snaps, clips, buckles, and other latching and/or cinching devices can also be used. In some implementations, the upper 18 extends over the ankle area, to provide additional support and immobilization of selected musculoskeletal structures of the foot relative to the shoe portion 12 . For example, the upper 18 may be similar to that of a high top sneaker, a hiking shoe, or boot.
[0043] Referring to FIG. 2 , a liner 24 is disposed inside the shoe 12 , and functions both as an insole and as a low-friction sliding surface. As shown in FIG. 1 , the liner 24 is sized such that it extends beyond the position of the toes when weight is carried by the foot, so that there is room for the toes to slide forward and outward when the wearer steps or stands on the foot. For example, the liner 24 extends horizontally a distance of approximately 0.25″ or more beyond the perimeter of expected movements of the forefoot when walking or standing, in order to ensure adequate space for unimpeded movement of the toes and to provide protection from side impacts. In some embodiments, this side protection can be enhanced by including an upstanding protective portion 25 that extends upward slightly and curves, forming a cavity to partially enclose one or more toes.
[0044] In use, and as shown in FIG. 6 , the liner 24 is disposed juxtaposing an injured musculoskeletal structure and healthy musculoskeletal structures adjacent to the injured musculoskeletal structure. The liner 24 includes a slippery surface 26 that provides an interface having a low coefficient of friction and can be formed of any material that, with the shoe, provides the necessary support for the particular application. The support device 10 additionally includes an interface member 27 that covers at least a portion of the wearer's skin to cooperate with the slippery surface 26 . As illustrated in FIG. 4 , the interface member 27 can be a sock 28 to cover a foot having an injured musculoskeletal structure. Depending on the material of the interface member 27 , suitable materials for the slippery surface 26 can include polytetrafluoroethylene, polyethylene, polypropylene, nylon, or the like. In some cases, the liner 24 may be formed of a heat moldable material, to allow the liner to be shaped to portions of the wearer's foot if desired. For example, the liner can be molded to serve as a supportive footbed, providing arch support and/or other ergonomic or therapeutic support to the foot while walking, in addition to providing a slippery surface for mobilization of injured musculoskeletal structures and/or adjacent musculoskeletal structures. One suitable material for use as the liner 24 is commercially available from Sammons Preston (www.sammonspreston.com) under the tradename Aquaplast®.
[0045] The stiffness or flexibility of all, or parts of, the support device 10 can be achieved by varying the flexibility of the shoe portion 12 and/or of the liner 24 , and can be varied as may be required for treating different conditions. The support device can be or can include portions that are rigid, semi-rigid, or flexible, as appropriate for a given implementation. In most cases, it will be desirable for the support device 10 to be rigid enough to minimize bending motion around the injury site. In some cases, the support device 10 can be supplied to a healthcare provider, or to the end user, with a set of liners 24 having different thicknesses, or other characteristics, to allow the shoe portion 12 to be easily adapted to treat a variety of different injuries or conditions. Similarly, the healthcare provider can be supplied with a plurality of shoe portions 12 having different sizes and/or performance characteristics, to allow the healthcare provider to select a shoe portion 12 to meet a particular patient's needs.
[0046] If desired, the liner 24 can include multiple layers, e.g., an upper layer to provide the slippery surface 26 and a lower layer to provide other properties such as cushioning or shock absorption. In such cases one of the layers, e.g., the upper layer, can provide the desired level of stiffness and support. Alternatively, the shoe portion 12 may include a layer of foam or other cushioning material disposed under the liner 24 , for example the sole 16 can provide cushioning.
[0047] As discussed above, interface member 27 can be formed as a sock 28 of conventional design, and should generally have elastic properties that allow the sock 28 to expand and contract along with the skin of the foot with minimal restriction of the natural expansion or contraction of the foot during standing or walking. In the area A of the injury site ( FIG. 6 ) where unrestrained sliding movement is desired, the fabric of the sock 28 should slide freely and readily on the liner 24 , with the interface therebetween having a low coefficient of friction to mobilize the injured toe. Additionally, musculoskeletal structures surrounding the injured toe, such as healthy musculoskeletal structures of the forefoot, including metatarsal structures, are mobilized. Preferably, the sock 28 includes materials or fibers that allow the foot to breathe and allow perspiration to be vented for general health as well as to minimize the possibility of moisture altering the coefficient of friction at the slippery surface 26 . Other physical properties, e.g.; elasticity or padding, of one or more areas of the sock 28 , or of any interface member 27 , can be varied as may be appropriate for differing health conditions.
[0048] In some implementations, the liner 24 has one or more slippery areas 26 A having a relatively low coefficient of friction, which are disposed juxtaposing the injury site(s), and one or more non-slip areas 29 having a relatively higher coefficient of friction, which are disposed away from the injury site, juxtaposing musculoskeletal structures of the foot that are adjacent to the injury site. For example, the liner can be sized and shaped to juxtapose substantially the entire bottom surface of the wearer's foot. An area 29 of the liner 24 that juxtaposes the wearer's heel has a relatively high coefficient of friction to limit the foot sliding forward in the shoe for limiting movement of the liner 24 relative to the heel or other adjacent healthy musculoskeletal structure of the limb. The area 26 A of the liner 24 that juxtaposes the toes is slippery and has a relatively low coefficient of friction to allow the toes to move as the foot spreads. In some implementations, the liner 24 can be formed by comolding two different polymeric compositions. Additionally, a separate insole portion can be disposed on the liner to limit sliding of the foot. In other implementations, the liner 24 is sized and shaped such that it does not juxtapose the heel and/or instep of the wearer's foot during use, and sliding between the wearer's heel and/or instep can be limited by the shoe portion 12 , as discussed above.
[0049] Referring to FIG. 4 , a sock 28 has a first region 30 juxtaposing the injury site having a low coefficient of friction, e.g., formed of a synthetic fiber or a combination of fibers or yarns, such as nylon and rayon, such as to provide a low friction interface with the slippery surface 26 . A second region 32 , e.g., in the heel area, has a relatively higher coefficient of friction. The second region 32 may be formed using a rougher texture knit, and/or using fibers or yarns having a higher coefficient of friction. This sock construction allows the toes to slide freely relative to the liner 24 as the foot spreads, while helping to keep the rest of the foot in place within the shoe.
[0050] Referring to FIG. 4A , a sock 34 may have two or more layers, to provide desired comfort characteristics. For example, in the embodiment shown the sock includes an inner, moisture wicking layer 36 , e.g., of cotton, a cotton blend, or a hydrophilic synthetic material. Also, in some implementations, the sock 28 or the sock 34 can be constructed of the same material, or combination of materials, throughout. In such embodiments, the variations of coefficient of friction are accomplished by variation of portions of the chosen interfacing surfaces.
[0051] Now referring to FIG. 6 , the interface member 27 can include, integrally or in combination, a splint 40 , or other device configured to support an injured musculoskeletal structure, such as a broken phalange of a toe. The splint 40 can be used for localized support, such as to support a joint or to maintain desired alignment of bone portions of the fracture bone, and can be used with or without a fabric covering the splint 40 , such as the sock 28 . While the splint 40 can be considered an immobilizing device, the slippery surface 26 of the liner 24 still allows the splint 40 to slide freely thereover during standing or walking. Additionally, even when the splint 40 is used, phalanges or metacarpals, can be mobilized relative to the slippery surface 26 of the liner 24 . The slippery surface 26 can be selected from a material that creates a low friction interface with an external surface of the splint 40 , including tape or the like that may be used to attach the splint 40 to the injured musculoskeletal structure. This splint can be rigid, semi-rigid or flexible, and can be formed from any combination of fabrics, foams, suitable metals and/or plastics, such as elastic sleeves, elastic or inelastic bandaging, or conventional splints for digits. To provide sliding interaction, the slippery surface 26 can be formed from polytetrafluoroethylene, polypropylene, or polyethylene, among other materials.
[0052] While the support device 10 of FIGS. 1-6 is suitable for mobilizing support of an injured musculoskeletal structure in the foot, including toes and joints, other support devices can be used to mobilize injured musculoskeletal structures of the foot, or of other parts of the body. Referring to FIG. 7 , a mobilizing support device 50 includes a rigid digit-receiving support shell 60 and a digit-covering interface member 70 for use in supporting an injured musculoskeletal structure of injured finger I, including injured interphalangeal joints and/or injured metacarpophalangeal joints. As illustrated in FIG. 8 , the support shell 60 juxtaposes the phalanges of the injured finger I to reduce injurious contact with foreign objects and undesired bending of the injured finger I. Particularly, the support shell 60 includes a tubular wall 61 having a slippery interior surface 65 and an exterior surface 66 . The tubular wall 61 defines a central cavity 69 accessible from at least one open end of the support shell 60 . The interface member 70 covers the injured finger I and includes a slippery external surface 75 that slides freely against the interior surface 65 of the support shell 60 . The support shell 60 can be formed from any suitable material, including plastics, metals, composite materials, and other materials used for splinting and casting.
[0053] In use, and as illustrated in FIG. 8 , a wearer, or a nurse, physician, or other caregiver, places the interface member 70 over the injured finger I. As discussed above with respect to the interface member 27 , the interface member 70 can include a sock and/or an elastic support material, or other flexible, rigid, or semi-rigid support devices. The wearer or caregiver also places the support shell 60 juxtaposing the injured musculoskeletal structure of the injured finger I. For example, the wearer or caregiver inserts the injured finger I into the support shell 60 such that the support shell partially or fully encloses the injured finger I to protect against injury and to support the injured finger I using an attachment device 80 . The wearer or caregiver secures the support shell 60 to an adjacent healthy finger H, or another adjacent healthy musculoskeletal structure of the limb, such as the hand, wrist, or forearm. The support shell 60 can be attached to a contiguous adjacent musculoskeletal structure, such as the palm, that is adjacent to the injured finger, using the attachment device 80 . For example, tape, ties, straps, or the like, are used to secure the shell 60 to the healthy finger H for limiting movement of the support shell 60 relative to an adjacent healthy musculoskeletal structure of the limb. Additionally, the interior cavity of the support shell 60 is large enough to provide clearance space between the support shell 60 and the interface member 70 to allow for radial movement of the enclosed interface member 70 . The space provided may be from about 0.1″ to about 0.3″ around the circumference of the interface member. Thus, as the healthy finger H moves, and as the support shell 60 moves with the healthy finger H, the injured finger I is mobilized to move freely within the support shell 60 . For additional protection, the distal end of the injured finger I should not extend beyond the distal end of the support shell 60 when in use. The distal end of the support shell 60 can be open, closed, or partially open for ventilation.
[0054] Instead of placing the interface member 70 on the injured finger I, the interface member 70 can be attached to the support shell 60 such that the interior surface 65 is covered by the interface member 70 . The interface member can be formed from an elastic tubular material such that the interface member 70 narrows within the support shell 60 to cushion the injured finger I during use. For example, the ends of the elastic tubular interface member 70 can be attached to the ends 61 and 62 of the support shell 60 such that the middle portion of the tubular elastic interface member 70 is free to slide over and move within the interior surface 65 of the support shell 60 . Thus, the support shell 60 and the interface member 70 in such a configuration can mobilize the injured finger by suspending, cushioning, and sliding. Furthermore, the support shell 60 can be sized such that the injured finger I can move with minimized contact with the interior surface 65 of the support shell 60 . For additional protection, the distal end of the injured finger I should not extend beyond the distal end of the support shell 60 when in use. The distal end of the support shell 60 can be open, closed, or partially open for ventilation.
[0055] As illustrated in FIGS. 9-9B , a support device 50 A includes a tab 90 A included with the support shell 60 A. The tab 90 A provides secure attachment to the wearer's hand H using the attachment device 80 . The tab 90 A can be rigid or resilient to limit or inhibit bending of the injured finger I. Alternatively, the tab 90 A can be flexible such that the tab 90 A does not inhibit bending of the injured finger I at the metacarpophalangeal joint. Support devices with different characteristics may be indicated for different applications. For example, the tab 90 A can be shaped to extend beneath one or more metacarpal heads depending on the circumstances.
[0056] As illustrated in FIGS. 10-10B , a support device 50 B supports an injured thumb T. The tab 90 B is configured as a body-engaging clip with arms 91 . The arms 91 are resilient and deformable to fit over the wearer's hand H. The arms 91 exert a retaining force, such as by spring action, to secure the support device 50 B to the wearer's hand H, as shown in FIG. 10A . Additionally or alternatively, as shown in FIG. 10B , the support device 50 B can be retained in a position juxtaposing the injured musculoskeletal structure of the thumb T using the attachment device 80 wrapped around and/or adhered to the hand H. The tab 90 B can be modified or extended to provide varying engagement or attachment with the hand, wrist or arm as deemed appropriate for a particular condition.
[0057] Referring now to FIGS. 11 and 11A , a support device 100 includes a contoured support shell 110 that, in use and as illustrated in FIG. 11A , juxtaposes musculoskeletal structures in the wearer's arm, wrist, and hand, including fingers. The support shell 110 can be used to support, for example, a fractured metacarpal bone adjacent to the arm, wrist and hand. Thus, the support shell 110 is sufficiently rigid to protect the fracture site. The support device 100 also includes an interface member 120 for covering the finger adjoining the fractured bone, and one or more fingers adjacent thereto. The support shell 110 includes a slippery interior surface 115 to allow the interface member 120 to slide freely thereover to mobilize the fingers adjoining the fractured bone relative to the support shell 110 . Thus, when the interface member 120 is placed over the finger adjoining the fracture and over the adjacent finger and when the support shell 110 is placed juxtaposing the fracture site, as illustrated in FIG. 11A , the interface member 120 mobilizes the fingers to slide freely over the slippery interior surface 115 to reduce forces applied to the fractured metacarpal bone as the fingers are flexed, or as the hand or arm pushes forward or pulls rearward in the support shell. For additional protection, the distal end of the interface member 120 does not extend beyond the distal end of the support shell 110 during use. The distal end of the support shell 110 can be open, closed, or partially open, such as including perforations or other ventilating structure.
[0058] The support shell 110 also includes a tab 117 that retains the support device 110 in position on the wearer's hand and arm. For example, the tab 117 can press inward against the wearer's hand to apply a retaining force. Alternatively, the tab 117 , and/or other portions of the support shell 110 can include a tacky surface that adheres to the wearer's skin. Alternatively, the support device 100 can be secured using a strap, tape, or other attachment device.
[0059] A number of implementations have been described, and share many features. For example, the various support shell implementations described above each extends a distance beyond an anticipated range of motion of an injured musculoskeletal structure, or a musculoskeletal structure adjacent thereto, in order to reduce the opportunity for contact with foreign objects. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention.
[0060] For example, a low friction interface can be created between a surface of any type of support or brace and the wearer's skin. As one example, a soft, elastomeric knee brace can be provided with a low friction surface facing the wearer's skin in the area of the kneecap, and can be worn with a thin liner, e.g., of fabric, that provides a low coefficient of friction interface where it contacts the low friction surface.
[0061] Moreover, in the context of the toe support device discussed above, other areas of the shoe portion 12 can be provided with a sliding surface, in addition to the footbed. For example, if the wearer has an injury to another part of the foot, or if a particular musculoskeletal condition requires additional controlled restraint of motion around the injury site, a sliding surface can be provided on the interior of the shoe upper in the area of that injury.
[0062] Additionally, injured musculoskeletal structures that can be supported and/or protected as described above include broken or bruised bones, torn or strained ligaments, torn or bruised cartilage, or torn or strained muscles. Similarly, malformed structures, and diseased structures, such as musculoskeletal structures affected by rheumatory diseases, can be supported and/or protected as described above. Moreover, while mobilization of musculoskeletal structures has been described above with respect to support and/or protection during healing of an injury, the musculoskeletal structures can be mobilized in many situations, which, for the purpose of this disclosure, are considered to be included in the term healing. For example, an injured musculoskeletal structure can be mobilized during support and/or protection thereof while more critical injuries are addressed. Additionally, in situations involving chronic diseases, pain management or other maintenance procedures are considered to be included in the term healing as used herein.
[0063] Accordingly, other embodiments are within the scope of the following claims. | An injured musculoskeletal structure is mobilized relative to a juxtaposing support structure surface to isolate the injured musculoskeletal structure from forces transferred from adjoining musculoskeletal structures in order to alleviate pain, discomfort, inflammation, and further injury associated with such transferred forces. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 13/221,335, which is a U.S. continuation application filed under 35 USC 111(a) claiming benefit under 35 USC 120 and 365(c) of PCT application JP2010/059211, filed on May 31, 2010, which claims priority to Japanese Application No. 2009-279805 filed on Dec. 9, 2009, the entire contents of the foregoing applications being incorporated herein by reference.
FIELD
The present invention is related to a selection device which selects outputs of a plurality of current sources or voltage sources in a digital/analog (D/A) converter. In particular, the present invention is related to a selection device used in a digital speaker system which converts a digital signal to analog audio using a plurality of coils (units) which are driven by a plurality of digital signals.
BACKGROUND
Generally, when forming a D/A converter, n number of unit cells (U) are selected in order to obtain a current output from the D/A converter corresponding to a digital output signal. In this way, an output (Y) becomes Y=U×n and digital/analog conversion takes place. In the case where a unit cell is a current source (IU), the output current becomes Y=IU×n and in the case where a unit cell is a voltage source (VU), the output voltage becomes Y=VU×n.
However, generally an output value (current value or voltage value) of a current source or a voltage source which forms a unit cell has errors due to the effects of manufacturing variations. When each error held by the unit cell is ε i the output Y can be expressed as the following formula.
Y = U × n + ∑ i = 1 n ɛ i [ Formula 1 ]
That is, there are errors in the formula which express the output Y. Differential linearity error (DNL) which is the indicator of the capability of a D/A converter becomes DNL=ε i because of these errors. Therefore, there is a problem whereby the extent of unit cell manufacturing variation determines the conversion accuracy of the D/A converter.
In order to overcome this type of problem, a dynamic element matching method (referred to as error diffusion technology hereinafter) is proposed for selecting units independently from inputting. For example, the operating principles of an error diffusion circuit are described in the section 8.8.3 of “Delta-Sigma Data Converters” IEEE Press 1997 ISBN 0-7803-1045-4.
