description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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TECHNICAL FIELD
[0001] The disclosure generally relates to a light emitting diode tube.
DESCRIPTION OF RELATED ART
[0002] In recent years, due to excellent light quality and high luminous efficiency, light emitting diodes (LEDs) have increasingly been used to substitute for incandescent bulbs, compact fluorescent lamps, or fluorescent tubes as light sources of illumination devices.
[0003] One characteristic of color is the color temperature, which is the temperature at which an ideal black-body radiator radiates light of comparable hue to that of the light source. Users may like to have light with different color temperatures depending on different ambiances. For example, users may like to have white light with a bit of yellow at one time, but may like to have white light with a bit of blue at another time. However, the color temperature of a lamp may be a fixed character of the light source at the time of manufacturing and may not be adjusted by the users.
[0004] Therefore, an LED tube is desired to overcome the above described shortcomings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0006] FIG. 1 is an isometric, assembled view of an LED tube in accordance with one embodiment of the present disclosure.
[0007] FIG. 2 is an exploded view of the LED tube in FIG. 1 .
[0008] FIG. 3 is a cross-sectional view of the LED tube in FIG. 1 .
[0009] FIG. 4 is a cross sectional view of the LED tube in FIG. 1 , wherein a housing of the LED tube is rotated to a first position.
[0010] FIG. 5 is a cross-sectional view of the LED tube in FIG. 1 , wherein the housing of the LED tube is rotated to a second position.
DETAILED DESCRIPTION
[0011] Embodiments of an LED tube will now be described in detail below and with reference to the drawings.
[0012] Referring to FIGS. 1-2 , an LED tube 100 in accordance with an embodiment includes a print circuit board 110 , a housing 120 for receiving the print circuit board 110 and a connector 130 connected to each end of the housing 120 .
[0013] The print circuit board 110 may be elongated and rectangular. Preferably, the print circuit board 110 is Al-based print circuit board with good heat dissipation. A length of the print circuit board 110 may be substantially the same as that of the housing 120 , while a width of the print circuit board 110 may be slightly less than that of the housing 120 . A plurality of LEDs 111 may be arranged on the print circuit board 110 . In one embodiment, the plurality of LEDs 111 is arranged on one side of the print circuit board 110 in a direction of the length of the printed circuit board 110 .
[0014] The housing 120 may be tubular and made of transparent or semi-transparent materials such as polycarbonate (PC) and polymethyl methacrylate (PMMA). A first phosphor layer 121 and a second phosphor layer 122 are arranged on different portions of an outer surface of the housing 120 . The first phosphor layer 121 and a second phosphor layer 122 are semi-circle cylinder shaped and made of different materials, thereby different colors of light may be generated when the light from the plurality of LEDs 111 passes through the first phosphors layer 121 , and/or second phosphor layers 122 . In one embodiment, each of the phosphor layer 121 and the second phosphor layer 122 covers substantially one half of the outer surface of the housing 120 , so that the combination of the first and second phosphor layers 121 and 122 covers the entire outer surface of the housing 120 . Referring also to FIG. 3 , the first phosphor layer 121 and the second phosphor layer 122 are symmetric to a plane on which a longitudinal central axis of the housing 120 is located. A protrusion 123 may be formed at an inner wall of the housing 120 to limit a rotating angle of the housing 120 relative to the plurality of LEDs 111 . In one embodiment, the protrusion 123 is aligned with a joint of the first phosphor layer 121 and the second phosphor layer 122 .
[0015] One connector 130 may be attached to each end of the housing 120 . Each connector 130 may include a base 131 and two electrode pins 132 extending through the base 131 for electrically connecting the plurality of LEDs 111 to an external power source. Referring also to FIG. 3 , two securing sections 133 may be formed on an inner sidewall of the base 131 to secure the print circuit board 110 to the base 131 . The base 131 may has an inner diameter substantially the same as an outer diameter of the housing 120 and the multiple layers of difference phosphors deposited on the outer surface of the housing 120 . The securing section 133 may be located on an imaginary circle having a diameter substantially the same as an inner diameter of the housing 120 and is homocentric as the base 131 . A gap is defined between an outer edge of the base 131 and the securing section 133 for receiving the housing 120 .
[0016] To assemble the LED tube 100 , the printed circuit board 110 with the plurality of LEDs 111 arranged thereon may be inserted into the housing 120 , one connector 130 may be attached to each end of the housing 120 with the securing sections 133 aligned with edges of the printed circuit board 120 , and each end of the print circuit board 110 may be securely attached to one connector 130 by the securing sections 133 . In one embodiment, each end of the housing 120 may be received in the gap between the base 131 and the securing section 133 such that the housing 120 may be rotated freely around the connector 130 and the print circuit board 110 .
[0017] Referring to FIG. 3 , the housing 120 may be rotated so that the plurality of LEDs face the first phosphor layer 121 and the second phosphor layer 122 synchronously, i.e., both the first phosphor layer 121 and the second phosphor layer 122 are in an illuminating area of the plurality of LEDs 111 . FIG. 3 shows an embodiment wherein a surface area of the first phosphor layer 121 facing the plurality of LEDs 111 is same as that of the second phosphor layer 122 . In other embodiments, the housing 120 may be rotated to achieve different ratios of coverage areas between the first phosphor layer 121 and the second phosphor layer 122 in the illuminating area of the plurality of LEDs 111 .
[0018] When a voltage is applied to the plurality of LEDs 111 , the plurality of LEDs 111 emit light with a first wavelength. The first phosphor layer 121 absorbs part of the light with the first wavelength and emits light with a second wavelength different from the first wavelength. The second phosphor layer 122 absorbs part of the light with the first wavelength and emits light with a third wavelength different from either of the first wavelength and second wavelength. Light with the first wavelength from the LEDs 111 , light with the second wavelength from the first phosphor layer 121 , and light with the third wavelength from the second phosphor 122 are mixed together to form mixed light with a first color temperature different from that of the light directly from the plurality of LEDs 111 .
[0019] Referring to FIG. 4 , to adjust the color temperature of the LED tube 100 , the housing 120 may be rotated to a position where plurality of the LEDs 111 only face the first phosphor layer 121 , i.e., only the first phosphor layer 121 is in the illuminating area of the plurality of LEDs 111 . The first phosphor layer 121 absorbs part of light with the first wavelength and emits light with a second wavelength. Light with the first wavelength and light with the second wavelength are mixed together to form mixed light with a second color temperature.
[0020] Referring to FIG. 5 , to further adjust the color temperature of the LED tube 100 , the housing 120 may be rotated to a second position where the plurality of LEDs 111 only faces the second phosphor layer 122 , i.e., only the second phosphor layer 122 is in the illuminating area of the plurality of LEDs 111 . The second phosphor layer 122 absorbs part of light with the first wavelength and emits light with a third wavelength. Light with the first wavelength and light with the third wavelength are mixed together to form mixed light with a third color temperature.
[0021] In the present disclosure, the housing 120 with the first and the second phosphor layers 121 and 122 deposited on the outer surface of the housing 120 may be rotated around the print circuit board 110 to obtain light with different color temperatures. To adjust the color temperature of the LED tube 100 , the user only needs to rotate the housing 120 to a position corresponding to the color temperature, without replacing the whole LED tube 100 . As a result, cost may be reduced.
[0022] The housing 120 may be rotated to other positions than the first position and the second position. When the illuminating area of the plurality of LEDs 111 are blocked by both the first phosphor layer 121 and the second phosphor layer 122 , the color temperature of the LED tube 100 will change according to the ratio of coverage areas between the first phosphor layer 121 and the second phosphor layer 122 . In other embodiments, three or more different phosphor layers may be arranged along a direction encircling the longitudinal central axis of the housing 120 .
[0023] It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the disclosure or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the disclosure. | A light emitting diode (LED) tube is disclosed. The LED tube comprises a print circuit board comprising a plurality of LEDs arranged on one side; a housing adapted to receive the print circuit board, the housing comprises a first phosphor layer and a second phosphor layer coated on an outer surface of the housing, the housing is rotatable around the print circuit board; and a connector attached to one end of the housing, the connector is adapted to provide electrical power to the plurality of LEDs. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 13/447,560, entitled “Methods and Compositions Comprising Kiln Dust and Metakaolin,” filed on Apr. 16, 2012, which is a continuation of U.S. patent application Ser. No. 12/821,412, entitled “Methods of Plugging and Abandoning a Well Using Compositions Comprising Cement Kiln Dust and Pumicite,” filed on Jun. 23, 2012, which is a continuation in part of U.S. patent application Ser. No. 12/606,381, issued as U.S. Pat. No. 7,743,828, entitled “Methods of Cementing Subterranean Formation Formations Using Cement Kiln Dust in Compositions Having Reduced Portland Cement Content,” filed on Oct. 27, 2009, which is a continuation in part of U.S. application Ser. No. 12/420,630, issued as U.S. Pat. No. 7,631,692, entitled “Settable Compositions Comprising a Natural Pozzolan and Associated Methods,” filed on Apr. 8, 2009, which is a continuation in part of U.S. patent application Ser. No. 12/349,676, issued as U.S. Pat. No. 7,674,332, entitled “Extended Settable Compositions Comprising Cement Kiln Dust and Associated Methods,” filed on Jan. 7, 2009, which is a divisional of U.S. patent application Ser. No. 12/034,886, issued as U.S. Pat. No. 7,478,675, entitled “Extended Settable Compositions Comprising Cement Kiln Dust and Associated Methods, filed on Feb. 21, 2008, which is a continuation in part of U.S. patent application Ser. No. 11/223,669, issued as U.S. Pat. No. 7,445,669, entitled “Settable Compositions Comprising Cement Kiln Dust and Additive(s),” filed Sep. 9, 2005, the entire disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] Settable compositions may be used in a variety of subterranean applications. As used herein, the term “settable composition” refers to any composition that over time will set to form a hardened mass. One example of a settable composition comprises hydraulic cement and water. Subterranean applications that may involve settable compositions include, but are not limited to, primary cementing, remedial cementing, and drilling operations. Settable compositions also may be used in surface applications, for example, construction cementing.
[0003] Settable compositions may be used in primary cementing operations whereby pipe strings, such as casing and liners, are cemented in well bores. In performing primary cementing, a settable composition may be pumped into an annular space between the walls of a well bore and the pipe string disposed therein. The settable composition sets in the annular space, thereby forming an annular sheath of hardened cement (e.g., a cement sheath) that supports and positions the pipe string in the well bore and bonds the exterior surface of the pipe string to the walls of the well bore.
[0004] Settable compositions also may be used in remedial cementing operations, such as sealing voids in a pipe string or a cement sheath. As used herein the term “void” refers to any type of space, including fractures, holes, cracks, channels, spaces, and the like. Such voids may include: holes or cracks in the pipe strings; holes, cracks, spaces, or channels in the cement sheath; and very small spaces (commonly referred to as “microannuli”) between the cement sheath and the exterior surface of the well casing or formation. Sealing such voids may prevent the undesired flow of fluids (e.g., oil, gas, water, etc.) and/or fine solids into, or from, the well bore.
[0005] The sealing of such voids, whether or not made deliberately, has been attempted by introducing a substance into the void and permitting it to remain therein to seal the void. If the substance does not fit into the void, a bridge, patch, or sheath may be formed over the void to possibly produce a termination of the undesired fluid flow. Substances used heretofore in methods to terminate the undesired passage of fluids through such voids include settable compositions comprising water and hydraulic cement, wherein the methods employ hydraulic pressure to force the settable composition into the void. Once placed into the void, the settable composition may be permitted to harden.
[0006] Remedial cementing operations also may be used to seal portions of subterranean formations or portions of gravel packs. The portions of the subterranean formation may include permeable portions of a formation and fractures (natural or otherwise) in the formation and other portions of the formation that may allow the undesired flow of fluid into, or from, the well bore. The portions of the gravel pack include those portions of the gravel pack, wherein it is desired to prevent the undesired flow of fluids into, or from, the well bore. A “gravel pack” is a term commonly used to refer to a volume of particulate materials (such as sand) placed into a well bore to at least partially reduce the migration of unconsolidated formation particulates into the well bore. While screenless gravel packing operations are becoming more common, gravel packing operations commonly involve placing a gravel pack screen in the well bore neighboring a desired portion of the subterranean formation, and packing the surrounding annulus between the screen and the well bore with particulate materials that are sized to prevent and inhibit the passage of formation solids through the gravel pack with produced fluids. Among other things, this method may allow sealing of the portion of the gravel pack to prevent the undesired flow of fluids without requiring the gravel pack's removal.
[0007] Settable compositions also may be used during the drilling of the well bore in a subterranean formation. For example, in the drilling of a well bore, it may be desirable, in some instances, to change the direction of the well bore. In some instances, settable compositions may be used to facilitate this change of direction, for example, by drilling a pilot hole in a hardened mass of cement, commonly referred to as a “kickoff plug,” placed in the well bore.
[0008] Certain formations may cause the drill bit to drill in a particular direction. For example, in a vertical well, this may result in an undesirable well bore deviation from vertical. In a directional well (which is drilled at an angle from vertical), after drilling an initial portion of the well bore vertically, the direction induced by the formation may make following the desired path difficult. In those and other instances, special directional drilling tools may be used, such as a whipstock, a bent sub-downhole motorized drill combination, and the like. Generally, the directional drilling tool or tools used may be orientated so that a pilot hole is produced at the desired angle to the previous well bore in a desired direction. When the pilot hole has been drilled for a short distance, the special tool or tools are removed, if required, and drilling along the new path may be resumed. To help ensure that the subsequent drilling follows the pilot hole, it may be necessary to drill the pilot hole in a kickoff plug, placed in the well bore. In those instances, prior to drilling the pilot hole, a settable composition may be introduced into the well bore and allowed to set to form a kickoff plug therein. The pilot hole then may be drilled in the kickoff plug, and the high strength of the kickoff plug helps ensure that the subsequent drilling proceeds in the direction of the pilot hole.
[0009] Settable compositions used heretofore commonly comprise Portland cement. Portland cement generally is a major component of the cost for the settable compositions. To reduce the cost of such settable compositions, other components may be included in the settable composition in addition to, or in place of, the Portland cement. Such components may include fly ash, slag cement, shale, metakaolin, micro-fine cement, and the like. “Fly ash,” as that term is used herein, refers to the residue from the combustion of powdered or ground coal, wherein the fly ash carried by the flue gases may be recovered, for example, by electrostatic precipitation. “Slag,” as that teen is used herein, refers to a granulated, blast furnace by-product formed in the production of cast iron and generally comprises the oxidized impurities found in iron ore. Slag cement generally comprises slag and a base, for example, such as sodium hydroxide, sodium bicarbonate, sodium carbonate, or lime, to produce a settable composition that, when combined with water, may set to form a hardened mass.
[0010] During the manufacture of cement, a waste material commonly referred to as “CKD” is generated. “CKD,” as that term is used herein, refers to a partially calcined kiln feed which is removed from the gas stream and collected in a dust collector during the manufacture of cement. Usually, large quantities of CKD are collected in the production of cement that are commonly disposed of as waste. Disposal of the waste CKD can add undesirable costs to the manufacture of the cement, as well as the environmental concerns associated with its disposal. The chemical analysis of CKD from various cement manufactures varies depending on a number of factors, including the particular kiln feed, the efficiencies of the cement production operation, and the associated dust collection systems. CKD generally may comprise a variety of oxides, such as SiO 2 , Al 2 O 3 , Fe 2 O 3 , CaO, MgO, SO 3 , Na 2 O, and K 2 O.
SUMMARY
[0011] The present invention relates to cementing operations and, more particularly, to settable compositions comprising water and CKD, and associated methods of use.
[0012] In one embodiment, the present invention provides a settable composition comprising: water; CKD; and an additive comprising at least one of the following group: shale; slag cement; zeolite; metakaolin; and combinations thereof.
[0013] Another embodiment of the present invention provides a foamed settable composition comprising: water; CKD; a gas; a surfactant; and an additive comprising at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof.
[0014] The features and advantages of the present invention will be apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] The present invention relates to cementing operations and, more particularly, to settable compositions comprising water and CKD, and associated methods of use. The settable compositions of the present invention may be used in a variety of subterranean applications, including primary cementing, remedial cementing, and drilling operations. The settable compositions of the present invention also may be used in surface applications, for example, construction cementing.
Settable Compositions of the Present Invention
[0016] In one embodiment, a settable composition of the present invention comprises water and CKD. In some embodiments, a settable composition of the present invention may be foamed, for example, comprising water, CKD, a gas, and a surfactant. A foamed settable composition may be used, for example, where it is desired for the settable composition to be lightweight. Other optional additives may also be included in the settable compositions of the present invention as desired, including, but not limited to, hydraulic cement, fly ash, slag cement, shale, zeolite, metakaolin, combinations thereof, and the like.
[0017] The settable compositions of the present invention should have a density suitable for a particular application as desired by those of ordinary skill in the art, with the benefit of this disclosure. In some embodiments, the settable compositions of the present invention may have a density in the range of from about 8 pounds per gallon (“ppg”) to about 16 ppg. In the foamed embodiments, the foamed settable compositions of the present invention may have a density in the range of from about 8 ppg to about 13 ppg.
[0018] The water used in the settable compositions of the present invention may include freshwater, saltwater (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated saltwater produced from subterranean formations), seawater, or combinations thereof. Generally, the water may be from any source, provided that it does not contain an excess of compounds that may adversely affect other components in the settable composition. In some embodiments, the water may be included in an amount sufficient to form a pumpable slurry. In some embodiments, the water may be included in the settable compositions of the present invention in an amount in the range of from about 40% to about 200% by weight. As used herein, the term “by weight,” when used herein to refer to the percent of a component in the settable composition, means by weight included in the settable compositions of the present invention relative to the weight of the dry components in the settable composition. In some embodiments, the water may be included in an amount in the range of from about 40% to about 150% by weight.
[0019] The CKD should be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost reduction. In some embodiments, the CKD may be present in the settable compositions of the present invention in an amount in the range of from about 0.01% to 100% by weight. In some embodiments, the CKD may be present in the settable compositions of the present invention in an amount in the range of from about 5% to 100% by weight. In some embodiments, the CKD may be present in the settable compositions of the present invention in an amount in the range of from about 5% to about 80% by weight. In some embodiments, the CKD may be present in the settable compositions of the present invention in an amount in the range of from about 10% to about 50% by weight.
[0020] The settable compositions of the present invention may optionally comprise a hydraulic cement. A variety of hydraulic cements may be utilized in accordance with the present invention, including, but not limited to, those comprising calcium, aluminum, silicon, oxygen, iron, and/or sulfur, which set and harden by reaction with water. Suitable hydraulic cements include, but are not limited to, Portland cements, pozzolana cements, gypsum cements, high alumina content cements, slag cements, silica cements, and combinations thereof. In certain embodiments, the hydraulic cement may comprise a Portland cement. In some embodiments, the Portland cements that are suited for use in the present invention are classified as Classes A, C, H, and G cements according to American Petroleum Institute, API Specification for Materials and Testing for Well Cements , API Specification 10, Fifth Ed., Jul. 1, 1990.
[0021] Where present, the hydraulic cement generally may be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the hydraulic cement may be present in the settable compositions of the present invention in an amount in the range of from 0% to about 100% by weight. In some embodiments, the hydraulic cement may be present in the settable compositions of the present invention in an amount in the range of from 0% to about 95% by weight. In some embodiments, the hydraulic cement may be present in the settable compositions of the present invention in an amount in the range of from about 20% to about 95% by weight. In some embodiments, the hydraulic cement may be present in the settable compositions of the present invention in an amount in the range of from about 50% to about 90% by weight.
[0022] In some embodiments, a pozzolana cement that may be suitable for use comprises fly ash. A variety of fly ashes may be suitable, including fly ash classified as Class C and Class F fly ash according to American Petroleum Institute, API Specification for Materials and Testing for Well Cements , API Specification 10, Fifth Ed., Jul. 1, 1990. Class C fly ash comprises both silica and lime so that, when mixed with water, it sets to form a hardened mass. Class F fly ash generally does not contain sufficient lime, so an additional source of calcium ions is required for the Class F fly ash to form a settable composition with water. In some embodiments, lime may be mixed with Class F fly ash in an amount in the range of from about 0.1% to about 25% by weight of the fly ash. In some instances, the lime may be hydrated lime. Suitable examples of fly ash include, but are not limited to, “POZMIX® A” cement additive, commercially available from Halliburton Energy Services, Inc., Duncan, Okla.
[0023] Where present, the fly ash generally may be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the fly ash may be present in the settable compositions of the present invention in an amount in the range of from about 5% to about 75% by weight. In some embodiments, the fly ash may be present in the settable compositions of the present invention in an amount in the range of from about 10% to about 60% by weight.
[0024] In some embodiments, a slag cement that may be suitable for use may comprise slag. Slag generally does not contain sufficient basic material, so slag cement further may comprise a base to produce a settable composition that may react with water to set to form a hardened mass. Examples of suitable sources of bases include, but are not limited to, sodium hydroxide, sodium bicarbonate, sodium carbonate, lime, and combinations thereof.
[0025] Where present, the slag cement generally may be included in the settable compositions in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the slag cement may be present in the settable compositions of the present invention in an amount in the range of from 0% to about 99.9% by weight. In some embodiments, the slag cement may be present in the settable compositions of the present invention in an amount in the range of from about 5% to about 75% by weight.
[0026] In certain embodiments, the settable compositions of the present invention further may comprise metakaolin. Generally, metakaolin is a white pozzolan that may be prepared by heating kaolin clay, for example, to temperatures in the range of from about 600° to about 800° C. In some embodiments, the metakaolin may be present in the settable compositions of the present invention in an amount in the range of from about 5% to about 95% by weight. In some embodiments, the metakaolin may be present in an amount in the range of from about 10% to about 50% by weight.
[0027] In certain embodiments, the settable compositions of the present invention further may comprise shale. Among other things, shale included in the settable compositions may react with excess lime to form a suitable cementing material, for example, calcium silicate hydrate. A variety of shales are suitable, including those comprising silicon, aluminum, calcium, and/or magnesium. An example of a suitable shale comprises vitrified shale. Suitable examples of vitrified shale include, but are not limited to, “PRESSUR-SEAL® FINE LCM” material and “PRESSUR-SEAL® COARSE LCM” material, which are commercially available from TXI Energy Services, Inc., Houston, Tex. Generally, the shale may have any particle size distribution as desired for a particular application. In certain embodiments, the shale may have a particle size distribution in the range of from about 37 micrometers to about 4,750 micrometers.
[0028] Where present, the shale may be included in the settable compositions of the present invention in an amount sufficient to provide the desired compressive strength, density, and/or cost. In some embodiments, the shale may be present in an amount in the range of from about 5% to about 75% by weight. In some embodiments, the shale may be present in an amount in the range of from about 10% to about 35% by weight. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the shale to include for a chosen application.
[0029] In certain embodiments, the settable compositions of the present invention further may comprise zeolite. Zeolites generally are porous alumino-silicate minerals that may be either a natural or synthetic material. Synthetic zeolites are based on the same type of structural cell as natural zeolites, and may comprise aluminosilicate hydrates. As used herein, the term “zeolite” refers to all natural and synthetic forms of zeolite.
[0030] In certain embodiments, suitable zeolites for use in present invention may include “analcime” (which is hydrated sodium aluminum silicate), “bikitaite” (which is lithium aluminum silicate), “brewsterite” (which is hydrated strontium barium calcium aluminum silicate), “chabazite” (which is hydrated calcium aluminum silicate), “clinoptilolite” (which is hydrated sodium aluminum silicate), “faujasite” (which is hydrated sodium potassium calcium magnesium aluminum silicate), “hannotome” (which is hydrated barium aluminum silicate), “heulandite” (which is hydrated sodium calcium aluminum silicate), “laumontite” (which is hydrated calcium aluminum silicate), “mesolite” (which is hydrated sodium calcium aluminum silicate), “natrolite” (which is hydrated sodium aluminum silicate), “paulingite” (which is hydrated potassium sodium calcium barium aluminum silicate), “phillipsite” (which is hydrated potassium sodium calcium aluminum silicate), “scolecite” (which is hydrated calcium aluminum silicate), “stellerite” (which is hydrated calcium aluminum silicate), “stilbite” (which is hydrated sodium calcium aluminum silicate), and “thomsonite” (which is hydrated sodium calcium aluminum silicate), and combinations thereof. In certain embodiments, suitable zeolites for use in the present invention include chabazite and clinoptilolite. An example of a suitable source of zeolite is available from the C2C Zeolite Corporation of Calgary, Canada.
[0031] In some embodiments, the zeolite may be present in the settable compositions of the present invention in an amount in the range of from about 5% to about 65% by weight. In certain embodiments, the zeolite may be present in an amount in the range of from about 10% to about 40% by weight.
[0032] In certain embodiments, the settable compositions of the present invention further may comprise a set retarding additive. As used herein, the term “set retarding additive” refers to an additive that retards the setting of the settable compositions of the present invention. Examples of suitable set retarding additives include, but are not limited to, ammonium, alkali metals, alkaline earth metals, metal salts of sulfoalkylated lignins, hydroxycarboxy acids, copolymers that comprise acrylic acid or maleic acid, and combinations thereof. One example of a suitable sulfoalkylate lignin comprises a sulfomethylated lignin. Suitable set retarding additives are disclosed in more detail in U.S. Pat. No. Re. 31,190, the entire disclosure of which is incorporated herein by reference. Suitable set retarding additives are commercially available from Halliburton Energy Services, Inc. under the tradenames “HR® 4,” “HR® 5,” HR® 7,” “HR® 12,” HR® 15,” HR® 25,” “SCR™ 100,” and “SCR™ 500.” Generally, where used, the set retarding additive may be included in the settable compositions of the present invention in an amount sufficient to provide the desired set retardation. In some embodiments, the set retarding additive may be present in an amount in the range of from about 0.1% to about 5% by weight.
[0033] Optionally, other additional additives may be added to the settable compositions of the present invention as deemed appropriate by one skilled in the art, with the benefit of this disclosure. Examples of such additives include, but are not limited to, accelerators, weight reducing additives, heavyweight additives, lost circulation materials, filtration control additives, dispersants, and combinations thereof. Suitable examples of these additives include crystalline silica compounds, amorphous silica, salts, fibers, hydratable clays, microspheres, pozzolan lime, latex cement, thixotropic additives, combinations thereof and the like.
[0034] An example of a settable composition of the present invention may comprise water and CKD. As desired by one of ordinary skill in the art, with the benefit of this disclosure, such settable composition of the present invention further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0035] Another example of a settable composition of the present invention may comprise water and CKD, and an additive comprising at least one of the following group: fly ash; shale; zeolite; slag cement; metakaolin; and combinations thereof. As desired by one of ordinary skill in the art, with the benefit of this disclosure, such settable composition of the present invention further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0036] As mentioned previously, in certain embodiments, the settable compositions of the present invention may be foamed with a gas. In some embodiments, foamed settable compositions of the present invention may comprise water, CKD, a gas, and a surfactant. Other suitable additives, such as those discussed previously, also may be included in the foamed settable compositions of the present invention as desired by those of ordinary skill in the art, with the benefit of this disclosure. The gas used in the foamed settable compositions of the present invention may be any gas suitable for foaming a settable composition, including, but not limited to, air, nitrogen, or combinations thereof. Generally, the gas should be present in the foamed settable compositions of the present invention in an amount sufficient to form the desired foam. In certain embodiments, the gas may be present in the foamed settable compositions of the present invention in an amount in the range of from about 10% to about 80% by volume of the composition.
[0037] Where foamed, the settable compositions of the present invention further comprise a surfactant. In some embodiments, the surfactant comprises a foaming and stabilizing surfactant. As used herein, a “foaming and stabilizing surfactant composition” refers to a composition that comprises one or more surfactants and, among other things, may be used to facilitate the foaming of a settable composition and also may stabilize the resultant foamed settable composition formed therewith. Any suitable foaming and stabilizing surfactant composition may be used in the settable compositions of the present invention. Suitable foaming and stabilizing surfactant compositions may include, but are not limited to: mixtures of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; mixtures of an ammonium salt of an alkyl ether sulfate surfactant, a cocoamidopropyl hydroxysultaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water; hydrolyzed keratin; mixtures of an ethoxylated alcohol ether sulfate surfactant, an alkyl or alkene amidopropyl betaine surfactant, and an alkyl or alkene dimethylamine oxide surfactant; aqueous solutions of an alpha-olefinic sulfonate surfactant and a betaine surfactant; and combinations thereof. In one certain embodiment, the foaming and stabilizing surfactant composition comprises a mixture of an ammonium salt of an alkyl ether sulfate, a cocoamidopropyl betaine surfactant, a cocoamidopropyl dimethylamine oxide surfactant, sodium chloride, and water. A suitable example of such a mixture is “ZONESEAL® 2000” foaming additive, commercially available from Halliburton Energy Services, Inc. Suitable foaming and stabilizing surfactant compositions are described in U.S. Pat. Nos. 6,797,054, 6,547,871, 6,367,550, 6,063,738, and 5,897,699, the entire disclosures of which are incorporated herein by reference.
[0038] Generally, the surfactant may be present in the foamed settable compositions of the present invention in an amount sufficient to provide a suitable foam. In some embodiments, the surfactant may be present in an amount in the range of from about 0.8% and about 5% by volume of the water (“bvow”).
Methods of the Present Invention
[0039] The settable compositions of the present invention may be used in a variety of subterranean applications, including, but not limited to, primary cementing, remedial cementing, and drilling operations. The settable compositions of the present invention also may be used in surface applications, for example, construction cementing.
[0040] An example of a method of the present invention comprises providing a settable composition of the present invention comprising water and CKD; placing the settable composition in a location to be cemented; and allowing the settable composition to set therein. In some embodiments, the location to be cemented may be above ground, for example, in construction cementing. In some embodiments, the location to be cemented may be in a subterranean formation, for example, in subterranean applications. In some embodiments, the settable compositions of the present invention may be foamed. As desired by one of ordinary skill in the art, with the benefit of this disclosure, the settable compositions of the present invention useful in this method further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0041] Another example of a method of the present invention is a method of cementing a pipe string (e.g., casing, expandable casing, liners, etc.) disposed in a well bore. An example of such a method may comprise providing a settable composition of the present invention comprising water and CKD; introducing the settable composition into the annulus between the pipe string and a wall of the well bore; and allowing the settable composition to set in the annulus to form a hardened mass. Generally, in most instances, the hardened mass should fix the pipe string in the well bore. In some embodiments, the settable compositions of the present invention may be foamed. As desired by one of ordinary skill in the art, with the benefit of this disclosure, the settable compositions of the present invention useful in this method further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean application.
[0042] Another example of a method of the present invention is method of sealing a portion of a gravel pack or a portion of a subterranean formation. An example of such a method may comprise providing a settable composition of the present invention comprising water and CKD; introducing the settable composition into the portion of the gravel pack or the portion of the subterranean formation; and allowing the settable composition to form a hardened mass in the portion. The portions of the subterranean formation may include permeable portions of the formation and fractures (natural or otherwise) in the formation and other portions of the formation that may allow the undesired flow of fluid into, or from, the well bore. The portions of the gravel pack include those portions of the gravel pack, wherein it is desired to prevent the undesired flow of fluids into, or from, the well bore. Among other things, this method may allow the sealing of the portion of the gravel pack to prevent the undesired flow of fluids without requiring the gravel pack's removal. In some embodiments, the settable compositions of the present invention may be foamed. As desired by one of ordinary skill in the art, with the benefit of this disclosure, the settable compositions of the present invention useful in this method further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0043] Another example of a method of the present invention is a method of sealing voids located in a pipe string (e.g., casing, expandable casings, liners, etc.) or in a cement sheath. Generally, the pipe string will be disposed in a well bore, and the cement sheath may be located in the annulus between the pipe string disposed in the well bore and a wall of the well bore. An example of such a method may comprise providing a settable composition comprising water and CKD; introducing the settable composition into the void; and allowing the settable composition to set to form a hardened mass in the void. In some embodiments, the settable compositions of the present invention may be foamed. As desired by one of ordinary skill in the art, with the benefit of this disclosure, the settable compositions of the present invention useful in this method further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0044] When sealing a void in a pipe string, the methods of the present invention, in some embodiments, further may comprise locating the void in the pipe string; and isolating the void by defining a space within the pipe string in communication with the void; wherein the settable composition may be introduced into the void from the space. The void may be isolated using any suitable technique and/or apparatus, including bridge plugs, packers, and the like. The void in the pipe string may be located using any suitable technique.
[0045] When sealing a void in the cement sheath, the methods of the present invention, in some embodiments, further may comprise locating the void in the cement sheath; producing a perforation in the pipe string that intersects the void; and isolating the void by defining a space within the pipe string in communication with the void via the perforation, wherein the settable composition is introduced into the void via the perforation. The void in the pipe string may be located using any suitable technique. The perforation may be created in the pipe string using any suitable technique, for example, perforating guns. The void may be isolated using any suitable technique and/or apparatus, including bridge plugs, packers, and the like.