When there is an error in a unit cell, the error remains in an adder without being cancelled out when outputting 0 as a value (outputting a value 0). This error deteriorates the DNL as stated above. Therefore, a selection device which is inserted between the D/A converter and a unit cell is used in error diffusion technology. The errors can be smoothed by changing the selection method of the unit cell even if an input to the selection device is the same. Here, “selection” means outputting a signal, which instructs an output of a predetermined value, to the unit cell. In addition, when outputting an instruction signal so that a value 0 is output by a unit cell, that unit cell is said to be not selected. Also, when instructing an output of a value other than 0 to a unit cell according to a selection signal, this unit cell is sometimes called “selected unit cell.”
A method for randomly changing a selection as an algorithm by which a selection device selects unit cells and a method by which a selection device selects in order the cells which are not to be selected are proposed. If an error can be smoothed faster than the necessary frequency (bandwidth) for a D/A converter using oversampling technology, it is possible to shift the error to a higher frequency region than a frequency region necessary for the output of the D/A converter.
In Japan Patent Laid Open H9-18660, a method is proposed whereby by inputting a signal which drives a plurality of unit cells to a selection device and controlling by the output from a circuit which integrates once or more the usage or the non usage of unit cells, the usage frequencies of unit cells are integrated and the selection device is controlled so that the integration results are maintained as a constant
For example, the operation of error diffusion technology using a conventional selection device in a circuit which selects a unit cell using a three value selection signal (−1, 0, 1) is explained below. Furthermore, a selection signal is a signal which instructs a unit cell, which is output with the selection signal, to perform outputting. In addition, in the case of denoting “a selection signal (−1, 0, 1)” the unit cell is instructed by the selection signal to perform outputting a value either corresponding to −1 value which is a negative value, corresponding to a value 0, or corresponding to 1 value which is a positive value. Also, this is sometimes called a 3 value selection signal because an output is instructed which corresponds to either −1, 0 or 1. Furthermore, the unit cell does not operate and a signal which is sometimes not output is also included in the case where an output of a value 0 is instructed to a unit cell.
The operation of an error diffusion method which uses a 3 value selection signal (−1, 0, 1) is explained concisely using FIG. 1 . A D/A converter which performs error diffusion is comprised of a digital signal X ( 301 ), a D/A converter ( 302 ), a plurality of digital selection signals Dn ( 303 ) from the D/A converter ( 302 ), a selection device ( 304 ), a selection signal Sn from the selection device ( 304 ), a plurality of unit cells ( 306 ), a plurality of outputs Ym ( 307 ) from the unit cell and an adder ( 308 ) which adds Ym. The digital selection signals Dn expresses the result of totaling the values of outputs of the unit cells ( 306 ) by the adder ( 308 ).
Table 1 shows a truth table (left side of table 1) of a selection signal Dn ( 303 ) from the D/A converter ( 302 ) and a truth table (right side of table 1) of output signals Ym ( 307 ) of unit cells are shown in table 1. The output of the D/A converter is a 2 value thermometer code and is weighted as below so that it corresponds to a 3 value selection signal by using two bits of the 2 value thermometer code in the unit cell.
TABLE 1
Truth table of
Truth table of D/A output signal (Dn)
cell selection(Ym)
X
D0
D1
D2
D3
D4
D5
D6
D7
Y0
Y1
Y2
Y3
Y
+4
0
0
0
0
1
1
1
1
1
1
1
1
+4
+3
0
0
0
0
1
1
1
0
1
1
1
0
+3
+2
0
0
0
0
1
1
0
0
1
1
0
0
+2
+1
0
0
0
0
1
0
0
0
1
0
0
0
+1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
−1
0
0
0
1
0
0
0
0
0
0
0
−1
−1
−2
0
0
1
1
0
0
0
0
0
0
−1
−1
−2
−3
0
1
1
1
0
0
0
0
0
−1
−1
−1
−3
−4
1
1
1
1
0
0
0
0
−1
−1
−1
−1
−4
Here, i = (1~n/2) and j = (n/2 + 1~n).
In the case where there are 4 (m=4) unit cells as is shown in FIG. 1 and Table 1, it is possible to take the values −4, −3, −2, −1, 0, 1, 2, 3, 4 (2m+1=9) for the output Y. For example, in the case of outputting 0, if 4 unit cells among 8 unit cells are selected by 0, it is possible to output 0.
A D/A converter which uses a multi-value selection signal such as 3 values as is shown in FIG. 1 and Table 1, can reduce the number of unit cells lower than the number of values that can be taken of the output Y. Therefore, because the number of unit cells required for configuring a D/A converter can be reduced, and the required circuit scale, number of parts and area required for installment can be reduced, it is possible to reduce consumption power.
However, a conventional selection device which uses a multi-level selection signal such as 3 values (−1, 0, 1) has the following problem.
For example, when the total of outputs of unit cells by an adder should be 0, in the case where a 3 value selection signal (−1, 0, 1) is used, the output of a value 0 is instructed to 8 unit cells. In other words, 0 is output as the total by not selecting any of the 8 unit cells. In an oversampling D/A converter, in the case where a value close to 0 is output, a value close to 0 is output by the time average between a state in which 1 unit cell is selected among 8 unit cells and a state in which none of the 8 unit cells are selected. In other words, among the selection signals the frequency with which −1, 1, are output decreases. That is, in the case of a 3 value selection signal (−1, 0, 1,), the frequency of outputting a selection signal which is not 0 decreases when outputting a level close to Y=0. In this way, the number of selected unit cells is reduced.
FIG. 2 shows modes in which unit cells Ym are selected in the time direction, by comparing the cases of (a) where a selection device is used and (b) where a selection device is not used, in the case where a 3 value selection signal (−1, 0, 1) is used.
In the examples in FIG. 2 , a D/A converter outputs a signal close to 0, that is, a selection signal so that either 0 or 1 among 4 is selected in turns. As shown in the diagram, a selection signal from the selection device is similarly output so that either 0 or 1 among 4 is selected in turns. In both cases, the same number of unit cells are selected, and in the case where a selection device is not used, a selection signal from a D/A converter always selects the same unit cell, whereas in the case where a selection device is used, the unit cell which is selected by a selection signal from the selection device changes with time. In FIG. 2 , in the case where a selection device is used, an algorithm is used which selects in order cells which are not selected. As a result, at first, (0001) the same as an input is selected, and (0000) is selected in the next time period, and because (0000) is also selected in the next time period, it takes time for all the unit cells to be output equally.
As stated above, in the error diffusion technology, by changing each time the method by which a unit cell is selected, the error is smoothed by equally using all the unit cells. Therefore, when the time required for using unit cells equally becomes longer, the error diffusion effects become weaker and the influence of the error on the unit cells cannot be removed.
As explained above, in the case where the error diffusion technology is used in a selection device which selects a unit cell using a 3 value selection signal (−1, 0, 1), because it is possible to reduce the number of unit cells lower than the number of values which can be output, the number of unit cells necessary for configuring a D/A converter can be decreased, the required circuit scale and number of parts and required area for realizing a semiconductor can be reduced and power consumption can also be reduced. However, when the total of unit cell outputs is a value close to 0 by a selection signal from a D/A converter, the number of cells selected by a selection signal from the selection device decreases. As a result, the time for smoothing the error becomes longer and the effects of the error diffusion become weaker.
In particular, a digital speaker system is proposed in WO2007/135928A1 which directly converts a digital signal into an analog signal using a circuit input with a digital audio signal and which outputs a plurality of digital signals and a plurality of coils (units) which are driven by the plurality of digital signals. In order to realize this digital speaker system, it is preferable to select a unit cell using a 3 value selection signal (−1, 0, 1) in order to secure an SNR with as few coils as possible. In addition, because a manufacturing error of a coil which is a mechanical part has a larger variation error compared to a semiconductor electronic part and can not be ignored, a selection device which has sufficient error diffusion effects is necessary for realizing a digital speaker system.
SUMMARY
One object of the present invention is to solve the problem whereby the number of unit cells selected by a selection signal from a selection device is reduced in the case where a 3 value selection signal (−1, 0, 1) is used when using error diffusion technology in a selection device for selecting a unit cell and in particular, when the total of outputs of unit cells selected by selection signals from a D/A converter is close to 0. In addition, another object of the present invention is to solve the problems whereby the time for smoothing an error becomes longer and the effects of error diffusion become weaker due a decrease in the number of unit cells selected by a selection signal.
As one embodiment of the present invention, a selection device comprising: an acquisition part which acquires a digital selection signal; and an output part which outputs a selection signal to each of a plurality of unit cells which can be instructed to output a value 0; wherein the selection signal instructs an output of a value corresponding to the selection signal to the unit cell; the total of a value of outputs instructed by the selection signals output to the plurality of unit cells is a value determined according to the digital selection signal; and when the output corresponding to the digital selection signal is value 0, a unit cell exists which is output with a selection signal which instructs an output of a value N which is not 0. Here “output of value 0” means an output the value of which is 0. In addition, “output of a value N which is not 0” means an output the value of which is not 0 and a result of measuring the output is indicated by a numerical value N.
According to the present invention, it is possible to prevent a weakening of the effects of the error diffusion when outputting a value 0 or a value close to 0 in the case where an error diffusion technology is used in a selection device which selects a unit cell using a 3 value selection signal (−1, 0, 1). In addition, by the present invention it is possible to reduce by half the number of unit cells compared to the case where the number of unit cells output 2 values by using a 3 value selection signal (−1, 0, 1).
BRIEF EXPLANATION OF DRAWINGS
FIG. 1 is a schematic diagram of a conventional example of a D/A converter which uses a 3 value selection signal,
FIG. 2 is a diagram which explains the operation principles of a selection device used in a conventional example of a D/A converter which uses a 3 value selection signal,
FIG. 3 is a diagram which explains the operation principles of a selection device used in a D/A converter related to one embodiment of the present invention which uses a 3 value selection signal,
FIG. 4 is a comparison diagram of the operations of a selection device which selects 0 by a conventional 3 value selection signal and the operation of a selection device which selects 0 by a 3 value selection signal of the present invention,
FIG. 5 is a schematic diagram of a D/A converter which uses a selection device related to a first embodiment of the present invention,
FIG. 6 is a schematic diagram of a D/A converter which uses a selection device related to a second embodiment of the present invention,
FIG. 7 is a diagram of a conversion table circuit of used in a selection device related to an embodiment of the present invention,
FIG. 8 is a schematic diagram of a selection device of a third embodiment of the present invention,
FIG. 9 is a schematic diagram of a digital speaker system which uses a selection device related to a fourth embodiment of the present invention,
FIG. 10 is a diagram which explains the operation principles of a selection device which selects 0 by a 3 value selection signal related to an embodiment of the present invention,
FIG. 11 is a diagram which explains the operation principles of a selection device which selects 0 by a 3 value selection signal related to an embodiment of the present invention,
FIG. 12 is a schematic diagram of a digital speaker system which uses a selection device related to a fifth embodiment of the present invention,
FIG. 13 is a schematic diagram of a selection device related to a sixth embodiment of the present invention,
FIG. 14 is a schematic of a D/A converter which uses a 2 value selection signal related to one embodiment of the present invention,
FIG. 15 is a diagram for explaining the operation principles of a selection device used in a D/A converter which uses a 2 value selection signal related to one embodiment of the present invention,
FIG. 16 is a structural diagram of a selection device related to a seventh embodiment of the present invention,
FIG. 17 is a structural diagram of a selection device of a selection device related to one embodiment of the present invention,
FIG. 18 is a structural diagram of a selection circuit of a selection device related to one embodiment of the present invention,
FIG. 19 is a structural diagram of a selection circuit of a selection device related to one embodiment of the present invention,
FIG. 20 is a structural diagram of a selection circuit of a selection device related to one embodiment of the present invention, and
FIG. 21 is a structural diagram of a selection circuit of a selection device related to one embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
The operating principles of the present invention are explained as embodiments while referring to the diagrams. Furthermore, it should be noted that the present invention is in no way limited to the embodiments explained below. The present invention can be carried out with changes and modifications without departing from the spirit and the scope of the invention. For example, while in the explanation below the cases where a 3 value selection signal is mainly used are explained, the present invention is not limited to a 3 value selection signal and it is possible to carry out the present invention even in the case where a general multiple value selection signal is used.
As one embodiment of the present invention, FIG. 3 shows a mode in which unit cells are selected in the time direction by comparing the cases (a) in which the selection device of the present invention is not used and in the case (b) in which the selection device of the present invention is used, where a 3 value selection signal (−1, 0, 1) is used.
In this example, a D/A converter outputs a signal close to 0, that is, a selection signal so that either 0 or 1 among 4 is selected in turns. A selection signal is output so that a value 0 is output to a selection cell which is not selected. On the other hand, with regards to the selection signal from the selection device of the present invention, when the total of the output of the unit cell becomes 0, it is not the case in which 0 unit cell from 4 unit cells is selected (no unit cell is selected); and a selection signal is output for performing an instruction for the output of +1 and −1 to 2 unit cells. When 2 unit cells perform output corresponding to +1 and −1 respectively, a level equivalent to 0 is output because these outputs are balanced by the adder. Furthermore, a signal which performs an instruction for the output of +1 is sometimes called “a selection signal which instructs for an output of a +1 value.” Similarly, a selection signal which performs an instruction for the output of −1 is sometimes called “a selection signal which instructs for an output of a −1 value.”
In this way, when the total of the output of a unit cell becomes 0, the selection device outputs an instruction for outputs of +1 and −1 to 2 unit cells, which is not equivalent to that 0 unit cell among 4 unit cells not selected (no unit cell is selected). In this way, the length of time for smoothing errors does not increase and there is no degradation of the effects of error diffusion.
In a conventional selection device, in the case where the total of an output of a unit cell is instructed by a signal input to a selection signal (herein after called a digital selection signal, for example) to become 0, it is only the case in which 0 unit cell is selected among 4 unit cells. In other words, a selection signal is output so that all the unit cells output a value 0. However, one feature of the selection device of the present invention is that value 0 of the result of adding is output by instructing some unit cells to output corresponding to +1 and −1. In addition, it is possible to instruct for each unit cell to perform an output corresponding to each of +2 and −2. Furthermore, it is possible to instruct for two unit cells to perform outputs corresponding to outputting +1 and for a unit cell to perform an output corresponding to −1. Generally, it is one of the features of the present invention that the sum of the total value of the outputs of unit cells which are instructed to perform outputs corresponding to positive values and the total value of the outputs of unit cells which are instructed to perform outputs corresponding to negative values becomes 0.
FIG. 4 shows a comparison of (a) a conventional example and (b) an example by one embodiment of the present invention, in the case where the total of the outputs of unit cells becomes 0 with regards to a combination of signals output by a selection device. According to the selection device related to one embodiment of the present invention, it is understood that the number of unit cells which are instructed to output non-zero by a selection signal increases. Furthermore, while the explanation above was related only to the case where the total of the outputs of unit cells becomes 0, one embodiment of the present invention is also effective in the case where the total of the outputs other is than 0, that is, when m−2 or less among m is selected and output is performed. In the case where m−2 or more is selected and output is performed, no problem arises because the number of selected unit cells increases and even in the case where a unit cell is selected using a 3 value selection signal (−1. 0, 1), there is no degradation of the effects of error diffusion.
A first example of a D/A converter which uses a selection device ( 700 ) of the present invention is shown in FIG. 5 . A digital signal X ( 701 ) is input to the D/A converter ( 700 ) and a plurality of digital selection signals Dn ( 703 ) which are obtained are input to a conversion table circuit ( 710 ) and a plurality of second digital selection signals Fn ( 711 ) are obtained. The second digital selection signals are input to a selection device ( 704 ) and a plurality of selection signals Sn ( 705 ) are obtained from the selection device ( 704 ). The plurality of selection signals Sn ( 705 ) select a plurality of unit cells ( 706 ), outputs Ym ( 707 ) of the plurality of unit cells are totaled together by an adder ( 708 ) and an output signal Y is obtained.
Table 2 shows truth tables for a plurality of first digital selection signals Dn from a D/A converter, a plurality of second digital selection signals Fn from the conversion table circuit, and output signals Ym from unit cells. The truth table for the plurality of the first digital selection signals Dn is shown on the left, the truth table for the plurality of the second digital selection signals Fn from a conversion table circuit is shown in the middle, and the truth table for output signals Ym of unit cells is shown on the right.
TABLE 2
By outputting Fn=(00011000) in the case where Dn=(00000000) is input to the conversion table circuit, when the total of the outputs of the unit cells becomes 0, 0 unit cell is not selected among 4 unit cells but it is possible to output a selection signal in order to instruct 2 unit cells to perform outputs corresponding to +1 and −1.
It is possible to obtain one effect of the present invention by arranging an arbitrary conversion table circuit as a stage before a conventional selection device as is shown in the selection device ( 700 ) of the present invention.
A second example of a D/A converter which uses a selection device ( 800 ) related to one embodiment of the present invention is shown in FIG. 6 . A digital signal X ( 801 ) is input to the D/A converter ( 800 ) and a plurality of first digital selection signals Dn ( 803 ) which are obtained are input to a conversion table circuit ( 810 ) and a plurality of second digital selection signals Fn ( 811 ) are obtained. The second digital selection signals are input to a selection device ( 804 ) and a plurality of selection signals Sn ( 805 ) are obtained from the selection device ( 804 ). The plurality of selection signals Sn ( 805 ) select a plurality of unit cells ( 806 ), outputs Ym ( 807 ) of the plurality of unit cells are totaled together by an adder ( 808 ) and an output signal Y is obtained. A control signal ( 821 ) from a sequential control circuit ( 820 ) is input to the conversion table circuit ( 810 ).
A plurality of conversion tables is included in the conversion table circuit ( 810 ) in the second example, and one is selected among the plurality of conversion tables by the control signal ( 821 ) from the sequential control circuit ( 820 ). If the sequential control circuit is formed with a counter circuit, it is possible to have a configuration where a unique conversion table is selected in order among the plurality of conversion tables. It is possible to configure the sequential control circuit with an arbitrary sequential circuit such as a random signal generation circuit.
A truth table of the first digital selection signal Dn from the D/A converter of the second example, a truth table of the second digital selection signal Fn from the conversion table circuit, and a truth table of output signals Ym of unit cells are shown in table. 3. The truth table for a plurality of the first digital selection signals Dn is shown on the left of table 3, the truth table for a plurality of the second digital selection signals Fn from a conversion table circuit is shown in the middle of table 3, and the truth table for output signals from unit cells is shown on the right of table 3. Two types of signal Fn=(00011000) and Fn=(00111100) can be selected in the case where the conversion table circuit is input with Dn=(00000000). When the selection device outputs 0, 0 unit cell from 4 cells is not selected, but a selection signal is output so that two unit cells become +1 and −1, or a selection signal is output so that 4 unit cells become +1 +1 and −1 −1, is selected by a control signal from the sequential control circuit.