[0046] Another example of a method of the present invention is a method of changing the direction of drilling a well bore. An example of such a method may comprise providing a settable composition comprising CKD; introducing the settable composition into the well bore at a location in the well bore wherein the direction of drilling is to be changed; allowing the settable composition to set to form a kickoff plug in the well bore; drilling a hole in the kickoff plug; and drilling of the well bore through the hole in the kickoff plug. In some embodiments, the settable compositions of the present invention may be foamed. As desired by one of ordinary skill in the art, with the benefit of this disclosure, the settable compositions of the present invention useful in this method further may comprise any of the above-listed additives, as well any of a variety of other additives suitable for use in subterranean applications.
[0047] Generally, the drilling operation should continue in the direction of the hole drilled through the kickoff plug. The well bore and hole in the kickoff plug may be drilled using any suitable technique, including rotary drilling, cable tool drilling, and the like. In some embodiments, one or more oriented directional drilling tools may be placed adjacent to the kickoff plug. Suitable directional drilling tools include, but are not limited to, whip-stocks, bent sub-downhole motorized drill combinations, and the like. The direction drilling tools then may be used to drill the hole in the kickoff plug so that the hole is positioned in the desired direction. Optionally, the directional drilling tool may be removed from the well bore subsequent to drilling the hole in the kickoff plug.
[0048] To facilitate a better understanding of the present invention, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the scope of the invention.
Example 1
[0049] A series of sample settable compositions were prepared at room temperature and subjected to 48-hour compressive strength tests at 140° F. in accordance with API Specification 10. The sample compositions comprised water, Class A CKD, and Class A Portland cement.
[0050] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 1
Unfoamed Compressive Strength Tests:
Class A Cement and Class A CKD
48-Hour
Portland
Compressive
Cement
CKD
Strength at
Density
Class A
Class A
140° F.
Sample
(ppg)
(% by wt)
(% by wt)
(psi)
No. 1
14
0
100
228
No. 2
15.15
25
75
701
No. 3
14.84
50
50
1,189
No. 4
15.62
75
25
3,360
No. 5
15.6
100
0
2,350
Example 2
[0051] Sample Compositions No. 6 and 7 were prepared at room temperature and subjected to thickening time and fluid loss tests at 140° F. and 240° F., respectively, in accordance with API Specification 10.
[0052] Sample Composition No. 6 comprised water, Class A Portland Cement (50% by weight), Class A CKD (50% by weight), “HALAD® 23” fluid loss control additive (0.75% by weight), and “HR®-5” set retarder (0.25% by weight). Accordingly, Sample Composition No. 6 had a Portland cement-to-CKD weight ratio of about 50:50. This Sample had a density of 14.84 ppg. “HALAD® 23” additive is a cellulose-based fluid loss control additive that is commercially available from Halliburton Energy Services, Inc., Duncan, Okla. HR®-5 retarder is a lignosulfonate set retarder that is commercially available from Halliburton Energy Services, Inc., Duncan, Okla.
[0053] Sample Composition No. 7 comprised water, Class A Portland Cement (50% by weight), Class A CKD (50% by weight), “HALAD® 413” fluid loss control additive (0.75% by weight), and “HR®-12” set retarder (0.3% by weight). Accordingly, Sample Composition No. 7 had a Portland cement-to-CKD weight ratio of 50:50. This Sample had a density of 14.84 ppg. “HALAD® 413” additive is a grafted copolymer fluid loss control additive that is commercially available from Halliburton Energy Services, Inc., Duncan, Okla. “HR®-12” retarder is a mixture of a lignosulfonate and hydroxycarboxy acid set retarder that is commercially available from Halliburton Energy Services, Inc., Duncan, Okla.
[0054] The results of the fluid loss and thickening time tests are set forth in the table below.
[0000]
TABLE 2
Unfoamed Thickening Time and Fluid Loss Tests:
Class A Cement and Class A CKD
Cement-to-
Test
Thickening
API Fluid
CKD Weight
Temperature
Time to 70 BC
Loss in 30 min
Sample
Ratio
(° F.)
(min:hr)
(ml)
No. 6
50:50
140
6:06
147
No. 7
50:50
240
2:20
220
Example 3
[0055] A series of sample settable compositions were prepared at room temperature and subjected to 48-hour compressive strength tests at 140° F. in accordance with API Specification 10. The sample compositions comprised water, Class H CKD, and Class H Portland cement.
[0056] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 3
Unfoamed Compressive Strength Tests:
Class H Cement and Class H CKD
48-Hour
Portland
Compressive
Cement
CKD
Strength at
Density
Class H
Class H
140° F.
Sample
(ppg)
(% by wt)
(% by wt)
(psi)
No. 8
15.23
0
100
74.9
No. 9
15.4
25
75
544
No. 10
16
50
50
1,745
No. 11
16.4
75
25
3,250
No. 12
16.4
100
0
1,931
Example 4
[0057] Sample Compositions No. 13 and 14 were prepared at room temperature and subjected to thickening time and fluid loss tests at 140° F. and 240° F., respectively, in accordance with API Specification 10.
[0058] Sample Composition No. 13 comprised water, Class H Portland Cement (50% by weight), Class H CKD (50% by weight), “HALAD® 23” fluid loss control additive (0.75% by weight), and 0.25% by weight “HR®-5” set retarder (0.25% by weight). Accordingly, Sample Composition No. 13 had a Portland cement-to-CKD weight ratio of about 50:50. This Sample had a density of 16 ppg.
[0059] Sample Composition No. 14 comprised water, Class H Portland Cement (50% by weight), Class H CKD (50% by weight), “HALAD® 413” fluid loss control additive (0.75% by weight), and “He-12” set retarder (0.3% by weight). Accordingly, Sample Composition No. 14 had a Portland cement-to-CKD weight ratio of about 50:50. This Sample had a density of 16 ppg.
[0060] The results of the fluid loss and thickening time tests are set forth in the table below.
[0000]
TABLE 4
Unfoamed Thickening Time and Fluid Loss Tests:
Class H Cement and Class H CKD
Cement-to-
Test
Thickening
API Fluid
CKD Weight
Temperature
Time to 70 BC
Loss in 30 min
Sample
Ratio
(° F.)
(min:hr)
(ml)
No. 13
50:50
140
5:04
58
No. 14
50:50
240
1:09
220
Example 5
[0061] A series of sample settable compositions were prepared at room temperature and subjected to 48-hour compressive strength tests at 140° F. in accordance with API Specification 10. The sample compositions comprised water, Class G CKD, and Class G Portland cement.
[0062] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 5
Unfoamed Compressive Strength Tests:
Class G Cement and Class G CKD
48-Hour
Portland
Compressive
Cement
CKD
Strength at
Density
Class G
Class G
140° F.
Sample
(ppg)
(% by wt)
(% by wt)
(psi)
No. 15
14.46
0
100
371
No. 16
14.47
25
75
601
No. 17
14.49
50
50
1,100
No. 18
14.46
75
25
3,160
No. 19
14.46
100
0
3,880
Example 6
[0063] Sample Compositions No. 20 and 21 were prepared at room temperature and subjected to thickening time and fluid loss tests at 140° F. and 240° F., respectively, in accordance with API Specification 10.
[0064] Sample Composition No. 20 comprised water, Class G Portland Cement (50% by weight), Class G CKD (50% by weight), “HALAD® 23” fluid loss control additive (0.75% by weight), and “HR®-5” set retarder (0.25% by weight). Accordingly, Sample Composition No. 20 had a Portland cement-to-CKD weight ratio of about 50:50. This Sample had a density of 15.23 ppg.
[0065] Sample Composition No. 21 comprised water, Class G Portland Cement (50% by weight), Class G CKD (50% by weight), “HALAD® 413” fluid loss control additive (0.75% by weight), and “HR®-12” set retarder (0.3% by weight). Accordingly, Sample Composition No. 21 had a Portland cement-to-CKD weight ratio of about 50:50. This Sample had a density of 15.23 ppg.
[0066] The results of the fluid loss and thickening time tests are set forth in the table below.
[0000]
TABLE 6
Unfoamed Thickening Time and Fluid Loss Tests:
Class G Cement and Class G CKD
Cement-to-
Test
Thickening
API Fluid
CKD Weight
Temperature
Time to 70 BC
Loss in 30 min
Sample
Ratio
(° F.)
(min:hr)
(ml)
No. 20
50:50
140
3:19
132
No. 21
50:50
240
1:24
152
[0067] Accordingly, Examples 1-6 indicate that settable compositions comprising Portland cement and CKD may have suitable thickening times, compressive strengths, and/or fluid loss properties for a particular application.
Example 7
[0068] A series of foamed sample compositions were prepared in accordance with the following procedure. For each sample, a base sample composition was prepared that comprised water, Class A Portland cement, and Class A CKD. The amounts of CKD and Portland cement were varied as shown in the table below. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 12 ppg. After preparation, the resulting foamed sample compositions were subjected to 72-hour compressive strength tests at 140° F. in accordance with API Specification 10.
[0069] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 7
Foamed Compressive Strength Test:
Class A Cement and Class A CKD
72-Hour
Portland
Compressive
Base
Foam
Cement
CKD
Strength at
Density
Density
Class A
Class A
140° F.
Sample
(ppg)
(ppg)
(% by wt)
(% by wt)
(psi)
No. 22
14.34
12
0
100
167.6
No. 23
14.15
12
25
75
701
No. 24
15.03
12
50
50
1,253
No. 25
15.62
12
75
25
1,322
No. 26
15.65
12
100
0
1,814
Example 8
[0070] A series of foamed sample compositions were prepared in accordance with the following procedure. For each sample, a base sample composition was prepared that comprised water, Class H Portland cement, and Class H CKD. The amounts of CKD and Portland cement were varied as shown in the table below. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 12 ppg. After preparation, the resulting foamed sample compositions were subjected to 72-hour compressive strength tests at 140° F. in accordance with API Specification 10.
[0071] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 8
Foamed Compressive Strength Tests:
Class H Cement and Class H CKD
72-Hour
Portland
Compressive
Base
Foam
Cement
CKD
Strength at
Density
Density
Class H
Class H
140° F.
Sample
(ppg)
(ppg)
(% by wt)
(% by wt)
(psi)
No. 27
15.07
12
0
100
27.2
No. 28
15.4
12
25
75
285
No. 29
16
12
50
50
845
No. 30
16.4
12
75
25
1,458
No. 31
16.57
12
100
0
1,509
Example 9
[0072] A series of foamed sample compositions were prepared in accordance with the following procedure. For each sample, a base sample composition was prepared that comprised water, Class G Portland cement, and Class G CKD. The amounts of CKD and Portland cement were varied as shown in the table below. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 12 ppg. After preparation, the resulting foamed sample compositions were subjected to 72-hour compressive strength tests at 140° F. in accordance with API Specification 10.
[0073] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 9
Foamed Compressive Strength Tests:
Class G Cement and Class G CKD
72-Hour
Portland
Compressive
Base
Foam
Cement
CKD
Strength at
Density
Density
Class G
Class G
140° F.
Sample
(ppg)
(ppg)
(% by wt)
(% by wt)
(psi)
No. 32
14.32
12
0
100
181
No. 33
14.61
12
25
75
462
No. 34
15
12
50
50
729
No. 35
15.43
12
75
25
1,196
No. 36
15.91
12
100
0
1,598
[0074] Accordingly, Examples 7-9 indicate that foamed settable compositions comprising Portland cement and CKD may have suitable compressive strengths for a particular application.
Example 10
[0075] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 140° F. in accordance with API Specification 10. Sufficient water was included in each sample to provide a density of about 14.2 ppg.
[0076] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 10
Unfoamed Compressive Strength Tests
Class A Cement, Class A CKD, Shale, Fly Ash, and Lime
24-Hour
Portland
Compressive
Cement
CKD
Vitrified
POZMIZ ® A
Hydrated
Strength at
Class A
Class A
Shale 1
Additive
Lime
140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 37
26
0
0
61
13
1,024
No. 38
19.5
6.5
0
61
13
766
No. 39
20.7
5.3
0
61
13
825
No. 40
23.3
2.7
0
61
13
796
No. 41
19.4
3.3
3.3
61
13
717
No. 42
20.7
2.65
2.65
61
13
708
No. 43
23.3
1.35
1.35
61
13
404
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 11
[0077] A series of sample compositions were prepared and subjected to thickening time tests at 140° F. in accordance with API Specification 10.
[0078] Sample Composition No. 44 comprised water, Class A Portland Cement (26% by weight), “POZMIX® A” cement additive (61% by weight), hydrated lime (13% by weight), “HALAD® 23” fluid loss control additive (0.6% by weight), and “HR®-5” set retarder (0.1% by weight). This Sample had a density of 14.2 ppg.
[0079] Sample Composition No. 45 comprised water, Class A Portland Cement (19.5% by weight), Class A CKD (6.5% by weight), “POZMIX® A” cement additive (61% by weight), hydrated lime (13% by weight), “HALAD® 23” fluid loss control additive (0.6% by weight), and “HR®-5” set retarder (0.1% by weight). This Sample had a density of 14.2 ppg. The vitrified shale was “PRESSUR-SEAL® FINE LCM” material.
[0080] Sample Composition No. 46 comprised water, Class A Portland Cement (19.5% by weight), Class A CKD (3.25% by weight), vitrified shale (3.25% by weight), “POZMIX® A” cement additive (61% by weight), hydrated lime (13% by weight), “HALAD® 23” fluid loss control additive (0.6% by weight), and “HR®-5” set retarder (0.1% by weight). This Sample had a density of 14.2 ppg. The vitrified shale was “PRESSUR-SEAL® FINE LCM” material.
[0081] The results of the fluid loss and thickening time tests are set forth in the table below.
[0000]
TABLE 11
Unfoamed Thickening Time Tests:
Class A Cement, Class A CKD, Shale, Fly ash, and Lime
Portland
Thickening
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
Time to 70
Class A
Class A
Shale 1
Additive
Lime
BC at 140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(min:hr)
No. 44
26
0
0
61
13
2:57
No. 45
19.5
6.5
0
61
13
2:20
No. 46
19.5
2.25
2.25
61
13
3:12
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 12
[0082] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 140° F. in accordance with API Specification 10. Sufficient water was included in each sample to provide a density of about 14.2 ppg.
[0083] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 12
Unfoamed Compressive Strength Tests:
Class H Cement, Class H CKD, Shale, Fly ash, and Lime
24-Hour
Portland
Compressive
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
Strength at
Class H
Class H
Shale 1
Additive
Lime
140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 47
26
0
0
61
13
704
No. 48
19.5
6.5
0
61
13
576
No. 49
20.7
5.3
0
61
13
592
No. 50
23.3
2.7
0
61
13
627
No. 51
19.4
3.3
3.3
61
13
626
No. 52
20.7
2.65
2.65
61
13
619
No. 53
23.3
1.35
1.35
61
13
594
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 13
[0084] Sample Composition No. 54 was prepared and subjected to a fluid loss test at 140° F. in accordance with API Specification 10. Sample Composition No. 54 comprised water, Class H Portland Cement (19.5% by weight), Class H CKD (3.3% by weight), vitrified shale (3.3% by weight), “POZMIX® A” cement additive (61% by weight), hydrated lime (13% by weight), “HALAD® 23” fluid loss control additive (0.6% by weight), and “HR®-5” set retarder (0.1% by weight). This Sample had a density of 14.2 ppg. Accordingly, Sample Composition No. 54 had a Portland cement-to-CKD weight ratio of 75:25. The vitrified shale was “PRESSUR-SEAL® FINE LCM” material.
[0085] The result of this fluid loss test is set forth in the table below.
[0000]
TABLE 13
Unfoamed Fluid Loss Test:
Class H Cement, Class H CKD, Shale, Fly ash, and Lime
Portland
Fluid Loss in
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
30 min API
Class H
Class H
Shale 1
Additive
Lime
at 140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(ml)
No. 54
19.5
3.3
3.3
61
13
117
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 14
[0086] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 140° F. in accordance with API Specification 10. Sufficient water was included in each sample to provide a density of about 14.2 ppg.
[0087] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 14
Unfoamed Compressive Strength Tests:
Class G Cement, Class G CKD, Shale, Fly ash, and Lime
24-Hour
Portland
Compressive
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
Strength at
Class G
Class G
Shale 1
Additive
Lime
140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 55
26
0
0
61
13
491
No. 56
19.5
6.5
0
61
13
526
No. 57
20.7
5.3
0
61
13
474
No. 58
23.3
2.7
0
61
13
462
No. 59
19.4
3.3
3.3
61
13
523
No. 60
20.7
2.65
2.65
61
13
563
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
[0088] Accordingly, Examples 10-14 indicate that settable compositions comprising Portland cement, CKD, fly ash, hydrated lime, and optionally vitrified shale may have suitable compressive strengths, thickening times, and/or fluid loss properties for a particular application.
Example 15
[0089] A series of foamed sample compositions were prepared in accordance with the following procedure. For each sample, a base sample composition was prepared that comprised water, Class A Portland cement, Class A CKD, vitrified shale, “POZMIX® A” cement additive (61% by weight), and hydrated lime (13% by weight). This Sample had a density of 14.2 ppg. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material. The amounts of CKD, Portland cement, and vitrified shale were varied as shown in the table below. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 12 ppg. After preparation, the resulting foamed sample compositions were subjected to 10-day compressive strength tests at 140° F. in accordance with API Specification 10.
[0090] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 15
Foamed Compressive Strength Tests:
Class A Cement, Class A CKD, Shale, Fly ash, and Lime
10-Day
Portland
Compressive
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
Strength at
Class A
Class A
Shale 1
Additive
Lime
140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 61
26
0
0
61
13
1,153
No. 62
19.5
6.5
0
61
13
1,151
No. 63
20.7
5.3
0
61
13
1,093
No. 64
23.3
2.7
0
61
13
950
No. 65
19.4
3.3
3.3
61
13
1,161
No. 66
20.7
2.65
2.65
61
13
1,009
No. 67
23.3
1.35
1.35
61
13
1,231
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 16
[0091] A series of foamed sample compositions were prepared in accordance with the following procedure. For each sample, a base sample composition was prepared that comprised water, Class A Portland cement, Class A CKD, vitrified shale, “POZMIX® A” cement additive (61% by weight), and hydrated lime (13% by weight). This Sample had a density of 14.2 ppg. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material. The amounts of CKD, Portland cement, and vitrified shale were varied as shown in the table below. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 12 ppg. After preparation, the resulting foamed sample compositions were subjected to 72-hour compressive strength tests at 140° F. in accordance with API Specification 10.
[0092] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 16
Foamed Compressive Strength Tests:
Class A Cement, Class A CKD, Shale, Fly Ash, and Lime
72-Hour
Portland
Compressive
Cement
CKD
Vitrified
POZMIX ® A
Hydrated
Strength at
Class A
Class A
Shale 1
Additive
Lime
140° F.
Sample
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 68
26
0
0
61
13
1,057
No. 69
19.5
6.5
0
61
13
969
No. 70
20.7
5.3
0
61
13
984
No. 71
19.4
3.3
3.3
61
13
921
No. 72
20.7
2.65
2.65
61
13
811
No. 73
23.3
1.35
1.35
61
13
969
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 17
[0093] Foamed Sample Composition No. 74 was prepared in accordance with the following procedure. A base sample composition was prepared that comprised water, Class G Portland cement (19.5% by weight), Class G CKD (6.5% by weight), “POZMIX® A” cement additive (61% by weight), and hydrated lime (13% by weight). This base sample had a density of 14.2 ppg. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, the base sample was foamed down to about 12 ppg. After preparation, the resulting Foamed Sample Composition was subjected to a 72-hour compressive strength test at 140° F. in accordance with API Specification 10.
[0094] The result of the compressive strength test is set forth in the table below.
[0000]
TABLE 17
Foamed Compressive Strength Tests:
Class G Cement, Class G CKD, Fly Ash, and Lime
72-Hour
Portland
Compressive
Cement
CKD
POZMIX ® A
Hydrated
Strength at
Class G
Class G
Additive
Lime
140° F.
Sample
(by wt)
(by wt)
(by wt)
(by wt)
(psi)
No. 74
19.5
6.5
61
13
777
[0095] Accordingly, Examples 15-17 indicate that foamed settable compositions comprising Portland cement, CKD, fly ash, hydrated lime, and optionally vitrified shale may have suitable compressive strengths for a particular application.
Example 18
[0096] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 180° F. in accordance with API Specification 10. The sample compositions comprised water, Class A CKD, Class A Portland cement, zeolite, vitrified shale, and hydrated lime. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material. The amount of each component was varied as shown in the table below.
[0097] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 18
Unfoamed Compressive Strength Tests:
Class A Cement, Class A CKD, Zeolite, Shale, and Lime
24-Hour
Portland
Compressive
Cement
CKD
Vitrified
Hydrated
Strength at
Density
Class A
Class A
Zeolite
Shale 1
Lime
180° F.
Sample
(ppg)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 75
13.3
50
25
25
0
0
1,915
No. 76
12.75
50
25
12.5
12.5
0
2,190
No. 77
11.6
0
75
10
25
0
31.6
No. 78
12.8
25
50
23.5
0
0
875
No. 79
12.5
25
50
12.5
12.5
0
923
No. 80
11.5
0
70
10
15
5
116.4
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 19
[0098] Foamed Sample Composition No. 81 was prepared in accordance with the following procedure. A base sample composition was prepared that comprised water, Class A Portland cement, Class A CKD, and zeolite. This base sample had a density of 14.2 ppg. “ZONESEAL® 2000” foaming additive was then added in an amount of 2% bvow. Next, the base sample was foamed down to about 12 ppg. After preparation, the resulting Foamed Sample Composition was subjected to a 72-hour compressive strength test at 140° F. in accordance with API Specification 10.
[0099] The result of the compressive strength test is set forth in the table below.
[0000]
TABLE 19
Foamed Compressive Strength Tests:
Class A Cement, Class A CKD, and Zeolite
72-Hour
Portland
CKD
Compressive
Base
Foam
Cement
Class A
Zeolite
Strength at
Density
Density
Class A
(%
(%
140° F.
Sample
(ppg)
(ppg)
(% by wt)
by wt)
by wt)
(psi)
No. 81
13.35
12
50
25
25
972
Example 20
[0100] Sample Composition No. 82 was prepared at room temperature and subjected to a 24-hour compressive strength test at 180° F. in accordance with API Specification 10. Sample Composition No. 82 comprised water, Portland Class H Cement, Class H CKD, Zeolite, and vitrified shale. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material.
[0101] The result of the compressive strength test is set forth in the table below.
[0000]
TABLE 20
Unfoamed Compressive Strength Tests:
Class H Cement, Class H CKD, Zeolite and Shale
Portland
24-Hour
Cement
CKD
Compressive
Class H
Class H
Zeolite
Vitrified
Strength at
Density
(%
(%
(%
Shale 1
180° F.
Sample
(ppg)
by wt)
by wt)
by wt)
(% by wt)
(psi)
No. 82
15.2
50
25
12.5
12.5
2,280
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 21
[0102] Sample Composition No. 83 was prepared at room temperature and subjected to thickening time and fluid loss tests at 140° F. in accordance with API Specification 10. Sample Composition No. 83 comprised Class A Portland Cement (50% by weight), Class A CKD (25% by weight), zeolite (12.5% by weight), vitrified shale (12.5% by weight), “HALAD® 23” fluid loss control additive (0.75% by weight), and “HR®-5” set retarder (0.5% by weight). This Sample had a density of 12.75 ppg. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material.
[0103] The results of the fluid loss and thickening time tests are set forth in the table below.
[0000]
TABLE 21
Unfoamed Thickening Time and Fluid Loss Tests:
Class A Cement, Class A CKD, Zeolite and Shale
Portland
Thickening
Cement
CKD
Time to 70
Fluid Loss
Class A
Class A
Zeolite
Vitrified
BC
in 30 min
Sam-
(%
(%
(%
Shale 1
at 140° F.
at 140° F.
ple
by wt)
by wt)
by wt)
(% by wt)
(min:hr)
(ml)
No.
50
25
12.5
12.5
8:54
196
83
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
[0104] Accordingly, Examples 18-21 indicate that foamed and unfoamed settable compositions comprising Portland cement, CKD, zeolite, and optionally vitrified shale may have suitable compressive strengths for a particular application.
Example 22
[0105] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 190° F. in accordance with API Specification 10. The sample compositions comprised water, slag cement, Class H CKD, Class H Portland cement, sodium carbonate, and hydrated lime. The slag cement contained sodium carbonate in an amount of 6% by weight. The amount of each component was varied as shown in the table below.
[0106] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 22
Unfoamed Compressive Strength Tests:
Class H Cement, Class H CKD, Slag Cement, and Lime
Portland
24-Hour
Cement
CKD
Slag
Compressive
Class H
Class H
Cement
Hydrated
Strength at
Density
(%
(%
(%
Lime
190° F.
Sample
(ppg)
by wt)
by wt)
by wt)
(% by wt)
(psi)
No. 84
13.2
0
50
45
5
123.6
No. 85
13.6
0
50
50
0
170.3
No. 86
14
30
50
20
0
183.2
No. 87
15
30
20
50
0
563
Example 23
[0107] A series of foamed sample settable compositions were prepared at room temperature and subjected to 72-hour compressive strength tests at 140° F. in accordance with API Specification 10. For each sample, a base sample composition comprised water, slag cement, Class H CKD, Class H Portland cement, and hydrated lime. The amount of each component was varied as shown in the table below. The slag cement contained sodium carbonate in an amount of 6% by weight. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to about 11 ppg. After preparation, the resulting Foamed Sample Composition was subjected to a 72-hour compressive strength test at 140° F. in accordance with API Specification 10.
[0108] The result of the compressive strength tests are set forth in the table below.
[0000]
TABLE 23
Foamed Compressive Strength Tests:
Class H Cement, Class H CKD, Slag Cement, and Lime
72-Hour
Portland
Compressive
Base
Foam
Cement
CKD
Slag
Hydrated
Strength at
Density
Density
Class H
Class H
Cement
Lime
140° F.
Sample
(ppg)
(ppg)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 88
13.63
11
0
50
45
5
148.9
No. 89
13.68
11
0
50
50
0
161.1
No. 90
14.07
11
30
50
20
0
125
[0109] Accordingly, Examples 22-23 indicate that foamed and unfoamed settable compositions comprising CKD, slag cement, optionally hydraulic cement, and optionally hydrated lime may have suitable compressive strengths for a particular application.
Example 24
[0110] A series of sample settable compositions were prepared at room temperature and subjected to 24-hour compressive strength tests at 180° F. in accordance with API Specification 10. The sample compositions comprised water, Portland Cement, CKD, metakaolin, and vitrified shale. The amount of each component was varied as shown in the table below. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material. Class A Portland Cement was used for this series of tests, except that Class H Portland Cement was used in Sample No. 93. Class A CKD was used for this series of tests, except that Class H CKD was used in Sample No. 93.
[0111] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 24
Compressive Strength Tests:
Cement CKD, Metakaolin, and Shale
24-Hour
Portland
CKD
Compressive
Cement
(%
Vitrified
Strength at
Sam-
Density
(%
by
Metakaolin
Shale 1
180° F.
ple
(ppg)
by wt)
wt)
(% by wt)
(% by wt)
(psi)
No.
12.75
50
25
12.5
12.5
1,560
91
No.
13.5
50
25
25
0
1,082
92
No.
13
25
50
12.5
12.5
1,410
93
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
Example 25
[0112] A series of foamed sample settable compositions were prepared at room temperature and subjected to 72-hour compressive strength tests at 180° F. in accordance with API Specification 10. For each sample, a base sample composition was prepared that comprised water, Portland Cement, CKD, metakaolin, and vitrified shale. The amount of each component was varied as shown in the table below. The vitrified shale used was “PRESSUR-SEAL® FINE LCM” material. Class A Portland Cement was used for this series of tests, except that Class H Portland Cement was used in Sample No. 96. Class A CKD was used for this series of tests, except that Class H CKD was used in Sample No. 96. “ZONESEAL® 2000” foaming additive was then added to each base sample composition in an amount of 2% bvow. Next, each base sample composition was foamed down to the density shown in the table below.
[0113] The results of the compressive strength tests are set forth in the table below.
[0000]
TABLE 25
Foamed Compressive Strength Tests:
Cement, CKD, Metakaolin, and Shale
72-Hour
Base
Foam
Portland
Vitrified
Compressive
Density
Density
Cement
CKD
Metakaolin
Shale 1
Strength at 180° F.
Sample
(ppg)
(ppg)
(% by wt)
(% by wt)
(% by wt)
(% by wt)
(psi)
No. 94
12.75
9.85
50
25
12.5
12.5
651
No. 95
13.5
9.84
50
25
25
0
512
No. 96
13
9.57
25
50
12.5
12.5
559
1 The vitrified shale used was “PRESSUR-SEAL ® FINE LCM” material.
[0114] Accordingly, Examples 24-25 indicate that foamed and unfoamed settable compositions comprising hydraulic cement, CKD, metakaolin, and optionally vitrified shale may have suitable compressive strengths for a particular application.
[0115] Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit of this invention as defined by the appended claims. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. | The present invention provides settable compositions and methods of using settable compositions that comprise a hydraulic cement; a partially calcined kiln feed comprising SiO 2 , Al 2 O 3 , Fe 2 O 3 , CaO, MgO, SO 3 , Na 2 O, and K 2 O; metakaolin; and water. The location to be cemented may be above ground or in a subterranean formation | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to electric double layer capacitors comprising carbonaceous electrodes soaked in an organic electrolytic solution.
[0003] 2. Description of the Related Art
[0004] Capacitors can repeat charge and discharge with a great amount of electric current and are hopeful for use as power storage devices accompanied with frequent charge and discharge. Capacitors, therefore, have been desired to be improved with respect to energy density, rapid charge-discharge characteristics, durability, etc.
[0005] The fact that carbonaceous electrodes are soaked in an organic electrolytic solution to form an electric double layer capacitor is known. Michio Okamura “Electric Double Layer Capacitors and Power Storage Systems” 2nd Edition, The Nikkan Kogyo Shimbun, Ltd., 2001, pages 34 to 37 discloses an electric double layer capacitor comprising a bath partitioned into two sections with a separator, an organic electrolytic solution filled in the bath and two carbonaceous electrodes, one electrode being soaked in one section of the bath and the other electrode being soaked in the other section of the bath. The organic electrolytic solution is a solution containing a solute dissolved in an organic solvent. The document discloses tetraethylammonium tetrafluoroborate (Et 4 NBF4) and the like as the solute and propylene carbonate as the solvent. As the carbonaceous electrodes, activated carbon is employed. The activated carbon refers to amorphous carbon which has a very large specific surface area because it has innumerable minute pores. In the present specification,. amorphous carbon having a specific surface area not less than about 1000 m 2 /g is called activated carbon.
[0006] Japanese Patent Laid-open Publication No. H11(1999)-317333 discloses a nonporous carbonaceous material as carbonaceous electrodes for use in electric double layer capacitors. The carbonaceous material comprises fine crystalline carbon similar to graphite and has a specific surface area not larger than 300 m 2 /g, which is smaller than that of activated carbon. Nonporous carbonaceous electrodes are considered to produce capacitance with the mechanism completely different from that of carbonaceous electrodes composed of activated carbon. It is believed that application of voltage makes electrolyte ions intercalate with solvent between layers of fine crystalline carbon similar to graphite, resulting in formation of an electric double layer.
[0007] Japanese Patent Laid-open Publication No. 2002-25867 discloses production of carbonaceous electrodes using needle coke or infusibilized pitch as a raw material. The needle coke refers to calcined coke with high graphitizability which has well-developed needle-form crystals. Needle coke possesses high electrical conductivity and extremely low proportion of thermal expansion. It also has high anisotropy based on its graphite crystal structure. Needle coke is generally produced by a delayed coking system using specially-treated coal tar pitch or petroleum heavy oil as a raw material.
[0008] Japanese Patent Laid-open Publication No. 2000-77273 discloses an electric double layer capacitor including nonporous carbonaceous electrodes soaked in an organic electrolytic solution. The organic electrolytic solution must have ion conductivity, and therefore the solute is a salt composed of a cation and an anion combined together. As the cation, lower aliphatic quaternary ammonium, lower aliphatic quaternary phosphonium, imidazolinium and the like are described. As the anion, tetrafluoroboric acid, hexafluorophosphoric acid and the like are described. The solvent of the organic electrolytic solution is a polar aprotic organic solvent. Specifically, ethylene carbonate, propylene carbonate, γ-butyrolactone, sulfolane and the like are disclosed.
[0009] The nonporous carbonaceous electrodes show electrostatic capacitance several times as much as those shown by porous electrodes made from activated carbon, and also has characteristics of expanding during electric field activation. When carbonaceous electrodes expand, the volume of the capacitor itself also increases. Thus, the increment of electrostatic capacitance per unit volume is lessoned and it is impossible to increase the energy density of the capacitor sufficiently.
[0010] It is possible to reduce the expansion of the capacitor itself by mechanically pressing the carbonaceous electrodes beforehand. However, when the carbonaceous electrodes have high expansion proportion (empirically, an expansion proportion more than about 150%), great load is applied to a container of the capacitor. This causes difficulty in maintaining sealability of the container, and also reduction in its durability. Thus, the expansion proportion of nonporous carbonaceous electrodes during electric field activation has been required to be reduced as much as possible. Nonporous carbonaceous electrodes exhibit a great expansion particularly on the cathode side of a capacitor. The reduction of such expansion is effective for increase in energy density.
[0011] It is believed that the expansion of nonporous carbonaceous electrodes is caused by expansion of gaps of a layer structure of the electrodes, which gap expansion occurs when electrolyte ions intercalate between layers of fine crystalline carbon. It, therefore, is preferable that the diameter of electrolyte ions be small in order to reduce the expansion of nonporous carbonaceous electrodes. For this reason, electrolytes comprising ions having low molecular weight and simple structure have heretofore been used as solutes for organic electrolytic solutions of electric double layer capacitors.
SUMMARY OF THE INVENTION
[0012] The present invention intends to solve the existing problems. The object of the present invention is to reduce the expansion proportion of an electric double layer capacitor by combining nonporous carbonaceous electrodes produced by a specific method with an electrolyte of a specific structure.
[0013] The present invention provides an electric double layer capacitor comprising nonporous carbonaceous electrodes soaked in an organic electrolytic solution, wherein the organic electrolytic solution contains a pyrrolidinium compound salt as a solute, and wherein the carbonaceous electrodes are electrodes obtained by the method comprising a step of obtaining a carbon powder by prebaking a needle coke green powder under an inert atmosphere, baking the prebaked needle coke powder in the presence of alkali hydroxide under an inert atmosphere, and removing the alkali hydroxide; and a step of shaping the carbon powder.
[0014] The carbon powder is preferably obtained by baking a needle coke green powder under an inert atmosphere at 600 to 900° C. for 2 to 4 hours, mixing the baked powder with an alkali hydroxide powder in a weight ratio of 1.8 to 2.2 times the baked powder, baking the powder mixture under an inert atmosphere at 650 to 850° C. for 2 to 4 hours, washing the baked powder mixture to remove the alkali hydroxide and then drying the washed mixture.
[0015] The electric double layer capacitor of the present invention has reduced proportion of expansion at the time of electric field activation. As a result, it has high energy density and also is superior in durability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an assembling diagram showing the structure of the electric double layer capacitor of the Example. In the FIG., 1 or 11 is an insulation washer; 2 is a top cover; 3 is a spring; 4 or 8 is a current collector; 5 or 7 is a carbonaceous electrode; 6 is a separator; 9 is a guide; 10 or 13 is an o-ring; 12 is a body; 14 is a pressing plate; 15 is a reference electrode; and 16 is a bottom cover.
DETAILED DESCRIPTION OF THE INVENTION
[0017] High temperature pyrolysis of petroleum heavy oil which is obtained during distillation of petroleum, provides a carbonaceous solid with needle-form structure. The solid right after its formation is called green (fresh) needle coke. When the solid is used for filler or the like, it is further calcined at a temperature of 1000° C. or higher. The solid after the calcination is called calcined needle coke, which is distinguished from green needle coke. In the present specification, powdery green needle coke is referred to as a needle coke green powder.
[0018] The nonporous carbonaceous electrodes of the present invention are produced using a needle coke green powder as a starting material. The needle coke green powder is easily crystallized even by baking conducted at relatively low temperatures. Accordingly, it is easy to control the ratio between its amorphous portion and its crystalline portion. An easily-graphitizable organic substance comes to have highly-oriented structure via heat treatment and is easily crystallized even by baking at relatively low temperatures. Accordingly, it is easy to control the ratio between its amorphous portion and its crystalline portion.
[0019] The needle coke green powder is generally produced using petroleum pitch as a raw material. In the present invention, however, it is permitted to use a coal-derived needle coke green powder resulting from carbonization using a refined material obtained by removal of quinoline insoluble matter from soft pitch contained in coal. Coal-derived needle coke generally has characteristics of having high true specific gravity, low proportion of thermal expansion and needle-form structure and being soft. In particular, coal-derived needle coke has characteristics of having larger grain size and lower proportion of thermal expansion in comparison to petroleum-derived needle coke. In addition, there is a difference in elemental composition. That is, the contents of sulfur and nitrogen of coal-derived needle coke are less than those of petroleum-derived needle coke (see, Takeuchi Yasushi “Porous Materials: Characterization, Production and Application”, Fujitec Corp., 1999, pages 56 to 61).
[0020] For the production of the carbonaceous electrodes for use in the present invention, a needle coke green powder is prepared first. The central particle diameter of the raw material is 10 to 5000 μm, preferably 10 to 100 μm. Ash in the carbonaceous electrodes influences the formation of surface functional groups. It is important to reduce the ash content. The needle coke green powder for use in the present invention has a fixed carbon content of 70 to 98% and an ash content of 0.05 to 2%. Preferred is one having a fixed carbon content of 80 to 95% and an ash content of 1% or less.
[0021] A needle coke green powder is baked under the inert atmosphere, for example, under the atmosphere of nitrogen or argon at 500 to 900° C., preferably 600 to 800° C., more preferably 650 to 750° C. for 2 to 4 hours. It is believed that a crystal structure of a carbon structure is formed during this baking step.
[0022] If the baking temperature is lower than 500° C., micropores grow too much in the activation treatment. If over 900° C., activation does not proceed. The baking time has nothing to do with the reaction by nature. If, however, it is shorter than about two hours, heat is transferred not throughout the reaction system and, therefore, no uniform nonporous carbon is formed. There is no point in using a baking time longer than four hours.
[0023] The carbon powder baked is mixed with sodium hydroxide in an amount of 1.8 to 2.2 times, preferably about 2 times the powder, in weight ratio. The powder mixture is baked in the inert atmosphere at 650 to 850° C., preferably 700 to 750° C. for 2 to 4 hours. This step is called alkali activation and is considered to be effective in relaxing crystal structure of the carbon through impregnation of the carbon structure with vapor of alkali metal atoms.
[0024] If the amount of alkali hydroxide is less than 1.0 time, the activation does not proceed sufficiently and, therefore, capacitance at the time of initial charge is not obtained satisfactorily. If it is over 2.5 times, the activation proceeds excessively and the surface area tends to increase. As a result, the carbon will result in a surface condition similar to that of normal activated carbon and, therefore, it becomes difficult to take a voltage endurance. Although KOH, CsOH, RbOH and the like may be used as the alkali hydroxide, KOH is preferred because it has a superior activation effect and is inexpensive.
[0025] If the baking temperature is lower than 650° C., KOH does not permeate carbon deeply enough and the effect of relaxing carbon layers is reduced. As a result, the increase in capacitance at the time of initial charging does not readily occur. If the baking temperature is over 850° C., it is difficult to control the conditions of carbon because inconsistent actions, namely, the activation by KOH and the crystallization of the base carbon proceed simultaneously. If the material can be heated sufficiently, the baking time is not important by nature. If, however, the baking time is shorter than two hours, heat does not spread throughout the material enough and some sites will remain unactivated. There is no point in baking longer than four hours.
[0026] Subsequently, alkali hydroxide is removed from the resulting powder mixture by washing. The washing may be carried out, for example, by recovering particles from the carbon after the alkali treatment, filling it in a stainless column, introducing pressurized water steam at 120 to 150° C. and 10 to 100 kgf, preferably 10 to 50 kgf, into the column, and continuing to introduce the pressurized water steam until the pH of the drain becomes up to 7 (generally for 6 to 10 hours). After the completion of the alkali removal step, inert gas such as argon and nitrogen is made flow in the column to dry the carbon. Thus, a desired carbon powder is obtained.
[0027] The carbon powder obtained through the above-described steps has a specific surface area of 300 m 2 /g or less. This is categorized as so-called “nonporous carbon”, which has few micropores as large as they can take various electrolyte ions, solvent, CO 2 gas and the like therein. The specific surface area can be determined by the BET method (110° C.) using CO 2 as an adsorbent.
[0028] The carbon powder prepared using a needle coke green powder as a raw material, however, is not just a “nonporous carbon,” but has some micropores. That is, the carbon powder for use in the present invention has a volume of micropores with a diameter up to 0.8 nm of 0.01 to 0.1 ml/g, preferably 0.02 to 0.06 ml/g.
[0029] If the volume of the micropores with a diameter up to 0.8 nm in the carbon powder is less than 0.01 ml/g, the powder will be swollen at a large swelling ratio at the time of capacitor charging. On the other hand, if the volume is greater than 0.1 ml/g, the dielectric characteristics will deteriorate. Regarding the volume of micropores referred to herein, the volume of micropores with a diameter up to 0.8 nm can be determined by analyzing the micropore volume by the DFT method (Density Function Theory) based on a high resolution adsorption isotherm of carbon dioxide (273 K, 10 −7 to 1 Torr) on the carbon in the material of the electrode. As a measuring device, an adsorption device for micropore measurements (Autosorb-1-MP (with a turbomolecular vacuum pump), manufactured by Quantachrome Instruments) may be used.
[0030] At present, no correlation has been found between the capacitance and the specific surface area of carbonaceous electrodes having high energy density. Elucidation of micropore structure is important for improvement in performance of carbon electrodes for electric double layers. Many of the conventional technologies use a surface area determined by the BET method as an index of micropore volume. The BET surface area, however, is estimated based on the hypothesis that a few molecules are adsorbed in layers on the surface of micropores having a diameter larger than 1 to 2 nm. The analysis of micropores with a diameter of 1 nm or less, which the present invention deals with, would not be achieved sufficiently by use of only the BET surface area.
[0031] Carbonaceous electrodes can be prepared by the methods similar to those conventionally used. For example, sheet-form electrodes are produced by pulverizing nonporous carbon prepared by the above-described method into a size of about 5 to 100 μm to regulate the particle size, subsequently adding an electrically-conductive aid, such as carbon black, for imparting electrical conductivity to the carbon powder and a binder, such as polytetrafluoroethylene (PTFE), kneading the mixture, and shaping the kneadate into sheet-form by rolling. In addition to carbon black, powdery graphite and the like may also be used as the electrically-conductive aid. PVDF, PE, PP and the like may also be used as the binder in addition to PTFE. The mixing ratio of the nonporous carbon, the electrically-conductive aid (carbon black) and the binder (PTFE) is generally about 10 to 1:0.5 to 10:0.5 to 0.25.
[0032] The thus-prepared carbonaceous electrodes for electric double layer capacitors may be used in electric double layer capacitors of structures conventionally known. Structures of electric double layer capacitors are shown, for example, in FIGS. 5 and 6 of Japanese Patent Laid-open Publication No. H11(1999)-317333, FIG. 6 of Japanese Patent Laid-open Publication No. 2002-25867 and FIGS. 1 to 4 of Japanese Patent Laid-open Publication No. 2000-77273. In general, such an electric double layer capacitor can be assembled by superposing sheet-form carbon electrodes via a separator to form positive and negative electrodes, and then impregnating the electrodes with an electrolytic solution.
[0033] The electrolytic solution is obtained, for example, by dissolving an electrolyte as a solute in an organic solvent. As the electrolyte, pyrrolidinium compound salts are employed. Preferable pyrrolidinium compound salts have a structure represented by the following formula:
[0034] wherein R independently represents an alkyl group or Rs form together an alkylene group, and X − represents a counter anion. Pyrrolidinium compound salts are conventionally known. Any one prepared by a method which a person skilled in the art knows may be employed.
[0035] The ammonium component of the pyrrolidinium compound salt is preferably one represented by the above formula wherein the R independently represents an alkyl group having 1 to 10 carbon atoms or the Rs form together an alkylene group having 3 to 8 carbon atoms. Ones in which the Rs form together an alkylene group having 4 or 5 carbon atoms and derivatives thereof are more preferable. Ones in which the Rs form together a butylene group and derivatives thereof are even more preferable. The ammonium component is called spirobipyrrolidinium (SBP).
[0036] Pyrrolidinium compounds, in particular, spirobipyrrolidinium evidently have complex structures and seem to have large ion diameters. However, use of such compounds as an electrolyte ion of an organic electrolytic solution provides significant effect of inhibiting expansion of the nonporous carbonaceous electrode of the cathode side and, as a result, energy density of the electric double layer capacitors greatly increases. Although not intending to limit theoretically, it is believed that the spread of electron clouds is controlled by a spiro ring structure and, therefore, pyrrolidinium compounds and spirobipyrrolidinium compounds may have small effective ion diameters.
[0037] The counter anion X − may be any one which has heretofore been used as an electrolyte ion of an organic electrolytic solution. Examples include a tetrafluoroborate anion, a fluoroborate anion, a borate anion partly substituted with a borofluoroalkyl group, a fluorophosphate anion, a hexafluorophosphate anion, a perchlorate anion, a borodisalicylate anion, a borodioxalate anion, an iodate ainon and the like. Preferable counter anions are a tetrafluoroborate anion and a hexafluorophosphate anion because these have low molecular weights and have simple structures and therefore expansion of the nonporous carbonaceous electrode of the anode ??? side can be controlled.
[0038] When the pyrrolidinium compound salt is dissolved in an organic solvent as a solute, an organic electrolytic solution for electric double layer capacitors is obtained. The concentration of the pyrrolidinium compound salt in an organic electrolyte solution is adjusted to 0.8 to 3.5% by mol, preferably 1.0 to 2.5% by mol. If the concentration of the pyrrolidinium compound salt is less than 0.8% by mol, the number of ions contained is not sufficient and enough capacitance is not produced. A concentration over 2.5% by mol is meaningless because it does not contribute to capacitance.
[0039] Pyrrolidinium compound salts may be used alone or as mixtures of two or more kinds of them. Such salts may be used together with electrolytes conventionally employed for organic electrolytic solutions. The content of the pyrrolidinium compound salts in the whole solute is set to 50% by weight or more, preferably 75% by weight or more of the weight of the whole solute. Examples of electrolytes suitable for use in combination with pyrrolidinium compound salts include triethylmethylammonium and tetraethylammonium.
[0040] As the organic solvent, ones which have heretofore been used for organic electric double layer capacitors may be used. For example, ethylene carbonate (EC), propylene carbonate (PC), γ-butyrolactone (GBL) and sulfolane (SL) are preferable because of their high dissolvability of pyrrolidinium compound salts and their high safety. Solvents containing these as main solvent and at least one selected from dimethyl carbonate (DMC), ethylmethyl carbonate (EMC) and diethyl carbonate (DEC) as auxiliary solvent are also useful because the low-temperature characteristics of electric double layer capacitors are improved. Use of acetonitrile (AC) as the organic solvent is preferable from the viewpoint of performances because it improves conductivity of electrolytic solutions. However, in some cases, the applications are restricted.
[0041] When nonporous carbonaceous electrodes obtained by using needle coke as a raw material and an electrolytic solution containing pyrrolidinium compound salts are used in combination, an effect of inhibiting expansion of cathodes is remarkably exhibited and energy density. of electric double layer capacitors greatly increases.
[0042] The present invention will be described in more detail below with reference to Examples, but the invention is not limited thereto. Note that the amounts expressed in “part(s)” or “%” in the Examples are by weight unless otherwise stated.
EXAMPLE 1
[0043] Potassium hydroxide pellets were ground into a powder using a mill. A coal-derived needle coke green powder (NCGP) manufactured by The Japan Steel Works, Ltd. was baked in alumina crucibles under nitrogen flow in a muffle furnace at temperatures given in Table 1 for three hours and then naturally cooled. The baked powders were each mixed with a potassium hydroxide powder of an amount of 1.5 times by weight the baked powder. These mixtures were each placed in nickel crucibles, which were then covered with nickel lids so that the external air was interrupted. These samples were activated in a muffle furnace under nitrogen flow at 750° C. for a retention time of four hours. The final baked samples were taken out, washed lightly with pure water and then subjected to ultrasonic cleaning for one minute. Then, water was removed using a Buchner funnel. The same cleaning operations were repeated until washings came to have a pH of about 7. The resulting samples were dried at 200° C. for 10 hours in a vacuum dryer.
[0044] Each of the resulting carbons were ground with 10-mmφ alumina balls in a ball mill (AV-1 manufactured by Fujiwara Scientific Company) for one hour. These were measured for their particle size using a Coulter counter and were found to be a powder with a central particle diameter about 10 micrometers. The specific surface area of each of the resulting powdery carbons was measured by the BET method to be 80 m 2 /g. The volume of micropores having a diameter equal to or smaller than 0.8 nm was 0.04 ml/g.
[0045] A powdery carbon (CB) was mixed with acetylene black (AB) and a polytetrafluoroethylene powder (PTFE) so that the mixing ratio became 10:1:1, and then the mixture was kneaded in a mortar. In about 10 minutes, the PTFE was extended to form flakes. The flake was pressed with a press machine, yielding a carbon sheet of 200 microns thick.
[0046] This carbon sheet was stamped into 20-mmφ disks, which were fabricated into a three-electrode cell shown in FIG. 1 . As the reference electrode, activated carbon #1711 processed into a sheet by a method similar to that described above was used. Each of the cells prepared in the same manner was dried in vacuo at 220° C. for 24 hours and cooled. An electrolytic solution was prepared by dissolving spirobipyrrolidinium tetrafluoroborate (SBPBF 4 ) in propylene carbonate so that the concentration of the solute became 2.0% by mol. The resulting electrolytic solution was poured into the cells. Thus, electric double layer capacitors were prepared.
[0047] To each of the electric double layer capacitors, a charge-discharge tester CDT-RD20 manufactured by Power Systems Co., Ltd. was connected and then a constant current charge at 5 mA was carried out for 7200 seconds. After the arrival at a programmed voltage, a constant current discharge was carried out at 5 mA. The charge and discharge cycle was repeated three times at programmed voltages of 4.0V and 3.5V each. Capacitance of each cell was calculated from the discharged power. The cell of the capacitor the measurement of which had been finished was disassembled and thickness of the electrodes was measured. The results are shown in Table 1.
COMPARATIVE EXAMPLE 1
[0048] Electric double layer capacitors were prepared and tested in the same manner as Example 1 except that 1.8% by mol of triethylmethylammonium tetrafluoroborate (TEMABF 4 ) was used instead of spirobipyrrolidinium tetrafluoroborate. The results are shown in Table 1.
TABLE 1 Thickness after activation Prebaking (thickness of Expansion Capacitance temperature single proportion Capacitance density (° C.) electrode/μm) (times) (F) (F/cc) Example 1 500 212 1.06 6.37 24.00 Solute: 600 242 1.21 8.68 28.57 SBPBF 4 700 292 1.46 10.81 29.55 800 340 1.70 11.87 27.85 900 386 1.93 1.44 2.96 1000 292 1.46 0.03 0.08 Comparative 500 246 1.32 5.69 17.14 Example 1 600 302 1.51 7.75 20.41 Solute: 700 364 1.82 9.66 21.11 TEMABF 4 800 424 2.12 10.60 19.89 900 482 2.41 1.28 2.12 1000 366 1.83 0.03 0.05
COMPARATIVE EXAMPLE 2
[0049] A green powder of mesophase pitch (HCMB) manufactured by Osaka Gas Co., Ltd. was baked in alumina crucibles under nitrogen flow in a muffle furnaced at temperatures given in Table 2 for three hours and then naturally cooled. The baked powders were each mixed with a potassium hydroxide powder of an amount of 1.5 times by weight the baked powder. These mixture were each placed in nickel crucibles, which were then covered with nickel lids so that the external air was interrupted. These samples were activated in a muffle furnace under nitrogen flow at 750° C. for a retention time of four hours. The final baked samples were taken out, washed lightly with pure water and then subjected to ultrasonic cleaning for one minute. Then, water was removed using a Buchner funnel. The same cleaning operations were repeated until washings came to have a pH of about 7. The resulting samples were dried at 200° C. for 10 hours in a vacuum dryer.
[0050] A carbon sheet was prepared in the same manner as Example 1 except using the carbon obtained above. The specific surface area of this carbon was measured by the BET method to be 122 m 2 /g.
[0051] This carbon sheet was stamped into 20-mmφ disks, which were fabricated into a three-electrode cell shown in FIG. 1 . As the reference electrode, activated carbon #1711 processed into a sheet by a method similar to that described above was used. Each of the cells prepared in the same manner was dried in vacuo at 220° C. for 24 hours. An electrolytic solution was prepared by dissolving triethylmethylammonium tetrafluoroborate (TEMABF 4 ) in propylene carbonate so that the concentration of the solute became 1.8 M/kg. The resulting electrolytic solution was poured into the cells. Thus, electric double layer capacitors were prepared.
[0052] The resulting electric double layer capacitors were examined in the same manner as Example 1. The results are shown in Table 2.
TABLE 2 Thickness after activation Prebaking (thickness of Expansion Capacitance temperature single proportion Capacitance density (° C.) electrode/μm) (times) (F) (F/cc) Comparative 500 582 2.91 5.56 7.60 Example 2 600 644 3.22 5.89 7.28 Solute: 700 706 3.53 8.50 9.58 TEMABF 4 800 762 3.81 9.78 10.22 900 784 3.92 9.33 9.47 1000 830 4.15 0.03 0.03
COMPARATIVE EXAMPLE 3
[0053] One part of formalin was mixed with one part of phenol. To the mixture, 1% of potassium hydroxide was added as a catalyst. The resulting mixture was introduced into a sealed glass vessel, which was then placed in a thermostatic oven of 50° C. Thus, the mixture was allowed to react. Ten hours later, when the vessel was taken out, the mixture resinified to form bakelite. The vessel was uncovered and excess formalin and phenol were vaporized off at 200° C. The residue was ground into a powder using a mill. Thus, a powder of pure bakelite powder was obtained. This powder was baked in alumina crucibles under nitrogen flow in a muffle furnace at temperatures given in Table 3 for three hours and then naturally cooled. The baked powders were each mixed with a potassium hydroxide powder of an amount of 1.5 times by weight the baked powder. These mixtures were each placed in nickel crucibles, which were then covered with nickel lids so that the external air was interrupted. These samples were activated in a muffle furnace under nitrogen flow at 750° C. for a retention time of four hours. The final baked samples were taken out, washed lightly with pure water and then subjected to ultrasonic cleaning for one minute. Then, water was removed using a Buchner funnel. The same cleaning operations were repeated until washings came to have a pH of about 7. The resulting samples were dried at 200° C. for 10 hours in a vacuum dryer.
[0054] A carbon sheet was prepared in the same manner as Example 1 except that the carbon obtained above was used. The specific surface area of this carbon was measured by the BET method to be 120 m 2 /g.
[0055] This carbon sheet was stamped into 20-mmφ disks, which were fabricated into a three-electrode cell shown in FIG. 1 . As the reference electrode, activated carbon #1711 processed into a sheet by a method similar to that described above was used. Each of the cells prepared in the same manner was dried in vacuo at 220° C. for 24 hours and cooled. An electrolytic solution was prepared by dissolving triethylmethylammonium tetrafluoroborate (TEMABF 4 ) in propylene carbonate so that the concentration of the solute became 1.8 M/kg. The resulting electrolytic solution was poured into the cells. Thus, electric double layer capacitors were prepared.
[0056] The resulting electric double layer capacitors were examined in the same manner as Example 1. The results are shown in Table 3.
TABLE 3 Thickness after activation Prebaking (thickness of Expansion Capacitance temperature single proportion Capacitance density (° C.) electrode/μm) (times) (F) (F/cc) Comparative 500 566 2.83 5.73 8.06 Example 3 600 670 3.35 6.16 7.32 Solute: 700 696 3.48 8.68 9.93 TEMABF 4 800 752 3.76 9.28 9.82 900 782 3.91 9.08 9.24 1000 746 3.73 0.03 0.03
[0057] As shown by the results indicated as expansion proportion and capacitance density in Tables 1 to 3, expansion of the nonporous carbonaceous electrodes during the electric field activation was controlled and energy density of the electric double layer capacitors are improved in the Example using the needle coke as a raw material of the carbonaceous electrodes and also using the pyrrolidinium compound salt as the solute of an organic electrolytic solution. | The invention is intended to reduce expansion proportion of electric double layer capacitors by combining nonporous carbonaceous electrodes produced by a specific method with an electrolyte of a specific structure. Provided is an electric double layer capacitor comprising nonporous carbonaceous electrodes soaked in an organic electrolytic solution, wherein the organic electrolytic solution contains a pyrrolidinium compound salt as a solute, and wherein the carbonaceous electrodes are electrodes obtained by the method comprising a step of obtaining a carbon powder by prebaking a needle coke green powder under an inert atmosphere, baking the prebaked needle coke powder in the presence of alkali hydroxide under an inert atmosphere, and removing the alkali hydroxide; and a step of shaping the carbon powder. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. Nos. 61/113,044, filed Nov. 10, 2008; 61/097,592, filed Sep. 17, 2008; 61/094,341, filed Sep. 4, 2008; 61/088,998, filed Aug. 14, 2008; 61/082,681, filed Jul. 22, 2008; 61/082,405, filed Jul. 21, 2008; and 61/041,103, filed Mar. 31, 2008.
FIELD OF INVENTION
[0002] The present invention relates to a process for the preparation of Sunitinib and salt thereof.
BACKGROUND OF THE INVENTION
[0003] Sunitinib base (“Sunitinib”) of the following formula:
[0000]
[0000] is an intermediate for Sunitinib salts, such as Sunitinib malate of the following formula:
[0000]
[0004] Sunitinib malate is marketed under the trade name Sutent® by Pfizer. It is an oral, multi-targeted tyrosine kinase inhibitor used for treatment of various types of cancer.
[0005] Sunitinib and salts thereof, process of preparation thereof and the use of these salts are disclosed in U.S. Pat. No. 6,573,293 B2 (“US '293 ”).
[0006] The preparation of Sunitinib disclosed in US '293 is done by amidation of 5-formyl-2,4-1H-pyrrole-3-carboxylic acid to obtain 5-formyl-2,4-1H-pyrrole-3-carboxylic acid (2-diethylaminoethyl) amide in a yield of 43%. The obtained amide is then condensed with 5-fluoro-1,3-dihydro-indol-2-one in EtOH in the presence of pyrrolidine, obtaining Sunitinib. The process can be illustrated in the following scheme:
[0000]
[0007] The amidation reaction in US '293 is performed on an activated carboxylic acid derivative. According to Journal of Organic Chemistry, 2003, 68, 6447, this reaction leads also to the formation of by-products. In addition, the amide coupling reagents, which are used in US '293 are toxic, dangerous and expensive reagents.
[0008] US 2006/0009510 (US '510) and Journal of Organic Chemistry, 2003, 68, 6447 disclose an alternative synthesis for the preparation of Sunitinib by reacting N-[2-(diethylamino) ethyl]-2,4-dimethyl-1H-pyrrole-3-carboxamide with 5-fluoro-2-oxindole, in a yield of 74%, in the presence of acetonitrile and Vislmeier reagent, as described in the following scheme:
[0000]
[0009] U.S. Pat. No. 7,119,209 also discloses an alternative process for the preparation of Sunitinib by first activation of the pyrrole moiety as imidazole derivative, which is then used in the second step for the in situ preparation of the amide, as described in the following scheme:
[0000]
[0010] There is a need in the art for an improved process for the preparation of Sunitinib and salts thereof which is also suitable for industrial scale.
SUMMARY OF THE INVENTION
[0011] In one embodiment, the present invention encompasses 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of the following formula 1;
[0000]
[0000] wherein X is either Cl or imidazole.
[0012] In another embodiment, the present invention encompasses the preparation of sunitinib and salts thereof of the following formula:
[0000]
[0013] from the compound of formula 1, wherein n is either 0 or 1, HA is a diacid, preferably, malic acid.
[0014] In another embodiment, the present invention encompasses a process for preparing 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1 comprising reacting 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 of the following structure:
[0000]
[0000] either with chlorinating agent or with 1,1-carbonyldiimidazole.
[0015] In another embodiment, the present invention encompasses a process for preparing sunitinib and salts thereof comprising preparing 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1 according to the process of the present invention, and converting it to sunitinib and salts thereof. Preferably, the sunitinib salt is sunitinib malate.
[0016] In another embodiment, the present invention encompasses a process for preparing sunitinib having the following structure:
[0000]
[0000] comprising reacting the compound of formula 1:
[0000]
[0000] with 2-diethylaminoethylamine of formula 3 of the following structure
[0000]
[0017] In yet another embodiment, the present invention encompasses a process for preparing sunitinib salts comprising, preparing sunitinib according to the process of the present invention, and converting it to sunitinib salt. Preferably, the sunitinib salt is sunitinib malate.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 shows a powder XRD pattern of crystalline Form 1 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0019] FIG. 2 shows a FTIR spectrum of crystalline Form 1 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0020] FIG. 3 shows a powder XRD pattern of crystalline Form 2 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0021] FIG. 4 shows a FTIR spectrum of crystalline Form 2 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0022] FIG. 5 shows a powder XRD pattern of crystalline Form 3 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0023] FIG. 6 shows a FTIR spectrum of crystalline Form 3 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0024] FIG. 7 shows a powder XRD pattern of crystalline Form 4 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0025] FIG. 8 shows a FTIR spectrum of crystalline Form 4 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0026] FIG. 9 shows a PXRD pattern of pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention offers processes for the preparation of sunitinib and salts thereof. Preferred embodiments of the invention are capable of achieving higher yields compared to known processes, such as via a new intermediate of the following structure:
[0000]
[0000] wherein X is either Cl or imidazole. The preparation of the compound of formula 1, is performed by first conducting a condensation reaction providing the carboxylic acid of formula 4, and then chlorinating it or reacting it with 1,1-carbonyldiimidazole to obtain 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of the following formula 1. Then, the obtained formula 1 is reacted with 2-diethylaminoethylamine of formula 3. Preferably, Sunitinib is produced in a yield of about 80% or greater, preferably at least 82%, and/or purity of at least 99.5% when X is Cl. Preferably, Sunitinib is produced in a yield of about 90% or greater, preferably at least 93%, and/or purity of at least 98% when X is imidazole.
[0028] However, when the chlorination is done before the condensation reaction, as described in the following scheme:
[0000]
[0000] about 48% of the starting PCA remains unreacted. See example 12. In addition, when the process is further continued, by performing the amidation reaction on the mixture containing PCA and its chlorinated derivatives, the compound of formula 5 is formed in a very low yield (3%). See example 12.
[0029] When X is Cl, the compound of formula 1 refers to 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride, designated formula 1a. 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride can be characterized by data selected from a group consisting of 1 H NMR (DMSO-d6, 400 MHz, 298 K): δ 13.84 (s, 1H), 11.03 (s, 1H), 7.78 (dd, J 9.4,2.5 Hz, 1H), 7.69 (s, 1H), 6.90 (ddd, J 9.4,8.5,2.5, 1H), 6.83 (dd, J 8.5,4.6. 1H), 2.51 (s, 3H), 2.48 (s, 3H); 13 C-NMR (DMSO-d6, 100.6 MHz, 298 K): δ 170.0, 166.6, 158.7, 141.3, 135.2, 133.8, 127.4, 126.5, 125.1, 116.1, 114.7, 113.1; FTIR: 3168, 3043, 1739, 1676, 1570, 1480, 1421, 1329, 1195, 1151, 1037, 821, 800; MS: m/z 301, which correspond to (M+H)+ and combination thereof.
[0030] When X is imidazole, the compound of formula 1 refers to 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole), designated formula 1b. 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole) can be characterized by data selected from a group consisting of 1 H NMR (DMSO-d6, 400 MHz, 298 K): δ 13.99 (s, 1H), 11.03 (s, 1H), 8.18 (s, 1H), 7.78 dd, J 9.3,2.5 Hz, 1H), 7.75 (s, 1H), 7.64 (m, 1H), 7.13 (bs, 1H), 6.96 (td, J 9.0,2.5 Hz, 1H), 6.85 (dd, J 8.4,4.5 Hz, 1H), 2.31 (s, 3H), 2.30 (s, 3H); 13 C-NMR (DMSO-d6, 100.6 MHz, 298 K): δ 170.0, 162.8, 158.8, 127.1, 117.7, 113.7, 110.8, 107.0, 13.8, 10.9; FTIR: 3106, 3047, 2829, 1658, 1570, 1478, 1416, 1334, 1200, 1153, 867, 803; GC/MS: at m/z 350, the ion has 2 main fragmentations m/z 283 and m/z 68 and combination thereof.