TABLE 3
In table 3, an example of a conversion table circuit having a plurality of types of output, for example 2, outputs Fn=(00011000) and Fn=(00111100) with respect to Dn=(00000000) is shown, however, a plurality of Fn maybe corresponded to an arbitrary Dn. In addition, an output Fn=(00000000) may also be corresponded with Dn=(00000000), which is a conventional example. Because the output Fn=(00000000) does not have a selected unit cell, the amount of power consumed by a selected cell becomes smaller. It is possible to optimize consumption power and error diffusion effects in a selected cell by outputting the output Fn=(00000000) at an appropriate frequency with respect to the conventional example Dn=(00000000).
An example of a conversion table circuit ( 900 ) of the present invention is shown in FIG. 7 . The conversion table circuit of the present example outputs an output Fn=(00011000) with respect to Dn=(00000000). The conversion table circuit is comprised of a circuit ( 901 ) which detects that Dn is (00000000) and a set circuit ( 902 ) which receives a signal from the detection circuit and outputs Fn=(00011000). An arbitrary logic circuit or memory circuit or an adder and subtractor can be used in the conversion table circuit other than the present example.
A third example of the present invention is shown in FIG. 8 . A first digital selection signal Dn ( 1001 ) and a plurality of second digital selection signals Fn ( 1003 ) from a conversion table circuit ( 1002 ) are provided and the second digital selection signals Fn are input to a selection circuit ( 1004 ). With regard to 3 value selection signals Sn ( 1005 ) from a selection circuit, the selection circuit operates so that unit cells are selected in order of low selection frequency by calculating the usage frequency of a unit cell by a selection signal with at least 2 or more integration circuits ( 1010 a , 1010 b ) and by a delay element and an adder. The conversion table circuit ( 1002 ) is input with a control signal ( 1021 ) from a sequential control circuit ( 1020 ).
The examples of the present invention are not limited to the first to third examples. For example, by arranging an arbitrary conversion table circuit between a D/A converter and an error diffusion selection circuit, it is possible to configure a selection device which outputs a selection signal so that an even number of unit cells output +1 and −1 instead of outputting 0s. At this time, the number of unit cells which output +1 and the number of cells which output −1 become equal.
While an example of a general D/A converter is used in the first to third examples of the present invention, it is possible to adopt a digital speaker system as a specific example of a D/A converter. For example, as is proposed in WO2007/1359281A1, one embodiment of the present invention can also be applied to a selection device for a digital speaker system which directly converts a digital signal to analog audio using a circuit which is input with a digital audio signal and outputs a plurality of digital signals and a plurality of coils (units) driven by the plurality of digital signals. The present invention can also be used in a selection device for a digital speaker system which drives a coil using a 3 value selection signal for securing a necessary SNR with few coils.
A fourth example of a digital speaker system which uses a selection device ( 1100 ) of the present invention is shown in FIG. 9 . A digital signal X ( 1101 ) is input to a D/A converter ( 1102 ) and the obtained plurality of first digital selection signals Dn ( 1103 ) is input to a conversion table circuit ( 1110 ) and a plurality of second digital selection signals Fn ( 1111 ) are obtained. The second digital signal is input to a selection device ( 1104 ) and a plurality of selection signals Sn ( 1105 ) are obtained from the selection device ( 1104 ). The plurality of selection signals Sn ( 1105 ) select a plurality of unit cells ( 1106 ) and a plurality of outputs Ym ( 1107 ) of the unit cells are totaled by a speaker device ( 1108 ) comprised of a plurality of coils (units) and an output signal Y is obtained. A control signal ( 1111 ) from a sequential control circuit ( 1120 ) is input to the conversion table circuit ( 1110 )
A second operation example of a selection device of the present invention is shown in FIG. 10 . FIG. 10 compares the case (a) when a selection device related to one embodiment of the present invention is not used and (b) when a selection device related to one embodiment of the present invention is used, in a time direction of selections of unit cells Ym in the case of using a 3 value (−1. 0, +1) selection signal.
The same as the explanation above, a signal close to 0 is output by the total of outputs of unit cells both in the case when a selection device related to one embodiment of the present invention is used as shown in FIG. 10 and in the case it is not used. In other words, a selection signal which selects 0 or 1 unit cell among 4 unit cells in turns is output. In the second operation example of the selection device related to one embodiment of the present invention, when the total of outputs of unit cells becomes 0, a selection signal does not select 0 unit cell among 4 unit cells, but operates so that a selection signal is output which instructs that −1 is output when 0 is to be output again after once instructing an output of +1. In the first operation example of a selection device related to one embodiment of the present invention a selection signal is output so that +1 and −1 are output at once, while in the second operation example of a selection device of the present invention, 0 is output by instructing a unit cell to output +1 and −1 in time series. 0 is output because +1 and −1 are cancelled out in time series by an adder circuit. That is, the total of an output of a unit cell becomes 0 by taking a time average.
As is the same as the first operation example of the selection device related to one embodiment of the present invention, 0 unit cell is not selected among 4 unit cells when 0 is to be output, but when the selection device outputs a selection signal so that 1 unit cell becomes +1 and −1 in time series, the length of time for smoothing errors does not increase and the effects of error diffusion are not lost.
A third operation example of a selection device related to one embodiment of the present invention is shown in FIG. 11 . FIG. 11 compares the case (a) when a selection device related to one embodiment of the present invention is not used and (b) when a selection device related to one embodiment of the present invention is used, in a time direction of selections of unit cells Ym in the case of using a 3 value (−1. 0, +1) selection signal.
As is the same as the explanation above, a signal close to 0, that is, a selection signal which selects 0 or 1 unit cell among 4 unit cells in turns is output. In the third operation example of the selection device related to one embodiment of the present invention, when the total of outputs of unit cells becomes 0, a selection signal does not select 0 unit cell among 4 unit cells, but operates so that a selection signal is output which instructs that −2 (+2) is output when 0 is output again after once instructing an output of +1 (−1), and when 0 is output again, instructs a unit cell so that +1 (−1) is output. In the first operation example of a selection device related to one embodiment of the present invention, for example, a selection signal is output so that +1 and −1 are respectively output at once by an even number of unit cells, while in the second operation example of a selection device related to one embodiment of the present invention, 0 is output by instructing one or a plurality of unit cells to output +1, −2 and +1 in time series. 0 is output because +1, −2 and +1 are cancelled out in time series by an adder. In this case also, the average time of the total of an output of a unit cell is 0.
As is the same as the first operation example of the selection device related to one embodiment of the present invention, 0 unit cell is not selected among 4 unit cells when 0 is to be output, but when the selection device outputs a selection signal so that the output of a unit cell becomes +1, −2 and +1 in time series, the length of time for smoothing errors does not increase and the effects of error diffusion are not lost.
A fifth example of a digital speaker system which uses a selection device ( 1400 ) related to one embodiment of the present invention is shown in FIG. 12 . A digital signal X ( 1401 ) is input to a D/A converter ( 1402 ) and the obtained plurality of first digital selection signals Dn ( 1403 ) are input to a conversion table circuit ( 1410 ) and a plurality of second digital selection signals Fn ( 1411 ) are obtained. The second digital signal is input to a selection device ( 1404 ) and a plurality of selection signals Sn ( 1405 ) are obtained from a selection device ( 1404 ). The plurality of selection signals Sn ( 1405 ) select a plurality of unit cells ( 1406 ) and a plurality of outputs Ym ( 1407 ) of the unit cells are totaled by a speaker device ( 1408 ) comprised of a plurality of coils (units) and an output signal Y is obtained. A control signal ( 1421 ) from a sequential control circuit ( 1420 ) is input to the conversion table circuit ( 1410 ). The control signal ( 1411 ) is input to a circuit which includes at least one or more delay elements ( 1430 ) and the output signal ( 1431 ) is fed back to a sequential control circuit ( 1420 )
By feeding back control data of a MAP circuit ( 1410 ) to a sequential control circuit via a delay device as is shown in FIG. 12 , it is possible to realize a circuit which cancels out an output value in time series such as that in the second and third operation examples of the selection device described above.
A sixth example of a selection device related to one embodiment of the present invention is shown in FIG. 13 . A first selection signal Dn ( 1501 ) and a plurality of second selection signals Fn ( 1503 ) from a conversion table circuit ( 1502 ) are provided, and the second selection signals Fn ( 1503 ) are input to a selection device ( 1504 ). 3 value selection signals Sn ( 1505 ) from a selection circuit operate the selection circuit by calculating the usage frequency of a unit cell by a selection signal with at least 2 or more integration circuits ( 1510 a , 1510 b ) configured with a delay element and an adder. The conversion table circuit ( 1502 ) is input with a control signal ( 1521 ) from a sequential control circuit ( 1520 ) and an internal state value ( 1521 ) of the integration circuits is input to the sequential control circuit ( 1520 )
In this way, it is possible to adaptively control the operation of the sequential control circuit according to the internal state of the selection device by inputting an internal state value of the integration circuits to the sequential control circuit. That is, in the case where the internal state of an integration circuit which controls the selection device becomes unstable (the length of time for smoothing an error becomes longer) it is possible to adaptively operate the MAP circuit ( 1502 ) and stably operate the selection device. In this way, it is possible to optimize the relationship between the length of time for smoothing an error and power consumption.
FIG. 14 concisely explains the operation of an error diffusion circuit which is used in a selection device related to another embodiment of the present invention. A D/A converter which performs error diffusion is comprised of a digital signal X ( 101 ), a D/A converter ( 102 ), a plurality of digital signals Dn ( 103 ) from the D/A converter, a selection device ( 104 ), a selection signal Sn ( 105 ) from the selection device, a plurality of unit cells ( 106 ), a plurality of outputs Yn ( 107 ) from the unit cells, and an adder ( 108 ) which adds the Yn.
In table 4, a truth table of the digital selection signal Dn ( 103 ) from the D/A converter is shown (left side), and a truth table of the output signal Yn ( 107 ) of unit cells is shown (right side). As is shown in table 4, the output of the D/A converter is a thermometer code. Furthermore, the unit cell is weighted as in table 5 with respect to a 2 value selection signal.
TABLE 4
Truth table of D/A output signal (Dn)
Truth table of cell selection(Yn)
X
D0
D1
D2
D3
D4
D5
D6
D7
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7
Y
+4
1
1
1
1
1
1
1
1
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
+4
+3
1
1
1
1
1
1
1
0
0.5
0.5
0.5
0.5
0.5
0.5
0.5
−0.5
+3
+2
1
1
1
1
1
1
0
0
0.5
0.5
0.5
0.5
0.5
0.5
−0.5
−0.5
+2
+1
1
1
1
1
1
0
0
0
0.5
0.5
0.5
0.5
0.5
−0.5
−0.5
−0.5
+1
0
1
1
1
1
0
0
0
0
0.5
0.5
0.5
0.5
−0.5
−0.5
−0.5
−0.5
0
−1
1
1
1
0
0
0
0
0
0.5
0.5
0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−1
−2
1
1
0
0
0
0
0
0
0.5
0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−2
−3
1
0
0
0
0
0
0
0
0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−3
−4
0
0
0
0
0
0
0
0
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−0.5
−4
TABLE 5
Sn
Yn
0
+0.5
1
−0.5
As is shown in FIG. 14 and table 4, in the case where there are 8 unit cells (n=8), it is possible for the output Y to take the values −4, −3. −2, −1, 0, 1, 2, 3, 4 (n+1=9). For example, in the case where 0 is to be output, when 4 unit cells among the 8 unit cells are instructed to output +0.5, and the remaining 4 unit cells are instructed to output −0.5, −2 and +2 are cancelled out by the adder and it is possible to output 0.
FIG. 15 compares the case where an error diffusion selection device is used and the case where it is not used, in a time direction of a selection of unit cells Yn. In the example of FIG. 15 , a D/A converter outputs a signal close to 0, that is, a selection signal which selects 4 or 5 among 8 in turn. As is shown in the diagram, a selection signal from the selection device outputs a selection signal so that 4 or 5 unit cells are selected in turns among 8 similarly. Both are signals which select the same number of unit cells, however, while the selection signal from the D/A converter always selects the same unit cells, the unit cells selected by the selection signal from the selection device change with time. In FIG. 15( b ) , because an algorithm which selects cells which have not been selected in order, first, in the time period after (000111111) the same as the input is selected, (11100001) is selected, and in the next time period, the selected cell such as (00011110) changes, and because all the unit cells are used equally during a short time period, errors are smoothed.
The operation of an example of a unit cell weighted with (−0.5, +0.5) with respect to a 2 value selection signal was explained above, however, the same effects can also be obtained in the case where other weightings are used. For example, because it is possible to take the values Y=0, 1, 2, 3, 4, 5, 6, 7, 8 (n+1=9) in the case where a weighting of (0, 1) is used, for example, in the case where 4 is output, when 4 unit cells are selected with 1 among 8 unit cells, and the remaining 4 unit cells are selected with 0, it is possible to use error diffusion technology by sequentially changing a method which selects 4 unit cells among 8 unit cells every time 4 is output the same as in the case where 4 can be output (−0.5, +0.5).
A seventh example of a selection device related to one embodiment of the present invention is shown in FIG. 16 . First digital selection signals Dn ( 1603 ) and a plurality of second digital selection signals Fn ( 1611 ) from a conversion table circuit ( 1610 ) are provided. The plurality of second digital selection signals Fn ( 1611 ) are input to a plus side selection circuit ( 1604 a ) and a minus side selection circuit ( 1604 b ). Here, “a plus side selection circuit” means a circuit which selects a unit cell which is instructed to perform an output of a plus side value. For example, the plus side selection circuit ( 1604 a ) outputs 0 or 1 as a selection signal. Similarly “a minus side selection circuit” means a circuit which selects a unit cell which is instructed to perform an output of a minus side value. For example, the minus side selection circuit ( 1604 a ) outputs 0 or −1 as a selection signal. In addition, a second digital selection signal which is input to a plus side selection circuit is referred to as “a plus side second digital selection signal” and a second digital selection signal which is input to a minus side selection circuit is referred to as “a minus side second digital selection signal.” In addition, a signal output by a plus side selection circuit is referred to as “a plus side selection signal” and a signal output by a minus side selection circuit is referred to as “a minus side selection signal.”
Furthermore, in the explanation below, a truth table (data which determines the relationship between a digital signal X ( 1610 ) and the second digital selection signal ( 1611 )) used by a conversion table circuit ( 1610 ) is not limited to being used in the first example to the sixth example. It is possible to use an arbitrary truth table.
3 value selection signals Sn ( 1605 a , 1605 b ) which are output as a whole by the two selection circuits ( 1604 a , 1604 b ) are output by calculating the frequency of the selection of the unit cell by the selection signals. At this time, each of the plus side selection device ( 1604 a ) and the minus side selection device ( 1604 b ) operate so that unit cells are selected in order from the smallest frequency of selection. In addition, a control signal ( 1621 ) is input to the conversion table circuit ( 1602 ) from the sequential control circuit ( 1620 ).
In this way, by inputting the plus side and minus side of a second digital selection signal Fn to separate selection circuits, it is possible to independently stabilize an operation for smoothing errors in the case where a plus side cell is selected and an operation for smoothing errors in the case where a minus side cell is selected. By this operation, it is possible to optimize the length of time for smoothing errors and power consumption.
An example of a selection circuit ( 1700 ) used in one embodiment of the present invention is shown in FIG. 17 . A plurality of second digital selection signals Fn ( 1701 ) from a conversion table circuit is provided and the second digital selection signal Fn is input to a selection circuit ( 1702 ). 3 value selection signals Sn ( 1705 ) output by the selection circuit is input to a circuit having at least two or more integration circuits configured with a delay element and an adder. An output signal ( 1707 ) from a first integration circuit ( 1705 ) is input to a second integration circuit ( 1706 ) and the selection signal Sn ( 1705 ) is accumulated. The usage frequency of a unit cell is represented by the result of this accumulation. By inputting an output signal ( 1708 ) from the second integration circuit ( 1706 ) to a sort circuit ( 1710 ) a signal which selects unit cells in order from the smallest selection frequency is generated and the selection circuit is controlled.
Another example of a selection circuit ( 1800 ) which is used in one embodiment of the present invention is shown in FIG. 18 . A plurality of second digital selection signals Fn from a conversion table circuit is divided into the plus side ( 1801 a ) and the minus side ( 1801 b ). The plus side second digital selection signals ( 1801 a ) are input to a selection circuit ( 1802 a ) and selection signals Sn ( 1804 a ) are output. The selection signals Sn are sequentially input to at least two or more integration circuits ( 1805 a , 1806 a ) configured with a delay circuit and an adder, and the output of the integration circuit ( 1806 a ) is input to a sort circuit ( 1810 a ). The sort circuit ( 1810 a ) generates a signal ( 1803 a ) which selects a unit cell which outputs a plus side value in order from the smallest selection frequency and the selection circuit ( 1802 a ) is controlled. In addition, the minus side second digital selection signals ( 1801 b ) are input to a selection circuit ( 1802 b ) and selection signals Sn ( 1804 b ) are output. The selection signals Sn are sequentially input to at least two or more integration circuits ( 1805 b , 1806 b ) configured with a delay circuit and an adder, and the output of the integration circuit ( 1806 b ) is input to a sort circuit ( 1810 b ). The sort circuit ( 1810 b ) generates a signal ( 1803 b ) which selects a unit cell which outputs a minus side value in order from the smallest selection frequency and the selection circuit is controlled. By inputting a plus side second digital selection signal and minus side second digital selection signal to separate selection circuits it becomes possible to independently stabilize an operation for smoothing errors in the case where a unit cell which outputs a plus value is selected and an operation for smoothing errors in the case where a unit cell which outputs a minus value is selected, and it is also possible to optimize the relationship between the length of time for smoothing errors and power consumption.