[0031] The compound of formula 1 can be used to prepare sunitinib and salts thereof having the following structure:
[0000]
[0000] wherein, n is either 0 or 1, HA is a diacid, preferably, malic acid.
[0032] When n is 0, the above formula corresponds to sunitinib base (“Sunitinib”). When n is 1, the above formula corresponds to sunitinib salt, preferably, sunitinib malate.
[0033] Initially, the process comprises the preparation of formula 1. The process can be illustrated by the following scheme:
[0000]
[0000] wherein, the carboxylic moiety reacts with chlorinating agent or with 1,1-carbonyldiimidazole (“CDI”). The process comprises reacting 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 either with chlorinating agent or with 1,1-carbonyldiimidazole. Preferably, the chlorinating agent is either thionylchloride or oxalylchloride, more preferably, thionylchloride.
[0034] In one embodiment, 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is prepared by a process comprising reacting 5-formyl-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (PCA) of the formula:
[0000]
[0000] and 5-fluoro-1,3-dihydro-indol-2-one (FDI) of the formula:
[0000]
[0000] and pyrrolidone, and adjusting the pH to acidic pH at a temperature of about 25° C. to about 70° C. to obtain a suspension.
[0035] Preferably, the reaction comprises combining 5-formyl-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (PCA), 5-fluoro-1,3-dihydro-indol-2-one (FDI) and the solvent to obtain a mixture. Preferably, this mixture is combined with pyrrolidine and a second amount of solvent to obtain a suspension.
[0036] Preferably, the solvent is selected from a group consisting of ethanol, methanol and mixture thereof.
[0037] Preferably, the suspension is stirred for a period of about 5 minutes to about 20 minutes, more preferably, for a period of about 10 minutes to about 15 minutes to obtain a solution.
[0038] Further, the solution may then be heated to facilitate the reaction. Preferably, heating is done to a temperature of about 40° C. to about 70° C. more preferably, of about 45° C. to about 55° C., most preferably, at about 50° C.
[0039] Preferably, heating is done for a period of about 0.5 hours to about 16 hours, more preferably, for a period of about 2 hours to about 6 hours; preferably the pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid forms and precipitates.
[0040] Optionally, the precipitated pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid can be recovered.
[0041] The recovery of pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid may be done by cooling and filtering the suspension, washing the precipitate and drying. Preferably, cooling is done to a temperature of about 30° C. to about 15° C, more preferably, to a temperature of about 25° C. to about 20° C., most preferably, to a temperature of about 25° C. Preferably, the washing is done with methanol.
[0042] The recovered pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid may be crystalline. Preferably, it is characterized by a PXRD pattern having peaks at about 5.1, 10.2, 11.5, 13.7, 15.4, 19.5, 21.7, 22.1, 25.5 and 28.0 deg. 2theta±0.2 deg and a PXRD pattern as depicted in FIG. 9 .
[0043] The recovered pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid can then be converted to 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 by adjusting the pH to acidic pH at a temperature of about 25° C. to about 70° C., preferably, 40° C. to about 60° C. to obtain a suspension.
[0044] A preferred process comprises suspending the pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid in a solvent, preferably water, and heating the suspension to the above temperature prior to adjustment of the pH.
[0045] More preferably, the adjustment of the pH is done at a temperature of about 45° C. to about 50° C. Most preferably, the adjustment of the pH is done at a temperature of about 50° C.
[0046] Typically, the adjustment of the pH is provided by addition of a mineral acid. Preferably, the mineral acid is HCl. The adjustment of the pH provides an acidic pH, preferably, the pH is to about 0 to about 5.0, more preferably, to about 1.0 to about 3.0.
[0047] Preferably, the adjustment of the pH at the above temperature provides a suspension from which 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is recovered easily due to enhanced filterability.
[0048] The recovered 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 can be washed and dried. The washing is done with a solvent and water. Preferably, the washing in the recovery step is done first with the solvent and then with water. Preferably, the solvent in the recovery step is either ethanol or methanol. Preferably, the drying is done at a temperature of about 60° C. to about 80° C. Preferably, the drying is conducted for a period of about 16 hours.
[0049] In a preferred embodiment, the obtained 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is crystalline. Reported herein are four crystalline forms of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4.
[0050] The first crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is characterized by data selected from a group consisting of PXRD pattern having peaks at about 5.0, 7.0, 7.6, 10.0, 10.7, 13.7, 15.0, 19.6, 22.7, 24.1, 25.5, 27.1 and 30.2 deg. 2theta±0.2 deg. 2theta and PXRD pattern as depicted in FIG. 1 .
[0051] The first crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 may be further characterized by FTIR spectrum as depicted in FIG. 2 .
[0052] The second crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is characterized by data selected from a group consisting of PXRD pattern having peaks at about 5.0, 6.9, 7.5, 8.1, 9.9, 13.6, 14.9, 19.5 and 27.1 deg. 2theta±0.2 deg. 2theta and PXRD pattern as depicted in FIG. 3 .
[0053] The second crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 may be further characterized by FTIR spectrum as depicted in FIG. 4 .
[0054] The third crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is characterized by data selected from a group consisting of PXRD pattern having peaks at about 4.8, 6.9, 7.4, 9.8, 10.6, 13.6, 14.8 and 27.1 deg. 2theta±0.2 deg. 2theta and PXRD pattern as depicted in FIG. 5 .
[0055] The third crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 may be further characterized by FTIR spectrum as depicted in FIG. 6 .
[0056] The forth crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 is characterized by data selected from a group consisting of PXRD pattern having peaks at about 5.0, 7.0, 7.6, 8.1, 9.9, 13.0, 13.7, 14.9, 20.0, 24.1, 25.5, 27.1 and 30.2 deg. 2theta±0.2 deg. 2theta and PXRD pattern as depicted in FIG. 7 .
[0057] The forth crystalline form of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 may be further characterized by FTIR spectrum as depicted in FIG. 8 .
[0058] The above described crystalline forms of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4, can be used to prepare 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1.
[0059] As described before the process comprises reacting 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 either with chlorinating agent or with 1,1-carbonyldiimidazole (“CDI”).
[0060] When X is Cl, the compound of formula 1 refers to 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride, designated formula 1a.
[0061] When X is imidazole, the compound of formula 1 refers to 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole), designated formula 1b.
[0062] When 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride, designated formula 1a, is prepared, a preferred process comprises reacting 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 with thionyl chloride in the presence or absence of a catalyst. Preferably, the catalyst is DMF.
[0063] Preferably, the mole ratio between 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 and thionyl chloride is of about 1:1.3 to about 1:1.8 respectively, more preferably, of about 1:1.4.
[0064] Preferably, the mole ratio between 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 and DMF is of about 1:0.1 to about 1:0.3, more preferably, of about 1:0.2.
[0065] When 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole) (designated formula 1b) is prepared, a preferred process comprises reacting 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 with CDI.
[0066] Typically, both reactions are done in the presence of a solvent. Preferably, the reaction with thionyl chloride is done in the presence of a solvent selected from a group consisting of: an aromatic hydrocarbon, cyclic ether and mixtures thereof.
[0067] Preferably, the aromatic hydrocarbon is C 6 -C 9 aromatic hydrocarbon, more preferably, is selected from the group consisting of chlorobenzene, and toluene, most preferably, toluene. Preferably, the cyclic ether is C 4 -C5 cyclic ether, more preferably, is either tetrahydrofuran or methyl-tetrahydrofuran.
[0068] Preferably, the reaction with CDI is done in the presence of a polar aprotic solvent. Preferably, the polar aprotic solvent is selected from a group consisting of 1-methyl-2-pyrrolidone, dimethylsulfoxide, dimethylformamide dioxane and tetrahydrofuran, more preferably, 1-methyl-2-pyrrolidone.
[0069] Typically, the above reactions are maintained for a sufficient time at a given temperature to allow the formation of the compound of formula 1. Preferably, the reactions are maintained with stirring. Preferably, the reactions are maintained at a temperature of about room temperature to about reflux. Preferably, the reaction with thionyl chloride is done at temperature of about 40° C. to about 80° C., more preferably, at a temperature of about 65° C. to about 75° C., most preferably, of about 70° C. Preferably, the reaction with CDI is done at about room temperature, more preferably, at about 20° C. to about 25° C.
[0070] The above reactions are preferably maintained for a period of about 4 hours to about overnight. Preferably, the reaction with thionyl chloride is maintained for a period of about 3 hours to about 5 hours, more preferably, for a period of about 4 hours. Preferably, the reaction with CDI is maintained for overnight, for about 12 to about 24 hours, or for about 15 to about 18 hours.
[0071] The above reactions result in a suspension comprising 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1.
[0072] The precipitated 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1 can then be recovered. The recovery may be done, for example, by cooling the heated suspension, filtering it, washing and drying under vacuum. Preferably, drying is done at a temperature of about 50° C. to about 60° C., preferably, for about 10 hours to about 18 hours.
[0073] Preferably, in the reaction with thionyl chloride the recovery process includes cooling to about room temperature. Preferably, the cooling is done for a period of about 1 hour to about 3 hours, more preferably for a period of about 2 hours.
[0074] The obtained 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1 is preferably recovered in high yield. For example, when X is Cl, the obtained 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride of formula 1a is preferably recovered in yield of at least 97.8%. When X is imidazole, the obtained 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole of formula 1b is preferably recovered in a yield of at least 95%.
[0075] 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl substitute of formula 1 can be converted to sunitinib and salts thereof, as shown below.
[0076] In one embodiment, the conversion to sunitinib having the following structure
[0000]
[0000] comprises reacting the compound of formula 1 having the following formula:
[0000]
[0000] with 2-diethylaminoethylamine of formula 3 having the following structure:
[0000]
[0000] wherein X is either Cl or imidazole. Typically, this reaction occurs in the presence of a solvent.
[0077] When X is imidazole the reaction is preferably done in the presence of a solvent selected from a group consisting of 1-methyl-2-pyrrolidone, dimethysulfoxide, dimethylformamide, dioxane and tetrahydrofuran, more preferably tetrahydrofuran.
[0078] When X is Cl the reaction is preferably done in the presence of a solvent selected from the group consisting of toluene, 2-methyl tetrahydrofuran, tetrahydrofuran, dimethylformamide and 1-methyl-2-pyrrolidone. More preferably, in the presence of 2-methyl tetrahydrofuran as a solvent.
[0079] When X is imidazole, the reaction comprises combining a solution comprising diethylenediamine of formula 3 and the solvent and reacting this solution with 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole), designated formula 1b.
[0080] Typically, excess of thionyl chloride can be removed by distillation, prior to the reaction with diethylenediamine of formula 3.
[0081] Preferably, the distillation is done at a temperature of about 40° C. to about 60° C., more preferably at about 50° C. Preferably, distillation is done under vacuum.
[0082] Typically, both reactions are maintained, preferably under stirring to allow the formation of sunitinib. Preferably, the reactions are maintained for a period of about 1 hour to about 24 hours, more preferably, for about 1 hour to about 5 hours. Preferably, the reactions are maintained at a temperature of about room temperature to about 70° C.
[0083] Preferably, when X is Cl the reaction is done for a period of about 0.5 to about 3 hours. More preferably, for a period of about 1 hour. Preferably, the reaction is done at a temperature of about 25° C. to about 80° C., more preferably at about 40° C.
[0084] Preferably, when X is imidazole the reaction is done for a period of about 18 hours to about 24 hours. Preferably, the reaction is done at a temperature of about 40° C. to about 80° C., more preferably at about 70° C.
[0085] The obtained sunitinib can then be recovered. The recovery process of sunitinib may comprise adding water to the reaction mixture to precipitate Sunitinib, filtering off the precipitated sunitinib, washing and drying.
[0086] Preferably, when X is Cl the recovery further comprises concentrating the obtained suspension, prior to the filtration, providing a new suspension.
[0087] Preferably, the concentration is done by evaporating some of the solvent at a temperature of about 40° C. to about 60° C., more preferably 50° C. Preferably, the evaporation is done under vacuum.
[0088] To increase the yield, the obtained new suspension is stirred, preferably, for a period of about 1 hour to about 3 hours, more preferably for about 2 hours.
[0089] Preferably, drying is done at a temperature of about 50° C. to about 80° C., more preferably at about 50° C. to about 60° C. Preferably, drying is done for period of about 4 hours to about overnight, more preferably, for about 10 hours to about 16 hours.
[0090] Preferably, when X is Cl the drying is done at a temperature of about 70° C. to about 80° C., more preferably at about 80° C. Preferably, the drying is done for a period of about 10 hours to about 16 hours.
[0091] Preferably, when X is imidazole the drying is done at a temperature of about 40° C. to about 65° C., more preferably, at about 60° C. Preferably, drying is done for a period of about 1 hour to about 4 hours.
[0092] Typically, the recovered sunitinib can then be converted to sunitinib salt, preferably, to sunitinib malate. The conversion can be done by reacting sunitinib base with an acid, preferably, malic acid. When the acid is malic acid, the conversion can be done, for example, according to the process disclosed in U.S. publication No. 2003/0069298, hereby incorporated by reference.
[0093] Optionally, sunitinib can be purified prior to the conversion to sunitinib salt. Preferably, the purification comprises acidifying sunitinib to obtain sunitinib salt, and then converting it back to sunitinib by reacting the salt with a base.
[0094] The process comprises dissolving Sunitinib in a mixture of water with an acid to obtain sunitinib salt. Preferably, the acid is an inorganic acid, more preferably, hydrochloric acid. Then, said solution is extracted either with ketone, preferably, methyl-isobutyl ketone or with 2-Methyl THF, providing a two-phase system. Typically, the phases are separated and a base is added to the aqueous phase providing sunitinib. Preferably, when the reaction is performed in 2-Methyl THF, the extraction is done with 2-Methyl THF.
[0095] Preferably, the base is aqueous ammonia. Preferably, the aqueous phase is basified to a pH of about 8 to about 9, more preferably, to a pH of about 8.5, to obtain a suspension comprising a precipitation of sunitinib in forms of crystals.
[0096] The crystalline sunitinib can then be recovered. The recovery process may comprise filtering off the precipitated sunitinib, washing and drying. Preferably, drying is done at a temperature of about 70° C. to about 80° C. Preferably, drying is done for a period of about 10 hours to about 16 hours.
EXAMPLES
[0097] PXRD
[0098] XRD diffraction was performed on X-Ray powder diffractometer: PanAlytical X'pert Pro powder diffractometer, CuKα radiation, λ=1.541874 Å. X'Celerator detector active length (2 theta)=2.122 mm, laboratory temperature 22-25° C., zero background sample-holders. Prior to analysis the samples were gently ground by means of mortar and pestle in order to obtain a fine powder. The ground sample was adjusted into a cavity of the sample holder and the surface of the sample was smoothed by means of a cover glass slide.
FTIR
[0099] FTIR spectra were collected by means of a spectrometer Nicolet Nexus. ATR technique was used for the measurement with the following settings:
[0100] Range: 4000-550 cm −1
[0101] Number of sample scans: 64
[0102] Resolution: 4.000
[0103] Apodization: Happ-Genzel
[0104] Sample gain: 8.0
[0105] Final format: Absorbance
[0106] The empty ATR crystal was measured as a background under the same conditions as were the samples. The resulting record was then subtracted automatically from the spectra of the samples.
Example 1
Preparation of sunitinib via 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride
[0107] 31.2 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid, obtained as described in U.S. Pat. No. 7,125,905, were refluxed under stirring for 4 hours in one liter flask with 310 g of toluene, 15 g of thionyl chloride and 1 g of dimethylformamide.
[0108] The stirred suspension was cooled at room temperature for 2 hours and filtered; the cake was washed with 50 g of toluene and dried at 50° under vacuum overnight.
[0109] Yield was 32.4 g (97.8%) of a compound corresponding by NMR and MS to the expected structure.
[0110] 20 g of diethylendiamine were dissolved in one liter flask with 300 g of tetrahydrofuran; about 200 g of solvent were distilled away at 50° under vacuum.
[0111] 20 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carbonyl chloride, prepared as above, were added under stirring and solution obtained was left for one hour to react without more heating. 300 g of water were added and suspension was evaporated at 50° under vacuum to eliminate most of organic solvent. After stirring 2 hours at room temperature the suspension was filtered, washed with 100 g of water and dried at 50° under vacuum overnight, obtaining 23.5 g of crude Sunitinib.
Purification
[0112] Crude material was dissolved with 560 g of water and 190 g of 1 M Hydrochloric acid, extracted with 200 g of methyl-isobutyl ketone.
[0113] Clarified aqueous phase was basified under stirring with concentrated aqueous ammonia to pH 8.5 and after 2 hours the suspension was filtered and crystals were washed with 100 g of water.
[0114] Product was dried at 50° under vacuum overnight obtaining 20.5 (82% yield, 99.6% purity by HPLC) of sunitinib.
Example 2
Preparation of Sunitinib via 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole)
[0115] 4.6 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid, obtained as described in U.S. Pat. No. 7,125,905, were stirred for 4 hours in 0.1 liter flask with 46 g of 1-methyl-2-pyrrolidone and 3 g of 1,1′-carbonyldiimidazole (CDI), after this time 0.7 g of CDI were added and reaction was left stirring overnight.
[0116] 46 g of water were added under stirring and after 1 hour the suspension was filtered and the cake washed with water.
[0117] Product was dried at 60° under vacuum obtaining 5.1 g (95% yield); NMR and MS confirmed the expected structure.
[0118] 1 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-3Z-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-(carbonyl-1-imidazole), prepared as above, was added to 10 g of 1-methyl-2-pyrrolidone and 0.5 g of diethylendiamine under stirring and the mixture was left for one day to react at 70°.
[0119] 10 g of water were added and after 2 hour at room temperature the suspension was filtered, the cake was washed with water and was dried at 60° under vacuum for 4 hours to constant weight.
[0120] 1.06 g of crude product (93% yield, 98% purity by HPLC) was obtained.
Example 3
Conversion of Sunitinib to Sunitinib Malate (according to Example 1, Preparation A of U.S. publication No. 2003/0069298)
[0121] Preparation of the Anhydrous Crystal Form I of the L-Malice Acid Salt of N-[2-(Diethylamino) ethyl]-5-[(5fluoro-1,2-dihydro-2-oxo-3H-indol-3-ylidene) methyl]-2,4-dimethyl-1H-pyrrole-3-carboxamide.
Preparation A:
[0122] N-[2-(Diethylamino)ethyl]-5-[(5-fluoro-1,2-dihydro-2-oxo-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxamide (130 mg, 0.326 mMol) was added to 20 mL methanol, and the mixture was stirred. L-malic acid (47.2 mg, 0.352 mMol) was added, resulting in rapid dissolution of all the solids. The methanol was removed under reduced pressure to produce a poorly crystalline orange solid. Acetonitrile (5 mL) was added, and the slurry was stirred and heated for about 10 minutes. Stirring was continued while the slurry was allowed to cool to room temperature. The crystals were filtered and dried, resulting in 149 mg of solids (86% yield).
Example 4
Preparation of crystalline form 1 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4
[0123] In a reactor under nitrogen atmosphere, 450 g of PCA (1.0 eq), 447.6 g of FDI (1.1 eq) and 9 L of absolute ethanol were loaded and vigorously stirred at room temperature. Then 229.95 g of pyrrolidine (1.2 eq) with 447 mL of ethanol were added and the suspension was stirred 10-15 minutes to dissolution.
[0124] The mixture was then heated to 50 ° C. and stirred at this temperature for 8 hours (precipitation of the product occurs during the heating). Then the mixture was neutralized with 1860 g of hydrochloric acid 2 mol.L −1 and the suspension was kept at 50° C. for 2 hours.
[0125] After this step, the mixture was cooled to room temperature for 2 hours and then the solid was filtered on gooch P3 and washed with 2.7 L of ethanol. The filtered product was washed with 13.5 L of water. It was dried at 80° C. overnight under vacuum yielding 777 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid derivative with 96.1% total yield.
Example 5
Preparation of crystalline form 2 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4
[0126] In a reactor under nitrogen atmosphere, 277 g of PCA (1.0 eq), 275.5 g of FDI (1.1 eq) and 5.54 L of absolute ethanol were loaded and vigorously stirred at room temperature. Then 141.54 g of pyrrolidine (1.2 eq) with 275 mL of ethanol were added and the suspension was stirred 10-15 minutes to dissolution.
[0127] Then the mixture was heated to 50° C. and stirred at this temperature for 8 hours (precipitation of the product occurs during the heating).
[0128] The mixture was neutralized with 1144 g of hydrochloric acid 2 mol.L −1 and the suspension was kept at 50° C. for 2 hours.
[0129] After this step, the mixture was cooled to room temperature for 2 hours and then the solid was filtered on gooch P3 and washed with 1.66 L of ethanol. The filtered product was washed with 8.3 L of water. It was dried at 80° C. overnight under vacuum yielding 448 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid derivative with 90.0% total yield.
Example 6
Preparation of crystalline form 3 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4
[0130] In a reactor under nitrogen atmosphere, 23 g of PCA (1.0 eq). 26.3 g of FDI (1.265 eq) and 633 mL of absolute ethanol were loaded and vigorously stirred at room temperature. Then 26 g of pyrrolidine (3 eq) were added and the suspension was stirred 10-15 minutes to dissolution.
[0131] The mixture was then heated to reflux and stirred at this temperature for 6 hours (precipitation of the product occurs during the heating).
[0132] Then the mixture was cooled to room temperature and the solid was filtered on gooch P3 and washed with 100 mL of ethanol. The obtained product was loaded again into the reactor and it was suspended into 200 mL of a mixture acetone/water 40/60 and 17.3 g of HCl 37% were added. The suspension was stirred for 2 hours at 25° C. and then filtered on gooch P3 washing the solid with 200 mL of water. It was dried at 60° C. for a night under vacuum yielding 32.6 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid derivative.
Example 7
Preparation of crystalline form 4 of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z -ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4
[0133] In a reactor under nitrogen atmosphere, 20 g of PCA (1.0 eq). 19.9 g of FDI (1.1 eq) and 400 mL of absolute ethanol were loaded and vigorously stirred at room temperature. Then 11.9 mL of pyrrolidine (1.2 eq) were added and the suspension was stirred 10-15 minutes to dissolution.
[0134] The mixture was then heated to 50° C. and stirred at this temperature for 6 hours (precipitation of the product occurs during the heating).
[0135] Then the temperature was maintained at 50° C. and 68 mL of HCl 2 mol.L −1 were slowly added up to pH 1.5-3.0. The suspension was stirred for 2 hours at 50° C. and then filtered on gooch P3 washing the solid with 2×50 mL of ethanol. It was dried at 60° C. for a night under vacuum, loaded again into the filter and washed with 3×150 mL of water.
[0136] The orange solid was dried in oven under vacuum at 60° C. for 16 hours yielding 27 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid derivative.
Example 8
Preparation of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid of formula 4 in methanol
[0137] In a reactor under nitrogen atmosphere 5 g of 5-formyl-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (PCA) (1.0 eq), 4.97 g of 5-fluoro-1,3-dihydro-indol-2-one (FDI) (1.1 eq) and 75 ml of methanol were loaded and vigorously stirred at room temperature. Then 2.97 ml of pyrrolidine (1.2 eq) were added and the suspension was stirred 10-15 minutes to dissolution.
[0138] The mixture was then heated to 50° C. and stirred at this temperature for 2-3 hours (precipitation of the product occurs during the heating).
[0139] Then, maintaining the temperature at 50° C., 20 ml of HCl 2M were slowly added up to pH 1.5-3.0. The suspension was stirred for 1 hour at 50° C. and then filtered on gooch P3 washing the solid with 2×12.5 ml of methanol and with 3×50 ml of water.
[0140] The obtained product was dried at 60° C. for a night under vacuum yielding 8.4 g of Sunitinib carboxylic acid derivative.
Example 9
Preparation of Sunitinib via Sunitinib carboxylic acid derivative
[0141] In a 500 ml reactor, 15.0 g of Sunitinib carboxylic acid derivative (Compound 4) were suspended into 300 ml of toluene (ratio 20/1.0 v/w. starting material) under vigorous stirring at room temperature. 0.755 g. of dimethylformamide (ratio 0.2/1.0 w/w) was added to the mixture.
[0142] The temperature was set at 70° C. and at this temperature, 5.1 g. of thionyl chloride (ratio 1.4/1.0 w/w) were dropped in a range of sixty minutes. The reaction was kept at 70° C. for 7 hours under stirring.
[0143] Then 140 ml of solvent were distilled to remove excess of thionyl chloride from the suspension and the reaction filtered on gooch P3 washing with 3v/w of toluene. The wet solid (sunitinib acyl chloride derivative) was re-loaded into the reactor and 300 ml Methyl-tetrahydrofuran loaded and stirred. Then the reaction mixture was heated to 70° C. and 6.35g of 2-diethylamino-ethylamine (ratio 1.1/1.0 w/w starting material) were dropped in five minutes at 70° C. After one hour the reaction was completed and 150 ml of water and HCl 2N until pH 2 were added to the suspension.
[0144] The mixture was filtered using a decalite pad to obtain a clarified phase. The two phases were separated at 50° C. and the organic phase discarded. The aqueous phase was washed once more with 300 ml of Methyl-tetrahydrofuran at 50° C. under stirring. The two phases separated again and the organic phase discarded. The aqueous phase was then basified to pH 8.5 with 5% arnmonia solution at 50° C. After one hour stirring, the suspension was filtered on gooch P3 and the wet solid dried at 60° C. under vacuum overnight.
[0145] 15.9 g. of sunitinib base were obtained with a purity of NLT 99.5% by HPLC.
Example 10
Preparation of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid
[0146] In a reactor under nitrogen atmosphere 10 g of 5-formyl-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (PCA) (1.0 eq), 9.94 g of 5-fluoro-1,3-dihydro-indol-2-one (FDI) (1.1 eq) and 150 ml of methanol were loaded and vigorously stirred at room temperature. Then 5.94 ml of pyrrolidine (1.2 eq) was added and the suspension was stirred 10-15 minutes to dissolution. The mixture was then heated to 50° C. and stirred at this temperature for 2-3 hours (precipitation of the product occurred during the heating).
[0147] The pyrrolidinium salt of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid thus obtained was cooled to 25° C., filtered on gooch P3 and washed with 50 ml of methanol. The wet solid (24 g) was then loaded again into the reactor and suspended into 150 ml of water and the mixture heated to 50° C.
[0148] Then, maintaining the temperature at 50° C., 23 ml of HCl 2M was slowly added up to pH 1.5-3.0. The suspension was stirred for 1 hour at 50° C. and then filtered on gooch P3 washing the solid with 2×50 ml of water.
[0149] The obtained product was dried at 75° C. for a night under vacuum yielding 15.5 g of 5-(5-fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid.
Example 11
Preparation of Sunitinib via Sunitinib carboxylic acid derivative
[0150] In a 500 ml reactor, 15.0 g. of Sunitinib carboxylic acid derivative (Compound 4) was suspended into 300 ml of toluene (ratio 20/1.0 v/w. starting material) under vigorous stirring at room temperature. 0.755 g. of dimethylformamide (ratio 0.2/1.0 mol of SM) were added to the mixture.
[0151] The temperature was set at 70° C. and at this temperature, 5.1 g. of thionyl chloride (ratio 1.4/1.0 mol of SM) were dropped in a range of sixty minutes. The reaction was kept at 70° C. for 7 hours under stirring.
[0152] Then 140 ml of solvent were distilled to remove excess of thionyl chloride from the suspension and the reaction was filtered on gooch P3 was washed with 3 v/w of toluene. The wet solid (sunitinib acyl chloride derivative) was re-loaded into the reactor and 225 ml Methyl-tetrahydrofuran were loaded under stirring. Then the reaction mixture was heated to 40° C. and 6.35 g of 2-diethylamino-ethylamine (ratio 1.1/1.0 w/w starting material) were dropped in five minutes at 40° C. After one hour the reaction was completed and 225 ml of water and HCl 2N until pH 2 were added to the suspension.
[0153] The mixture was filtered using a decalite pad to obtain a clarified phase. The two phases were separated at 40° C. and the organic phase was discarded. The aqueous phase was washed once more with 225 ml of Methyl-tetrahydrofuran at 40° C. under stirring. The two phases were separated again and the organic phase was discarded.
[0154] The aqueous phase was then basified to pH 8.5 with 5% ammonia solution at 40° C. After one hour stirring, the suspension was filtered on gooch P3 and the wet solid was dried at 80° C. under vacuum overnight.
[0155] 16.5 g. of sunitinib base were obtained (83% yield) with a purity of NLT 99.5% by HPLC.
Comparative Example 12
Unsuccessful chlorination of pyrrole carboxylic acid with thionylchloride
[0156] In a 100 ml reactor, 5.0 g. of PCA were suspended into 75 ml of toluene under vigorous stirring at room temperature. 15 ml of toluene are thus distilled at 50° C. under vacuum reaching a final volume of 50 ml (10 volumes on weight SM).
[0157] At 50° C., 0.44 g. of dimethylformamide (ratio 0.2/1.0 mol of SM) and 5 g of thionyl chloride (ratio 1.4/1.0 mol of SM) were added to the mixture.
[0158] The reaction was kept at 50° C. for 3 hours under stirring. The HPLC control reveals still 48% unreacted pyrrole and no changing with respect to the control done after 2 hours. The reaction looks very dark with a presence of a lot of tars.
[0159] Then 15 ml of solvent were distilled to remove excess of thionyl chloride from the suspension and then other 15 ml are added to reach the starting 75 ml of toluene.
[0160] Maintaining at 50° C., 3.83 g of N,N′-diethylaminoethylamine (ratio 1.1/1.0 w/w starting material) were dropped in five minutes. After one hour the reaction was completed and 50 ml of water and HCl 2N until pH 2 were added to the suspension.
[0161] The precipitate was filtered and the two phases separated, the aqueous phase was basified with NaOH 2M to pH 9.0 and extracted with 70 ml of dichloromethane. Difficult separation is observed, the extraction is done with a volume of 200 ml of water and 500 ml of dichloromethane.
[0162] The aqueous phase once more extracted with another 500 ml of dichloromethane. The organic phase is then evaporated to residue and triturated with a mixture hexane/ethylether 3:1.
[0163] The obtained solid is filtered on gooch P3 and dried in oven under vacuum at 35° C., 0.25 g of the desired product are obtained (3% yield, 80% purity).
Example 13
Chlorination
[0164] In a 100 ml reactor, 6.0 g of Sunitinib Carboxylic acid derivative were suspended into 60 ml of toluene under vigorous stirring at room temperature. 30 ml of toluene are thus distilled at 50° C. under vacuum reaching a final volume of 60 ml (10 volumes on weight SM).
[0165] At 70° C., 1.24 ml of dimethylformamide (ratio 0.8/1.0 mol of SM) and 9.72 ml of thionyl chloride (ratio 6.5/1.0 mol of SM) were added to the mixture. The reaction was kept at 70° C. for 8 hours under stirring then it is cooled to room temperature and filtered on gooch P3, washed with 20 ml of toluene and the obtained solid used as is.
[0166] 3 g of the solid is suspended in 20 ml of Me-THF and, at 50° C., 1.45 ml of N,N′-diethylaminoethylamine (ratio 1.1/1.0 w/w starting material) were dropped in five minutes. After one hour the reaction was completed. Sunitinib was obtained.
Example 14
Chlorination
[0167] In a 100 ml reactor, 6.0 g of Sunitinib Carboxylic acid derivative were suspended into 60 ml of toluene under vigorous stirring at room temperature. 30 ml of toluene are thus distilled at 50° C. under vacuum reaching a final volume of 60 ml (10 volumes on weight SM).
[0168] At 40° C., 0.31 ml of dimethylformamide (ratio 0.2/1.0 mol on SM) and 1.75 ml of thionyl chloride (ratio 1.2/1.0 mol on SM) were added to the mixture. The reaction was kept at 40° C. for 7 hours and it is checked by HPLC. Formula 1 (when X is Cl) was obtained. | Methods for preparing sunitinib or salts thereof are described using novel intermediates and chemical pathways. One such intermediate is: | 2 |
This is a continuation of application Ser. No. 450,347, filed Mar. 12, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a process for the manufacture of flat sheets or webs of natural fiber material which have been comminuted (broken down) into individual fibers such as cellulose fibers, in general, and more particularly to an improved method of making such sheets and webs which uses only a minimal amount of water.
In the conventional paper making processes large amounts of water are used for the suspension of cellulose fibers. Of this large amount of water required, only approximately 1% of the water ends up in the finished paper product. As a result, large quantities of water must be used and handled during the process. In particular, this large quantity of water must be removed from the paper as it is processed. This is generally done at least in part by using mechanical means, i.e., using squeezing or suction to remove the water, or through thermal means such as drying cylinders. Whichever type of removal is employed, a large amount of expensive equipment is needed, which equipment also requires great amounts of energy for driving, thereby substantially increasing the cost of making the paper. In this prior method of making paper, the floating of the cellulose material in the water leads to the formation of sheets through a purely mechanical process in that the relative movement of the individual fibers with respect to one another and their sliding together to form a netted sheet-like structure is enhanced. The adherance between fibers in the finished sheet however, is not only due to the purely mechanical netting but is also a result of chemical bonding forces of various kinds, the action of which is promoted or even made possible by the aqueous phase. A chemical part of the bonding causes the netted fibers to be fixed in their arrangement with respect to one another and to form a sheet structure engendering these common bonding forces. It can thus be seen that this process requires at least a minimum amount of water.
Other methods of forming sheet structures which do not use water have been developed. In general, these have substituted separate bonding means for the mechanical and chemical bonding forces developed from the water and the fibers themselves in the above described method. In one method disclosed in British Pat. No. 897,295, a sheet with bonded fibers is shown in which a substrate surface is coated with a bonding material and with the aid of an electrostatic field the fibers are then transferred to this bonding layer, after which the resulting sheet is separated from the substrate or forming surface. A similar process is described in Danish Pat. No. 120,930, in which process the electrostatic field is used to orient the fibers perpendicularly before their transferal to the bonding layer with the fibers then being blown over into the binding layer through the use of air jets. A plurality of layers of different orientations are positioned one above the other. A further process is shown in British Pat. No. 1,239,642. In this process which is used for bonding the fibers of a cellulose web, the cellulose is brought into contact with dimethylsulfoxide containing 3 to 30% by weight of NO 2 . This solution softens the cellulose fibers and results in a form of welding of the areas of contact of neighboring fibers without destroying the cohesiveness of the web. After a certain amount of time the solution is washed out and the web thereafter exhibits a substantially greater mechanical cohesiveness.
Although these various methods work quite well, it will be recognized that they require additional equipment, materials and so on. Thus, it can be seen that there is a need for an improved method which utilizes the inherent binding potential of the fibers themselves along with water without requiring the great amounts of water needed for the prior art process.
SUMMARY OF THE INVENTION
The present invention provides such a process in which the binding properties of small individual fibers of natural fiberous material such as cellulose when suspended in water are utilized in forming a flat sheet or web. This is accomplished without the need for a large amount of water. To accomplish this, a mass of substantially dry fibers is used as the starting material. The dry fibers are then moistened with an amount of water which is less than the amount of water which can be absorbed by the fibers. Thereafter the moistened mass is heated to a temperature above 100° C while being subjected to a flattening pressure forming the mass into a sheet. Pressure and temperature are applied to the flattened sheet continuously for a predetermined time of sufficient length to ensure good fiber bonding.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a schematic illustration of a type of press apparatus which can be used in carrying out the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Prior to describing in detail the manner of carrying out the method of the present invention, a typical press apparatus which can be used to obtain the necessary temperatures and pressures will be described. On the FIGURE, this apparatus is shown in a more or less schematic form. More details as to a specific type of apparatus which may be used are shown in Swiss Pat. No. 327,433. The apparatus illustrated on the FIGURE and designated generally as a press 10 includes two pressure generating means 12 and 13 which apply pressure in the direction of arrows 14 through two pressure belts 18 and 19 to a web 16 moving therebetween. The lower belt 18 and upper belt 19 are supported against the pressure generating means 12 and 13 through friction reducing means such as rollers not shown in detail on the FIGURE. In one zone of the pressing means 12 and 13 a plurality of heating means such as heating channels 15 are provided to which a heating medium can be admitted to raise the temperature in the zone therebetween to above 100° C. Also installed within the pressure zone between the two pressing means are cooling means such as cooling channels 17 through which a cooling medium can be passed. Material enters the press as a heap of fibers 16', is formed into a fiber layer or web 16 between the pressure belts 18 and 19 and exits the press as a sheet 16".
In carrying out the process of the present invention, the fibers are first placed on a support during processing in some form of layer corresponding in general to the starting material layer in a standard paper machine with the exception that the fibers of the present invention are not suspended in a large amount of water but rather from a dry heap. In terms of the apparatus of the FIGURE, this dry heap 16' is formed at the left hand side of the lower belt 18. As noted above, at least a certain amount of water is required in order to produce bonding between the fibers. As will be described in more detail below, the water increases the pliancy of the fibers and is a necessary pre-requisite for causing chemical bonding. Thus, the next step is the addition of water to the dry fibers. In accordance with the present invention, the maximum amount of water used in moistening the fibers is an amount equal to the moisture absorptive capacity of the fibers. By moisture absorptive capacity is meant the amount of liquid per weight of fiber that the fiber can absorb at a given temperature and which cannot subsequently be removed by mechanical means such as squeezing or suction. What is involved is that the water permeates the cell structures of the fibers remaining therein as distinguished from water within the web remaining on the surface of the fibers. The moisture absorptive capacity of the fibers decreases sharply with increasing temperatures.
A particularly advantageous method of moistening the fibers with the relatively small amount of water required is by subjecting the mass of dry fibers at normal temperature to steam which condenses thereupon in an easily controllable amount. For a short period after introduction of the water to the dry fibers, the water remains on the surface of the fibers in the form of a film or small drops. The next step in accordance with the method of the present invention is subjecting the fibers to a temperature of over 100° C while being subjected to a sheet-forming pressure. At this higher temperature, the permeation of the water into the fibers and the pliancy of the fibers is enhanced. Moreover, the increased temperature results in the formation of bonds such as are present in the form of hydrogen linkages between the cellulose fibers in the completed paper. Both of these results which are attributable to an increase in the speed of diffusion caused by the increase in temperature, result from its effects first on the diffusion of water into the fiber and further from the diffusion within the water itself.
As noted above, the amount of water added should be below the moisture absorptive capacity of the fibers in their normal temperature condition. As the temperature increases, the moisture absorptive capacity of the fibers decreases sharply so that the amount of water which has been added is greater than the moisture absorptive capacity of the fibers. Thus, at this increased temperature, only a portion of the added water is absorbed into the fibers. As also noted above, this absorption increases their pliancy. The remainder of the water outside the fiber causes both the formation of chemical bonding and also results in evaporation or steam formation causing equal distribution of the water assuring that water absorption will occur uniformerly in the mass of the fibers. Furthermore, according to the present invention, along with the increasing of the temperature, pressure is applied. In the illustrated embodiment, the application of this high temperature and pressure is accomplished by causing the fiber heap 16' on the belt 18 to pass into the pressure zone between the belts 18 and 19 in the direction of arrow 20. The pressure is applied as described above by the pressing means 12 and 13 through the belts 18 and 19 with heat supplied by the heating medium which is provided to the channels 15 in the pressing means 12 and 13.
The application of the pressure causes a mechanical compression of the fibers which have been made pliable by the water thereby increasing the surface contact between the fibers and improving the conditions for adhesion. Adhesion results from Van der Waal's forces between the molecules of the cellulose fibers and has its maximum at a particular proximity between the fibers which is herein achieved through the application of pressure. The contact points of the fibers, which are held together by the applied pressure and are ready for bonding, have water available both internally in the fibers and externally in the form of steam or surface water thereby permitting the water to exercise its bonding effect at the points of contact. Through these means a maximum amount of bonding is achieved with a minimum amount of water.
In order to achieve good bonding it is necessary that the pressure be maintained for a predetermined time. This is required since the water applied to the fibers permeates the fibers by diffusion, which process of diffision is dependent on time. Furthermore, the heating which is necessary for the evaporation of water not within the fibers and for the formation of a uniform steam atmosphere in the pressed together fiber layer takes place by means of conduction from the channels 15 through the pressing means and belts to the fiber layer. This process is also dependent on time since only a given amount of heat can be transmitted into the fiber layer during a given amount of time. As a result, the sheet formation of the present invention does not occur as an instantaneous reaction but takes place over a predetermined period of time, during which time pressure and temperature must be maintained.
The required duration of pressure and temperature exertion is longer than that which would occur if the web was passed through the pressure zones of one or a plurality of pairs of pressed rollers. Furthermore, the use of pressed rollers would result in a relief of pressure between the individual pairs of rollers and would not maintain the necessary condition of constant pressure needed to achieve good bonding according to the present invention. As a consequence, an attempt to use the process of the present invention with such rollers would result in improper bonding. Such pressure and temperature application for the required period of time is attained in the apparatus of the present invention by having the fiber heap 16' pass through the pressure zone between the two pressing means 12 and 13, which cover a considerable area. Here it is formed into a fiber layer or web 16. Thus, any increment of the web 16 is subjected to temperature and pressure for at least the time it takes to travel from the beginning of the pressing means to the end of the zones containing the heating channels 15. In general terms, the time during which the temperature and pressure must be applied is the time necessary for the evaporation of the applied water needed for good fiber bonding. Experiments have shown that satisfactory sheet formation occurs if the sheet forming pressure is maintained for a period longer than one second. Based on this it is then only necessary to insure that the velocity of the fiber layer moving through the press apparatus within the heated pressure zone is such that it is heated under pressure for at least one second. In addition, experiments have shown that the best results are achieved if the sheet forming pressure is in the range of 10 to 50 kg per cm 2 .
In order to avoid complications resulting from trapped air in the fiberous mass during the application of the sheet forming pressure it is advantageous to subject the mass to a predensification subsequent to the application of water but prior to the application of the sheet forming pressure. As noted above, the sheet forming pressure is applied in the present invention between pressure surfaces maintained at a temperature of over 100° C. In the apparatus shown on the FIGURE, a certain amount of predensification will occur in the area between the belts 18 and 19 prior to entering the pressure zone defined by the pressure applying means 12 and 13. It should be noted that although this particular embodiment of apparatus is disclosed that other types of apparatus may be used. This depends at least to some degree on the nature of the shape or web being produced. For example, if sheets which are individual sheets are to be produced, a conventional stamp press with appropriate pressure surfaces can be used. In most cases however, it is preferable that the sheets or webs be produced in a continuous manner in the form of traveling webs. For this purpose, the apparatus disclosed on the FIGURE is preferable.
The steam generated by the application of heat during the pressure in the heated zone is normally trapped between the pressure surfaces. If pressure is removed, i.e., either by lifting a conventional press or when the web leaves a heated pressure application zone, the steam escapes. If thin paper sheets are being manufactured, this is of no consequence since, by virtue of the small volume, only a small amount of steam is present which must travel only a short way within the fiber layer. However, an important application of the present invention is in the formation of thicker sheets of paper board or cardboard which in some cases can be several milimeters thick. In these sheets certain amounts of steam can accumulate and, because of the increased thickness, the web will provide additional resistance to the escape of steam. As a result, upon the removal of pressure, the rapidly expanding and escaping steam can split the sheet. To avoid problems of this nature, the cooling section of the press apparatus shown on the FIGURE is provided. Thus, after having passed through the heated pressure zone within the area of the heating channels 15, the web 16 then passes through a further pressure zone which is cooled by cooling medium flowing from the channels 17 so that upon exiting from the pressure zone as sheet 16 it is cooled down. During the cooling, the steam condenses and is absorbed by the fibers. Since initially the amount of water added is only that amount of water that can be absorbed by the fibers at normal temperature, and it was from this water that the steam was formed, all water present is capable of being absorbed by the fibers and a web free of surface moisture will result. Thus, after cooling, there will be no steam pressure in the web thereby avoiding any ripping or spliting upon removal of the pressure and all of the condensed water will have been or will shortly be absorbed into the fibers resulting in a web free of any surface moisture. The pressure applied to the web in the cooling zone in the area of the cooling ducts 17 can be less than the pressure applied during the sheet forming. It is only necessary that there be no sudden release of the steam within the web. When using other types of press apparatus, similar measures may be taken when forming heavy sheets to insure that cooling of the sheet or web takes place before removal of the pressure.
Thus, an improved method of making sheets or webs from natural fibers such as cellulose and which utilizes the inherent bonding properties of the fibers with water has been described. Although specific steps and apparatus for carrying out those steps has been shown and described, it will be obvious to those skilled in the art that various modifications may be made without departing from the spirit of the invention which is intended to be limited solely by the appended claims. | A process for the manufacture of flat sheets or webs from a natural fiber material such as cellulose fibers in which the fibers to be processed are first placed on a substrate in the form of a dry heap after which an amount of water not exceeding the amount of moisture which can be absorbed by the fiber is added, whereupon the wetted fibers are subjected to pressure and temperature causing them to bond together forming a sheet or web. When sheets or webs of greater thickness are being made according to the present invention a further step of cooling before relieving pressure is carried out to avoid steam pockets formed within the web from breaking through upon release of pressure. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 09/378,124, filed Aug. 19, 1999, U.S. Pat. No. 6,325,146 which claims the benefit of the filing date of provisional application serial No. 60/127,106, filed Mar. 31, 1999, such prior applications being incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to operations performed in conjunction with subterranean wells and, in an embodiment described herein, more particularly provides a method of performing a downhole test of a subterranean formation.
In a typical well test known as a drill stem test, a drill string is installed in a well with specialized drill stem test equipment interconnected in the drill string. The purpose of the test is generally to evaluate the potential profitability of completing a particular formation or other zone of interest, and thereby producing hydrocarbons from the formation. Of course, if it is desired to inject fluid into the formation, then the purpose of the test may be to determine the feasibility of such an injection program.
In a typical drill stem test, fluids are flowed from the formation, through the drill string and to the earth's surface at various flow rates, and the drill string may be closed to flow therethrough at least once during the test. Unfortunately, the formation fluids have in the past been exhausted to the atmosphere during the test, or otherwise discharged to the environment, many times with hydrocarbons therein being burned off in a flare. It will be readily appreciated that this procedure presents not only environmental hazards, but safety hazards as well.
Therefore, it would be very advantageous to provide a method whereby a formation may be tested, without discharging hydrocarbons or other formation fluids to the environment, or without flowing the formation fluids to the earth's surface. It would also be advantageous to provide apparatus for use in performing the method.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a method is provided in which a formation test is performed downhole, without flowing formation fluids to the earth's surface, or without discharging the fluids to the environment. Also provided are associated apparatus for use in performing the method.
In one aspect of the present invention, a method includes steps wherein a formation is perforated, and fluids from the formation are flowed into a large surge chamber associated with a tubular string installed in the well. Of course, if the well is uncased, the perforation step is unnecessary. The surge chamber may be a portion of the tubular string. Valves are provided above and below the surge chamber, so that the formation fluids may be flowed, pumped or reinjected back into the formation after the test, or the fluids may be circulated (or reverse circulated) to the earth's surface for analysis.
In another aspect of the present invention, a method includes steps wherein fluids from a first formation are flowed into a tubular string installed in the well, and the fluids are then disposed of by injecting the fluids into a second formation. The disposal operation may be performed by alternately applying fluid pressure to the tubular string, by operating a pump in the tubular string, by taking advantage of a pressure differential between the formations, or by other means. A sample of the formation fluid may conveniently be brought to the earth's surface for analysis by utilizing apparatus provided by the present invention.
In yet another aspect of the present invention, a method includes steps wherein fluids are flowed from a first formation and into a second formation utilizing an apparatus which may be conveyed into a tubular string positioned in the well. The apparatus may include a pump which may be driven by fluid flow through a fluid conduit, such as coiled tubing, attached to the apparatus. The apparatus may also include sample chambers therein for retrieving samples of the formation fluids.
In each of the above methods, the apparatus associated therewith may include various fluid property sensors, fluid and solid identification sensors, flow control devices, instrumentation, data communication devices, samplers, etc., for use in analyzing the test progress, for analyzing the fluids and/or solid matter flowed from the formation, for retrieval of stored test data, for real time analysis and/or transmission of test data, etc.
These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a well wherein a first method and apparatus embodying principles of the present invention are utilized for testing a formation;
FIG. 2 is a schematic cross-sectional view of a well wherein a second method and apparatus embodying principles of the present invention are utilized for testing a formation;
FIG. 3 is an enlarged scale schematic cross-sectional view of a device which may be used in the second method;
FIG. 4 is a schematic cross-sectional view of a well wherein a third method and apparatus embodying principles of the present invention are utilized for testing a formation;
FIG. 5 is an enlarged scale schematic cross-sectional view of a device which may be used in the third method; and
FIG. 6 is a schematic cross-sectional view of a well wherein a fourth method and apparatus embodying principles of the present invention are utilized for testing a formation.
DETAILED DESCRIPTION
Representatively illustrated in FIG. 1 is a method 10 which embodies principles of the present invention. In the following description of the method 10 and other apparatus and methods described herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. Additionally, it is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., without departing from the principles of the present invention.
In the method 10 as representatively depicted in FIG. 1, a wellbore 12 has been drilled intersecting a formation or zone of interest 14 , and the wellbore has been lined with casing 16 and cement 17 . In the further description of the method 10 below, the wellbore 12 is referred to as the interior of the casing 16 , but it is to be clearly understood that, with appropriate modification in a manner well understood by those skilled in the art, a method incorporating principles of the present invention may be performed in an uncased wellbore, and in that situation the wellbore would more appropriately refer to the uncased bore of the well.
A tubular string 18 is conveyed into the wellbore 12 . The string 18 may consist mainly of drill pipe, or other segmented tubular members, or it may be substantially unsegmented, such as coiled tubing. At a lower end of the string 18 , a formation test assembly 20 is interconnected in the string.
The assembly 20 includes the following items of equipment, in order beginning at the bottom of the assembly as representatively depicted in FIG. 1 : one or more generally tubular waste chambers 22 , an optional packer 24 , one or more perforating guns 26 , a firing head 28 , a circulating valve 30 , a packer 32 , a circulating valve 34 , a gauge carrier 36 with associated gauges 38 , a tester valve 40 , a tubular surge chamber 42 , a tester valve 44 , a data access sub 46 , a safety circulation valve 48 , and a slip joint 50 . Note that several of these listed items of equipment are optional in the method 10 , other items of equipment may be substituted for some of the listed items of equipment, and/or additional items of equipment may be utilized in the method and, therefore, the assembly 20 depicted in FIG. 1 is to be considered as merely representative of an assembly which may be used in a method incorporating principles of the present invention, and not as an assembly which must necessarily be used in such method.
The waste chambers 22 may be comprised of hollow tubular members, for example, empty perforating guns (i.e., with no perforating charges therein). The waste chambers 22 are used in the method 10 to collect waste from the wellbore 12 immediately after the perforating gun 26 is fired to perforate the formation 14 . This waste may include perforating debris, wellbore fluids, formation fluids, formation sand, etc. Additionally, the pressure reduction in the wellbore 12 created when the waste chambers 22 are opened to the wellbore may assist in cleaning perforations 52 created by the perforating gun 26 , thereby enhancing fluid flow from the formation 14 during the test. In general, the waste chambers 22 are utilized to collect waste from the wellbore 12 and perforations 52 prior to performing the actual formation test, but other purposes may be served by the waste chambers, such as drawing unwanted fluids out of the formation 14 , for example, fluids injected therein during the well drilling process.
The packer 24 may be used to straddle the formation 14 if another formation therebelow is open to the wellbore 12 , a large rathole exists below the formation, or if it is desired to inject fluids flowed from the formation 14 into another fluid disposal formation as described in more detail below. The packer 24 is shown unset in FIG. 1 as an indication that its use is not necessary in the method 10 , but it could be included in the string 18 , if desired.
The perforating gun 26 and associated firing head 28 may be any conventional means of forming an opening from the wellbore 12 to the formation 14 . Of course, as described above, the well may be uncased at its intersection with the formation 14 . Alternatively, the formation 14 may be perforated before the assembly 20 is conveyed into the well, the formation may be perforated by conveying a perforating gun through the assembly after the assembly is conveyed into the well, etc.
The circulating valve 30 is used to selectively permit fluid communication between the wellbore 12 and the interior of the assembly 20 below the packer 32 , so that formation fluids may be drawn into the interior of the assembly above the packer. The circulating valve 30 may include openable ports 54 for permitting fluid flow therethrough after the perforating gun 26 has fired and waste has been collected in the waste chambers 22 .
The packer 32 isolates an annulus 56 above the packer formed between the string 18 and the wellbore 12 from the wellbore below the packer. As depicted in FIG. 1, the packer 32 is set in the wellbore 12 when the perforating gun 26 is positioned opposite the formation 14 , and before the gun is fired. The circulating valve 34 may be interconnected above the packer 32 to permit circulation of fluid through the assembly 20 above the packer, if desired.
The gauge carrier 36 and associated gauges 38 are used to collect test data, such as pressure, temperature, etc., during the formation test. It is to be clearly understood that the gauge carrier 36 is merely representative of a variety of means which may be used to collect such data. For example, pressure and/or temperature gauges may be included in the surge chamber 42 and/or the waste chambers 22 . Additionally, note that the gauges 38 may acquire data from the interior of the assembly 20 and/or from the annulus 56 above and/or below the packer 32 . Preferably, one or more of the gauges 38 , or otherwise positioned gauges, records fluid pressure and temperature in the annulus 56 below the packer 32 , and between the packers 24 , 32 if the packer 24 is used, substantially continuously during the formation test.
The tester valve 40 selectively permits fluid flow axially therethrough and/or laterally through a sidewall thereof. For example, the tester valve 40 may be an Omni™ valve, available from Halliburton Energy Services, Inc., in which case the valve may include a sliding sleeve valve 58 and closeable circulating ports 60 . The valve 58 selectively permits and prevents fluid flow axially through the assembly 20 , and the ports 60 selectively permit and prevent fluid communication between the interior of the surge chamber 42 and the annulus 56 . Other valves, and other types of valves, may be used in place of the representatively illustrated valve 40 , without departing from the principles of the present invention.
The surge chamber 42 comprises one or more generally hollow tubular members, and may consist mainly of sections of drill pipe, or other conventional tubular goods, or may be purpose-built for use in the method 10 . It is contemplated that the interior of the surge chamber 42 may have a relatively large volume, such as approximately 20 barrels, so that, during the formation test, a substantial volume of fluid may be flowed from the formation 14 into the chamber, a sufficiently low initial drawdown pressure may be achieved during the test, etc. When conveyed into the well, the interior of the surge chamber 42 may be at atmospheric pressure, or it may be at another pressure, if desired.
One or more sensors, such as sensor 62 , may be included with the chamber 42 , in order to acquire data, such as fluid property data (e.g., pressure, temperature, resistivity, viscosity, density, flow rate, etc.) and/or fluid identification data (e.g., by using nuclear magnetic resonance sensors available from Numar, Inc.). The sensor 62 may be in data communication with the data access sub 46 , or another remote location, by any data transmission means, for example, a line 64 extending external or internal relative to the assembly 20 , acoustic data transmission, electromagnetic data transmission, optical data transmission, etc.
The valve 44 may be similar to the valve 40 described above, or it may be another type of valve. As representatively depicted in FIG. 1, the valve 44 includes a ball valve 66 and closeable circulating ports 68 . The ball valve 66 selectively permits and prevents fluid flow axially through the assembly 20 , and the ports 68 selectively permit and prevent fluid communication between the interior of the assembly 20 above the surge chamber 42 and the annulus 56 . Other valves, and other types of valves, may be used in place of the representatively illustrated valve 44 , without departing from the principles of the present invention.
The data access sub 46 is representatively depicted as being of the type wherein such access is provided by conveying a wireline tool 70 therein in order to acquire the data transmitted from the sensor 62 . For example, the data access sub 46 may be a conventional wet connect sub. Such data access may be utilized to retrieve stored data and/or to provide real time access to data during the formation test. Note that a variety of other means may be utilized for accessing data acquired downhole in the method 10 , for example, the data may be transmitted directly to a remote location, other types of tools and data access subs may be utilized, etc.
The safety circulation valve 48 may be similar to the valves 40 , 44 described above in that it may selectively permit and prevent fluid flow axially therethrough and through a sidewall thereof. However, preferably the valve 48 is of the type which is used only when a well control emergency occurs. In that instance, a ball valve 72 thereof (which is shown in its typical open position in FIG. 1) would be closed to prevent any possibility of formation fluids flowing further to the earth's surface, and circulation ports 74 would be opened to permit kill weight fluid to be circulated through the string 18 .
The slip joint 50 is utilized in the method 10 to aid in positioning the assembly 20 in the well. For example, if the string 18 is to be landed in a subsea wellhead, the slip joint 50 may be useful in spacing out the assembly 20 relative to the formation 14 prior to setting the packer 32 .
In the method 10 , the perforating guns 26 are positioned opposite the formation 14 and the packer 32 is set. If it is desired to isolate the formation 14 from the wellbore 12 below the formation, the optional packer 24 may be included in the string 18 and set so that the packers 32 , 24 straddle the formation. The formation 14 is perforated by firing the gun 26 , and the waste chambers 22 are immediately and automatically opened to the wellbore 12 upon such gun firing. For example, the waste chambers 22 may be in fluid communication with the interior of the perforating gun 26 , so that when the gun is fired, flow paths are provided by the detonated perforating charges through the gun sidewall. Of course, other means of providing such fluid communication may be provided, such as by a pressure operated device, a detonation operated device, etc., without departing from the principles of the present invention.
At this point, the ports 54 may or may not be open, as desired, but preferably the ports are open when the gun 26 is fired. If not previously opened, the ports 54 are opened after the gun 26 is fired. This permits flow of fluids from the formation 14 into the interior of the assembly 20 above the packer 32 .
When it is desired to perform the formation test, the tester valve 40 is opened by opening the valve 58 , thereby permitting the formation fluids to flow into the surge chamber 42 and achieving a drawdown on the formation 14 . The gauges 38 and sensor 62 acquire data indicative of the test, which, as described above, may be retrieved later or evaluated simultaneously with performance of the test. One or more conventional fluid samplers 76 may be positioned within, or otherwise in communication with, the chamber 42 for collection of one or more samples of the formation fluid. One or more of the fluid samplers 76 may also be positioned within, or otherwise in communication with, the waste chambers 22 .
After the test, the valve 66 is opened and the ports 60 are opened, and the formation fluids in the surge chamber 42 are reverse circulated out of the chamber. Other circulation paths, such as the circulating valve 34 , may also be used. Alternatively, fluid pressure may be applied to the string 18 at the earth's surface before unsetting the packer 32 , and with valves 58 , 66 open, to flow the formation fluids back into the formation 14 . As another alternative, the assembly 20 may be repositioned in the well, so that the packers 24 , 32 straddle another formation intersected by the well, and the formation fluids may be flowed into this other formation. Thus, it is not necessary in the method 10 for formation fluids to be conveyed to the earth's surface unless desired, such as in the sampler 76 , or by reverse circulating the formation fluids to the earth's surface.
Referring additionally now to FIG. 2, another method 80 embodying principles of the present invention is representatively depicted. In the method 80 , formation fluids are transferred from a formation 82 from which they originate, into another formation 84 for disposal, without it being necessary to flow the fluids to the earth's surface during a formation test, although the fluids may be conveyed to the earth's surface if desired. As depicted in FIG. 2, the disposal formation 84 is located uphole from the tested formation 82 , but it is to be clearly understood that these relative positionings could be reversed with appropriate changes to the apparatus and method described below, without departing from the principles of the present invention.
A formation test assembly 86 is conveyed into the well interconnected in a tubular string 87 at a lower end thereof. The assembly 86 includes the following, listed beginning at the bottom of the assembly: the waste chambers 22 , the packer 24 , the gun 26 , the firing head 28 , the circulating valve 30 , the packer 32 , the circulating valve 34 , the gauge carrier 36 , a variable or fixed choke 88 , a check valve 90 , the tester valve 40 , a packer 92 , an optional pump 94 , a disposal sub 96 , a packer 98 , a circulating valve 100 , the data access sub 46 , and the tester valve 44 . Note that several of these listed items of equipment are optional in the method 80 , other items of equipment may be substituted for some of the listed items of equipment, and/or additional items of equipment may be utilized in the method and, therefore, the assembly 86 depicted in FIG. 2 is to be considered as merely representative of an assembly which may be used in a method incorporating principles of the present invention, and not as an assembly which must necessarily be used in such method. For example, the valve 40 , check valve 90 and choke 88 are shown as examples of flow control devices which may be installed in the assembly 86 between the formations 82 , 84 , and other flow control devices, or other types of flow control devices, may be utilized in the method 80 , in keeping with the principles of the present invention. As another example, the pump 94 may be used, if desired, to pump fluid from the test formation 82 , through the assembly 86 and into the disposal formation 84 , but use of the pump 94 is not necessary in the method 80 .
Additionally, many of the items of equipment in the assembly 86 are shown as being the same as respective items of equipment used in the method 10 described above, but this is not necessarily the case.
When the assembly 86 is conveyed into the well, the disposal formation 84 may have already been perforated, or the formation may be perforated by providing one or more additional perforating guns in the assembly, if desired. For example, additional perforating guns could be provided below the waste chambers 22 in the assembly 86 .
The assembly 86 is positioned in the well with the gun 26 opposite the test formation 82 , the packers 24 , 32 , 92 , 98 are set, the circulating valve 30 is opened, if desired, if not already open, and the gun 26 is fired to perforate the formation. At this point, with the test formation 82 perforated, waste is immediately received into the waste chambers 22 as described above for the method 10 . The circulating valve 30 is opened, if not done previously, and the test formation is thereby placed in fluid communication with the interior of the assembly 86 .
Preferably, when the assembly 86 is positioned in the well as shown in FIG. 2, a relatively low density fluid (liquid, gas (including air, at atmospheric or greater or lower pressure) and/or combinations of liquids and gases, etc.) is contained in the string 87 above the upper valve 44 . This creates a low hydrostatic pressure in the string 87 relative to fluid pressure in the test formation 82 , which pressure differential is used to draw fluids from the test formation into the assembly 86 as described more fully below. Note that the fluid preferably has a density which will create a pressure differential from the formation 82 to the interior of the assembly at the ports 54 when the valves 58 , 66 are open. However, it is to be clearly understood that other methods and means of drawing formation fluids into the assembly 86 may be utilized, without departing from the principles of the present invention. For example, the low density fluid could be circulated into the string 87 after positioning it in the well by opening the ports 68 , nitrogen could be used to displace fluid out of the string, a pump 94 could be used to pump fluid from the test formation 82 into the string, a difference in formation pressure between the two formations 82 , 84 could be used to induce flow from the higher pressure formation to the lower pressure formation, etc.
After perforating the test formation 82 , fluids are flowed into the assembly 86 via the circulation valve 30 as described above, by opening the valves 58 , 66 . Preferably, a sufficiently large volume of fluid is initially flowed out of the test formation 82 , so that undesired fluids, such as drilling fluid, etc., in the formation are withdrawn from the formation. When one or more sensors, such as a resistivity or other fluid property or fluid identification sensor 102 , indicates that representative desired formation fluid is flowing into the assembly 86 , the lower valve 58 is closed. Note that the sensor 102 may be of the type which is utilized to indicate the presence and/or identity of solid matter in the formation fluid flowed into the assembly 86 .
Pressure may then be applied to the string 87 at the earth's surface to flow the undesired fluid out through check valves 104 and into the disposal formation 84 . The lower valve 58 may then be opened again to flow further fluid from the test formation 82 into the assembly 86 . This process may be repeated as many times as desired to flow substantially any volume of fluid from the formation 82 into the assembly 86 , and then into the disposal formation 84 .
Data acquired by the gauges 38 and/or sensors 102 while fluid is flowing from the formation 82 through the assembly 86 (when the valves 58 , 66 are open), and while the formation 82 is shut in (when the valve 58 is closed) may be analyzed after or during the test to determine characteristics of the formation 82 . Of course, gauges and sensors of any type may be positioned in other portions of the assembly 86 , such as in the waste chambers 22 , between the valves 58 , 66 , etc. For example, pressure and temperature sensors and/or gauges may be positioned between the valves 58 , 66 , which would enable the acquisition of data useful for injection testing of the disposal zone 84 , during the time the lower valve 58 is closed and fluid is flowed from the assembly 86 outward into the formation 84 .
It will be readily appreciated that, in this fluid flowing process as described above, the valve 58 is used to permit flow upwardly therethrough, and then the valve is closed when pressure is applied to the string 87 to dispose of the fluid. Thus, the valve 58 could be replaced by the check valve 90 , or the check valve may be supplied in addition to the valve as depicted in FIG. 2 .
If a difference in formation pressure between the formations 82 , 84 is used to flow fluid from the formation 82 into the assembly 86 , then a variable choke 88 may be used to regulate this fluid flow. Of course, the variable choke 88 could be provided in addition to other flow control devices, such as the valve 58 and check valve 90 , without departing from the principles of the present invention.
If a pump 94 is used to draw fluid into the assembly 86 , no flow control devices may be needed between the disposal formation 84 and the test formation 82 , the same or similar flow control devices depicted in FIG. 2 may be used, or other flow control devices may be used. Note that, to dispose of fluid drawn into the assembly 86 , the pump 94 is operated with the valve 66 closed.