Another example of a selection circuit ( 1900 ) used in one embodiment of the present invention is shown in FIG. 19 . A plurality of second digital selection signals Fn from a conversion table circuit are divided into a plus side second selection signal ( 1901 a ) and a minus side selection signal ( 1901 b ). The plus side second digital selection signal ( 1901 a ) is input to a selection circuit ( 1902 a ) and selection signals Sn ( 1905 a ) are output. The minus side second digital selection signal ( 1901 b ) is input to a selection circuit ( 1902 b ) and selection signals Sn ( 1905 b ) are output. After the selection signals Sn output by the plus side selection circuit ( 1902 a ) and the minus side selection circuit ( 1902 b ) are added by an adder ( 1905 ), the selection signals Sn are sequentially input to at least two or more integration circuits ( 1906 , 1907 ) configured with a delay circuit and an adder. The output of the integration circuit ( 1907 ) is input to a sort circuit ( 1908 ). The sort circuit ( 1908 ) generates a signal ( 1903 b ) which selects a plus side unit cell and a signal which selects a minus side unit cell in order from the smallest selection frequency, and each selection circuit is controlled. In the present invention, it is possible to reduce the number of necessary integration circuits by adding signals from a plus side selection circuit and signals from a minus side selection circuit using an adder. In addition, because there are separate selection circuits it becomes possible to independently stabilize an operation for smoothing errors in the case where a plus side unit cell is selected and an operation for smoothing errors in the case where a minus side unit cell is selected, and it is also possible to optimize the relationship between the length of time for smoothing errors and power consumption.
Another example of a selection circuit ( 2000 ) used in one embodiment of the present invention is shown in FIG. 20 . A plurality of second digital selection signals Fn from a conversion table circuit are divided into a plus side digital selection signal ( 2001 a ) and a minus side digital selection signal ( 2001 b ), which are input into each selection circuit. The plus side second digital selection signal ( 2001 a ) is input to a selection circuit ( 2002 a ) and selection signals Sn ( 2005 a ) are output. The minus side second digital selection signal ( 2001 b ) is input to a selection circuit ( 2002 b ) and selection signals Sn ( 2005 b ) are output. After the plus side and minus side selection signals Sn are added by an adder ( 2005 a ) they are sequentially input to at least two or more integration circuits ( 2006 a , 2007 a ) configured with a delay element and an adder. The output of the integration circuit ( 2007 a ) is input to a sort circuit ( 2008 a ). The sort circuit ( 2008 a ) generates a signal ( 2003 a ) which selects a plus side unit cell in order from the smallest selection frequency and the selection circuit ( 2002 a ) is controlled. Similarly, after the plus side and minus side selection signals Sn are added by the adder ( 2005 b ) they are sequentially input to at least two or more integration circuits ( 2006 b , 2007 b ) configured with a delay element and an adder. The output of the integration circuit ( 2007 b ) is input to a sort circuit ( 2008 b ). The sort circuit ( 2008 b ) produces a signal ( 2003 b ) which selects a minus side unit cell in order from the smallest selection frequency and the selection circuit ( 2002 b ) is controlled. An addition coefficient is independently selected when the signals from the plus side and minus side selection circuits are added by an adder and by weighting and adding using the addition coefficient it is possible to optimize an error diffusion operation. In addition, because there are separate selection circuits it becomes possible to independently stabilize an operation for smoothing errors in the case where a plus side unit cell is selected and an operation for smoothing errors in the case where a minus side unit cell is selected, and it is also possible to optimize the relationship between the length of time for smoothing errors and power consumption.
In one embodiment of the present invention, a signal which selects unit cells in order from the smallest selection frequency is generated using a sort circuit and a selection circuit is controlled as in the examples stated above. However, an embodiment of the present invention is not limited to using a sort circuit. A logic circuit following arbitrary algorithms may be used instead of a sort circuit.
Another example of a selection circuit ( 2100 ) used in one embodiment of the present invention is shown in FIG. 21 . A plurality of second digital selection signals Fn from a conversion table circuit are divided into a plus side second digital selection signal ( 2101 a ) and a minus side second digital selection signal ( 2101 b ), the plus side second digital selection signal ( 2101 a ) is input to a selection circuit ( 2102 a ) and a selection signal ( 2105 a ) is output. The minus side second digital selection signal ( 2101 b ) is input to a selection circuit ( 2102 b ) and a selection signal Sn ( 2105 b ) is output. After the plus side and minus side selection signals Sn are added by an adder ( 2105 ) they are sequentially input to at least three ( 2106 , 2107 , 2108 ) or more integration circuits configured with a delay element and an adder. The output of the integration circuit ( 2108 ) is input to a logic circuit ( 2103 a ) and a signal ( 2103 a ) which selects a plus side unit cell and a signal ( 2103 b ) which selects a minus side unit cell according to an algorithm of the logic circuit are produced. Each selection circuit is controlled respectively by the signal ( 2103 a ) and the signal ( 2103 b ). In the present example, the selection data is filter calculated using at least three or more integration circuits. Because it is possible to obtain stable error diffusion effects regardless of the number of selections of an element per time period by using three or more integration circuits, it is possible to apply the present invention to a digital speaker device which uses a multi-unit.
In the explanation above, a selection device is disclosed which includes an acquisition part (for example, the conversion table circuit ( 710 )) which acquires a digital selection signal, and an output part (for example, the selection circuit ( 704 )) which outputs a selection signal to each of a plurality of unit cells which can be instructed to output a value 0, wherein a digital selection signal is a signal which instructs the output of a value which corresponds to a selection signal to a unit cell, the total of the values of selection signals which are output to a plurality of unit cells is a value which is determined according to a digital selection signal, and if an output corresponding to a digital selection signal is 0, a unit cell which is output with a selection signal which instructs the output of a value Ns which are not 0 exist. Here, a selection signal may be a multi-value signal such as a 3 value signal (1, 0, −1) or a 5 value signal (2, 1, 0, −1, −2).
In addition, in the case of supposing that there are no errors in the outputs of unit cells, it is possible to obtain a value 0 as a result of the addition (it is also possible to include measuring average time in “addition”) of the total value of outputs of unit cells which are output with selection signals which instruct an output of a plus value and the total value of outputs of unit cells which is output with selection signals which instruct an output of a minus value.
In addition, if the output corresponding to a digital selection signal is not a value 0, a unit cell which is output with a selection signal which instructs an output of a plus signal and a unit cell which is output with a selection signal which instructs an output of a minus signal exist, and the total value of outputs of unit cells which are output with selection signals which instruct outputs of plus values and the total value of outputs of unit cells which are output with selection signals which instructs outputs of minus values can become a value of an output corresponding to a digital selection signal.
In addition, a selection device is disclosed having an acquisition part (for example, the conversion table circuit ( 1610 )) which acquires a digital selection signal, and an output part (for example, the selection circuits ( 1604 a , 1604 b )) which output a selection signal to a plurality of unit cells, wherein the output part includes a first selection circuit (for example, the selection circuit ( 1604 a )) which outputs a plus value, and a second selection circuit (for example, the selection circuit ( 1604 b )) which outputs a minus value.
In addition, this selection device may also include a first integration part (for example, the integration circuit ( 1805 a , 1806 a ) which accumulates selection signals which are output by the first selection circuit, and a second integration part (for example, the integration circuits ( 1805 b , 1806 b ) which accumulates selection signals which are output by the second selection circuit. In this case, the first selection circuit can select unit cells in order from the smallest selection frequency which represents the results of the accumulation by the first integration part and the second selection circuit can select unit cells in order from the smallest selection frequency which represents the results of the accumulation by the second integration part.
In addition, the first integration part may accumulate with an addition coefficient the sum of weighting a selection signal which is output by the first selection circuit and a selection signal which is output by the second selection circuit. In addition, the second integration part may accumulate using an addition coefficient the sum of weighting a selection signal which is output by the second selection circuit and a selection signal which is output by the first selection circuit. At this time, it is not necessary that the addition coefficient used by the first integration part and the addition coefficient used by the second integration be the same.
In addition, the selection device does not need to be arranged with two integration parts. One integration part (third integration part) may be arranged. In this case, the third integration part accumulates the sum of a selection signal which is output by the first selection circuit and a selection signal which is output by the second selection circuit. Also, each of the first selection circuit and the second selection circuit selects unit cells in order from the smallest selection frequency which represents the result of accumulation by the third integration part.
Furthermore, the first integration part, second integration part and third integration part can be arranged with one, two or three integration circuits. In the case where two or more integration circuits are arranged, it is possible to connect the integration circuits in series as shown in FIG. 17 and FIG. 21 . | Provided is a selection device including an acquisition section for acquiring digital selection signals, and an output section for outputting selection signals to respective unit cells, each unit cell capable of being commanded to output the value zero. The selection device is characterized in that: each selection signal is for commanding the unit cell to output a value corresponding to that selection signal; the sum of the values to be output as commanded by the respective selection signals, which are output to the respective unit cells, is a value determined in association with the digital selection signal; and if the output corresponding to the digital selection signal is the value zero, then selection signals each commanding to output a non-zero value (N) are output to some of the unit cells. | 7 |
CLAIM OF PRIORITY
[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Ser. No. 60/824,381, filed Sep. 1, 2006, the entire disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention pertains to methods and devices for treating cutaneous disease.
BACKGROUND
[0003] Fungal infection, especially of the toes and feet is a common problem. One such fungus, tinea pedis, causes athelete's foot. Fungal infections may also occur in the nail bed, matrix, or nail plate of fingers and toes. The medical terms for this type of fungal infection are onychomycosis or tinea unguium. Fungal infections of the nail are due to many factors and may affect a significant portion of the population in developed countries. The most common type of fungal nail infection involves the end of the nail when the fungi invade the hyponychium. Initially, the nail plate splits from the nail bed, a process called onycholysis. The end of the nail then turns yellow or white, and keratin debris develops under the nail causing further separation. The fungus grows in the substance of the nail, causing it to become fragile and crumble. The fungal organism responsible for most fungal nail infections is trichophyton rubrum.
[0004] Once the fungus establishes itself under a toenail or fingernail, it is difficult to cure. Topical preparations are not usually effective in treating fungal nail infections. The only generally effective approach involves oral medications that enter the nail from the blood. All of these medications have significant side effects and interact with many other medications. Anyone taking oral antifungal medications must have periodic tests done to monitor liver and blood cell function. The medications are also expensive and must be taken for several months.
SUMMARY
[0005] Described herein are methods and apparatus for treating fungal nail infections and similar diseases with light therapy. In one embodiment, an apparatus that utilizes one or more blue light emitting diodes (LED) to irradiate fungus residing under and around the nail is applied externally to a toe or finger in order to kill the fungus and restore normal nail growth. Light therapy may be applied in this manner periodically at scheduled times. Another embodiment involves the use of a bootie-like structure having blue light emitting diodes for irradiating the toes, heal, and foot bottom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS. 1 through 3 illustrate different embodiments of apparatus for delivery cutaneous light therapy.
DETAILED DESCRIPTION
[0007] Research has demonstrated the effectiveness of blue light at approximately 470 m wavelength in causing retarded growth and cell death. Such effects have been found to occur with light exposure time periods of between 8 and 72 hours. Described herein are apparatus having one or more blue light LEDs that are adapted to kill fungus residing on the body on such areas as the fingers, toes and feet. The blue light LEDs may be designed to emit light at a wavelength of 470 nm or within a range of 400 to 500 nm and with an intensity of 7500 mcd or within a range of 1000 to 10000 mcd.
[0008] One embodiment includes a clip designed to fit over toe or finger in a manner similar to clips worn on the finger for use in pulse oximetry. The clip in this embodiment is a toe or finger clip that includes two hinging portions with a spring to keep the clip closed around the toe or finger. The clip may contain one or more blue light LEDs mounted in the clip light is emitted into the nail when the clip is worn. The apparatus may include a battery, an on/off switch, and control circuitry for controlling the operation of the LEDs, all or part of which may be incorporated into the clip or be located externally.
[0009] Another embodiment includes a bootie that may be worn on the foot while sitting or laying down such as during sleep. The bootie may contain an array of blue LEDs across the front, back and bottom facing towards the inserted foot. The bootie may also incorporate a clear foam-like padding between the LEDs and foot for providing comfort. The apparatus may include a battery, an on/off switch, and control circuitry for controlling the operation of the LEDs, all or part of which may be incorporated into the bootie or be located externally. In one embodiment, power for the LEDs within the bootie is provided by batteries housed on a cuff worn around the ankle above the foot needing treatment, and a wire cable connects the cuff to the bootie. The cuff in this embodiment may also have an on/off switch.
[0010] Other embodiments include a disposable clip or substrate containing blue LEDs that can be fixed to the area needing treatment, where fixation may be performed with an adhesive. Power, switch and control circuitry in this embodiment may be provided by a separate module worn by the person on the ankle or wrist.
[0011] In any of the apparatus for delivering light therapy as described herein, a timer may be incorporated into the control circuitry of the apparatus to limit the light exposure time. The timer may be controlled by a user interface that allows a patient to manually set the time for which light is to be delivered. A predetermined exposure time, such as eight hours, may be programmed in the timer. In certain cases, only one eight hour treatment may be necessary. Time is then allowed for new nail material to grow and the old nail with deceased fungus to be removed.
[0012] FIG. 1 depicts one embodiment of an apparatus for delivering cutaneous light therapy to a toenail or fingernail. A clip 100 comprises a lower portion 101 and an upper portion 102 that are opposed to one another and each pivotally attached to a spring 103 . The two portions may be pivoted apart around the spring in order to open the clip, while the spring acts to hinge the two portions together and close the clip around a toe or finger. The upper portion of the clip incorporates one or more blue LEDs 104 disposed so as to emit light toward the nail when the clip is closed around a toe or finger. A foam padding 105 may be fitted over the inner surfaces of the upper and lower clip portions for patient comfort. Mounted within a body portion 106 of the clip are control circuitry 107 and a battery 108 which connect to the LEDs by wires 109 . The control circuitry controls operation of the LEDs by gating power from the battery. Interfaced to the control circuitry is an on-off switch 110 that may be actuated by the patient. Timing circuitry may also be incorporated into the control circuitry to allow therapy to be delivered for predetermined periods. A timer switch 111 may be provided to allow the patient to set a specified duration for the therapy.
[0013] FIG. 2 shows another embodiment of an apparatus for delivering cutaneous light therapy that includes a bootie 200 . This embodiment may be used to treat not only nail infections but other cutaneous infections as well such as athlete's foot. The bootie 200 is a contoured structure into which may be fitted a patient's foot. The bootie 200 incorporates one or more blue LEDs 201 disposed on its inner surface so as to radiate toward the patient's skin. A liner 202 made of clear foam material may be interposed between the LEDs and the patient's skin to enhance patient comfort while still allowing light transmission. The apparatus also includes a cuff 206 that may be worn around the patient's arm or ankle. Mounted within the cuff 206 are control circuitry 207 and a battery 208 which connect to the LEDs by wires 209 . The control circuitry controls operation of the LEDs by gating power from the battery. Interfaced to the control circuitry is an on-off switch 210 that may be actuated by the patient. Timing circuitry may also be incorporated into the control circuitry to allow therapy to be delivered for predetermined periods. A timer switch 211 may be provided to allow the patient to set a specified duration for the therapy.
[0014] FIG. 3 shows another embodiment that includes a substrate 300 that incorporates one or more blue LEDs 301 . The substrate 300 includes a midportion 302 for containing the LEDs 301 which are disposed so as to radiate toward the patient's skin. The substrate 300 also includes peripheral portions 303 which are adapted for fixation to the patient's skin such as by an adhesive or by being wrapped around an extremity and then mechanically connected together (e.g., by a hook and loop fastener). In one embodiment, the LEDs are connected to an external control device such as the cuff 206 described above which contains the battery and control circuitry. In another embodiment, the midportion 302 has a compartment for containing the LEDs and battery 304 . The apparatus may be constructed so that the LEDs are activated when inserted into the midportion with the battery. In this embodiment, the substrate may be made disposable after removal of the battery and LEDs.
[0015] Although the invention has been described in conjunction with the foregoing specific embodiment, many alternatives, variations, and modifications will be apparent to those of ordinary skill in the art. Such alternatives, variations, and modifications are intended to fall within the scope of the following appended claims. | Described herein are methods and apparatus for treating fungal nail infections and similar diseases with light therapy. In one embodiment, an apparatus that utilizes one or more blue light emitting diodes (LED) to irradiate fungus residing under and around the nail is applied externally to a toe or finger in order to kill the fungus and restore normal nail growth. Light therapy may applied in this manner periodically at scheduled times. Another embodiment involves the use of a bootie-like structure having blue light emitting diodes for irradiating the toes, heal, and foot bottom. | 0 |
CROSS-REFERENCES
[0001] The subject matter of this application is related to the application entitled Method of Optimizing Channel Characteristics Using Multiple Masks To Form Laterally-Crystallized ELA Poly-Si Films by inventors Apostolos Voutsas, John W. Hartzell and Yukihiko Nakata filed on the same date as this application (Attorney Docket No. SLA 0511).
[0002] The subject matter of this application is also related to the application entitled Mask Pattern Design to Improve Quality Uniformity in Lateral Laser Crystallized Poly-Si films by inventor Apostolos Voutsas filed on the same date as this application (Attorney Docket No. SLA 0512).
[0003] All of these applications, which are not admitted to be prior art with respect to the present invention by their mention here, are incorporated herein by this reference.
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to semiconductor technology and more particularly to a method of forming polycrystal line silicon within an amorphous silicon film.
[0005] Polycrystalline silicon thin film transistors (TFTs) can be used in a variety of microelectronics applications, especially active matrix liquid crystal displays (LCDs).
[0006] Thin film transistors (TFTs) used in liquid crystal displays (LCDs) or flat panel displays of the active matrix display type are fabricated on silicon films deposited on a transparent substrate. The most widely used substrate is glass. Amorphous silicon is readily deposited on glass. Amorphous silicon limits the quality of TFTs that can be formed. If driver circuits and other components are to be formed on the display panel, as well as switches associated with each pixel, crystalline silicon is preferred.
[0007] Silicon is often referred to as either amorphous or crystalline, including single crystal silicon. The term crystalline silicon can refer to either single crystal silicon, polycrystalline silicon, or in some cases materials with significant quantities of micro-crystal structures. For many application, single crystal material is most desirable. But, single crystal silicon is not readily producible. Amorphous silicon can be crystallized to form crystalline silicon by solid-phase crystallization. Solid-phase crystallization is carried out by high temperature annealing. But, glass substrates cannot withstand the temperatures necessary to melt and crystallize silicon. Quartz substrates can withstand high temperature annealing, but quartz substrates are too expensive for most LCD applications.