In a similar manner, the check valves 104 of the disposal sub 96 may be replaced with other flow control devices, other types of flow control devices, etc.
To provide separation between the low density fluid in the string 87 and the fluid drawn into the assembly 86 from the test formation 82 , a fluid separation device or plug 106 which may be reciprocated within the assembly 86 may be used. The plug 106 would also aid in preventing any gas in the fluid drawn into the assembly 86 from being transmitted to the earth's surface. An acceptable plug for this application is the “OMEGA™” plug available from Halliburton Energy Services, Inc. Additionally, the plug 106 may have a fluid sampler 108 attached thereto, which may be activated to take a sample of the formation fluid drawn into the assembly 86 when desired. For example, when the sensor 102 indicates that the desired representative formation fluid has been flowed into the assembly 86 , the plug 106 may be deployed with the sampler 108 attached thereto in order to obtain a sample of the formation fluid. The plug 106 may then be reverse circulated to the earth's surface by opening the circulation valve 100 . Of course, in that situation, the plug 106 should be retained uphole from the valve 100 .
A nipple, no-go 110 , or other engagement device may be provided to prevent the plug 106 from displacing downhole past the disposal sub 96 . When applying pressure to the string 87 to flow the fluid in the assembly 86 outward into the disposal formation 84 , such engagement between the plug 106 and the device 110 may be used to provide a positive indication at the earth's surface that the pumping operation is completed. Additionally, a no-go or other displacement limiting device could be used to prevent the plug 106 from circulating above the upper valve 44 to thereby provide a type of downhole safety valve, if desired.
The sampler 108 could be configured to take a sample of the fluid in the assembly 86 when the plug 106 engages the device 110 . Note, also, that use of the device 110 is not necessary, since it may be desired to take a sample with the sampler 108 of fluid in the assembly 86 below the disposal sub 96 , etc. The sampler could alternatively be configured to take a sample after a predetermined time period, in response to pressure applied thereto (such as hydrostatic pressure), etc.
An additional one of the plug 106 may be deployed in order to capture a sample of the fluid in the assembly 86 between the plugs, and then convey this sample to the surface, with the sample still retained between the plugs. This may be accomplished by use of a plug deployment sub, such as that representatively depicted in FIG. 3 . Thus, after fluid from the formation 82 is drawn into the assembly 86 , the second plug 106 is deployed, thereby capturing a sample of the fluid between the two plugs. The sample may then be circulated to the earth's surface between the two plugs 106 by, for example, opening the circulating valve 100 and reverse circulating the sample and plugs uphole through the string 87 .
Referring additionally now to FIG. 3, a fluid separation device or plug deployment sub 112 embodying principles of the present invention is representatively depicted. A plug 106 is releasably secured in a housing 114 of the sub 112 by positioning it between two radially reduced restrictions 116 . If the plug 106 is an Omega™ plug, it is somewhat flexible and can be made to squeeze through either of the restrictions 116 if a sufficient pressure differential is applied across the plug. Of course, either of the restrictions could be made sufficiently small to prevent passage of the plug 106 therethrough, if desired. For example, if it is desired to permit the plug 106 to displace upwardly through the assembly 86 above the sub 112 , but not to displace downwardly past the sub 112 , then the lower restriction 116 may be made sufficiently small, or otherwise configured, to prevent passage of the plug therethrough.
A bypass passage 118 formed in a sidewall of the housing 114 permits fluid flow therethrough from above, to below, the plug 106 , when a valve 120 is open. Thus, when fluid is being drawn into the assembly 86 in the method 80 , the sub 112 , even though the plug 106 may remain stationary with respect to the housing 114 , does not effectively prevent fluid flow through the assembly. However, when the valve 120 is closed, a pressure differential may be created across the plug 106 , permitting the plug to be deployed for reciprocal movement in the string 87 . The sub 112 may be interconnected in the assembly 86 , for example, below the upper valve 66 and below the plug 106 shown in FIG. 2 .
If a pump, such as pump 94 is used to draw fluid from the formation 82 into the assembly 86 , then use of the low density fluid in the string 87 is unnecessary. With the upper valve 66 closed and the lower valve 58 open, the pump 94 may be operated to flow fluid from the formation 82 into the assembly 86 , and outward through the disposal sub 96 into the disposal formation 84 . The pump 94 may be any conventional pump, such as an electrically operated pump, a fluid operated pump, etc.
Referring additionally now to FIG. 4, another method 130 of performing a formation test embodying principles of the present invention is representatively depicted. The method 130 is described herein as being used in a “rigless” scenario, i.e., in which a drilling rig is not present at the time the actual test is performed, but it is to be clearly understood that such is not necessary in keeping with the principles of the present invention. Note that the method 80 could also be performed rigless, if a downhole pump is utilized in that method. Additionally, although the method 130 is depicted as being performed in a subsea well, a method incorporating principles of the present invention may be performed on land as well.
In the method 130 , a tubular string 132 is positioned in the well, preferably after a test formation 134 and a disposal formation 136 have been perforated. However, it is to be understood that the formations 134 , 136 could be perforated when or after the string 132 is conveyed into the well. For example, the string 132 could include perforating guns, etc., to perforate one or both of the formations 134 , 136 when the string is conveyed into the well.
The string 132 is preferably constructed mainly of a composite material, or another easily milled/drilled material. In this manner, the string 132 may be milled/drilled away after completion of the test, if desired, without the need of using a drilling or workover rig to pull the string. For example, a coiled tubing rig could be utilized, equipped with a drill motor, for disposing of the string 132 .
When initially run into the well, the string 132 may be conveyed therein using a rig, but the rig could then be moved away, thereby providing substantial cost savings to the well operator. In any event, the string 132 is positioned in the well and, for example, landed in a subsea wellhead 138 .
The string 132 includes packers 140 , 142 , 144 . Another packer may be provided if it is desired to straddle the test formation 134 , as the test formation 82 is straddled by the packers 24 , 32 shown in FIG. 2 . The string 132 further includes ports 146 , 148 , 150 spaced as shown in FIG. 4, i.e., ports 146 positioned below the packer 140 , ports 148 between the packers 142 , 144 , and ports 150 above the packer 144 . Additionally the string 132 includes seal bores 152 , 154 , 156 , 158 and a latching profile 160 therein for engagement with a tester tool 162 as described more fully below.
The tester tool 162 is preferably conveyed into the string 132 via coiled tubing 164 of the type which has an electrical conductor 165 therein, or another line associated therewith, which may be used for delivery of electrical power, data transmission, etc., between the tool 162 and a remote location, such as a service vessel 166 . The tester tool 162 could alternatively be conveyed on wireline or electric line. Note that other methods of data transmission, such as acoustic, electromagnetic, fiber optic etc. may be utilized in the method 130 , without departing from the principles of the present invention.
A return flow line 168 is interconnected between the vessel 166 and an annulus 170 formed between the string 132 and the wellbore 12 above the upper packer 144 . This annulus 170 is in fluid communication with the ports 150 and permits return circulation of fluid flowed to the tool 162 via the coiled tubing 164 for purposes described more fully below.
The ports 146 are in fluid communication with the test formation 134 and, via the interior of the string 132 , with the lower end of the tool 162 . As described below, the tool 162 is used to pump fluid from the formation 134 , via the ports 146 , and out into the disposal formation 136 via the ports 148 .
Referring additionally now to FIG. 5, the tester tool 162 is schematically and representatively depicted engaged within the string 132 , but apart from the remainder of the well as shown in FIG. 4 for illustrative clarity. Seals 172 , 174 , 176 , 178 sealingly engage bores 152 , 154 , 156 , 158 , respectively. In this manner, a flow passage 180 near the lower end of the tool 162 is in fluid communication with the interior of the string 132 below the ports 148 , but the passage is isolated from the ports 148 and the remainder of the string above the seal bore 152 ; a passage 182 is placed in fluid communication with the ports 148 between the seal bores 152 , 154 and, thereby, with the disposal formation 136 ; and a passage 184 is placed in fluid communication with the ports 150 between the seal bores 156 , 158 and, thereby, with the annulus 170 .
An upper passage 186 is in fluid communication with the interior of the coiled tubing 164 . Fluid is pumped down the coiled tubing 164 and into the tool 162 via the passage 186 , where it enters a fluid motor or mud motor 188 . The motor 188 is used to drive a pump 190 . However, the pump 190 could be an electrically-operated pump, in which case the coiled tubing 164 could be a wireline and the passages 186 , 184 , seals 176 , 178 , seal bores 156 , 158 , and ports 150 would be unnecessary. The pump 190 draws fluid into the tool 162 via the passage 180 , and discharges it from the tool via the passage 182 . The fluid used to drive the motor 188 is discharged via the passage 184 , enters the annulus, and is returned via the line 168 .
Interconnected in the passage 180 are a valve 192 , a fluid property sensor 194 , a variable choke 196 , a valve 198 , and a fluid identification sensor 200 . The fluid property sensor 194 may be a pressure, temperature, resistivity, density, flow rate, etc. sensor, or any other type of sensor, or combination of sensors, and may be similar to any of the sensors described above. The fluid identification sensor 200 may be a nuclear magnetic resonance sensor, an acoustic sand probe, or any other type of sensor, or combination of sensors. Preferably, the sensor 194 is used to obtain data regarding physical properties of the fluid entering the tool 162 , and the sensor 200 is used to identify the fluid itself, or any solids, such as sand, carried therewith. For example, if the pump 190 is operated to produce a high rate of flow from the formation 134 , and the sensor 200 indicates that this high rate of flow results in an undesirably large amount of sand production from the formation, the operator will know to produce the formation at a lower flow rate. By pumping at different rates, the operator can determine at what fluid velocity sand is produced, etc. The sensor 200 may also enable the operator to tailor a gravel pack completion to the grain size of the sand identified by the sensor during the test.
The flow controls 192 , 196 , 198 are merely representative of flow controls which may be provided with the tool 162 . These are preferably electrically operated by means of the electrical line 165 associated with the coiled tubing 164 as described above, although they may be otherwise operated, without departing from the principles of the present invention.
After exiting the pump 190 , fluid from the formation 134 is discharged into the passage 182 . The passage 182 has valves 202 , 204 , 206 , sensor 208 , and sample chambers 210 , 212 associated therewith. The sensor 208 may be of the same type as the sensor 194 , and is used to monitor the properties, such as pressure, of the fluid being injected into the disposal formation 136 . Each sample chamber has a valve 214 , 216 for interconnecting the chamber to the passage 182 and thereby receiving a sample therein. Each sample chamber may also have another valve 218 , 220 (shown in dashed lines in FIG. 5) for discharge of fluid from the sample chamber into the passage 182 . Each of the valves 202 , 204 , 206 , 214 , 216 , 218 , 220 may be electrically operated via the coiled tubing 164 electrical line as described above.
The sensors 194 , 200 , 208 may be interconnected to the line 165 for transmission of data to a remote location. Of course, other means of transmitting this data, such as acoustic, electromagnetic, etc., may be used in addition, or in the alternative. Data may also be stored in the tool 162 for later retrieval with the tool.
To perform a test, the valves 192 , 198 , 204 , 206 are opened and the pump 190 is operated by flowing fluid through the passages 184 , 186 via the coiled tubing 164 . Fluid from the formation 134 is, thus, drawn into the passage 180 and discharged through the passage 182 into the disposal formation 136 as described above.
When one or more of the sensors 194 , 200 indicate that desired representative formation fluid is flowing through the tool 162 , one or both of the samplers 210 , 212 is opened via one or more of the valves 214 , 216 , 218 , 220 to collect a sample of the formation fluid. The valve 206 may then be closed, so that the fluid sample may be pressurized to the formation 134 pressure in the samplers 210 , 212 before closing the valves 214 , 216 , 218 , 220 . One or more electrical heaters 222 may be used to keep a collected sample at a desired reservoir temperature as the tool 162 is retrieved from the well after the test.
Note that the pump 190 could be operated in reverse to perform an injection test on the formation 134 . A microfracture test could also be performed in this manner to collect data regarding hydraulic fracturing pressures, etc. Another formation test could be performed after the microfracture test to evaluate the results of the microfracture operation. As another alternative, a chamber of stimulation fluid, such as acid, could be carried with the tool 162 and pumped into the formation 134 by the pump 190 . Then, another formation test could be performed to evaluate the results of the stimulation operation. Note that fluid could also be pumped directly from the passage 186 to the passage 180 using a suitable bypass passage 224 and valve 226 to directly pump stimulation fluids into the formation 134 , if desired.
The valve 202 is used to flush the passage 182 with fluid from the passage 186 , if desired. To do this, the valves 202 , 204 , 206 are opened and fluid is circulated from the passage 186 , through the passage 182 , and out into the wellbore 12 via the port 148 .
Referring additionally now to FIG. 6, another method 240 embodying principles of the present invention is representatively illustrated. The method 240 is similar in many respects to the method 130 described above, and elements shown in FIG. 6 which are similar to those previously described are indicated using the same reference numbers.
In the method 240 , a tester tool 242 is conveyed into the wellbore 12 on coiled tubing 164 after the formations 134 , 136 have been perforated, if necessary. Of course, other means of conveying the tool 242 into the well may be used, and the formations 134 , 136 may be perforated after conveyance of the tool into the well, without departing from the principles of the present invention.
The tool 242 differs from the tool 162 described above and shown in FIGS. 4 & 5 in part in that the tool 242 carries packers 244 , 246 , 248 thereon, and so there is no need to separately install the tubing string 132 in the well as in the method 130 . Thus, the method 240 may be performed without the need of a rig to install the tubing string 132 . However, it is to be clearly understood that a rig may be used in a method incorporating principles of the present invention.
As shown in FIG. 6, the tool 242 has been conveyed into the well, positioned opposite the formations 134 , 136 , and the packers 244 , 246 , 248 have been set. The upper packers 244 , 246 are set straddling the disposal formation 136 . The passage 182 exits the tool 242 between the upper packers 244 , 246 , and so the passage is in fluid communication with the formation 136 . The packer 248 is set above the test formation 134 . The passage 180 exits the tool 242 below the packer 248 , and the passage is in fluid communication with the formation 134 . A sump packer 250 is shown set in the well below the formation 134 , so that the packers 248 , 250 straddle the formation 134 and isolate it from the remainder of the well, but it is to be clearly understood that use of the packer 250 is not necessary in the method 240 .
Operation of the tool 242 is similar to the operation of the tool 162 as described above. Fluid is circulated through the coiled tubing string 164 to cause the motor 188 to drive the pump 190 . In this manner, fluid from the formation 134 is drawn into the tool 242 via the passage 180 and discharged into the disposal formation 136 via the passage 182 . Of course, fluid may also be injected into the formation 134 as described above for the method 130 , the pump 190 may be electrically operated (e.g., using the line 165 or a wireline on which the tool is conveyed), etc.
Since a rig is not required in the method 240 , the method may be performed without a rig present, or while a rig is being otherwise utilized. For example, in FIG. 6, the method 240 is shown being performed from a drill ship 252 which has a drilling rig 254 mounted thereon. The rig 254 is being utilized to drill another wellbore via a riser 256 interconnected to a template 258 on the seabed, while the testing operation of the method 240 is being performed in the adjacent wellbore 12 . In this manner, the well operator realizes significant cost and time benefits, since the testing and drilling operations may be performed simultaneously from the same vessel 252 .
Data generated by the sensors 194 , 200 , 208 may be stored in the tool 242 for later retrieval with the tool, or the data may be transmitted to a remote location, such as the earth's surface, via the line 165 or other data transmission means. For example, electromagnetic, acoustic, or other data communication technology may be utilized to transmit the sensor 194 , 200 , 208 data in real time.
Of course, a person skilled in the art would, upon a careful reading of the above description of representative embodiments of the present invention, readily appreciate that modifications, additions, substitutions, deletions and other changes may be made to these embodiments, and such changes are contemplated by the principles of the present invention. For example, although the methods 10 , 80 , 130 , 240 are described above as being performed in cased wellbores, they may also be performed in uncased wellbores, or uncased portions of wellbores, by exchanging the described packers, tester valves, etc. for their open hole equivalents. The foregoing detailed description is to be clearly understood as being given by way of illustration and example only. | Methods and apparatus are provided which permit well testing operations to be performed downhole in a subterranean well. In various described methods, fluids flowed from a formation during a test may be disposed of downhole by injecting the fluids into the formation from which they were produced, or by injecting the fluids into another formation. In several of the embodiments of the invention, apparatus utilized in the methods permit convenient retrieval of samples of the formation fluids and provide enhanced data acquisition for monitoring of the test and for evaluation of the formation fluids. | 4 |
STATEMENT OF FEDERAL FUNDING
[0001] This invention was made in part with government support under contract W91CRB-04-C-0001 awarded by the US Department of Defense and Technical Support Working Group, Department of Homeland Security.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a device for monitoring tampering and false positive or false negative signals for materials and items such as self-developing instant radiation alert dosimeter (SIRAD) which are sensitive to UV light, time-temperature and higher temperatures.
[0004] 2. Brief Description of Prior Art
[0005] Radiation sensitive materials, such as diacetylenes (R—C≡C—C≡C—R, where R is a monovalent group) and processes that can be used for making radiation sensitive coatings or strips for making self-indicating instant radiation alert dosimeter (referred herein to as SIRAD) are described in patent application numbers WO 2004/077097 and WO 2004/017095 and references cited therein. Coatings, films or plaques of radiation sensitive materials which are used for making SIRAD are individually or collectively, referred herein to as “radiation sensitive coating”, “radiation sensitive strip” or “sensing strip” or “sensor”. The self-developing instant radiation sensitive dosimeter (SIRAD) is typically made by sandwiching a sensitive strip between two plastic layers, wherein one is highly opaque and the other is transparent. A photo of a dual-sensor SIRAD badge is shown in FIG. 1 . The SIRAD is typically used as a personal and area dosimeter for monitoring low dose (1-1,000 rads) of high energy radiation, such as X-ray, gamma ray, electrons and neutrons.
[0006] The materials that can be used for making the sensor are disclosed in patent application numbers WO 2004/077097 and WO 2004/017095 and references cited therein. One class of materials that can be used for making the sensor are conjugated alkynes referred to as diacetylenes, R—C≡C—C≡C—R, where R is a substituent group. Diacetylenes polymerize in the solid state either upon thermal annealing or exposure to high-energy radiation, such as UV and X-ray [Adv. Polym. Sci., vol. 63, 1 (1984)]. The term diacetylene(s) is used herein to designate a class of compounds having at least one —C≡C—C≡C— functionality group. The solid monomers are colorless or white. The partially polymerized diacetylenes are blue or red. Polydiacetylenes appear metallic typically having a copper or gold color. Polydiacetylenes are highly colored because the “π” electrons of the conjugated backbone are delocalized. The color intensity of the partially polymerized diacetylenes is proportional to the percent polymer conversion. Diacetylenes which develop blue color are referred to herein as blue diacetylenes or blue developing diacetylenes and those that develop red color are referred to as red diacetylenes or red developing diacetylenes.
[0007] Diacetylenes are known to crystallize into more than one crystallographic modification or phase. The following terminologies are used for defining the reactivity (polymerizability) of a diacetylene. The polymerizable form of a diacetylene(s) is referred to as “active”. If a diacetylene is polymerizable with radiation having energy higher than 4 eV, wavelength shorter than 300 nm, then it is referred to as “radiation active”. If it is polymerizable upon thermal annealing then it is referred to as “thermally active”. A form of diacetylene, which displays little or no polymerization, is referred to as “inactive”. If it displays little polymerization with radiation (having energy higher than 4 eV) then it is referred to as “radiation inactive” and if it is significantly nonpolymerizable upon thermal annealing, then it is referred to as “thermally inactive”. Diacetylenes having reactivity/polymerizability characteristics in between these definitions are referred to as “moderately active”. The most preferred form of diacetylene for the sensor of SIRAD is one which is highly radiation reactive and displays little or no thermal reactivity. However, diacetylenes, which are radiation active also usually, have some thermal reactivity.
[0008] The radiation sensor remains active and can keep on accumulating dose unless fixed, or made inactive. In order to archive the exposure/results, the dosimeter needs to be fixed. The dosimeter can be fixed, by heating the sensor of the dosimeter till diacetylene becomes inactive and crystallizes into an inactive phase or forms a solid solution with binder or dissolution with other additives and does not re-crystallize in active form. For example, diacetylene 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] can be fixed by heating above about 80° C. and many diacetylenes can be fixed by forming a solid solution with a proper binder. Exemplary examples include 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] and 344 [R—C≡C—C≡C—R, where R is a (CH 2 ) 3 OCONH(CH 2 ) 3 CH 3 ] with binders such as polyvinylacetate and polymethylmethacrylate. Many additives, such as trihydroxybenzoic acid which react and/or dissolve the diacetylene can also be used to fix the dosimeter.
[0009] The sensing materials, diacetylenes, used to make the sensor of SIRAD for monitoring X-ray, are also sensitive to UV light. In order to make the sensor less sensitive to UV light, UV absorbers are preferably added in the coating formulation and the sensor is further protected with a UV absorbing coating or a film. The sensor of SIRAD is sensitive to prolonged exposure to UV and/or sunlight. It is not possible to filter off 100% of the UV light. A small fraction of UV light, preferably less than a percent, passes through the UV absorbing materials and upon such prolonged exposure, the sensor develops a faint color, which is a false positive indication for high energy radiation. The sensor can accidentally, inadvertently or unintentionally be over exposed to sunlight which can provide a false positive. At the same time, someone can tamper with the sensor by exposing the sensor to sunlight, intentionally or otherwise, and claiming exposure to ionizing radiation. Hence, there is a need for detecting a false positive due to unintentional or intentional exposure to UV/sunlight.
[0010] SIRAD dosimeters also have limited shelf life of typically about one year at room temperature and they develop color with time and temperature. If stored at higher temperature, such as at body temperature, during the use or at higher temperature during storage, the color development is faster. Storing SIRAD dosimeters at higher temperatures will reduce the shelf life and could also provide a false positive signal. Hence, there is a need for monitoring shelf-life, and particularly integrated time and temperature. These shelf life, or time-temperature, indicators are referred herein to as TTI or shelf life indicators. If the SIRAD dosimeters are over exposed to time and temperature, a TTI can indicate expiration of shelf life. The TTI can also indicate false positive due to storage for a longer time and at higher temperatures.
[0011] Depending upon the conditions and composition, the reactivity (polymerization) of diacetylenes sometimes changes when heated above their melting point followed by cooling/crystallizing at room temperature (RT). Some diacetylenes become inactive while others change their reactivity to temperature and radiation upon crystallization from a melt. If a diacetylene used for making the sensor changes its reactivity upon heating at high temperatures by any process including melting, phase change, dissolution, formation solid solution with other compounds and chemical reaction, the sensor could provide false positive or false negative signal. Hence, such heating above a pre-determined temperature should be monitored, i.e., the SIRAD type dosimeters need a temperature indicator.
[0012] A partially polymerized diacetylene (PPD) is a solid solution of monomer molecules and polymer chains. PPDs are either blue or red. Some PPDs change their colors, e.g., blue-to-red or red-to-blue, when heated above the melting point of the monomer. For example, when a partially polymerized 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] is heated above its melting point, or above about 80° C., it changes from blue-to-red irreversibly. Similarly when a partially polymerized 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] is heated above its melting point, or above about 80° C., it changes from red-to-blue irreversibly. Thus partially polymerized diacetylenes, including those used for making sensors, if pre-partially polymerized, such as with UV light, can be used for monitoring the exposure of a pre-determined high temperature.
[0013] Diacetylenes are known yet their use in monitors has been somewhat limited due to the propensity for false positive readings, due to UV exposure and the like, and false negative readings, due to thermal deactivation or change in reactivity.
[0014] SIRAD type dosimeters are typically of credit card size and there is no room for applying monitors/indicators/detectors for the above four processes. Sometimes SIRAD indicators are even smaller, e.g., a small sticker of 1 cm×1 cm, known as stick-on SIRAD. These stick-on SIRAD are useful for instantly monitoring exposure to high dose, especially when applied on to other dosimeters, such as those based on X-ray film, TLD (thermoluminescence dosimeter) and OSL (optically simulated luminescence). Hence, there is a need for a small and all-in-one indicator which can monitor all of the above processes and indicate via color change.
[0015] In order to detect/monitor the effect of time and temperature, UV exposure and/or temperature there is a need for such indicators. These indicators which monitor/detect effects of time-temperature, UV light and/or temperature are referred to herein as TUT indicators for monitoring integral value of “Time-temperature”, UV light”, and/or a pre-determined higher “Temperature”.
[0016] Diacetylenes are also proposed as TTI e.g., U.S. Pat. Nos. 3,999,946; 4,276,190; 4,208,186; as thermochromic materials e.g., 4,215,208; 4,235,108; 4,452,995 and as radiation dosimeter e.g., 4,788,432. Patent application number WO 2004/077097 and WO 2004/017095 disclose use of time-temperature indicator, UV indicator and temperature indicators for monitoring shelf life, over exposure to UV light and higher temperature as an individual indicator for SIRAD. However, it has not been previously considered to use diacetylenes as TTI, radiation and temperature indicator all-in-one.
[0017] The SIRAD dosimeter cards could be made by techniques and materials described in Patent Application # WO2004077097—“Personal And Area Self-Indicating Instant Radiation Alert Dosimeter” and the following patent applications: “A Stick-on Self-indicating Instant Radiation Dosimeter” filed with the US Patent and Trademark Office as U.S. patent application Ser. No. 11/269,147, filed Nov. 8, 2005; and “Tamper Resistant Self Indicating Instant Alert Radiation Dosimeter” filed with the US Patent and Trademark Office as U.S. patent application Ser. No. 11/235,892, filed Sep. 27, 2005.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a representation of a single sensor SIRAD card without any indicator before (left hand side) and after (right hand side) exposure to 100 rads of 100 KeV X-ray.
[0019] FIG. 2 is a schematic representation of SIRAD cards with a TUT indicator under different treatments.
[0020] FIG. 3 is a schematic representation of SIRAD cards with a TUT indicator a portion of the sensor having capability of undergoing a color change.
[0021] FIG. 4 is a photograph of a representative SIRAD card of the present invention.
SUMMARY OF THE INVENTION
[0022] Disclosed is an indicating device undergoing at least one color change, color intensification, color development including change in fluorescence, composed of at least one color changing compound, e.g., diacetylene (R—C≡C—C≡C—R, where R is a group) for monitoring integral value of time and temperature, exposure to UV light and a pre-determined high temperature. Such device is referred to as TUT indicator.
[0023] Provided is the TUT device for monitoring a false positive signal, false negative and tampering in a radiation sensitive device (SIRAD).
[0024] Provided is the TUT device for monitoring expiration of shelf life.
[0025] Provided is the TUT device for monitoring UV exposure.
[0026] Provided is the TUT device for monitoring exposure to a temperature above a pre-determined level.
[0027] Provided is a process of applying the TUT indicator on SIRAD.
[0028] Provided is a process of monitoring exposure to time-temperature, UV light and/or a pre-determined higher temperature and tampering by monitoring the color of the TUT.
[0029] Further provided is a process of monitoring for tampering of a radiation sensitive device like SIRAD by comparing color of the TUT indicator with a color bar, or a color bar of a color reference bar printed on SIRAD.
[0030] Further provided is a process of monitoring the effect of time-temperature, UV light and/or a pre-determined higher temperature by monitoring color changes of a TUT indicator with an optical densitometer or a spectrophotometer.
[0031] These and other advantages, as will be realized, are provided in an indicating device with a high energy radiation monitor capable of undergoing at least one color change in proportion to a dose of the high energy radiation and a second monitor capable of monitoring at least one of integral value of time and temperature, exposure to UV light and/or a pre-determined high temperature.
[0032] Yet another embodiment is provided in a detector or monitor for high energy radiation. The detector or monitor has a first indicator capable of changing first color density in response to a primary radiation at a first rate and in response to a second radiation at a second rate. A second indicator or monitor is provided which is capable of changing second color density in response to the second radiation at a third rate wherein the first rate and said third rate are faster than the second rate.
[0033] Yet another embodiment is provided in a detector or monitor with a high energy radiation detector or monitor having a first diacetylene capable of changing a first color density proportional to a dose of the high energy radiation. The high energy radiation detector or monitor also changes first color density proportion to at least one of time-temperature, UV exposure or excessive heat. A second detector or monitor has a second diacetylene wherein the second detector or monitor changes second color density proportional to at least one of time-temperature, UV exposure or excessive heat.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] The sensing materials, diacetylenes, used for making the sensor for monitoring X-ray, are also sensitive to UV light. In order to make the sensor less sensitive to UV light, UV absorbers are preferably added in the coating formulation and the sensor is further protected with a UV absorbing film as described in Patent Application No. WO2004077097. However, the sensor of SIRAD is sensitive to prolonged exposure to UV light. The sensor can accidentally or unintentionally be over exposed to sunlight which can provide a false positive. At the same time, someone can tamper with the sensor by exposuring the sensor intentionally to sunlight and claiming exposure to ionizing radiation. Hence, there is a need for detecting a false positive due to unintentional or intentional exposure to UV/sunlight.
[0035] The sensing materials, diacetylenes, used for making the sensor for monitoring X-ray, are also sensitive to prolonged exposure to higher temperatures. The sensor has limited shelf life, of about one year at room temperature (RT). In order to make the sensor less sensitive to temperature and to increase the shelf life, shelf life extenders are added in the coating formulation as described in Patent Application No. WO2004077097. However, the sensor of SIRAD is sensitive to prolonged exposure to higher temperatures. The sensor can accidentally or unintentionally be over exposed to temperature higher than RT or recommended use temperature which can provide a false positive. At the same time, someone can tamper, with the device and expose the sensor intentionally to higher temperature, such as 60° C. for a month. Hence, there is a need for detecting a false positive due to unintentional or intentional exposure to higher temperatures.
[0036] The sensing materials, diacetylenes, used for making the sensor for monitoring X-ray, often become inactive to ionizing radiation if heated near or above their melting points. In order to keep the sensor active during normal use, including a pass through a laundry cycle (washing and drying usually below 80° C.), diacetylenes used for making the sensor should have a melting point higher than 80° C. However, the sensor of SIRAD becomes inactive to radiation if the diacetylene melts. The sensor can accidentally or unintentionally be heated above the melting point of the diacetylene used for making the sensor. This will make the SIRAD inactive to radiation and therefore it will not be able to monitor X-ray or may monitor lower dose. If this is the case, SIRAD can provide a false negative signal. Hence, there is a need for detecting a false negative due to unintentional or intentional exposure of the sensor to a very high temperature or inactivation temperature. The temperature indicator is required especially when diacetylene used for making the sensing strips changes it reactivity at a much lower temperature such as 50° C.
[0037] Diacetylenes change their radiation and thermal reactivities near and above their melting points. When heated near or above the melting point and cooled to a lower temperature, e.g. ambient temperature, the resultant re-crystallized diacetylene could have different radiation and thermal reactivities. If the reactivity is higher, for a given dose it could provide a darker color which would be a false positive result. If the radiation reactivity is lower, for a given dose it could provide a lighter color which would be a false negative result. Hence, there is a need to monitor the temperature of the SIRAD dosimeter.
[0038] Provided is an indicator which can monitor one or more of the above described events. The invention can be best described by reference to the FIGS. 1-3 .
[0039] FIG. 1 shows a representation of a single sensor SIRAD card without any indicator before (left hand side) and after (right hand side) exposure to 100 rads of 100 KeV X-ray. The card has a black protective film cover which is not shown. The sensor of the SIRAD card also develops blue color upon prolonged exposure to UV light and higher temperatures. A person who is unaware of the X-ray exposure, can determine if the color development is genuine or false positive and vice versa.
[0040] FIG. 2 is a schematic presentation of SIRAD cards with a TUT indicator under different treatments. The cards can have printing (not shown in FIG. 2 ) to indicate how to interpret the card such as: “If the bottom half of the TUT indicator has changed from blue to red, SIRAD is inactive to X-ray and if the upper half is bluer than the 10-rads bar, the shelf life has expired and/or exposure to UV light and/or higher temperature for a prolonged period has occurred. Don't use this SIRAD card in such cases”.