[0008] Because glass deforms when exposed to temperatures above 600° C., low-temperature crystallization (preferably below 550° C.) is used for solid-phase processing of silicon on glass. The low-temperature process requires long anneal times (at least several hours). Such processing is inefficient and yields polycrystalline silicon TFTs that have relatively low field effect mobility and poor transfer characteristics. Polycrystalline silicon produced by solid-phase crystallization of as-deposited amorphous silicon on glass suffers due to small crystal size and a high density of intragrain defects in the crystalline structure.
[0009] Excimer laser annealing (ELA) has been actively investigated as an alternative to low-temperature solid-phase crystallization of amorphous silicon on glass. In excimer laser annealing, a high-energy pulsed laser directs laser radiation at selected regions of the target film, exposing the silicon to very high temperatures for short durations. Typically, each laser pulse covers only a small area (several millimeters in diameter) and the substrate or laser is stepped through an exposure pattern of overlapping exposures, as is known in the art.
[0010] Lateral crystallization by excimer laser annealing (LC-ELA) is one method that has been used to form high quality polycrystalline films having large and uniform grains. LC-ELA also provides controlled grain boundary location.
[0011] According to one method of conducting LC-ELA, an initially amorphous silicon film is irradiated by a very narrow laser beamlet, typically 3-5 micrometers wide. Passing a laser beam through a mask that has slits forms the beamlet, which is projected onto the surface of the silicon film.
[0012] The beamlet crystallizes the amorphous silicon in its vicinity forming one or more crystals. The crystals grow within the area irradiated by the beamlet. The crystals grow primarily inward from edges of the irradiated area toward the center. The distance the crystal grows, which is also referred to as the lateral growth length, is a function of the amorphous silicon film thickness and the substrate temperature. Typical lateral growth lengths for 50 nm films is approximately 1.2 micrometers. After an initial beamlet has crystallized a portion of the amorphous silicon, a second beamlet is directed at the silicon film at a location less than half the lateral growth length from the previous beamlet. Moving either the laser, along with its associated optics, or by moving the silicon substrate, typically using a stepper, changes the location of the beamlet. Stepping a small amount at a time and irradiating the silicon film causes crystal grains to grow laterally from the crystal seeds of the poly-Si material formed in the previous step. This achieves lateral pulling of the crystals in a manner similar to zone-melting-crystallization (ZMR) methods or other similar processes.
[0013] As a result of this lateral growth, the crystals produced tend to attain high quality along the direction of the advancing beamlets, also referred to as the “pulling direction.” However, the elongated crystal grains produced are separated by grain boundaries that run approximately parallel to the long grain axes, which are generally perpendicular to the length of the narrow beamlet.
[0014] When this poly-Si material is used to fabricate electronic devices, the total resistance to carrier transport is affected by the combination of barriers that a carrier has to cross as it travels under the influence of a given potential. Due to the additional number of grain boundaries that are crossed when the carrier travels in a direction perpendicular to the long grain axes of the poly-Si material, the carrier will experience higher resistance as compared to the carrier traveling parallel to the long grain axes. Therefore, the performance of TFTs fabricated on poly-Si films formed using LC-ELA will depend upon the orientation of the TFT channel relative to the long grain axes, which corresponds to the main growth direction. Typically, TFT performance varies by a factor of between 2 and 4 as a function of orientation relative to the main growth direction.
[0015] This difference in performance is undesirable from the point of view that as LCD resolution increases, or as panel size decreases, size limitations make it more desirable to have column drivers and row drivers oriented at ninety degrees relative to each other. Potentially resulting in one set of drivers having significantly different characteristics relative to the other.
SUMMARY OF THE INVENTION
[0016] Accordingly, a method of forming polycrystalline regions on a substrate is provided. A first mask orientation is selected. A laser beam is directed through the mask to irradiate the substrate over an initial region on the substrate. The region is annealed using a lateral crystallization process. A second mask orientation is selected. The laser beam is directed through the mask to irradiate the substrate over a second region on the substrate. The region is annealed using a lateral crystallization process. If the first and second mask orientations are different, the first region will have a different crystal orientation than the second region following annealing. The mask orientation is selected by rotating the mask or the substrate.
[0017] The method of the present invention is well suited for processing LCD devices. An LCD substrate, which can be composed of quartz, glass, plastic or other suitable transparent material, is used. An amorphous semiconductor material is deposited on the LCD substrate to form a thin layer of amorphous silicon. Preferably the semiconductor material will be silicon. A first region of the amorphous silicon is annealed using a first mask orientation in connection with a lateral crystallization ELA process to form a first polycrystalline region having elongated grain structures with a first crystal orientation. A second region of the amorphous silicon is annealed using a second mask orientation in connection with a lateral crystallization ELA process to form a second polycrystalline region having elongated grain structures with a second crystal orientation. The second crystal orientation is different from the first crystal orientation, and preferably the crystal orientations are substantially perpendicular with respect to each other.
[0018] For certain applications it is desirable to form thin film transistors (TFTs) using the polycrystalline material formed by laser annealing. In a preferred embodiment of the present method, TFTs having a first channel orientation are formed over the region with the first crystal orientation. The channel orientation is preferably substantially parallel to the crystal orientation, whereby the fewest number of crystal grain boundaries are crossed by the channel. TFTs having a second channel orientation formed over the region with the second crystal orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic cross-sectional view showing an ELA apparatus used in connection with the present method.
[0020] [0020]FIG. 2 shows a mask pattern.
[0021] [0021]FIG. 3 illustrates a step in the process of lateral crystallization using ELA.
[0022] [0022]FIG. 4 illustrates a step in the process of lateral crystallization using ELA.
[0023] [0023]FIG. 5 illustrates a step in the process of lateral crystallization using ELA.
[0024] [0024]FIG. 6 is a flowchart diagram of an embodiment of the present invention.
[0025] [0025]FIG. 7 illustrates the formation of a substrate with multiple regions of different crystal orientation.
[0026] [0026]FIG. 8 illustrates the formation of TFTs with channels aligned to the crystal orientation to optimize performance.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to FIG. 1 a lateral crystallization excimer laser annealing (LC-ELA) apparatus 10 is shown. LC-ELA apparatus 10 has a laser source 12 . Laser source 12 may include a laser (not shown) along with optics, including mirrors and lens, which shape a laser beam 14 (shown by dotted lines) and direct it toward a substrate 16 , which is supported by a stage 17 . The laser beam 14 passes through a mask 18 supported by a mask holder 20 . The laser beam 14 preferably has an output energy in the range of 0.8 to 1 Joule when the mask 18 is 50 mm×50 mm. Currently available commercial lasers such as Lambda Steel 1000 can achieve this output. As the power of available lasers increases, the energy of the laser beam 14 will be able to be higher, and the mask size will be able to increase as well. After passing through the mask 18 , the laser beam 14 passes through demagnification optics 22 (shown schematically). The demagnification optics 22 reduce the size of the laser beam reducing the size of any image produced after passing through the mask 18 , and simultaneously increasing the intensity of the optical energy striking the substrate 16 at a desired location 24 . The demagnification is typically on the order of between 3× and 7× reduction, preferably a 5× reduction, in image size. For a 5× reduction the image of the mask 18 striking the surface at the location 24 has 25 times less total area than the mask, correspondingly increasing the energy density of the laser beam 14 at the location 24 .
[0028] The stage 17 is preferably a precision x-y stage that can accurately position the substrate 16 under the beam 14 . The stage 17 is preferably capable of motion along the z-axis, enabling it to move up and down to assist in focusing or defocusing the image of the mask 18 produced by the laser beam 14 at the location 24 . In another embodiment of the method of the present invention, it is preferable for the stage 17 to also be able to rotate.
[0029] The mask holder 20 is preferably able to rotate between at least two desired positions. The mask holder 20 is also capable of x-y movement. In some embodiments both the mask holder 20 and the stage 17 are capable of rotating.
[0030] [0030]FIG. 2 shows the mask 18 having a plurality of slits 30 with a slit spacing 32 . The mask 18 is shown as a square, but it is also possible for the mask to be rectangular.
[0031] [0031]FIGS. 3 through 5 show the sequence of lateral crystallization employed as a portion of the present method. A region 34 of amorphous or polycrystalline silicon overlies the substrate. The rectangular area 36 corresponds to an image of one of the slits 30 projected onto the substrate. The dashed line 38 corresponds to the centerline of the image of the opening on the substrate.
[0032] [0032]FIG. 3 shows the region 34 just prior to crystallization. A laser pulse is directed at the rectangular area 36 causing the amorphous silicon to crystallize. After each pulse the image of the opening is advanced by an amount not greater than half the lateral crystal growth distance. A subsequent pulse is then directed at the new area. By advancing the image of the slits 30 a small distance, the crystals produced by preceding steps act as seed crystals for subsequent crystallization of adjacent material. By repeating the process of advancing the image of the slits and firing short pulses the crystal is effectively pulled in the direction of the slits movement.
[0033] [0033]FIG. 4 shows the region 34 after several pulses. As is clearly shown, the area 40 that has already been treated has formed elongated crystals that have grown in a direction substantially perpendicular to the length of the slit. Substantially perpendicular means that a majority of lines formed by crystal boundaries 42 could be extended to intersect with dashed line 38 .
[0034] [0034]FIG. 5 shows the region 34 after several additional pulses following FIG. 4. The crystals have continued to grow in the direction of the slits' movement to form a polycrystalline region. The slits will preferably continue to advance a distance substantially equal to a distance on the substrate corresponding to the slit spacing 32 . Each slit will preferably advance until it reaches the edge of a polycrystalline region formed by the slit immediately preceding it.
[0035] Referring now to FIG. 6, a flow chart of the steps of the method of the present invention is shown. Step 110 selects a first mask orientation For consistency of description, the orientation is described relative to the substrate surface.
[0036] Step 120 performs lateral crystallization using excimer laser annealing (ELA) to produce a polycrystalline region having a first crystal orientation. A laser beam is used to project an image of the mask onto the substrate. The laser beam energy is sufficient to cause amorphous silicon to crystallize. As discussed above a sequence of laser pulses can be used to crystallize a region with a first crystal orientation.
[0037] Step 130 selects a second mask orientation. This second mask orientation is preferably substantially perpendicular to the first mask orientation.
[0038] Step 140 performs lateral crystallization ELA to produce a polycrystalline region having a second crystal orientation. The second crystal orientation is preferably substantially perpendicular to the first crystal orientation.
[0039] The steps of selecting a mask orientation (steps 110 and 130 ) can be accomplished by rotating the mask itself while leaving the substrate fixed. Alternatively, the substrate can be reoriented while leaving the mask fixed. Rotating the substrate may be harder to implement, but may be preferred if a rectangular beam profile is used due to the loss of point symmetry. A rectangular beam profile is sometimes used to make more effective use of the total laser power.
[0040] It is possible, and within the scope of the method of the present invention, to rotate both the mask and the substrate to achieve the desired mask orientation relative to the substrate.
[0041] In performance of the method, if multiple regions of the same orientation are desired, it is preferable to produce all of the regions with the first crystal orientation prior to reorienting the mask and producing regions of the second crystal orientation. Multiple regions with the same orientation are preferred when producing multiple devices on a single substrate.
[0042] [0042]FIG. 7 shows the substrate 16 with two display regions 210 and 220 . Each display region corresponds to the location of a final LCD or other display device. The first mask orientation is selected. Then the image 222 of the mask is projected at a first starting position 224 .
[0043] In an embodiment of the present method, the image 222 is moved one step at a time by moving the mask stage. At each step a laser pulse crystallizes a portion of the silicon material. Once the image 222 has moved a distance corresponding to the slit spacing, the substrate is moved to position the image 222 over an adjacent position 226 . The mask is then moved to crystallize the underlying region. By repeating this process across the substrate, a line of polycrystalline material having predominantly a first crystal orientation is formed. The image 222 is repositioned at a position corresponding the start of the adjacent uncrystallized region. The process is repeated until a region 230 is formed having predominantly a first crystal orientation. As shown this orientation is horizontal. After a first region 230 is formed, repeating the process discussed above can produce a second region 240 having the same general crystal orientation as the first region 230 .
[0044] In a preferred embodiment, once regions of a first crystal orientation have been produced, the mask is reoriented relative to the substrate 16 . The process is then repeated to produce regions with a second crystal orientation. Preferably, the second crystal orientation will be substantially perpendicular to the first crystal orientation. A third region 250 is formed by positioning the rotated image 245 over another starting point and processing the region as discussed above until the region 250 has been crystallized. A fourth region 260 could then be crystallized to have the same orientation as the third region 250 .
[0045] In this manner, multiple regions can be crystallized with two or more crystal orientations. The order of crystallization is not critical to the present invention.
[0046] Once the substrate 16 has been processed to form regions with the desired crystal orientation, device elements are formed on the substrate as illustrated in FIG. 8. FIG. 8 is for illustration purposes, and as with the other drawings, is not drawn to scale. The substrate 16 has a first polycrystalline region 330 and a second polycrystalline region 340 with the same crystal orientation. A first set of TFTs 345 have been formed within polycrystalline regions 330 and 340 . First set of TFTs 345 have channels 347 oriented to match the crystal orientation of the underlying regions 330 and 340 . As shown in the figure, both the crystal orientation of regions 330 and 340 , and the channels 347 are horizontal. Third polycrystalline region 350 and fourth polycrystalline region 360 are shown having a crystal orientation substantially perpendicular to the crystal orientation of regions 330 and 340 . A second set of TFTs 365 having channels 367 are substantially perpendicular to the first set of TFTs 345 and channels 347 , and substantially parallel to the crystal orientation of the underlying regions 350 and 360 .
[0047] Since FIG. 8 illustrates a display device, pixel regions 370 are shown. The pixel regions 370 can have the same underlying crystal orientation as either the regions under the first set of TFTs 345 , also referred to as row drivers, or the second set of TFTs 360 , also referred to as the column drivers. As shown in FIG. 8, the pixel region is matched to the column drivers. If the substrate shown in FIG. 7 were used, the pixel region would match the row drivers. For some applications, it may not be necessary to crystallize the entire substrate. Some regions may not need to be crystallized including, but not limited to the pixel regions.
[0048] Although the present method is well suited to producing display devices, it is also suited to other types of device produced using a polycrystalline material produced on an underlying substrate. In addition to row and column drivers, other circuitry unrelated to displays can be produced.
[0049] The terms perpendicular and parallel should not be construed narrowly to limit the scope of the present method, especially in reference to crystal orientation. The terms substantially perpendicular and substantially parallel should be construed broadly. A broader definition of these term parallel is therefore provided. If a feature, or structure, is said to be parallel to the crystal orientation, the structure crosses the fewest crystal grain boundaries in the relevant direction.
[0050] Several embodiments of the method of the present invention have been described. Variations on these embodiments will be readily ascertainable by one of ordinary skill in the art. Therefore, the description here is for illustration purposes only and should not be used to narrow the scope of the invention, which is defined by the claims as interpreted by the rules of patent claim construction. | A method is provided to optimize the channel characteristics of thin film transistors (TFTs) on polysilicon films. The method is well suited to the production of TFTs for use as drivers on liquid crystal display devices. Regions of polycrystalline silicon can be formed with different predominant crystal orientations. These crystal orientations can be selected to match the desired TFT channel orientations for different areas of the device. The crystal orientations are selected by rotating a mask pattern to a different orientation for each desired crystal orientation. The mask is used in connection with lateral crystallization ELA processes to crystallize deposited amorphous silicon films. | 2 |
BACKGROUND OF THE INVENTION
Cross-Reference to Related Application
This application is a continuation-in-part of U.S. application Ser. No. 631,050 filed July 16, 1984, now abandoned.
1. Field of Invention
The present invention relates to treatment of glass sheets, and particularly to decreasing the frequency of venting in glass sheets during thermal treatment such as tempering.
2. Description of the Problem
Tempered glass sheets are commonly used in many applications. In fabrication, the glass is generally scored, drilled, heated, formed and quenched. These scored and drilled regions are highly susceptible to fracture or venting during such thermal treatment. More particularly, during tempering, glass is heated to a temperature greater than its strain point. After the glass has reached this condition, it is rapidly cooled or quenched setting up temporary internal stresses in the glass. The stresses may become so severe that the glass fractures. It is frequently observed that venting originates from scored or drilled regions in the glass.
Many motor vehicles have movable tempered glass windows which require drilled holes for connections to opening and closing actuator mechanisms. In drilling holes, a drill on one side of the glass sheet bores approximately halfway through the glass thickness. As it is removed, a drill on the other side of the glass sheet bores through to complete the hole. As a result, there is a rough parting line on the inner hole wall caused by mid-plane core breakout. This is the weakest area of the hole, and it must withstand extremely high tension stresses that develop during tempering. In addition, these windows are usually cut to irregular shapes. Unless considerable attention is given to seaming the edge of the window or smoothing the inner hole wall, vents will tend to occur along the window edge and hole region during thermal treatment.
U.S. Pat. No. 4,416,930 to Kelly, the disclosure of which is incorporated herein by reference, recognizes that venting is a problem associated with glass breakage during thermal treatment operations. Kelly discloses the use of a sodium silicate composition to coat scored and drilled regions of a glass sheet to decrease the frequency of venting. Although the sodium silicate coating decreases venting, thus increasing yield, the residual compressive edge stress at a sodium silicate coated hole is lower than that for an untreated hole.
U.S. Pat. No. 3,765,859 to Seymour discloses protecting a portion of the peripheral edge of glass prior to heat treating with a composition having a low coefficient of thermal expansion compared to glass and/or a heat transfer coefficient not greater than glass. The glass is heated to an elevated temperature and then rapidly cooled by contacting it with a liquid quenching medium. The treating composition typically contains silica, alumina, lithium, lead, and boron.
U.S. Pat. No. 3,498,773 to Grubb et al discloses a method of strengthening glass by ion exchange. The glass is coated in the desired area with an aqueous composition containing an alkali metal salt before heat treating. Grubb et al. replaces lithium or potassium ions in the glass with the alkali metal ions of the salt.
U.S. Pat. No. 3,287,201 to Chisholm et al also discloses a method of strengthening glass by replacing the alkali metal ions in the glass surface with selected smaller electropositive metal ions during thermal treatment.
The present invention provides a method for minimizing or eliminating venting during thermal treatment of glass sheets with drilled holes that does not have the limitations of the previously discussed references.
SUMMARY OF THE INVENTION
This invention relates to a method of minimizing or eliminating the venting of thermally treated soda-lime-silica glass sheets by applying to any scored region prior to thermal treatment a sol composition, prepared from a metal alkoxide, which gels and ultimately forms a glassy coating at a temperature below the melting temperature of the glass sheet. For the sake of simplicity, the term scored region refers to any area subjected to a cutting tool, be it a circular scored region from a drill used for boring a hole in the glass sheet or a linearly scored region. As the glass sheet is heated, the coating composition fills in any cracks or imperfections at the surface of the scored region. During heating, the coating composition polymerizes into a glass that fuses with the glass sheet surface thus healing imperfections. The residual compressive stress in the coated scored region after thermal treatment will approximately equal the residual compressive stress of an untreated scored region subject to the same thermal treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a major surface of an irregularly shaped glass piece illustrating venting paths originating from a hole in the glass piece.
FIG. 2 is a view taken through line 2--2 in FIG. 1 illustrating the rough edges at each glass surface and at the mid-plane core breakout.
FIG. 3 is a cross-section of a drilled hole coated with a sol-gel coating composition in accordance with the teachings of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an irregularly shaped glass sheet 10 with hole 12 drilled therethrough. In general, fractures originate at the hole 12 and extend to an edge of the glass sheet 10, e.g., as shown in FIG. 1. Fracture lines 14 and 16 illustrate venting paths that commonly occur when the glass sheet 10 is subjected to thermal treatment such as tempering.
FIG. 2 illustrates the rough edges usually associated with a drilled hole. Rough edge 18 on glass surface 20 at the hole 12 results from a drill (not shown) boring through the surface 20 to approximately halfway through the glass sheet 10. Rough edge 22 on glass surface 24 results from a second drill (not shown) completing the hole by boring through the surface 24 and remaining glass. Edge 26 is the mid-plane breakout edge which may be caused by any misalignment of the drills such that the bores through each half of the glass are not colinear.
In a preferred embodiment of this invention, a silica-containing sol-gel composition is applied to the hole and surrounding region. Referring to FIG. 3, the sol-gel composition 28 coats the inner wall 30 of the hole 12, thus covering the breakout edge 26. To insure that the edges 18 and 22 are also fully coated, the sol-gel composition 28 also coats the glass surfaces 20 and 24 with coating collars 32 and 34, respectively, in the immediate vicinity of the hole 12.
A sol is prepared by at least partially hydrolyzing a metal alkoxide with a small amount of water in an organic solvent base, preferably alcohol. For the silicon-containing compositions of the present invention, a preferred alkoxide is tetraethylorthosilicate. The sol may comprise additional metals such as boron, sodium and/or titanium, which may be added as metal alkoxides such as sodium methoxide and titanium isopropoxide or as inorganic compounds such as boric anhydride. As the organic solvent evaporates and inorganic polymerization proceeds, the sol forms a gel. Upon sufficient heating, the gel densifies, ultimately to yield a glassy composition which is fused to the coated hole surface of the glass substrate.
In a particularly preferred embodiment, a silicon alkoxide, preferably tetraethylorthosilicate (TEOS), is partially hydrolyzed with one mole of water per mole of TEOS. Preferably, the TEOS, a small amount of inorganic acid, such as nitric acid, and one mole of water per mole of TEOS are heated in alcohol at a temperature of about 50° to 55° C. for about 30 minutes. To the partially hydrolyzed TEOS sol is added a titanium alkoxide, preferably titanium isopropoxide, in an appropriate amount to provide the desired final ratio of SiO 2 :TiO 2 . After continued heating at 50° to 55° C. for about 30 minutes, additional water is added to fully hydrolyze the alkoxides. Preferably, the additional water is mixed with an equal volume of alcohol and is added in aliquots with mixing and heating continued between additions. After heating the fully hydrolyzed composition, a clear sol is produced which may be applied to the scored glass surface.
In another particularly preferred embodiment of this invention, a silica-boron sol-gel composition is applied to the scored region of the hole in sol form. After applying the sol-gel composition, the coated area is air dried prior to thermal treatment of the glass. There is no minimum coating thickness required in the application of the sol-gel nor is there any pretreatment of the region to be coated.
After drying, the coated scored glass is subjected to thermal treatment. In the instance of tempering, the glass is typically heated to a temperature in the vicinity of 1200° F. (650° C.) and then rapidly air chilled to a temperature below its strain point. The quenching causes a temporary temperature gradient from the surfaces of the glass towards the center, and temporary internal stresses that result in a surface region stressed in compression surrounding an interior region stressed in tension. This stress condition is normally associated with tempering. During heating, the sol-gel composition polymerizes, densifies and fuses to form a glassy coating. The glass thus formed has a lower viscosity than the glass sheet and will flow into any coated flaws, cracks, or chips. The polymer fuses with the adjoining glass sheet surface in these regions, healing the imperfections so as to reduce the tendency for the glass sheet to vent when it is subjected to the high stresses developed during thermal treatment.
During thermal treatment, the glassy coating does not restrict or adversely affect the tempering of the glass region that it coats, so that the residual compressive edge stresses in the coated region are comparable with scored regions of untreated tempered glass.
TESTING
The following coatings were tested to evaluate the effectiveness of each coating material in preventing venting and maintaining residual compressive edge stress of a drilled and tempered glass sheet.
Coating No. 1--Sodium Silicate Solution
The sodium silicate solution, Na 2 O.SiO 2 , used in the testing was purchased from Fisher Scientific, Pittsburgh, Pa., under stock designation No. SO-S-338. The sodium silicate solution was applied as taught in U.S. Pat. No. 4,416,930 to Kelly.
Coating No. 2--Silica-Titanium Sol-Gel
A sol was prepared by mixing 101.89 grams of reagent alcohol, 5.66 grams of deionized water and 1.18 grams of nitric acid at room temperature, adding 50.34 grams of tetraethyl orthosilicate, heating at 53° C. for 15 minutes in a water bath, adding 7.64 grams of titanium i-proproxide, and heating the final composition at 53° C. for one hour. This sol will gel and ultimately yield a glassy composition with a molar ratio of 90% SiO 2 and 10% TiO 2 .
Coating No. 3--Lithium Silicate Solution
The lithim silicate solution, Li 2 O.SiO 2 , used in the testing was purchased from Lithium Corporation of America, Bessemer City, N.C. under the designation Lithsil-6. The lithium silicate solution does not produce a sol-gel composition.
Coating No. 4--Silica Sol-Gel
A sol was prepared by mixing 0.9 grams of deionized water and 99.1 grams of 2-propanol, heating to 53° C. using a water bath for uniform heating, adding 21.0 grams of tetraethyl orthosilicate and 0.42 grams of glacial acetic acid, and heating final mixture at 53° C. for 30 minutes. Other acids may be used in place of glacial acetic acid: 0.22 grams of nitric acid or 0.9 grams of dichloroacetic acid. This 5 percent solids sol will gel and ultimately yield a glassy silica composition.
Coating No. 5--Silica-Boron Sol-Gel
A sol was prepared by heating 349.8 grams of reagent alcohol to 53° C. in a covered glass container with a stirring apparatus using a water bath for uniform heating, adding 125 grams of tetraethyl orthosilicate, 0.5 grams of nitric acid and 10.8 grams of deionized water, heating at 53° C. for 15 minutes, adding 13.9 grams of boric anhydride to the mixture, and heating at 53° C. for 30 minutes. After heating, the mixture was cooled and stored in tightly sealed containers. This 10 percent solids sol will gel and ultimately yield a glass composition comprising a molar ratio of 75% SiO 2 and 25% B 2 O 3 .
Coating No. 6--Silica-Sodium-Titanium Sol-Gel
A sol was prepared by mixing 345.0 grams of methanol, 2.31 grams of deionized water and 26.75 grams of tetraethyl orthosilicate at room temperature; mixing 33.91 grams of methanol and 1.74 grams of sodium methoxide and adding to the first mixture; and finally adding 4.57 grams of titanium i-propoxide. This 10 percent solids sol will gel and ultimately yield a glassy composition with a molar ratio of 80% SiO 2 , 10% Na 2 O and 10% TiO 2 .
Coating No. 7--Silica-Sodium Sol-Gel
A sol was prepared by mixing 73.92 grams of methanol, 20.11 grams of tetraethyl orthosilicate, 2.38 grams of deionized water and 3.59 grams of sodium methoxide at room temperature. This 7.75 percent solids sol will gel and ultimately yield a glassy composition with a molar ratio of 75% SiO 2 and 25% Na 2 O.
TEST I
The objective of Test I was to produce venting in drilled holes to test the effectiveness of selected coatings in preventing venting. Four hundred eighty three curved quarter windows of 3.2 mm SOLEX® float glass were tested. Four groups of samples were coated with a SiO 2 sol-gel, a SiO 2 -TiO 2 sol-gel, a lithium silicate solution, and a sodium silicate solution. These four groups were tested along with one group of uncoated plates (regular holes) as a control group.
The glass plates were 61/2"×17 3/8"×91/2"×18". Two 1/2 inch holes were drilled approximately 11/2" from the lower corners of each plate and coated prior to tempering. The plates were tong tempered in pairs, as required for the right and left hand window parts, and press bent. Two plates of each test group were processed at a time, alternating the coated and control test groups through the furnace.
The furnace exit temperature was 1275° F. (about 691° C.) with furnace speed at 185 inches (about 4.7 meters) per minute. At these conditions, the glass was in the furnace 2.15 minutes and entered the air quench 7.9 seconds after exiting the furnace. Air pressures were 18 and 27 oz/in 2 right and left in quench plenums. Typical process venting conditions were successfully produced by the heating and cooling cycle to effectively evaluate the hole coatings.
TABLE I______________________________________PERCENT HOLE YIELDS FOR DIFFERENTCOATINGS OF 1/2 INCH HOLES IN 3.2 mm SOLEX ® GLASS No. No. of of Plates No. of Vented % HoleCoating Tested Holes holes Yields______________________________________Sodium Silicate 98 196 1 99.590% SiO.sub.2 --10% TiO.sub.2 100 200 32 84Sol GelLithium Silicate 101 202 57 71.8SiO.sub.2 Sol-Gel 100 200 58 71Control-Uncoated Holes 84 168 75 55.4______________________________________
Table I above presents a summary of the test results, showing the number of vents produced at the plate hole locations during quenching for the various test groups and the percentage hole yields. Any visible crack at the hole was considered to be a vent and thus a defect. As indicated on the control samples, extensive hole venting occurred upon quenching. Of the uncoated holes, 55 percent vented. The best venting performance was obtained when using the sodium silicate coating on the holes, with 99.5 percent hole yield. The second best performance was obtained when using the 90% SiO 2 -10% TiO 2 sol-gel coating, with 84 percent hole yield. With the SiO 2 sol-gel and lithium silicate coated hole plates, lower test results were obtained, with yields of 71 and 72 percent respectively, indicating some improvement in comparison with the uncoated control holes.
TABLE II______________________________________RESIDUAL COMPRESSIVE EDGE STRESSFOR DIFFERENT COATINGS OF 1/2 INCHHOLES IN 3.2 mm SOLEX ® GLASS Ave. Residual Compressive Edge StressCoatings (PSI)______________________________________Sodium Silicate 659590% SiO.sub.2 10% TiO.sub.2 13915Sol-GelLithium Silicate 11598SiO.sub.2 Sol-Gel 14015Control Uncoated 13970Holes______________________________________
Table II shows the average residual compressive edge stress on the tempered plates measured at the drilled holes. The control, SiO 2 , SiO 2 TiO 2 , and lithium silicate coated plates all showed quartz wedge edge compression stress values at the holes of over 10,000 psi, which is considered the minimum allowable for fully tempered glass. Hole edge compressive stress values measured on the sodium silicate coated plates were only about half or even less than half compared to the control untreated holes, indicating a substantial edge strength decrease.
Test II
Test II was conducted to examine the effectiveness of additional sol-gel coating compositions in coating 1/2 inch drilled holes before tempering automotive 3.2 mm (0.128 inch) SOLEX® float glass quarter windows.
Four hundred and eighty curved quarter window lights of the type used in Test I were tested. The sol-gel compositions tested included: 75% SiO 2 -25% B 2 O 3 ; 75% SiO 2 -25% Na 2 O, and 80% SiO 2 - 10% Na 2 O-10% TiO 2 . These three test groups were tested along with the standard sodium silicate solution. One group of uncoated plates (regular holes) was run as a control group.
On each plate, two 1/2 inch holes were drilled 11/2" from the top edge corners and coated prior to tempering. The coating composition was dried at room temperature for several hours before tempering. The plates were vertically tong-tempered in pairs, as required for the right and left hand window parts, and press bent. Two plates of each coated test group were processed at a time, run through the furnace intermittently with the uncoated control plates.
Furnace exit temperature was recorded as 1275° F. (about 691° C.). It is believed that the actual temperature may have been 10° to 20° F. lower. At these conditions, the glass was in the furnace 2.15 minutes and air quenched 7.9 seconds after exiting the furnace. Air pressures were 18 and 27 oz/in 2 right and left in the quench plenums. The object was to process the glass at similar tempering conditions as existed in Test I.
Severe process venting conditions, attributed to a lower furnace exit temperature, developed at quenching during the test trial, but it was determined that this test would nonetheless be effective for the evaluation of the hole coatings.
TABLE III__________________________________________________________________________PERCENT YIELDS FOR DIFFERENTCOATINGS OF 1/2 INCH HOLE IN 3.2 mm SOLEX ® GLASS No. of Plates No. of No. of % HoleCoatings Tested Holes Vented Holes Yields__________________________________________________________________________Sodium Silicate 100 200 39 80.575% SiO.sub.2 --25% B.sub.2 O.sub.3 100 200 41 79.5Sol-Gel80% SiO.sub.2 --10% Na.sub.2 O--10% TiO.sub.2 100 200 93 53.5Sol-Gel75% SiO.sub.2 --25% Na.sub.2 O 100 200 119 40.5Sol-GelControl Uncoated 80 160 103 36Holes__________________________________________________________________________
Table III above is a summary of the test results. On the uncoated control samples, extensive hole venting occurred at quenching, resulting in 103 vents in 160 holes for a percentage hole yield of 36%. The test group of SiO 2 -B 2 O 3 sol-gel coated holes showed substantial improvement, with a percentage hole yield of 79.5%. This performance was comparable to the performance of sodium silicate coated hole plates, which had a yield of 80.5%. Significant improvement was achieved using the SiO 2 -Na 2 O and SiO 2 -Na 2 O-TiO 2 sol-gel coatings with yields of 40.5% and 53.5%, respectively.
TABLE IV______________________________________RESIDUAL COMPRESSIVE EDGE STRESS FORDIFFERENT COATINGS OF 1/2 INCH HOLES IN3.2 mm SOLEX ® GLASS Ave. Residual CompressiveCoatings Edge Stress (PSI)______________________________________Sodium Silicate 646875% SiO.sub.2 --25% B.sub.2 O.sub.3 12943Sol-Gel80% SiO.sub.2 --10% Na.sub.2 O--10% TiO.sub.2 12200Sol-Gel75% SiO.sub.2 --25% NaO.sub.2 13890Sol-GelControl-Uncoated 12568Holes______________________________________
Average quartz wedge edge residual compressive stress values measured at the drilled holes are shown in Table IV. Values at the holes on the control and sol-gel coated plates ranged from 12200 to 13890. Edge stress values measured at the holes coated with sodium silicate were only half as high or less, indicating a significant decrease of strength.
It is believed that the disadvantageous lowering of residual compressive edge stress associated with the use of the sodium silicate coating is due to its insulating properties. With sodium silicate, a white foam forms at the holes during firing, apparently restricting cooling at the edges and thereby reducing the edge compression development. This coating appears to provide a thermal insulating effect by reducing the tension stresses that develop during quenching. As a result, the coated area is not tempered to the same extent as the uncoated region of glass.
The overall best results were obtained with the 75% SiO 2 -25% B 2 O 3 sol-gel composition, which gave both a high percentage hole yield and high residual compressive edge stresses. The expected shelf life of the silica-boron sol-gel as prepared herein is two months for optimum results.
According to the silica-boron phase diagram, silica-boron glass with a 75%/25% ratio melts and fuses at approximately 1960° F. (about 1071° C.). It was found in testing that the 75% SiO 2 -25% B 2 O 3 sol-gel coating did in fact melt and fuse during tempering at a glass surface temperature estimated to be 1200° F. (about 649° C.). Extrapolating this temperature relationship to a tempering operation with a maximum glass surface temperature estimated to be 1300° F. (about 704° C.), it is believed that a sol-gel composition with a molar ratio of 80% SiO 2 and 20% B 2 O 3 would give results comparable to that of the tested 75% SiO 2 -25% B 2 O 3 sol-gel composition.
Microscopic examination of tempered glass with silica-boron sol-gel coatings of varying molar percentages shows that where the sol-gel is less than 55% SiO 2 , there is not enough silica to form a coating on the glass. As a result, the glass is coated with B 2 O 3 particles rather than a glassy coating. It is believed that a 55% SiO 2 -45% B 2 O 3 sol-gel composition is the lower limit for silica-boron sol-gels to attain results comparable to the tested 75% SiO 2 -25% B 2 O 3 sol-gel composition.
The other tested sol-gel compositions also produced high residual compressive edge stresses, although the hole yields were lower than the hole yields for the silica-boron sol-gel compositions. These lower percentage hole yields may indicate that some sol-gel compositions require a temperature higher than that reached in normal glass tempering in order to densify and form a glassy coating. Therefore, higher percentage hole yields would be expected for these other sol-gel compositions at higher tempering temperatures.
It should be noted that the tests were conducted on SOLEX® glass. The principle difference between SOLEX® glass and clear float glass is that the former has a higher iron content. It is expected that application of the tested coatings will result in the same outcome for both SOLEX® glass and clear float glass.
The treated glass sheet may also be shaped and/or exposed to a film forming composition between the heating step and the rapid cooling step of a tempering operation. Also, if desired, a glass sheet having a scored region that is to be annealed rather than tempered, with or without the other processing steps such as shaping and/or coating, may have its scored region treated with a sol-gel composition prior to the thermal treatment of heating followed by a more gradual controlled cooling.