[0041] In FIG. 2 , the top left card is illustrated before any treatment. The card comprises a central vertical bar which represents no exposure by a lack of shading. On either side of the central vertical bar is a progressive scale indicating the color of the central bar as a function of exposure. While not indicated the central vertical bar preferably turns progressively darker blue with high energy radiation with the degree of radiation indicated by matching the blue color with that of the scale. A TUT indicator, labeled FIT, is illustrated on the right side in approximately the middle of the card. The upper portion of the TUT indicator is either colorless or very light blue indicating no exposure to UV-light, heat or excessive time. The card of the top right illustrates the effect of overheating. The central vertical bar indicates no exposure whereas the lower half of the TUT indicator is red indicative of heating. This indicates that the card has been inactivated relative to detection of high energy radiation. The bottom half of the TUT indicator changed from blue to red which indicates that the sensor is inactive to X-ray. The card at the central left is illustrated to indicate that the card has been used for some time, such as till a ⅓ of shelf life is expired, or that the card has been stored at higher temperatures or exposed to UV light for a short period but not sufficient for the sensor to develop any noticeable color. The TUT indicator has developed a very faint blue color but not darker than the 10-rad bar indicating that the card is active and usable. This 10-rad bar reference point can be changed depending upon the reactivities of the sensor and that of TUT indicator. The card at the central right hand side is indicative of a card after heating above the melting point of the sensor. The bottom half of the TUT indicator changed from blue to red and the top half changed to faint blue to faint red. If the TUT indicator is red, it indicates that the card is inactive. The card at the bottom left hand side is indicative of shelf life expiration or exposure for a sufficiently long time to UV light for the sensor to develop a noticeable color. This is indicated by the upper half of the TUT indicator which is bluer than the 10-rad bar. This means SIRAD is either deliberately or inadvertently exposed to higher temperatures and/or UV light for a prolonged period and must not be used or the card must be replaced. The bottom right hand side card illustrates a card after heating above the melting point of the sensor. The bottom half of TUT indicator changed from blue to red and the top half change from light blue to light red. If the TUT indicator is red, it indicates that the card is inactive.
[0042] A particular advantage of the present invention is the coupling of a primary SIRAD detector or monitor which has the primary function of increasing color density in response to high energy radiation with a secondary TUT indicator which provides multiple degrees of detection and which can provide an indication that the card has been subjected to energy which will neutralize the SIRAD detector or monitor. It is particularly preferred that the SIRAD detector has an increasing color density with ionizing radiation particularly an increasing blue color. It is preferred that the TUT indicator have increasing blue density with time and/or UV exposure but a red density with exposure to excessive temperature. This combination allows the user to rapidly determine if the card has been subjected to excessive temperature, excess UV irradiation or excessive time all of which allow any indication of high energy radiation to be verified as authentic. It is preferred that the TUT indicator develops blue color at a rate which exceeds the development of color density in the SIRAD detector or monitor when exposed to UV radiation. This preference is based on the desire to insure that a SIRAD detector or monitor which has been damaged is detected prior to reliance on the detector or monitor for high energy radiation.
[0043] The TUT indicator either does not develop or develops a very faint color upon exposure to high energy ionizing radiation such as X-ray. Hence, in the case of a genuine X-ray exposure only the sensor develops color and not the TUT indicator. It also has significantly higher reactivity, or higher color development upon exposure to UV and temperature. As a result, when exposed to UV light or higher temperatures, it develops color faster than the sensor and can be easily differentiated.
[0044] If the sensor has no TUT indicator and is heated above its melting point or inactivation temperature, it becomes inactive to X-ray. In such a case, the sensor will not develop any color or will develop a very light color upon exposure to X-ray and can provide a false negative. If it has a TUT indicator, the temperature indicator (e.g., the bottom half) will change color from blue to red. This will indicate that SIRAD is inactive and must be replaced with an active one.
[0045] FIG. 3 is a schematic presentation of a SIRAD card having the ability to indicate an exposure and to distinguish the type of exposure. At the lower extent of the central SIRAD detector or monitor is a TUT indicator. Prior to exposure to heat the TUT indicator is blue as illustrated by the card on the left. The card at the right illustrates a card after heating above the melting point of the sensor. The bottom portion of the SIRAD sensor is changed from blue to red. The bottom portion of the sensor of this type of SIRAD card is a temperature indicator. This is possible with certain diacetylenes which partially polymerize to a color upon exposure to UV light and change color when heated above a certain temperature, usually above the melting point of the monomer. For example, when a partially polymerized 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] is heated above its melting point, or above about 90° C., it changes from blue-to-red irreversibly. Diacetylene fatty acids, such as tricosa-10,12-diynoic acid (TC), pentacosa-10,12 diynoic acid (PC) partially polymerize to blue color and when heated above their melting points, e.g. above about 55° C., they change to red irreversibly. Similarly when a partially polymerized 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] is heated above its melting point, or above about 80° C., it changes from red-to-blue irreversibly.
[0046] A preferred class of compounds for the TUT indicator are diacetylenes having general formula, R′—C≡C—C≡C—R″, where R′ and R″ are the same or different substituent groups. Though this class of diacetylenes is preferred, other diacetylenes having the following general formulas can also be used: higher acetylenes: R′—(C≡C) n —R″, where n=3-5; split di and higher acetylenes: R′—(C≡C) m -Z-(C≡C) o —R″, where Z is any diradical, such as —(CH 2 ) n — and —C 6 H 4 —, and m and o is 2 or higher; and polymeric di and higher acetylenes: [-A-(C≡C) n —B—] x , where A and B can be the same or different diradical, such as —(CH 2 ) b —, —OCONH—(CH 2 ) b —NHCOO—, and —OCO(CH 2 ) b OCO—. where R′ and R″ can be the same or different groups.
[0047] The preferred diacetylenes include those where R′ and R″ are selected from: (CH 2 ) b —H; (CH 2 ) b OH; (CH 2 ) b —OCONH—R1; (CH 2 ) b —O—CO—R1; (CH 2 ) b —O—R1; (CH 2 ) b —COOH; (CH 2 ) b —COOM; (CH 2 ) b —NH 2 ; (CH 2 ) b —CONHR1; (CH 2 ) b —CO—O—R1; where b=1-10, preferably 1-4, and R1 is an aliphatic or aromatic radical, e.g. C 1 -C 20 alkyl or phenyl or substituted phenyl, and M is a cation, such as Na + or (R1) 3 N + .
[0048] The preferred diacetylenes are the derivatives of 2,4-hexadiyne, 2,4-hexadiyn-1,6-diol, 3,5-octadiyn-1,8-diol, 4,6-decadiyn-1,10-diol, 5,7-dodecadiyn-1,12-diol and diacetylenic fatty acids, such as tricosa-10,12-diynoic acid (TC), pentacosa-10,12-diynoic acid (PC), their esters, organic and inorganic salts and cocrystallized mixtures thereof. The most preferred derivatives of the diacetylenes, e.g. 2,4-hexadiyn-1,6-diol, are the urethane and ester derivatives.
[0049] Preferred urethane derivatives are alkyl, aryl, benzyl, methoxy phenyl, alkyl acetoacetate, fluoro phenyl, alkyl phenyl, halo-phenyl, cyclohexyl, toyl and ethoxy phenyl of 2,4-hexadiyn-1,6-diol, 3,5-octadiyn-1,8-diol, 4,6-decadiyn-1,10-diol, 5,7-dodecadiyn-1,12-diol. The prefer urethane derivatives are methyl, ethyl, propyl and butyl derivatives of 2,4-hexadiyn-1,6-diol, 3,5-octadiyn-1,8-diol, 4,6-decadiyn-1,10-diol, 5,7-dodecadiyn-1,12-diol.
[0050] The further preferred diacetylenes are derivatives of 3,5-octadiyn-1,8-urethane, 4,6-decadiyn-1,10-urethane and 5,7-dodecadiyn-1,12-urethane, e.g., hexyl urethane: R′═OCONH(CH 2 ) 5 CH 3 ; pentyl urethane: R′═OCONH(CH 2 ) 4 CH 3 ; butyl urethane: R′═OCONH(CH 2 ) 3 CH 3 ; propyl urethane: R′═OCONH(CH 2 ) 2 CH 3 ; ethyl urethane: R′═OCONHCH 2 CH 3 ; methyl urethane: R′═OCONHCH 3 .
[0051] The urethane derivatives can be prepared by reacting diacetylene-diol, e.g., 2,4-hexadiyn-1,6-diol with appropriate isocyanates (e.g. n-hexylisocyanate) in a solvent, such as tetrahydrofuran, using catalysts, such as di-t-butyltin bis(2-ethylhexanoate) and triethylamine as indicated below:
[0000]
[0052] Ester derivatives can be prepared by reacting e.g., 2,4-hexadiyn-1,6-diol with appropriate acid chlorides in a solvent, such as dichloromethane, using a base, such as pyridine as the catalyst; i.e.,
[0000]
[0053] Asymmetrical diacetylenes can be prepared by the Cadiot-Chodkiewicz type reaction methods.
[0054] Though individual diacetylenes can be used, it is desirable to alter the reactivity of diacetylenes by cocrystallization. Cocrystallization can be achieved by dissolving two or more diacetylenes, preferably conjugated, prior to molding. For example, when TC and PC are co-crystallized, the resulting cocrystallized diacetylene mixture, such as TP41 (4:1 mixture of TC:PC) has a lower melting point and significantly higher radiation reactivity. The reactivity can also be varied by partial neutralization of diacetylenes having —COOH and —NH 2 functionalities by adding a base, such as an amine, NaOH, Ca(OH) 2 , Mg(OH) 2 or an acid, such as a carboxylic acid, respectively.
[0055] Other preferred diacetylenes are amides of fatty chain acid, such as TC and PC. The preferred amides are: TCAP═CH 3 (CH 2 ) 9 —C≡C—C≡C—(CH 2 ) 8 —CONH—(CH 2 ) 3 CH 3 ; PCAE=CH 3 (CH 2 ) 11 —C≡C—C≡C—(CH 2 ) 8 —CONH—CH 2 CH 3 ; PCAP═CH 3 (CH 2 ) 11 —C≡C—C≡C—(CH 2 ) 8 —CONH—(CH 2 ) 3 CH 3 ; PCACH═CH 3 (CH 2 ) 11 —C≡C—C≡C—(CH 2 ) 8 —CONH—C 6 H 5 ; and TCACH═CH 3 (CH 2 ) 9 —C≡C—C≡C—(CH 2 ) 8 —CONH—C 6 H 5 .
[0056] Polymers having diacetylene functionality [e.g., {—R′—(C≡C) n —R″—} x , where R′ and R″ can be the same or different diradical, such as —(CH 2 ) n —, —OCONH—(CH 2 ) n —NHCOO— and —OCO(CH 2 ) n OCO— in their backbones are also preferred because of the fact that they are polymeric and do not require a binder.
[0057] The most preferred diacetylenes are those which partially polymerize to blue color and change to red or vice versa when heated above certain temperature, e.g., when a partially polymerized 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] is heated above its melting point, e.g., above 90° C., it changes from blue-to-red irreversibly. Similarly when a partially polymerized 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] is heated above its melting point, e.g., above 80° C., it changes from red-to-blue irreversibly.
[0058] Diacetylenes are the preferred materials however other commercially available temperature indicators, UV monitors and temperature indicators can be utilized if desired.
[0059] The TUT indicator could have any symmetrical or asymmetrical shape. It can be circular, oval, square, rectangular or any other shape. The preferred shapes are square and circular.
[0060] The TUT indicator could be of any size desired, preferably sufficiently large to be used on SIRAD card and readable. The most preferred size is about a square centimeter.
[0061] The TUT indicator can be applied anywhere on SIRAD, e.g., in the front or back of the card. It can also be applied on other parts of SIRAD, e.g., black protective cover. The preferred location is the front of the card and near the sensor.
[0062] The TUT indicator can be made separately and applied on SIRAD or can be directly coated on SIRAD.
[0063] Any chemical/formulation which can undergo a noticeable change, e.g., change in color and/or fluorescence with time-temperature, UV light and/or temperature can be used for making the TUT indicator. For example, the chemicals/formulation/processes described in Patent Application No. WO2004077097—“Personal and Area Self-Indicating Instant Radiation Alert Dosimeter” can be used for making TUT indicator. The most preferred class of compounds are diacetylenes. The most preferred diacetylenes are those which have higher thermal and UV reactivities than that used for making the sensor and/or whose partially polymerized diacetylenes which undergo a color change, e.g., blue to red when the sensor becomes inactive to radiation. For example, preferred diacetylenes for TUT indicator are (1) 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] which develops red color faster thermally and upon exposure to UV light and whose partially polymerized form changes from red to blue when heated above about 80° C.; and (2) 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] which develops blue color faster thermally and upon exposure to UV light and whose partially polymerized formed changes from blue to red when heated above about 80° C.
[0064] The thermal and UV reactivities of diacetylenes suitable for TUT indicator can be varied with additives such as UV absorbers and shelf life extenders as described in Patent Application No. WO2004077097—“Personal and Area Self-Indicating Instant Radiation Alert Dosimeter”.
[0065] Just like the sensor, the TUT indicator could also have color reference bars of its own. However, by selecting a proper diacetylene one can use one of the bar of the color reference bars of the sensor.
[0066] It is preferred that only one TUT is used. However, more than one TUT can be used, especially if SIRAD has more than one sensor. Each sensor may have its own TUT sensors.
[0067] The coating thickness of the TUT indicator could be from a fraction of a micron to about a millimeter. The preferred thickness is about 2-50 microns.
[0068] The preferred TUT indicator should have significantly higher thermal and UV reactivities, preferably more than ten times, most preferably about twenty times that of diacetylene used for making the sensor.
[0069] The preferred temperature for the color change of the TUT indicator is at or slightly below the inactivation or change in reactivity temperature of the sensor.
[0070] One can use individual indicators for each process. A time-temperature indicator for monitoring shelf life can be used in conjunction with an indicator for over exposure to higher temperatures for a prolong period or a UV indicator for monitoring over exposure to UV light. A temperature indicator can be used to monitor change in activity of the sensor as described in Patent Application No. WO2004077097—“Personal and Area Self-Indicating Instant Radiation Alert Dosimeter”. The most preferred one is the TUT indicator having all of the above in one.
[0071] The TUT indicator undergoing any noticeable color change, including intensification of a color can be used. The preferred color changes for the TUT indicator for monitoring inactivation of the sensor are blue to red or red to blue. The preferred color change/development of the TUT indicator for monitoring shelf life and UV exposure is gradual color development, e.g., blue or red. The most preferred colors are those which can match the color reference bars printed for the sensor.
[0072] The colors of the TUT indicator can be monitored visually or with an electronic equipment such a spectrophotometer or densitometer.
[0073] The composition/formulation of the TUT indicator can be dispersed in a polymeric binder so it can be coated. It may have other protective layers.
[0074] The TUT indicator can also be used for other items and devices which are sensitive to time-temperature, radiation and/or temperature. These items include radiation dosimeters such as TLD, OSL, photographic film, polymerizable monomers, radiation curable inks, printed circuit board and alike.
[0075] False signals, either positive or negative, whether inadvertent or due to tampering can create problems for the users and issuing agencies or organizations. A TUT indicator will minimize the occurrence of inappropriate or unnecessary response. A TUT indicator can detect or monitor shelf life and expiration of shelf life, prolonged exposure to elevated temperature, exposure to UV light or sunlight, exposure to high temperature sufficient to inactive the detector. These indications may be naturally occurring as a result of standard use or evidence of tampering. Therefore, the TUT indicators provide a reliability and mitigate the impact of false indications of radiation exposure or failure to accurately detect the level of radiation exposure.
EXAMPLES
Example 1
Synthesis of 166, 344 and 4BCMU Diacetylenes
[0076] Diacetylenes 166 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ], 344 [R—C≡C—C≡C—R, where R is a (CH 2 ) 3 OCONH(CH 2 ) 3 CH 3 ] and 4BCMU [R—C≡C—C≡C—R, where R is a (CH 2 ) 4 OCONHCH 2 COO(CH 2 ) 3 CH 3 ] were synthesized as described in U.S. Pat. No. 5,420,000.
Example 2
Making of SIRAD Cards
[0077] Sensors for making SIRAD cards similar to that shown in FIG. 1 were made using diacetylene 344 [R—C≡C—C≡C—R, where R is a CH 2 OCONH(CH 2 ) 5 CH 3 ] using formulations and procedures described in example #2 of Patent application WO2004077097.
Example 3
Making of TUT Indicator
[0078] A coating formulation of 4BCMU in polyvinyl alcohol solution was prepared according to example #20 of Patent application WO2004077097. The formulation was coated on a 50 micron thick polyester film having a coating of pressure sensitive adhesive and a release paper to get a 3 micron dry thick coating on the top. The coated film was cut into 1 square centimeter pieces and half of each piece was exposed to short wavelength UV light till it turned dark blue while keeping the other half of each piece colorless/white by covering it from UV light with a UV absorbing polyester film.
Example 4
SIRAD Card with TUT Indicator
[0079] A number of SIRAD cards with the TUT indicators of example #3 were made by applying TUT indicators on the bottom right hand side corner of SIRAD cards of Example 2.
Example 5
Monitoring Inactivation of the Sensor
[0080] A SIRAD card with a TUT indicator was placed in an oven at 100° C. for five minutes. The card was removed from the oven and cooled to room temperature. The bottom half portion of the TUT indicator had changed from blue to red. The heated card was then irradiated with 200 rads of 100 KeV X-ray along with a control card which was not heated. The sensor of the card which was heated did not develop any blue color while that of the unheated control card developed a blue color.
Example 6
Tampering SIRAD with Sunlight
[0081] A SIRAD card with a TUT indicator was placed under sunlight for a day. The sensor developed a light blue color while the upper half of the TUT indicator changed from colorless/white to a dark blue color equivalent to that developed upon exposure to a thousand rads of X-ray.
Example 7
Tampering with Higher Temperature for a Prolonged Period
[0082] A SIRAD card with a TUT indicator was placed in an oven at 70° C. for three weeks. The sensor developed a faint blue color (equivalent to about a few rads of X-ray) while the upper half of the TUT indicator changed from colorless/white to a light blue color equivalent to that developed upon exposure about 100 rads of X-ray.
Example 8
Sensor as Temperature Indicator
[0083] A sensor was made from 4BCMU as per example #21 of Patent application No. WO2004077097. About ⅛ of the 4BCMU-sensor was exposed to short wavelength UV light from a UV lamp for about ten seconds. The UV exposed portion developed a dark blue color as shown schematically in FIG. 3 . A SIRAD card made from this sensor was heated in an oven at 100° C. for a few minutes. The UV exposed portion of the sensor changed from blue to red.
[0084] Similar devices were made using diacetylenes having fatty acids, such as tricosa-10,12-diynoic acid (TC), pentacosa-10,12-diynoic acid (PC).
[0085] A photograph of an actual SIRAD detector is provided in FIG. 4 . | Disclosed is a device for monitoring one or more of integral value of time and temperature, UV light exposure and a pre-determined temperature of an item. The device is useful for monitoring items or materials which are sensitive to time-temperature, UV light and/or a pre-determined temperature. Radiation sensitive devices such as self-indicating instant radiation alert dosimeters (SIRAD) can be accidentally, inadvertently or intentionally over exposed to time-temperature, UV light and a pre-determined higher temperature. Such over exposure can provide a false positive or false negative signal. A device based on polymerization of diacetylenes and melting of partially polymerized diacetylenes, both of which are associated with color changes, are proposed as false positive, false negative, and tamper indicator. | 6 |
TECHNICAL FIELD
This invention relates generally to the electronic switches and specifically to grounding switches that operate in the presence of negative voltage signals.
BACKGROUND ART
Typically, grounding switches, often comprising a single field effect transistor (FET), are used to ground an input or an output to a zero or ground voltage. In audio applications this can be used to prevent audio artifacts such as audible pops. For example, to prevent an undesirable audible pop a grounding switch can be used to ground an input to an audio circuit during an initialization phase before the audio circuit is equipped to handle an input signal. The switch can release the input from ground once the audio circuit has been initialized. Another application is where a grounding switch is used to ground an output during the startup of an audio circuit, when the audio circuit may produce glitches in the output leading to an audible pop.
SUMMARY OF INVENTION
A grounding switch is described which operates properly in the presence of negative voltages on a signal line. In one embodiment, the switch comprises an n-channel field effect transistor (NFET) with an isolated substrate which allows the substrate near the NFET to have a different potential than the substrate around the other circuitry in the grounding switch. A pull down element is used to turn this NFET off.
In one embodiment, the switch comprises a pull up circuit and the substrate of the NFET is coupled to a negative supply voltage. When the control signal is low, the pull up circuit is inactive and the pull down element pulls the gate of the NFET down to the negative supply voltage causing the NFET to turn off even in the presence of a signal with a negative voltage on its source or drain. A second NFET, which does not have to have an isolated substrate, can be added in series with the first NFET to prevent damage to the first NFET due to large voltage swings. In one variant, the pull down element comprises a single resistor.
In another embodiment where a negative supply voltage is not available, the substrate of the isolated NFET is tied to the signal line. The switch comprises a second NFET, which need not have a separate substrate connection, in series with the isolated NFET. When the control input is high, both NFETs turn on, turning the switch on. When the control input is low, the isolated NFET switches off when the signal has a negative voltage and the second NFET switches off when the signal has a positive voltage, thus switching the grounding switch off regardless of the signal voltage.
In one embodiment the pull down element comprises a circuit having another isolated NFET where the drain and substrate are connected to the signal. In another embodiment, the pull-up circuit comprises a p-channel field effect transistor (PFET), optionally a second PFET, and an inverter.
In another embodiment, the grounding switch is a circuit comprising two transistors in series operable to turn on when the control input is high. In operation, the first transistor is turned off when the control input is low and the signal voltage is positive, and the second transistor is turned off when the control input is low and the signal voltage is negative. The second transistor can be turned on by pulling the gate of the transistor to the positive supply voltage and can be turned off by pulling the gate down to the negative supply voltage while maintaining its substrate at the negative supply voltage. Alternately, the second transistor can be turned off when the signal voltage is negative by pulling the gate down to the signal voltage while maintaining its substrate at the signal voltage.
In one embodiment, the grounding switch is used in an audio driver to suppress audible pops. The audio driver can be used to suppress an undesired audio artifact in many electronic devices including but not limited to personal computer sound cards, voice-over-IP telephones, cellular telephones, digital picture frames, universal serial bus headsets, televisions, video game consoles, MP3 players and Bluetooth headsets.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF DRAWINGS
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1A shows an embodiment of a system employing a grounding switch to tie a single ended input to ground;
FIG. 1B shows an embodiment of a system employing a grounding switch to tie a single ended output to ground;
FIGS. 1C and 1D shows differential analogs of the systems described in FIGS. 1A and 1B ;
FIG. 2 shows an embodiment of a grounding switch comprising a single NFET;
FIG. 3 shows an embodiment of a grounding switch which can tolerate negative voltages seen at the signal line;
FIG. 4 shows an embodiment of a grounding switch which can tolerate negative voltages on a signal line without a negative reference voltage;
FIG. 5 shows an embodiment of a grounding switch;
FIG. 6 shows another embodiment of a grounding switch; and
FIG. 7 an embodiment of audio driver employing a grounding switch to suppress audible pop during the power up and power down of the audio driver.
DETAILED DESCRIPTION
A detailed description of embodiments of the present invention is presented below. While the disclosure will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the disclosure as defined by the appended claims.
FIG. 1A shows an embodiment of a system employing a grounding switch to tie a single ended input to ground. System 102 can be any system which receives a single ended input signal. Grounding switch 104 ties the input to ground when closed. An example of such a system is an audio driver which employs grounding switch 104 to zero the signal during power up and power down to prevent the occurrence of a pop sound.
FIG. 1B shows an embodiment of a system employing a grounding switch to tie a single ended output to ground. System 102 can be any system which produces a single ended output signal. Grounding switch 106 ties the output to ground when closed. As an example, an audio driver can employ grounding switch 106 to zero the output signal during power up and power down to prevent the occurrence of a pop sound.
FIGS. 1C and 1D shows differential analogs of the systems described in FIGS. 1A and 1B . In particular, FIG. 1C shows an embodiment of system 112 employing switch 114 to tie the two differential inputs together. Though the switch does not specifically tie a signal to ground, for the purposes of this disclosure, a grounding switch can also be used to zero a differential signal by tying the differential signal lines together. System 112 has a differential input which is zeroed by switch 114 when switch 114 is closed. Similarly, FIG. 1D shows an embodiment of system 116 employing switch 118 to tie the two differential outputs together. System 116 has a differential output which is zeroed by switch 118 when switch 118 is closed.
FIG. 2 shows an embodiment of a grounding switch comprising a single NFET. The gate of NFET 202 is connected to a control input, the drain of NFET 202 is connected to signal line 204 and the source is connected to a ground potential. If the switch is used to zero a differential input, signal line 204 is one of the signal lines (e.g., the positive signal line) and the drain is connected to the other signal line (e.g., the negative signal line). When the control input is tied to the positive supply voltage the switch turns on. When the control input is tied to ground, NFET 202 acts as a reverse bias diode and the switch turns off. However, if signal line 204 permits a negative voltage, and NFET 202 is a standard NFET that has a grounded substrate, NFET 202 acts as a forward bias diode when the gate is grounded causing the switch to conduct even though it is supposed to be off. For this reason use of a single NFET is undesirable in many applications, such as audio applications where the voltage can swing in both a positive and negative direction.
FIG. 3 shows an embodiment of a grounding switch which can tolerate negative voltages seen at signal line 204 . Grounding switch 300 comprises controllable pull up circuit 304 , isolated NFET 306 , optional NFET 308 , pull down element 310 , and isolated NFET 312 Controllable pull-up circuit 304 is responsive to a control signal and pulls the voltage of the gate of isolated NFET 306 to the positive supply voltage (shown as V DD ) when the control signal is high and provides high impedance when the control signal is low. Isolated NFET 306 is electrically isolated from the substrate and more specifically, its p-well is isolated. This allows the p-well surrounding the NFET 306 to be tied to a different “substrate voltage” from the rest of the circuitry. In this case, NFET 306 has an “isolated substrate connection” tied to a negative supply voltage (for example −V DD shown in the figure), represented by a fourth connection to the usually three connection NFET symbol. Many techniques exist to fabricate isolated FETs including deep n-well fabrication. Finally pull down element 310 which can be a resistor is tied to the negative supply voltage.
When the control input to grounding switch 300 is tied to the supply voltage, NFET 308 is turned on. In addition, pull up circuit 304 pulls up the gate voltage of NFET 306 so it turns on as well, thus turning switch 300 on. This pulls the voltage on signal line 204 to ground.
When the control input to grounding switch 300 is tied to ground, pull-up circuit 304 is deactivated and pull-down element 310 can pull the voltage down to the negative supply voltage which causes NFET 306 to turn off, even in the presence of a negative voltage on signal line 204 . However, if the voltage on signal line 204 is positive such as V DD the gate to drain voltage of NFET 306 as a result of the pull down element would be 2 V DD , which can exceed the tolerance of NFET 306 . Therefore, NFET 312 is included to protect NFET 306 . Because the gate of NFET 306 does not need to pull down to −V DD , NFET 312 is used to counteract pull down element 310 . In fact, when the voltage on signal line 204 is positive, NFET 312 permits a current to flow which allows the voltage on the gate to NFET 306 to rise so that the gate to drain voltage can be within the tolerance of the technology. Because of the potential for a negative source voltage on NFET 312 , NFET 312 has a substrate voltage coupled to the negative supply line. NFET 312 Optional NFET 308 can be included to protect NFET 306 from excessive voltages that can occur especially if the signal line swings between the extreme positive and negative voltages, when complementary metal-oxide-semiconductor (CMOS) technology is used. In other technologies or even other CMOS technologies with different design rules, NFET 308 can be omitted. In the present embodiment, the switch operates only so long as the voltage on signal line 204 remains greater than the negative supply voltage.
FIG. 4 shows an embodiment of a grounding switch which can tolerate negative voltages on a signal line without the need for a negative supply voltage. Grounding switch 400 comprises controllable pull-up circuit 402 , pull-down element 404 , isolated NFET 406 and NFET 408 . Controllable pull-up circuit 402 functions in a manner similar to that describe for circuit 302 above. NFET 406 is isolated in the same manner as that described for NFET 306 above however the substrate voltage is tied to the drain voltage.
When a positive supply voltage is applied to the control signal, NFET 404 turns on. In addition, pull-up circuit 402 pulls up the gate voltage on NFET 406 causing NFET 406 to turn on, thus turning the switch on. When the control signal is grounded and the voltage on signal line 204 is positive, NFET 408 is turned off. Since NFET 408 is in series with NFET 406 , the switch is turned off. When the control signal is grounded and the voltage on signal line 204 is negative, pull-up circuit 402 is left in a high impedance state, allowing pull-down element 404 to pull down the gate voltage of NFET 406 down to the voltage of signal line 204 which is also the drain voltage of NFET 406 , causing NFET 406 to turn off. Since NFET 408 and NFET 406 are in series, the switch is turned off.
FIG. 5 shows an embodiment of grounding switch 500 . Pull up circuit 402 includes an inverter 502 and PFET 504 , and pull-down element 404 includes isolated NFET 506 . When a control signal is high, inverter 502 grounds the gate of PFET 504 which turns on PFET 504 , causing a positive gate voltage at NFET 406 which turns NFET 406 on. Because both NFET 406 and NFET 408 are turned on, the switch is turned on. When the control signal is grounded, inverter 502 imposes a positive supply voltage on the gate of PFET 504 turning the PFET off effectively disconnecting the pull-up circuit 402 from NFET 406 . With the pull-up circuit disconnected, NFET 506 can manipulate the voltage on the gate of NFET 406 . When the voltage on signal line 204 is positive, the drain and substrate of NFET 506 is positive, NFET 506 acts as a forward biased diode between the source and the substrate connections. As a result, NFET 506 pulls up the gate of NFET 406 . Likewise, because the drain and substrate of NFET 406 is also positive, NFET 406 acts as a forward biased diode and pulls up on the drain of NFET 408 . However, because the control line is low, NFET 408 is turned off, so the switch is turned off. When the voltage on signal line 204 is negative, the role of the source and drain are essentially reversed. The drain to gate voltage is negative, but can be viewed as a positive gate-to-source voltage of NFET 506 where the source and drain are reversed. This causes NFET 506 to turn on which pulls down (because the signal line is negative it is a pull down rather than a pull up) the gate voltage of NFET 406 to the signal line 204 voltage. Because the drain (which now functions as a source) voltage and the gate voltage are made equal by NFET 506 , NFET 406 turns off, turning the switch off. One advantage in this embodiment of NFET 506 as the pull-up element over a resistor described in FIG. 3 is that NFET 506 only draws current in the specific case where the voltage on signal line 204 is negative, whereas a resistor would draw current all the time.
FIG. 6 shows another embodiment of a grounding switch. In this embodiment, the voltage of the signal line swings between V DD and −V DD , Thus, the total voltage between the source and drain of PFET 502 could be 2V DD which can be outside the specifications of the transistor technology. This can potentially cause PFET 502 to operate out of specification, which can damage PFET 502 . To address this problem PFET 602 is added to pull up circuit 402 , by adding PFET 602 to grounding switch 600 , the worst case voltage between the source and drain of each transistor is V DD .
FIG. 7 an embodiment of audio driver employing a grounding switch to suppress audible pop during the power up and power down of the audio driver. The audio driver is shown comprising a two stage audio amplifier. For a digital audio driver, it can further comprise a digital to analog converter (not shown) as well as other audio processing components. In the example shown, the two stage audio amplifier comprises amplifier stage 702 , and output stage 720 . Output stage 720 comprises output driver 708 , capacitor 704 , resistor 706 and grounding switch 600 . Capacitor 704 and resistor 706 are used to provide stability to the two stage amplifier. Grounding switch 600 is used to ground the output of output driver 708 during power up and power down so that an audible pop is not heard by the listener. Control signal ctrl is set high during power up and power down so grounding switch 600 is closed. Once the amplifier stage powers up and has settled into an operational mode. The grounding switch is opened by setting ctrl low and the audio signal is allowed to pass externally where a listener can hear it. It should be noted that while grounding switch 600 is used as an example, other embodiments, including any of the grounding switches described above, can also be used. Furthermore, since voltages are relative, the grounding switches described herein can also be used to tie differential inputs or outputs together.
Audio drivers such as that described are integral to a wide variety of electronic devices including but not limited to personal computer sound cards, voice-over-IP telephones, cellular telephones, digital picture frames, universal serial bus headsets, televisions, video game consoles, MP3 players and Bluetooth headsets.
It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. | A grounding switch is described which operates properly even in the presence of negative voltages on a signal line. The grounding switch uses isolated field effect transistors that have their substrates tied to different voltages. The isolated field effect transistor has a gate voltage and substrate voltage which can be pulled down to a negative voltage when the signal line has a negative voltage allowing the switch to remain open even with a negative voltage. | 7 |
FIELD OF THE INVENTION
The field of the invention is downhole valves and more particularly valves that can be operated between an open and closed position using the well fluid that flows through them.