While preferred embodiments of the invention have been illustrated and described herein, variations become apparent to one of ordinary skill in the art. Accordingly, the invention is not to be limited to the specific embodiments described herein, and the true scope and spirit of the invention are to be determined by reference to the claims. | A method and composition for coating scored regions or holes in glass articles prior to heat treatment in order to maintain residual compressive stresses and reduce venting are disclosed. The method and composition of the present invention utilize silica-containing sols which gel and density and ultimately form glassy films during the heat treatment of the coated glass articles. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to the following commonly assigned applications, all filed concurrently herewith:
Ser. No. 509,694 entitled CAMERA CARRYING CASE OR SIMILAR ARTICLE, filed in my name and Ser. No. 509,694 entitled IMPROVED EVER-READY CAMERA CASE, filed in the name of Thomas A. Svatek.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to an ever-ready carrying case for photographic cameras and in particular to a case for securely retaining and supporting a camera of the compact collapsible type.
2. Description of the Prior Art
Carrying cases which permit a photograph to be taken without removing the camera from the carrying case are well known in the art and are often referred to as ever-ready cases. However, even though it is possible in these prior art instances to take photographs without removing the camera from the carrying case, it is nevertheless generally required that the camera be removed from the carrying case when the film is to be changed. This presents a recognizable disadvantage to the quick, efficient and convenient use of the camera.
Furthermore, the prior art is silent, or at best, has never completely solved the problem of providing a carrying case that will accommodate and adequately support a camera of the compact collapsible self-developing type which may take the form of a foldable camera of the single-lens reflex type which is folded to a slim compact storage configuration when not in use and which may be erected to a fully upright position when it is to be used. This is particularly true when considering a camera of the type disclosed and described in U.S. Pat. No. 3,810,211 by Richard R. Wareham and Richard Paglia entitled Self-Developing Camera System where the camera includes a plurality of housing members which are pivotally coupled to one another for relative movement between the compact collapsed inoperative position and the extended or erected operative position.
SUMMARY OF THE INVENTION
The present invention has as its primary object the provision of a carrying case for a collapsible type camera which will adequately support the camera in all conditions, namely from a fully inoperative collapsed position to a fully erected operative position and with which full access is available to the camera for performing normal photographic procedures including the changing of film cassettes, thus overcoming the referred to disadvantages of the prior art.
This is accomplished by forming the carrying case of specially constructed top and bottom case portions that are provided with hinged sections and cooperating linkage which permit the parts of the case to move with the camera's pivoted housing sections during the erection of the camera to an operative position and during the return of the sections to a fully collapsed inoperative position.
Other objects of the invention will in part be obvious and will in part appear hereinafter.
The invention accordingly comprises a carrying case possessing the construction, combination of elements and arrangement of parts which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings wherein like numerals have been employed in the different figures to denote the same parts and wherein:
FIG. 1 is a perspective view of the carrying case and camera in the extended or erected operative position that the camera will take for all normal photographic procedures; and
FIG. 2 is an enlarged perspective view of the carrying case of the present invention with the case shown in closed position and housing the camera in closed and collapsed condition, with a cover flap of the case unfastened and folded out of the way to disclose the opening in the top sections of the case to accommodate the viewfinder of the camera and to permit access thereto for erecting the camera and case to their operative positions.
DETAILED DESCRIPTION OF THE INVENTION
The carrying case of the present invention is generally designated 10 in the drawings where it is shown in its preferred embodiment as providing a novel construction for housing and carrying of a camera of the general type disclosed in U.S. Pat. No. 3,810,211 which includes a plurality of housing sections 12, 14, 16 and 18 pivotally coupled to one another for relative movement between a compact folded or collapsed inoperative position, as shown in FIG. 2, and an extended or erected operative position, as shown in FIG. 1 wherein sections 12 and 16 define an acute angle therebetween. Extending forwardly of housing section 12 is a spread roller housing 20. Housing 20 is pivotally coupled to an inner frame of the camera at hinge 22 for pivotal movement in a counterclockwise manner to a position wherein a film cassette may be inserted into a cassette receiving chamber located within housing section 12, as is well known in the art.
The case 10 may be made of various materials customarily used in the art of camera carrying cases, such as natural leather, artificial leather, and even plastic material, all of which are particularly well suited to carry out the intended function of the case. Case 10, preferably formed of leather, comprises a top portion 22 which is intergrally hinged at 24 to a bottom portion 26 at the right hand side of the case, as viewed in the drawings. Both top and bottom portions 22 and 26 of the case are provided with relatively rigid side walls 28 and 30 which are secured by stitching, or the like, to the flexible leather portions of the top and bottom portions, with the edges of side walls 28 of the top portion adapted to abut the edges of side walls 30 of the bottom portion 26 when the case is closed, as seen in FIG. 2. Additionally, the bottom portion 26 of the case is provided with upstanding end walls 32 at the front end of the case and 34 at the rear of the case, which are rigidly supported in position by upstanding rigid portions 36 and 38 of the side walls on each side of the case, said rigid portions 36 and 38 extending upwardly about twice the height of the side walls 30 of the bottom portion to thereby abut the ends of side walls 28 and provide end walls that completely close off both ends of the case when the top portion 22 is in the position shown in FIG. 2.
At the front end of the case, flexible cover flap 40 is provided which forms an integral extension of the upper portion of the end wall 32 and is adapted to cover a major portion of the top portion 22 of the case and be securely held in place by suitable means, such as snap fastener elements 42 and 44 carried by the flap and top portion, respectively.
An adjustable neck strap 46 is secured to the rear end of the case with each end of the strap being secured to a ring 48 securely held by a strap loop 50 riveted or otherwise fastened to the side wall portions 38.
In the preferred form of the invention as shown, the flap 40, the end walls 32 and 34 and the top and bottom wall portions 22 and 26 are formed of a flexible leather and preferably this may be a single, integral piece of flexible leather. This is important since as will be explained hereinafter, wherever the rigid side wall support for the top or bottom portions is omitted or cut-away, on both sides of the case, a flexible integral hinge connection is formed and these hinges become very important in the specific functioning of the carrying case.
Both the top and bottom portions 22 and 26 have cut-out sections in their respective rigid side walls 28 and 30 on each side of the case to divide each portion into hinged sections. For example, the side wall 28 of top portion 22 are cut-away at 52 to form a hinged connection at 54 between section 56 and 58 of the top portion 22 so that the sections 56 and 58 may move to the position shown in FIG. 1 to accommodate housing sections 14 and 16 of the erected camera.
The side walls 30 of the bottom portion 26 are cut-away at 60 to divide this portion into two sections 62 and 64 connected by an integral flexible hinge 66. This will permit the section 62 of the bottom portion 26 carrying end wall 32 and cover flap 40 to swing downwardly about the hinge 66 to open up the front end of the case for the removal and insertion of film cassettes into housing section 12.
Additionally, each of the side walls 30 at the end of section 64 in the vicinity of the cut-out 60 are provided with upstanding ears or flanges 68 to which are pivotally mounted one end of links 70, the other end of said links being pivotally mounted on the side walls 28 of top section 56 near the forward end thereof.
By virtue of the particular construction and arrangement of elements, the parts of the carrying case may be completely collapsed to the position shown in FIG. 2 with the sectional top and bottom case portions 22 and 26 completely encasing the collapsed camera and with the links 70 so positioned as to permit this movement with the links 70 nearly parallel to the case body.
In effect the case comprises a four section enclosure for the camera embodying the two upper sections 56 and 58 and the two lower sections 62 and 64. Additionally, the case defines a four bar linkage consisting of the side walls 28 of sections 56 and 58, the side walls 30 of section 64 and the links 70. This four bar linkage prevents the camera from falling out of the case when the sections of the case are in the positions shown in FIG. 1 and the camera is hanging from the user's neck.
The top portion 22 is also provided with a relatively large cut-out portion 72 extending from the forward portion of section 56, which lies close to the end wall 32 when the case is closed, across the hinge 54 and well into section 58. This cut-out portion is generally rectangular in configuration and of sufficient size and dimensions to accommodate the outer cover or cap 74 of the viewfinder of the self-developing camera, which cap protrudes through the opening. Cut-out portion 72 is provided with a pair of outwardly extending recesses 76 and 78 which facilitate the grasping of cap 74 prior to erecting the camera and case 10.
The camera in folded and collapsed form is readily inserted through the front end of the case. The flap 40 is then pulled over the top and fastened in position. The flap is of sufficient length and width to fully cover and protect the viewfinder cap 74. The case and camera may then be carried by the neck strap in an inoperative and collapsed condition.
When the camera is to be used and while the case and camera are still supported by the neck strap, the flap 40 is unfastened and allowed to hang down from the front end of the case. The front end wall 32 at this point will still snugly fit the camera and together with a section 80 of portion 56 which engages the left end of the cap 74 will prevent the camera from sliding forward and falling out of the case. The cap 74 of the viewfinder which protrudes through the rectangular opening 72 is then grasped at each side at 82 and pulled upwardly and to the rear while the camera and case is firmly held with the other hand. This movement of the viewfinder will erect the camera to its operative position and the upper portions 56 and 58 of the case will follow the camera's movement until the parts reach the position shown in FIG. 1. In this opened position, the camera is securely held by the parts of the case and the same may still be safely hung from the neck.
When the camera is erected and the parts of the case moved to the position of FIG. 1, the front end section 62 of the bottom portion of the case will be allowed to pivot downwardly about the hinge 66 which will permit the user to have access to the spread roller housing 20 which is pivotally connected to the front end of the camera about hinge 22. The integral hinge 66 between the two bottom sections 62 and 64 is located at a point approximately 1/4 inch to the right of the hinge 22 of the roller housing 20, so as to permit the roller housing 20 to be pivoted downwardly through approximately a 90° angle in a counterclockwise direction, as viewed in FIG. 1, to enable a film cassette to be inserted into or removed from the main housing section 12 of the camera. If the hinge 66 is too close to the pivot point 22, or forward of it, the user will not be able to pivot the spread roller housing 20 properly to remove or insert film cassettes. Furthermore, if the hinge 66 is spaced too far to the right of pivot point 22, the center of gravity of the camera may be forward or to the left of the point at which the user's hand grasps bottom section 64, thereby making it uncomfortable for the user to handle.
Furthermore, the hinge 54 between top sections 56 and 58 and the links 70 should be so designed and placed as to accommodate the pivoted parts of the camera body, including the erected bellows section 84 and the camera lens front included in housing section 18.
By virtue of the particular carrying case structure described and disclosed in the drawings, it will be seen that many photographic procedures and operations may be performed, including the changing of film cassettes or cleaning of the processing rollers of the camera without having to remove the camera from the carrying case.
Since certain changes may be made in the above-described carrying case without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description, or shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense. | A carrying case is disclosed for photographic cameras of the compact collapsible type which may be extended or erected to an operative position without removal of the camera from the case. The case is constructed to safely contain the camera and securely support the same in all positions of camera movement from a compact folded position to a fully erected position and to permit complete operation of the camera during all normal photographic procedures, including the removal and insertion of film cassettes into a film magazine receiving chamber of the camera without the necessity of removing the camera from the case. The case is formed of specially constructed top and bottom case members that are provided with hinged sections and cooperating linkage which are movable with the camera's housing sections during the erection of the camera to its operative position. | 0 |
TECHNICAL FIELD
[0001] The invention relates generally to an electrohydraulic valve assembly and, more particularly, to an independent metering valve having a fluid make-up function.
BACKGROUND
[0002] An independent metering valve includes a first pair of independently controlled electrohydraulic displacement controlled spool valves for controlling pump-to-cylinder communication between an inlet conduit and a pair of control conduits and a second pair of independently controlled electrohydraulic displacement controlled spool valves for controlling cylinder-to-tank fluid flow between the pair of control conduits and an outlet. Each of the spool valves has a displacement controlled solenoid valve for controlling the position of the spool valve. The spool valves are normally biased to a closed position and are selectively actuated to provide several modes of actuation.
[0003] This system can provide many functions normally requiring separate valves simply by actuating one or more of the four independently controlled electrohydraulic displacement controlled spool valves. However, one problem that arises is that the pressure control functions requiring fast response, such as pressure relieving and fluid make-up, typically require a line relief valve and a fluid make-up valve, respectively, to be installed on an actuator supply conduit. Both the line relief valve and fluid make-up valve are, many times, large in size and capacity.
[0004] In a more recent development, as disclosed in U.S. Pat. No. 5,868,059, the valve element of an independent metering valve includes both the fluid relief function and the fluid make-up function. A fluid make-up means provides communication between the control chamber of the valve and an actuator supply conduit so that the valve element moves to an open position when the fluid pressure in the supply conduit drops below a predetermined level. However, this independent metering valve has a relatively complicated valve structure.
[0005] The present invention is directed to overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
[0006] In one aspect of the present invention, a control valve in fluid communication with an actuator to controllably move an output member of the actuator may include a valve body defining a passageway, a pressurized pilot supply fluidly connected to the passageway, and a fluid reservoir fluidly connected to the passageway. A pilot operator is selectively moveable within the passageway, and a flow metering operator is moveably disposed within the passageway. A fluid make-up operator is disposed in the passageway and in fluid communication with the fluid reservoir and the actuator. The fluid make-up operator operates to direct an amount of pressurized pilot supply fluid in response to a decrease in actuator pressure coinciding with a cavitation condition within the actuator. A control chamber within the valve body is structured and arranged to contain pressurized fluid from the pressurized pilot supply. The control chamber is in fluid communication with the flow metering operator. The flow metering operator is urged to fluidly connect the actuator with the fluid reservoir under the influence of the pressurized fluid within the control chamber through activation by either the pilot operator or the fluid make-up operator.
[0007] In another aspect of the invention, a method for controllably moving an output member of an actuator includes supplying a pressurized pilot supply fluid to a passageway defined by a valve body. The passageway includes a control chamber. The method also includes selectively moving a pilot operator within the passageway and controllably moving a flow metering operator within the passageway to provide fluid communication between the actuator and a fluid reservoir. A fluid make-up operator is provided in the passageway and in fluid communication with the fluid reservoir and the actuator. The method includes operating the fluid make-up operator to direct an amount of pressurized pilot supply fluid in response to a decrease in actuator pressure coinciding with a cavitation condition within the actuator, and activating either the pilot operator or the fluid make-up operator to urge the flow metering operator to fluidly connect the actuator with the fluid reservoir under the influence of the pressurized fluid within the control chamber
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention. In the drawings,
[0010] [0010]FIG. 1 is a diagrammatic and schematic illustration of an embodiment of the present invention with portions shown in cross-section for illustrative convenience;
[0011] [0011]FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1;
[0012] and
[0013] [0013]FIG. 3 is a cross-sectional view taken along line III-III of FIG. 1.
DETAILED DESCRIPTION
[0014] Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0015] In accordance with the present invention, an electrohydraulic valve assembly is provided. Referring to FIG. 1, an electrohydraulic valve assembly 110 is shown in combination with a main pump 112 , a fluid reservoir such as a tank 114 , and an actuator such as a hydraulic cylinder 116 . The main pump 112 may include, for example, a high pressure pump. The hydraulic cylinder 116 may include, for example, a rod end chamber 118 , a head end chamber 120 , and an output member 119 . The valve assembly 110 includes a valve body 122 having a plurality of passageways 130 , 132 , 134 , 136 . The diameter of each passageway varies along its length. The valve assembly also includes a plurality of independently-operated, electronically-controlled metering valves 140 , 142 , 144 , 146 individually seated in the passageways 130 , 132 , 134 , 136 , respectively.
[0016] Each metering valve 140 , 142 , 144 , 146 includes a proportional electromagnetic device 121 , 123 , 125 , 127 , respectively, at a proximal end 124 of the valve body 122 . Throughout the description of the invention, the term “proximal” will refer to a position or a direction toward the proximal end 124 of the valve body 122 . The term “distal” will refer to a position or a direction toward the distal end 126 of the valve body 122 , which lies opposite the proximal end 124 .
[0017] The plurality of metering valves 140 , 142 , 144 , 146 control fluid flow between the pump 112 , the tank 114 , and the hydraulic cylinder 116 . The metering valves are referred to individually as a cylinder-to-tank head end (CTHE) metering valve 140 , a pump-to-cylinder head end (PCHE) metering valve 142 , a pump-to-cylinder rod end (PCRE) metering valve 144 , and a cylinder-to-tank rod end (CTRE) metering valve 146 , as shown in FIG. 1.
[0018] Each metering valve 140 , 142 , 144 , 146 includes a flow metering operator, for example, a metering spool. For example, the metering valve 140 includes a metering spool 150 slideably disposed within the passageway 130 for controlling fluid communication between a pair of annular cavities 160 , 170 , which are axially spaced along and open into the passageway 130 . Similarly, a metering spool 152 of the metering valve 142 controls fluid communication between a pair of annular cavities 162 , 172 , a metering spool 154 of the metering valve 144 controls fluid communication between a pair of annular cavities 164 , 174 , and a metering spool 156 of the metering valve 146 controls fluid communication between a pair of annular cavities 166 , 176 .
[0019] A head end cylinder conduit 180 provides fluid communication between the annular cavities 160 , 162 and the head end chamber 120 of the hydraulic cylinder 116 . A rod end cylinder conduit 182 connects the annular cavities 164 , 166 with rod end chamber 118 of the hydraulic cylinder 116 . An inlet conduit 184 provides communication between the pump 112 and the annular cavities 172 , 174 and contains a load-hold check valve 186 . Tank conduits, for example, annular cavities 170 , 176 are fluidly connected to the tank 114 .
[0020] Each metering valve 140 , 142 , 144 , 146 also includes a pilot operator, for example, a control spool. For example, the metering valve 140 includes a control spool 151 slideably disposed within the passageway 130 between a pair of control chambers 161 , 171 , which are axially spaced along the passageway 130 and configured to hydraulically balance the control spool 151 . Similarly, a control spool 153 of the metering valve 142 is hydraulically balanced between a pair of control chambers 163 , 173 , a control spool 155 of the metering valve 144 is hydraulically balanced between a pair of control chambers 165 , 175 , and a control spool 157 of the metering valve 146 is hydraulically balanced between a pair of control chambers 167 , 177 .
[0021] In addition, the metering valve 140 includes a second pair of annular cavities 181 , 191 located in the valve body 122 . The annular cavities 181 , 191 are axially spaced along and open into the passageway 130 within the axial range of the control spool 151 . Annular cavities 183 , 193 are similarly configured in the metering valve 142 , annular cavities 185 , 195 are similarly configured in the metering valve 144 , and annular cavities 187 , 197 are similarly configured in the metering valve 146 .
[0022] A pilot supply 190 provides a low pressure fluid to the proximal annular cavities 181 , 183 , 185 , 187 about the control spools 151 , 153 , 155 , 157 . The pilot supply 190 may include the main pump with an associated pressure-reducing valve, a separate pilot pump with an associated relief valve, or any other conventional source of pressurized fluid known in the art. The distal annular cavities 191 , 193 , 195 , 197 about the control spools 151 , 153 , 155 , 157 are in fluid communication with the tank 114 via a common drain passage 192 .
[0023] As shown in FIG. 1, pilot valves 194 , 196 are connected to cylinder conduits 180 , 182 , respectively. One or both of the pilot valves 194 , 196 may be configured as a needle valve. An exemplary pilot valve 194 is disposed at the cylinder conduit 180 . The exemplary pilot valve 194 includes a valve spring 106 configured to urge a poppet 105 toward a closed position against a valve seat 107 . A pilot valve passage 108 is configured to provide fluid communication between the cylinder conduit 180 and the distal control chamber 171 when fluid pressure in the cylinder conduit 180 urges the poppet 105 to an open position away from the valve seat 107 .
[0024] Further, none, one, or both of the pilot valves 194 , 196 may include an optional proportional electromagnetic device 109 , for example, a solenoid, as shown associated with the exemplary pilot valve 196 . The proportional electromagnetic device 109 provides the capability to adjust the force of the spring 106 acting on the poppet 105 . Thus, the first predetermined pressure may be adjusted easily from an external location at any time and at the option of an operator.
[0025] While FIG. 2 is a sectional view taken through the metering valve 142 , it discloses the basic structural features of all four metering valves 140 , 142 , 144 , 146 . As shown in FIG. 2, the control spool 153 has a first land 202 axially spaced from a second land 204 . A first limiting collar 206 is disposed at a proximal end 208 of the first land 202 and limits the movement of the control spool 153 in the distal direction. A first spring 210 is disposed in the proximal control chamber 163 between the electromagnetic device 123 and a spring shoulder 212 disposed on the first limiting collar 206 .
[0026] The control spool 153 and the first limiting collar 206 include a longitudinal throughbore 207 extending the length thereof. The throughbore 207 provides fluid communication between the proximal control chamber 163 and the distal control chamber 173 . As a result, the control spool 153 remains hydraulically balanced. The force of the first spring 210 biases the control spool 153 in a direction away from the electromagnetic device 123 to close communication between the annular cavity 183 and the passageway 132 and to open communication between the passageway 132 and the annular cavity 193 .
[0027] The control spool 153 comprises a reduced-diameter portion 214 forming an annular chamber 216 between the axially-spaced lands 202 , 204 . The reduced-diameter portion 214 includes at least one transverse throughbore 218 that opens to the annular chamber 216 , for example, at diametrically-opposed sides of the reduced-diameter portion 214 . Additional throughbores may be provided to meet desired performance criteria. The distal end 220 of the control spool 153 also includes an annular groove 222 forming a distally-facing shoulder 224 .
[0028] The control spool 153 and the metering spool 152 define the distal control chamber 173 within the passageway 132 . A second spring 226 is disposed in the control chamber 173 between the distally-facing shoulder 224 of the control spool 153 and a proximal end 228 of the metering spool 152 . Thus, the second spring 226 biases the control spool 153 away from the metering spool 152 and against the bias of the first spring 210 .
[0029] The metering spool 152 comprises a first land 230 axially spaced from a second land 232 and a reduced-diameter portion 234 between the axially-spaced lands 230 , 232 and adjacent with the annular cavity 172 . The metering spool 152 also comprises a reduced-diameter distal portion 236 disposed in a spring chamber 138 . An expanded-diameter passageway 240 and the distal end 126 of the valve body 122 define the spring chamber 138 . A groove 242 may be cut into the distal end 126 of the valve body 122 . As shown in FIG. 1, the spring chamber 138 is in communication with the tank 114 so that any fluid leakage into the spring chamber 138 is drained.
[0030] A second limiting collar 244 is disposed on the distal portion 236 of the metering spool 152 and limits the movement of the metering spool 152 in a proximal direction. A third spring 246 is disposed between a shoulder of the collar 244 and the distal end 126 of the valve body 122 . Thus, the third spring 246 biases the metering spool 152 in a direction toward the control spool 153 .
[0031] The second land 232 of the metering spool 152 includes metering slots 248 at its proximal end 233 . In one embodiment, the second land 232 comprises four metering slots 248 disposed in two diametrically-opposed pairs. The metering slots 248 may be semi-circular as shown in FIG. 2. However, it should be appreciated that the second land may include more or less than four metering slots. It should further be appreciated that the metering slots 248 may be shaped and positioned as necessary to achieve desired performance results. The metering slots 248 are configured to provide fluid communication between the annular cavities 162 , 172 when the metering spool 152 moves distally a sufficient distance for the metering slots 248 to open to the annular cavity 162 .
[0032] [0032]FIG. 3 shows additional structural detail specifically related to the metering valves 140 , 146 . The structural detail of metering valve 140 , as illustrated in FIG. 3, is essentially identical to the structure of metering valve 146 .
[0033] As shown in FIG. 3, a first land 330 of the metering spool 150 includes an annular groove 350 defining, in combination with the valve body 122 , a pilot pressure chamber 352 . A second land 332 of the metering spool 150 comprises a make-up valve 354 configured to provide make-up fluid in the event the cylinder conduit 180 reaches a cavitation condition.
[0034] A pair of longitudinal passages 356 , 358 extend from the make-up valve 354 through the reduced-diameter portion 334 and first land 330 of the metering spool 150 and to the distal control chamber 171 . A plug 360 is disposed at a proximal end of the first longitudinal passage 356 to close off the passage 356 from the distal control chamber 171 . The second longitudinal passage 358 opens to the distal control chamber 171 , thus being capable of providing fluid communication between the control chamber 171 and the make-up valve 354 . The longitudinal passages 356 , 358 may be positioned radially opposite to one another, substantially the same radial distance from a central longitudinal axis 300 of the metering valve 140 , as shown in FIG. 3. However, it should be appreciated that the longitudinal passages may be positioned in an asymmetrical fashion as necessary to achieve desired performance results.
[0035] A first lateral passage 362 provides fluid communication between the first longitudinal passage 356 and the pilot pressure chamber 352 . The first lateral passage 362 may extend diagonally between the first longitudinal passage 356 and the pilot pressure chamber 352 , as shown, or it may extend radially perpendicular to the central longitudinal axis 300 of the metering valve 140 . Again, it should be appreciated that the configuration of the first lateral passage 362 may be varied to achieve desired performance results.
[0036] The make-up valve 354 comprises a fluid make-up operator, for example, a valve element 364 , slidably disposed in a valve passageway 366 . The valve element 364 includes a first land 368 axially spaced from a second land 370 and a reduced-diameter portion 372 between the first and second lands 368 , 370 . The valve element 364 further includes a proximal end portion 374 .
[0037] A head chamber 376 is defined between the proximal end of the valve passageway 366 and a proximal end 378 of the first land 368 . A diagonally-extending second lateral passage 380 provides communication between the head chamber 376 and the annular cavity 170 .
[0038] The reduced-diameter portion 372 of the valve element 364 and the valve passageway 366 define an annular chamber 382 . A radially-extending notch 384 is formed in the valve passageway 366 and provides fluid communication between the annular chamber 382 and the first longitudinal passage 356 . The valve passageway 366 also includes a first annular groove 386 axially spaced from the radial notch 384 in the distal direction. The first annular groove 386 is configured such that it provides fluid communication between the annular chamber 382 and the second longitudinal passage 358 in response to movement of the valve element 364 in the distal direction.
[0039] A second annular groove 388 is disposed at a distal end 390 of the valve passageway 366 . A fourth spring 371 , for example, a weakly loaded spring, is disposed between the second land 370 of the valve element 364 and the distal end 390 of the valve passageway 366 . The fourth spring 371 urges valve element 364 in a direction away from the distal end 390 of the valve passageway 366 .
[0040] A third lateral passage 392 is disposed in the second land 332 of the metering spool 150 and provides fluid communication between the second annular groove 388 and the cylinder conduit 180 through the annular cavity 160 (FIG. 1). The third lateral passage 392 may extend radially, perpendicular to the central longitudinal axis 300 of the metering valve 140 . Again, it should be appreciated that the configuration of the third lateral passage 392 may be varied to achieve desired performance results.
[0041] Industrial Applicability
[0042] In use, the metering valves 140 , 146 control cylinder-to-tank fluid flow while the metering valves 142 , 144 control pump-to-cylinder fluid flow.
[0043] Conventional extension of the hydraulic cylinder 116 is achieved by substantially simultaneous, operator-controlled actuation of the metering valves 142 , 146 , and retraction is achieved by simultaneous operator controlled actuation of the metering valves 144 , 140 .
[0044] For example, actuation of the valve 142 moves the metering spool 152 distally establishing fluid flow from the pump 112 to the head end chamber 120 , and actuation of the metering valve 146 moves the metering spool 156 distally establishing fluid flow from the rod end chamber 118 to the tank 114 . Similarly, actuation of the metering valve 144 moves the metering spool 154 distally establishing flow from the pump 112 to the rod end chamber 118 , and actuation of the metering valve 140 moves the metering spool 150 distally establishing fluid flow from the head end chamber 120 to the tank 114 .
[0045] Numerous less conventional operating modes can be achieved by actuation of a single metering valve or actuation of various combinations of two or more metering valves. However, an understanding of the primary features of the present invention can be achieved by describing the general operation of the metering valve 142 shown in FIG. 2 combined with the additional features of the metering valve 140 , more specifically shown in FIG. 3.
[0046] When a proportional electromagnetic device 123 , for example a solenoid, of PCHE metering valve 142 is energized, the first spring 210 is compressed. The control spool 153 is urged toward a proximal end 124 (FIG. 1) of the valve body 122 by the force of the second spring 226 . As a result, the first land 202 moves axially toward the proximal end 124 such that the annular chamber 216 is opened to the pilot supply 190 (FIG. 1). The pilot supply 190 is then in fluid communication with the proximal and distal control chambers 163 , 173 by way of the transverse throughbore 218 and the longitudinal throughbore 207 .
[0047] The pressure of the fluid in the distal control chamber 173 acts on the proximal end 228 of the first land 230 urging the metering spool 152 in the direction toward the distal end 126 of the valve body 122 . As a result, the compressed load of the second spring 226 is reduced, and the control spool 153 is urged toward the distal end 126 of the valve body 122 by the force of the first spring 210 . As the control spool 153 moves axially in the distal direction, the first land 202 of the control spool 153 reduces the opening between the annular chamber 216 and the pilot supply 190 . The opening between the annular chamber 216 and the pilot supply 190 and the opening between the annular chamber 216 and the tank 114 are reduced until the control chambers 163 , 173 hydraulically balance the control spool 153 .
[0048] As the opening between the annular chamber 216 and the pilot supply 190 is reduced, the metering spool 152 is urged in the direction of the proximal end 124 by spring 246 and the metering slots 248 provide fluid communication between the annular cavities 172 , 162 . Then, pump 112 provides pressurized fluid, via the load-hold check valve 186 and the supply conduit 184 , to the annular cavity 172 . From there, the pressurized fluid is metered to the annular cavity 162 , which directs the fluid to the cylinder conduit 180 , which in turn supplies the fluid to the head end chamber 120 of the hydraulic cylinder 116 .
[0049] Likewise, a CTHE metering valve 140 may also be controlled with the aid of a proportional electromagnetic device, for example a solenoid. In the CTHE metering valve 140 , the metering slots 248 provide communication between the annular cavities 160 , 170 . As a result, fluid in the cylinder conduit 180 , received from the head end chamber 120 , is supplied to the tank 114 . The PCRE metering valve 144 and CTRE metering valve 146 function similarly to the PCHE metering valve 142 and CTHE metering valve 140 , respectively, but in relation to the rod end chamber 118 of the hydraulic cylinder 116 .
[0050] Referring to the CTHE metering valve 140 , such as that shown in FIG. 3, when pressure of fluid in the cylinder conduit 180 exceeds a first predetermined pressure, an amount of the pressurized fluid must be released from the cylinder conduit 180 . Release of the fluid reduces the pressure of the fluid in the cylinder conduit 180 and prevents potential damaging effects to the hydraulic circuit. If, on the other hand, the pressure of fluid in the cylinder conduit 180 drops below a second predetermined pressure, make-up fluid must be supplied to the cylinder 180 to prevent a cavitation condition.
[0051] As shown in FIG. 1, a pilot valve 194 is connected to the cylinder conduit 180 . When the pressure of fluid in the cylinder conduit 180 exceeds a first predetermined pressure, the pressurized fluid in the cylinder conduit 180 urges the poppet 105 to an open position away from the valve seat 107 against the force of the valve spring 106 . Pressurized fluid then flows through the pilot valve 194 and through the pilot valve passage 108 to the distal control chamber 171 at the proximal end 228 of the metering spool 150 . The pressurized fluid then passes through the longitudinal throughbore 207 and the transverse throughbore 218 into the annular chamber 216 and out to the tank 114 .
[0052] Since the proximal and distal pressurized fluid chambers 161 , 171 are in communication with one another, the control spool 151 will not move since it is hydraulically-balanced. As a result, fluid flowing from the pilot supply 190 and into control chamber 173 is restricted at location 203 (FIG. 1). However, rather than flow becoming choked at location 203 , the pressure acts on the proximal end 228 of the metering spool 150 through the distal control chamber 171 and moves the metering spool 150 in a distal direction against the force of the third spring 246 and the flow is relieved to the tank 114 through the metering slots 248 .
[0053] As the metering spool 150 moves in an axial direction toward the distal end 126 of the valve body 122 , the metering slots 248 provide fluid communication between the annular cavities 160 , 170 . Consequently, the pressurized fluid in the cylinder conduit 180 is relieved to the tank 114 through the annular cavities 160 , 170 and the metering slots 248 . Thus, the pilot valve 194 achieves the relief function for a large amount of pressurized fluid by operating the metering spool 150 to provide a substantial fluid path from the cylinder conduit 180 to the tank 114 .
[0054] Further, as discussed above, one or both of the pilot valves 194 , 196 may include an optional proportional electromagnetic device 109 , for example a solenoid, thereby providing the capability to adjust the force of the spring 106 acting on the poppet 105 . Thus, the first predetermined pressure may be adjusted easily from an external location at any time and at the option of an operator.
[0055] Referring again to FIG. 3, a make-up valve 354 is disposed in the metering spool 150 . When the pressure of fluid in the cylinder conduit 180 drops below the second predetermined pressure, the make-up valve 354 functions in cooperation with the valving element 150 to supply pressurized fluid to the cylinder conduit 180 to prevent a cavitation condition.
[0056] As shown in FIG. 3, the pilot pressure chamber 352 is in fluid communication with the annular chamber 382 of the make-up valve 354 by way of first lateral passage 362 , first longitudinal passage 356 , and radial notch 384 .
[0057] The tank 114 communicates with the head chamber 376 of the make-up valve 354 by way of annular cavity 170 and the diagonally-extending second lateral passage 380 . Thus, the pressure of fluid in the tank 114 acts on the proximal portion 374 of the make-up valve element 364 , compressing the fourth spring 371 in a direction toward the distal end 390 of the valve passageway 366 . The cylinder conduit 180 is in communication with the distal end 390 of the valve passageway 366 by way of annular cavity 160 , third lateral passage 392 , and second annular groove 388 .
[0058] When the cylinder conduit 180 approaches cavitation, the force acting against the second land 370 in a proximal direction becomes less than the force acting on the first land 368 in the distal direction. As a result, the make-up valve element 364 moves in a direction toward the distal end 126 of the valve body 122 against the force of the fourth spring 371 . Consequently, pressurized fluid supplied by the pilot supply 190 flows from the pilot pressure chamber 352 , through the first lateral passage 362 , the first longitudinal passage 356 , the radial notch 384 , the annular chamber 382 of the make-up valve 354 , and the second longitudinal passage 358 into the distal control chamber 171 .
[0059] From the distal control chamber 171 , the pressurized fluid supplied by the pilot supply 190 can pass through the longitudinal throughbore 207 and the transverse throughbore 218 into the annular chamber 216 . Again, since the proximal and distal pressurized fluid chambers 161 , 171 are in communication with one another, the control spool 151 will tend to remain in a hydraulically-balanced position. As a result, the opening between the annular chamber 216 and the pilot supply 190 and the opening between the annular chamber 216 and the tank 114 remain minimized. The flow of pressurized fluid is restricted at the opening between the annular chamber 216 and the tank 114 , thus causing a resistant pressure. This resistant pressure acts on the proximal end 228 of the metering spool 150 through the distal control chamber 171 and moves the metering spool 150 in a distal direction against the force of the third spring 246 .
[0060] As the metering spool 150 moves axially toward the distal end 126 of the valve body 122 , the metering slots 248 provide fluid communication between the annular cavities 160 , 170 . Consequently, a make-up flow of fluid is supplied to the cylinder conduit 180 by way of the annular cavities 160 , 170 and the metering slots 248 , thereby eliminating the cavitation condition. Thus, the make-up valve 354 disposed in the metering spool 150 supplies a large amount of make-up fluid by operating the metering spool 150 .
[0061] In view of the above, it is readily apparent that the structure of the present invention provides an improved and simplified electrohydraulic valve assembly in which the fluid make-up function is integrally formed as part of a metering valve. This provides fast response for pressure relieving and fluid make-up, without special pressure sensors and the need for increased micro-processor computing speed. Moreover, the structure of the assembly is relatively uncomplicated.
[0062] It will be apparent to those skilled in the art that various modifications and variations can be made in the electrohydraulic valve assembly without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims and their equivalents. | A control valve in fluid communication with an actuator may include a pressurized pilot supply and a fluid reservoir fluidly connected to a passageway defined by a valve body. A pilot operator is selectively moveable within the passageway, and a flow metering operator is moveably disposed within the passageway. A fluid make-up operator, disposed in the passageway and in fluid communication with the fluid reservoir and the actuator, directs pressurized pilot supply fluid in response to a decrease in actuator pressure coinciding with a cavitation condition within the actuator. A control chamber within the valve body contains pressurized fluid from the pilot supply and is in fluid communication with the flow metering operator. The flow metering operator fluidly connects the actuator with the fluid reservoir under the influence of the pressurized fluid within the control chamber through activation by either the pilot operator or the fluid make-up operator. | 5 |
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