BACKGROUND OF THE INVENTION
Downhole valves have been used to provide selective access from different strata into a well. Typically these valves employ a sliding sleeve to selectively align or mis-align openings on an inner sliding sleeve mounted concentrically with a housing. The sliding sleeve can have grooves or recesses near its end for engagement by a tool to slide the sleeve in one direction or another. Typically the tool to operate the sliding sleeve is delivered on coiled tubing or wireline, however, rigid tubing could also be used.
Many applications in deviated wellbores, particularly those with long horizontal sections, present unique difficulties to the traditional methods of operating sliding sleeve valves with tools delivered on coiled tubing or wireline. Other applications, such as junctions in multi-lateral systems have such small inside diameters so as to make operation of the sleeve using coiled tubing or wireline, virtually impossible.
One solution to this problem of lack of access for traditional tools to shift the sleeve has been to provide a local source of power, such as a battery, and use it to power the sleeve between the open and closed positions. However, there are still reliability issues with using battery power and should the valve fail to close, there is no backup way to get access to it to get it to close.
The need to use valves in applications where traditional type of access is not available, has spurred the need for the present invention. In seeking a more reliable way to operate a valve that, in effect, cannot be mechanically accessed, the valve of the present invention has been developed. The valve features, in a preferred embodiment, an annular passage lined with a material that is sensitive to some fluids but not to others. It can remain open until contacted by a fluid that makes the liner swell. The swelling closes off the flow path through the valve body to allow subsequent operations to take place. This valve type has particular application to screened main bores used in conjunction with open laterals. In such applications, high mud flow rates are experienced during completion operations making it desirable to bypass screens in the main bore completion. However, when production of hydrocarbons begins, it is desirable to close the bypass for the screens and direct production of hydrocarbons through such screens. The valve of the present invention can do this. Exposure to produced hydrocarbons can result in sufficient swelling to make the valve close. When this happens, the produced fluid can be directed to flow through a screen on the way to the surface. These and other advantages of the present invention will become apparent to those skilled in the art from a review of the description of the preferred embodiment and the drawings and the claims that appear below.
SUMMARY OF THE INVENTION
A valve for downhole use allows flow of mud or completion fluids but closes when subjected to produced hydrocarbons. The flow through the valve is through an annular passage that features a sleeve preferably made of rubber. The passage remains open during completion operations, but when hydrocarbons are produced the rubber swells and the passage is closed off. Applications include completions involving long horizontal runs and small inside diameter laterals where access to a sliding sleeve with coiled tubing or a wireline run tool is not practical.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a wellbore showing the main bores completed with screens and the valve of the present invention positioned in the screen assemblies adjacent laterals with no production pipe;
FIG. 2 is a detailed view from FIG. 1 , showing the valve of the present invention in the open position;
FIG. 3 is the view of FIG. 2 with the valve in the closed position;
FIG. 4 is a section view through the valve, shown in the open position;
FIG. 5 is a section through line 5 - 5 of FIG. 4 ; and
FIG. 6 is a section view through line 6 - 6 of FIG. 4 with the valve in the closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an application of the present invention. Well 10 has production tubing 12 going to a lateral 14 . At lateral 14 the well 10 splits into branches 16 and 18 , which are respectively cased with casing 20 and 22 . The production tubing 24 and 26 extends respectively through casing 20 and 22 to respectively terminate in screen assemblies 28 and 30 . Branch 16 has several branches 32 and 34 which are left “barefoot”, that is to say there is no production tubing in them and this is their condition during completion and in subsequent production. Similarly branch 18 has several branches such as 36 and 38 that are likewise barefoot. Screen assembly 28 has a valve 40 that allows high flow rates down annulus 42 , represented by arrow 44 shown in FIG. 2 . These high flow rates of drilling mud or other completion fluids can bypass screen assembly 28 from branch 32 by flowing through screen assembly 28 after passing through open valve 40 . This return flow is represented by arrow 46 . The same flow pattern exists from branches 36 and 38 into branch 18 and branch 32 into branch 16 . The may be an offset between the start of a branch and the valve through which completion fluids or mud will flow. If that is the case the flow will go through the annular space around the screen assembly, such as 28 or 30 until reaching a valve such as 40 or 48 .
As shown in FIG. 3 , when the valve 40 moves to a closed position because branch 32 is in production, the flow uphole 50 goes into annulus 42 and through the screen assembly 28 . Essentially the production flow is forced through the screen assemblies 28 and 30 with the valves 40 and 48 closed due to production from the branches below them. This is to be contrasted with the flow pattern bypassing the screen assemblies 28 and 30 when valves 40 and 48 are open during completion with mud or other fluids.
FIGS. 4-6 show the operation of one embodiment of the valve 40 or 48 . The valve such as 40 has a circular inlet 52 made of a plurality of smaller openings 54 . Valve 40 has a mandrel 56 with a central passage 58 . An annular path 60 begins near openings 54 and terminates at end wall 62 . A series of openings 64 allow access from annular path 60 into central passage 58 . Connection 66 is secured to the screen assembly 28 to allow returning mud or other completion fluid to pass through the interior of the screen assembly, such as 28 . A sleeve 68 is disposed in annular passage 60 and when drilling mud or completion fluids are flowing has a small enough thickness to allow high flow rates through annular passage 60 and up through the screen assembly 28 to the surface. However, if a branch feeding flow to valve 40 is allowed to come in and produce hydrocarbons, the sleeve 68 comes in contact with the hydrocarbons and proceeds to swell to such an extent so as to block annular passage 60 against further flow. The produced stream can no longer short circuit the screen assembly 28 by flowing through passage 58 . Rather, the produced flow proceeds outside of coupling 66 until it comes upon a screen section from screen assembly 28 . At that time, as desired, the produced fluids are forced through a screen to limit production of sand or other impurities. FIG. 5 shows sleeve 68 before swelling and FIG. 6 shows sleeve 68 after swelling toward the closed position.
While the preferred material for sleeve 68 is an elastomer, rubber, EPDM or Halobutyl which swells dramatically when exposed to hydrocarbons, the valve of the present invention encompasses other designs that will pass mud and completion fluids and can be triggered to close upon commencement of production flow. Thus the sleeve 68 can be made of other materials than rubber, such as elastomers, and does not need to be uniform along its length. It can comprise of combinations of materials that exhibit swelling or expand to close a flow path when exposed to hydrocarbons. Alternatively, the sleeve material can be sensitive to produced or injected water, such as a clay like bentonite. Alternatively, the material that will close the valve 40 can be sensitive to any downhole fluid but isolated from it during the completion process. Later, when it is desired to put the branches below valve 40 into production such that production from those branches will flow through the screen the layer 70 that is placed over the sleeve can be defeated, in a variety of ways to expose the produced fluids to the sleeve 68 so that it can swell and close the annular passage 60 . For example the sleeve 68 can be made from clays that expand with water such as bentonite or cements or fly ash or other materials that will swell and stay rigid enough to redirect flow. The protective cover 70 can be removed by being dissolved such as by chemical reaction or other form of attack. Alternatively, high flow rates or applied pressure differentials can erode or physically displace the protective covering 70 . Water can be from produced fluids or deliberately introduced from the surface.
Those skilled in the art can readily see that the various designs described above allow for a valve to operate reliably in situations where using coiled tubing or wireline is not practical. The design removes the uncertainties of relying on a downhole battery as the power source to operate the valve. Because of its simplicity and reliability of operation, it provides a useful tool when trying to bring in barefoot branches that require high flow rates for completion making it imperative to bypass a screen assembly while still having the flexibility to later direct produced flow from the barefoot branches through a screen assembly, due to the closure of such a valve. Other, more common applications of sliding sleeve valves downhole can also benefit from the valve of the present invention.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the invention. | A valve for downhole use allows flow of mud or completion fluids but closes when subjected to produced hydrocarbons. The flow through the valve is through an annular passage that features a sleeve preferably made of rubber. The passage remains open during completion operations, but when hydrocarbons are produced the rubber swells and the passage is closed off. Applications include completions involving long horizontal runs and small inside diameter laterals where access to a sliding sleeve with coiled tubing or a wireline run tool is not practical. | 4 |
BACKGROUND OF THE INVENTION
[0001] The field of invention relates generally to micro-fabrication of structures. More particularly, the present invention is directed to a functional patterning material suited for use in imprint lithographic processes to form optical components.
[0002] Optical communication systems include numerous optical devices, such as planar optical slab waveguides, channel optical waveguides, rib waveguides, optical couplers, optical splitters, optical switches, micro-optical elements and the like. Many of these optical devices are employed using standard photolithographic processes. As a result, many photopolymers have been developed. The photopolymers, such as acrylate materials, are light sensitive to facilitate recordation of a pattern therein. Furthermore, the photopolymers must demonstrate suitable operational and process characteristics. For example, it is desired that the photopolymers have good clarity and low birefringence over a range of temperatures. As a result, the thermal stability of the photopolymers is an important factor and should be such that the probability of color changes in the photopolymers is minimized during prolonged operation. Additionally, the photopolymers should withstand stresses so as not to crack during the baking process or during use. Finally, maximizing the miniaturization of the optical devices is desired. Recent advances in micro-fabrication techniques, have showed promising results in miniaturizing optical devices.
[0003] An exemplary micro-fabrication technique, commonly referred to as imprint lithography, is shown in U.S. Pat. No. 6,334,960 to Willson et al. Willson et al. disclose a method of forming a relief image in a structure. The method includes providing a substrate having a transfer layer. The transfer layer is covered with a polymerizable fluid composition. A mold makes mechanical contact with the polymerizable fluid. The mold includes a relief structure, and the polymerizable fluid composition fills the relief structure. The polymerizable fluid composition is then subjected to conditions to solidify and polymerize the same, forming a solidified polymeric material on the transfer layer that contains a relief structure complimentary to that of the mold. The mold is then separated from the solid polymeric material such that a replica of the relief structure in the mold is formed in the solidified polymeric material. The transfer layer and the solidified polymeric material are subjected to an environment to selectively etch the transfer layer relative to the solidified polymeric material such that a relief image is formed in the transfer layer. The time required and the minimum feature dimension provided by this technique is dependent upon, inter alia, the composition of the polymerizable material. However, Willson et al. does not disclose material suitable for use in forming optical devices employed in communication systems that may be formed using imprint lithography.
[0004] It is desired, therefore, to provide techniques to form optical devices using imprint lithographic processes.
SUMMARY OF THE INVENTION
[0005] The present invention includes a method for forming an optical coupling device on a substrate by disposing a material onto the substrate that is polymerizable in response to actinic radiation. A stack of the material is formed by contacting the material with a template having a stepped-recess formed therein. The material is then solidified into an optically transparent body with a surface having a plurality of steps by subjecting the stack to actinic radiation. To that end, the material may comprise a polymerizable acrylate component selected from a set of acrylates consisting essentially of ethylene di diacrylate, t-butyl acrylate, bisphenol A diacrylate, acrylate terminated polysiloxane, polydifluoromethylene diacrylate, perfluoropolyether diacrylates and chlorofluorodiacrylates. Alternatively, the material may include a silylated component selected from a group consisting essentially of (3-acryloxypropyltristrimethylsiloxy) silane. In yet another embodiment of the present invention, a stress relief layer may be disposed on the substrate before formation of the stack to reduce the probability of the stack cracking during operation. Thereafter, the material may be disposed on the stress relief layer. One embodiment of the stress relief layer may be formed from rubbers, such as polysiloxane rubber and fluorosilocane rubber. These and other embodiments are described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a simplified elevation view of a lithographic system in accordance with the present invention;
[0007] [0007]FIG. 2 is a simplified representation of material from which an imprint layer, shown in FIG. 1, is comprised before being polymerized and cross-linked;
[0008] [0008]FIG. 3 is a simplified representation of cross-linked polymer material into which the material shown in FIG. 2 is transformed after being subjected to radiation;
[0009] [0009]FIG. 4 is a simplified elevation view of an imprint device, shown in FIG. 1, in mechanical contact with an imprint layer disposed on a substrate, in accordance with one embodiment of the present invention;
[0010] [0010]FIG. 5 is a simplified elevation view of the imprint layer, shown in FIG. 4, after patterning; and
[0011] [0011]FIG. 6 is a simplified elevation view of material in an imprint device and substrate employed with the present invention in accordance with an alternate embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring to FIG. 1, a lithographic system in accordance with an embodiment of the present invention includes a substrate 10 , having a substantially planar region shown as surface 12 . Disposed opposite substrate 10 is an imprint device 14 having a plurality of features thereon, forming a plurality of spaced-apart stepped-recesses 16 separated by a groove 18 , which should be deeper than stepped-recesses 16 , typically 10-20 μm. Although two stepped-recessed regions 16 are shown, any number may be present. The stepped recesses 16 extend parallel to groove 18 . A translation device 20 is connected between imprint device 14 and substrate 10 to vary a distance “d” between imprint device 14 and substrate 10 . A radiation source 22 is located so that imprint device 14 is positioned between radiation source 22 and substrate 10 . Radiation source 22 is configured to impinge radiation on substrate 10 . To realize this, imprint device 14 is fabricated from material that allows it to be substantially transparent to the radiation produced by radiation source 22 .
[0013] Referring to both FIGS. 1 and 2, an imprint layer 24 is disposed adjacent to surface 12 , between substrate 10 and imprint device 14 . Although imprint layer 24 may be deposited using any known technique, in the present embodiment, imprint layer 24 is deposited as a plurality of spaced-apart discrete beads 25 of material 25 a on substrate 10 , discussed more fully below. Imprint layer 24 is formed from a material 25 a that may be selectively polymerized and cross-linked to record a desired pattern. Material 25 a is shown in FIG. 3 as being cross-linked at points 25 b , forming cross-linked polymer material 25 c.
[0014] Referring to FIGS. 1, 2 and 4 , the pattern recorded by imprint layer 24 is produced, in part, by mechanical contact with imprint device 14 . To that end, translation device 20 reduces the distance “d” to allow imprint layer 24 to come into mechanical contact with imprint device 14 , spreading beads 25 so as to form imprint layer 24 with a contiguous formation of material 25 a over regions 12 a of surface 12 , which are in superimposition with stepped-recesses 16 . A region 12 b of surface 12 in superimposition with groove 18 is devoid of material 25 a . This occurs by providing beads 25 with a requisite volume so that stepped-recesses 16 become filled, but, due to capillary action, material from which beads 25 are formed does not enter groove 18 . As a result, the material of beads 25 are provided with the requisite viscosity that may vary, dependent, inter alia, upon the size of groove 18 , stepped-recess 16 and distance “d”. As a result there is a discontinuity, or hiatus 26 , in layer 24 . In one embodiment, distance “d” is reduced to allow sub-portions 24 a of imprint layer 24 to ingress into and fill stepped-recesses 16 , while avoiding filling of groove 18 .
[0015] To facilitate filling of stepped-recesses 16 and avoiding the presence of material 25 a in hiatus 26 , material 25 a is provided with the requisite viscosity to completely fill stepped-recesses 16 in a timely manner, while covering regions 12 a of surface 12 with a contiguous formation of material 25 a , on the order of a few milliseconds to a few seconds. In the present embodiment, sub-portions 24 a of imprint layer 24 coextensive with regions 12 a have a stepped profile and are separated from adjacent sub-portions 24 a by hiatus 26 , after distance “d” has reached a desired distance, usually a minimum distance. After a desired distance “d” has been reached, radiation source 22 produces actinic radiation that polymerizes and cross-links material 25 a , forming cross-link polymer material 25 c , shown in FIG. 3.
[0016] Referring to FIGS. 1 and 3, an exemplary radiation source 22 may produce ultraviolet radiation. Other radiation sources may be employed, such as thermal, electromagnetic and the like. The selection of radiation employed to initiate the polymerization of the material in imprint layer 24 is known to one skilled in the art and typically depends on the specific application that is desired. After imprint layer 24 is transformed to consist of material 25 c , translation device 20 increases the distance “d” so that imprint device 14 and imprint layer 24 are spaced-apart.
[0017] Referring to FIGS. 1, 2 and 3 , additional processing may be employed to complete the patterning of substrate 10 . For example, substrate 10 and imprint layer 24 may be etched to remove residual material (not shown) present on imprint layer 24 after patterning has been completed. Residual material (not shown) may consist of un-polymerized material 25 a , solid polymerized and cross-linked material 25 c , substrate 10 or a combination thereof. Well known etching processes may be employed to that end, e.g., argon ion milling, a plasma etch, reactive ion etching or a combination thereof. Further, removal of residual material (not shown) may be accomplished during any stage of the patterning. For example, removal of residual material (not shown) may be carried out before etching the polymerized and cross-linked material 25 c.
[0018] Referring to FIGS. 2, 3, and 5 , polymerization of material 25 a solidifies the surface of sub-portions regions 24 a with a shape conforming to a shape of stepped-recesses 16 . This provides sub-portions 24 a with multiple steps, s 1 -s 14 having differing thicknesses, with thickness being measured in a direction parallel to distance “d”. Material 25 a is selected so that steps s 1 -s 14 define an optical coupling device 28 that propagates optical energy impinging thereupon after polymerization into material 25 c . For example, optical energy may impinge upon surface 29 and propagate outwardly away from optical coupling device 28 through the surfaces associated with steps s 1 -s 14 .
[0019] As a result, optical coupling device 28 , which includes sub-portions 24 a and regions 10 a of substrate 10 that are coextensive with regions 12 a , shown in FIG. 4, should be formed with material that is transparent to desired optical frequencies. An exemplary embodiment forms optical coupling device 28 from materials that facilitates propagation of optical energy in a range of 850 nm to 1,550 nm. In addition, the materials should demonstrate operational characteristics so as to withstand various environmental stresses without varying the optical properties of the optical coupling device 28 by, for example, 5 to 10%.
[0020] Another operational characteristic that optical coupling device 28 should satisfy is maintaining structural integrity during operation. To that end, optical coupling device 28 should withstand thermal cycling without cracking. Thus, for a given material from which substrate 10 is formed, material 25 c should maintain structural integrity when subjected changes in the ambient temperature, e.g., 0° C. to 70° C. in which optical coupling device 28 is employed. Material 25 c should also maintain structural integrity when subjected to temperature changes due to the periodicity at which optical energy impinges upon optical coupling device 28 , as well as, differences in coefficient of thermal expansion (ΔCTE) of material 25 c from which optical coupling device 28 is formed and the material from which substrate 10 is formed.
[0021] Referring to FIGS. 1, 2, 3 and 4 , in addition to the operational characteristics that material 25 c should satisfy, it is desirous to have material 25 a satisfy numerous processing characteristics considering the unique deposition process employed. As mentioned above, material 25 a is deposited on substrate 10 as a plurality of discrete and spaced-apart beads 25 . The combined volume of beads 25 is such that the material 25 a is distributed appropriately over an area of regions 12 a , while avoiding the presence of material in region 12 b . As a result, imprint layer 24 is spread and patterned concurrently, with the pattern being subsequently set by exposure to actinic radiation, such as ultraviolet radiation. Thus, in addition to the operational characteristics mentioned above, it is desired that material 25 a have certain processing characteristics to facilitate rapid and even spreading of material 25 a in beads 25 over regions 12 a while avoiding the presence of material 25 a in region 12 b.
[0022] The desirable processing characteristics include having a viscosity approximately that of water, (H 2 O), 1 to 2 centepoise (csp), or in some cases as high as 20-50 cps, dependent upon the lateral dimensions of the features, as well as the ability to wet surface of substrate 10 to avoid subsequent pit or hole formation after polymerization. To that end, in one example, the wettability of imprint layer 24 , as defined by the contact angle method, should be such that the angle, θ 1 , is defined as follows:
0≧θ 1 <75°
[0023] With these two characteristics being satisfied, imprint layer 24 may be made sufficiently thin while avoiding formation of pits or holes in the thinner regions.
[0024] Referring to FIGS. 1, 2, 3 and 5 , another desirable characteristic that it is desired for material 25 a to possess is thermal stability during further manufacturing processes and post process testing. To that end, it is desired that the structural integrity of optical coupling device 28 be maintained when subjected to wave soldering at 260° C. for ninety (90) seconds, e.g., three (3) intervals at thirty (30) seconds per interval. Additionally, it is desirous to have optical coupling device 28 maintain structural integrity when subjected to thermal cycling between −40° to 100° C. with a fifteen (15) minute dwell time at the endpoints of the temperature ranges and a five (5) minute transition time between temperatures. Finally, it is desirous to have optical coupling device 28 maintain structural integrity when subjected to an 85° C. ambient of 85% humidity for 1,000 hours. It is further desired that the wetting of imprint device 14 by imprint layer 24 be minimized. To that end, the wetting angle, θ 2 , should be greater than 75°.
[0025] Referring to FIGS. 2 and 4, the constituent components that form material 25 a to provide the aforementioned operational and process characteristics may differ. This results from substrate 10 being formed from a number of different materials. For example, substrate 10 may be formed from silica, polymers, cadmium telluride, quartz and virtually any other electro-optic material. Additionally, substrate 10 may include one or more layers in regions 12 a , discussed more fully below.
[0026] Referring to FIGS. 2 and 3, in one embodiment of the present invention the constituent components of material 25 a consist of acrylated polymerizable compositions and an initiator. The polymerizable compositions are selected to provide material 25 a with a minimal viscosity, e.g., viscosity approximating the viscosity of water (1-2 cps) or up to 10-50 cps, and to provide the aforementioned operational and process characteristics. The initiator is provided to produce a free radical reaction in response to actinic radiation, causing the polymerizable compositions to polymerize and cross-link, forming cross-linked polymer material 25 c . In the present example, a photo-initiator responsive to ultraviolet radiation is employed.
[0027] Examples of polymerizable compositions include, but are not limited to, ethylene diol diacrylate, t-butyl acrylate, bisphenol A diacrylate, acrylate terminated polysiloxane, as well as compositions thereof. Other acrylates may also include fluorinated acrylates as described by Blomquist et al. in the article entitled FLUORINATED ACRYLATES IN MAKING LOW-LOSS, LOW-BIREFRINGENCE, AND SINGLE-MODE OPTICAL WAVEGUIDES WITH EXCEPTIONAL THERMO-OPTIC PROPERTIES, SPIE Vol. 3799, pp. 266-279 (1999). Examples of the fluorinated acrylates include polydifluoromethylene diacrylates, perfluoropolyether diacrylates and chlorofluorodiacrylates. The initiator may be any component that initiates a free radical reaction in response to radiation, produced by radiation source 22 , shown in FIG. 1, impinging thereupon and being absorbed thereby. Suitable initiators may include, but are not limited to, photo-initiators such as 1-hydroxycyclohexyl phenyl ketone or phenylbis(2,4,6-trimethyl benzoyl) phosphine oxide. The initiator may be present in material 25 a in amounts of up to 5% by weight, but is typically present in an amount of 2-4% by weight. Were it desired to include silylated polymerizable compositions in material 25 a , suitable silylated polymerizable compositions may include, but are not limited to, 1,3-bis(3-methacryloxypropyl)tetramethyldisiloxane, (3-acryloxypropyl)tris(tri-methoxysiloxy)-silane.
[0028] Other compositions that material 25 a may consist of include epoxies, such as cyclo aliphatic epoxies. An exemplary cyclo aliphatic epoxy that may demonstrate the aforementioned operational and process characteristics is available from Union Carbide as part number ERL 4221. Additionally some vinyl ethers may demonstrate the aforementioned operational and process characteristics, e.g., polyvinyl ether and copolymers, such as isobutyl ethers used in conjunction with acrylics.
[0029] Specific examples of compositions for material 25 a are as follows:
COMPOSITION 1
96% ethylene dio diacrylate+4% Initiator
COMPOSITION 2
96% 1,3-bis(3-methacryloxypropyl)tetramethyldisiloxane+4% Initiator
COMPOSITION 3
44% (3-acryloxypropyl)tris(tri-methoxysiloxy)-silane+15% ethylene dio diacrylate+37% t-butyl acrylate+4% Initiator
COMPOSITION 4
48% acrylate Terminated poly siloxane+48% t-butyl acrylate+4% Initiator
COMPOSITION 5
96% bisphenol A diacrylate+4% Initiator
[0030] It should be understood that the relative mixture between the non-initiator components of the aforementioned compositions could vary by as much as 20%, dependent upon the stoichiometry. Also, the above-identified compositions may also include stabilizers that are well known in the chemical art to increase the operational life, as well as initiators.
[0031] Referring to FIG. 6, another embodiment in accordance with the present invention provides an optical coupling device 128 that includes a stress relief layer 130 disposed between substrate 110 and sub-portions 124 a . Stress relief layer 130 increases the selection of materials that may be employed to form optical coupling device 128 . Specifically, stress relief layer 130 typically has a classification temperature Tg that is lower than the operational temperature of optical coupling device 128 . This allows the use of materials having a Tg that is higher than the operational temperature of optical coupling device 128 without exacerbating the probability of cracking, because of the flexibility introduced by the presence of stress relief layer 130 . To provide stress relief layer 130 with optical transparence to the radiation that will be used during operation, stress relief layer 130 may be formed from polysiloxane rubbers, with an acrylic end group attached thereto to facilitate cross-linking when exposed to ultraviolet radiation. Alternatively, the polysiloxane rubber may be thermally cross-linked. Stress relief layer 130 may be disposed upon substrate 110 using spin-on techniques. It is desired that the material from which stress relief layer 130 is formed does not swell in acrylate polymerizable compositions. As a result, fluorosilocane rubbers may be beneficial to include in stress relief layer.
[0032] Referring to FIGS. 2 and 6, an additional benefit provide by stress relief layer 130 is that the same may function as a planarization layer. As a result, stress relief layer 130 may provide an additional function of ensuring surface 112 is planar. To that end, stress relief layer 130 may be fabricated in such a manner so as to possess a continuous, smooth, relatively defect-free surface that may exhibit excellent adhesion to sub-portions 124 a.
[0033] Referring again to FIG. 1, to ensure that imprint layer 24 does not adhere to imprint device 14 , imprint device 14 may be treated with a modifying agent. One such modifying agent is a release layer (not shown) formed from a fluorocarbon silylating agent. Release layer (not shown) and other surface modifying agents, may be applied using any known process. For example, processing techniques that may include chemical vapor deposition method, physical vapor deposition, atomic layer deposition or various other techniques, brazing and the like. In this configuration, imprint layer 24 is located between substrate 10 and release layer (not shown), during imprint lithography processes.
[0034] The embodiments of the present invention described above are exemplary. Many changes and modifications may be made to the disclosure recited above, while remaining within the scope of the invention. For example, although the present embodiment is discussed with respect to having fourteen steps, any number of steps may be formed. The scope of the invention should, therefore, be determined not with reference to the above description, but instead with reference to the appended claims along with their full scope of equivalents. | The present invention provides a method for forming an optical coupling device on a substrate by disposing a material onto the substrate that is polymerizable in response to actinic radiation. A stack of the material is formed by contacting the material with a template having a stepped-recess formed therein. The material is then solidified into an optically transparent body with a surface having a plurality of steps by subjecting the stack to actinic radiation. To that end, the material may comprise an acrylate component selected from a set of acrylates consisting essentially of ethylene dio diacrylate, t-butyl acrylate, bisphenol A diacrylate, acrylate terminated polysiloxane, polydifluoromethylene diacrylate, perfluoropolyether diacrylates and chlorofluorodiacrylates. Alternatively, the material may include a silylated component selected from a group consisting essentially of (3-acryloxypropyltristrimethylsiloxy) silane. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fluid connections. More particularly, this invention relates to fluid connections for hydraulic or similar cylindrical assemblies having a thin metal liner reinforced by a layer of resin impregnated filament.
2. Description of the Prior Art
Hydraulic cylinder assemblies such as those utilized for actuating aircraft controls are generally constructed of a relatively thin metal liner reinforced to withstand normal operational pressure. Resin impregnated filament composites are often used as the reinforcing material of choice because of the resulting low weight, cost, and resistance to malfunction if the device is penetrated by a projectile.
Existing assemblies utilize integral, side-mounted tubes or connections for conducting hydraulic fluid. These tubes are welded to the exterior of the metal liner prior to application of the reinforcing material. Alternately, concentric tubes or connections extending axially from either end of a cylindrical assembly may be used.
The first arrangement complicates emplacement of the reinforcing wrapping due to the need to pass filaments around or under the installed tubes. The second arrangement requires seals and element internally of the liner thereby increasing the cost of manufacture and resulting weight of the finished unit. The second arrangement is also impractical for use with a cylinder assembly having a plurality of internal coaxially related pistons.
SUMMARY OF THE INVENTION
In accordance with the broader aspects of this invention, there is provided a connection comprising a tubular fluid source and a beveled interior end section communicating with the assembly interior. The cylinder assembly preferably is of composite construction having a thin metal liner with one or more bosses formed on the liner surface. The liner is reinforced by a layer or layers of resin impregnated filament. A channel or passageway is drilled through the exterior filament layer so as to pass through the liner and at least one boss providing a conduit into the cylinder cavity. The port thus formed has an internal beveled surface which diverges radially outwardly of the liner. The tubular insert is positioned in the channel until the beveled interior end section abutts the internal beveled surface of the boss. A resilient O-ring or similar seal is provided at the juncture of the boss beveled surface and the beveled interior end section of the tubular insert to provide a fluid tight seal.
OBJECTS OF THE INVENTION
It is, therefore, a primary object of the present invention to provide articles such as pressure vessels, fluid actuated cylindrical assemblies and the like having fluid connections provided subsequent to the manufacture of the device.
It is a further object of the invention to provide a method for providing a fluid connection in a molded or cast container having a reinforced metallic inner liner by cutting or drilling through the outer structural filamentary material and the metallic inner layer boss surface to form a connection conduit.
Yet another object of the invention is to provide improved articles such as pressure vessels, fluid actuated cylindrical assemblies and the like, and improvements in the manufacture thereof.
These and other objects of the invention will become more readily apparent from the following specification when read in light of the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of one embodiment of the invention wherein a connection is provided in a fluid actuated assembly.
FIG. 2 is an enlarged cross-sectional view of the connection in greater detail.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring concurrently to FIGS. 1 and 2, a hydraulic cylinder assembly 10 is disclosed having a thin metal inner liner 12 reinforced with an outer layer 14 of resin impregnated filament composite material. The liner is provided with a central bulkhead 16, a pair of opposing heads 18 and 20 retained on liner 12 by filament layer 14, and four bosses or boss surfaces, designated at 22. A fluid driven piston rod 24 extends medially through assembly 10 and central bulkhead 16. A pair of pistons 26 and 28 are attached to rod 24 and positioned in chambers 30 and 32 defined by central bulkhead 16. Conventional fluid seals 34 are provided in head 20 and bulkhead 16. Four tubular fluid connections 36 including a threaded exterior portion 38 and a beveled interior end section 40 are provided for introducing fluid into assembly 10. Each connection is located above and in vertical alignment with each boss surface 22.
The cylinder assembly is initially constructed without fluid connections. The liner, including the bulkhead, opposing heads, piston rod, and boss surfaces, is first covered with the resin impregnated filament composite material layer. Upon curing the outer layer, a channel 42 is drilled through the layer of filament material and passing through each boss surface in the metallic liner so as to form an internal beveled boss surface 44 diverging radially outwardly of the liner. It is evident from FIG. 1 that channel 42 has a first portion through layer 14 and a second portion through the corresponding boss 22 of layer 12 and it is evident that the second portion is cut in the same operation as the first portion as an extension thereof. Next, a resilient seal 46 is inserted into channel 42 and retained on beveled boss surface 44. Finally, a fluid connection 36 is inserted into each channel 42 until the beveled interior end section 40 is in abutting engagement in a direction lengthwise of the channel with the resilient seal, as best shown in FIG 2. The connection may be sealed in place within the channel by any suitable means such as by gluing or utilizing a compatable resin.
While the preparation of only one connection has been described in detail, it is to be understood that multiple connections may be provided utilizing the disclosed method.
Obviously, many modifications and variations of the invention are possible without departing from the scope of the appended claims. | A fluid connection for a container and a method of making the connection isescribed. The connection is provided subsequent to the manufacture of the container according to the teachings of the present invention. | 5 |
BACKGROUND
[0001] The present invention relates to clock distribution circuitry, and more particularly, to low power clock distribution circuitry.
[0002] In integrated circuit designs, a clock distribution network (also referred to as a “clock tree”) consumes a considerable percentage of the total active power of the integrated circuit. Therefore, in the related art, a power savings technique referred to as “clock-gating” is widely applied to moderate overall power consumption within the integrated circuit.
[0003] The clock-gating technique reduces the power consumption of the clock distribution tree by disabling or “gating off” the clocks fed to some circuit units of the integrated circuit while those circuit units are not in use.
[0004] A problem with clock gating is that it requires additional logic (e.g., clock gating logic) and a control unit to manage the clock gating control signals. In order to have a net power savings, the clock gating logic must consume less power than is saved by gating the clocks off.
[0005] Unfortunately, the related art clock gating techniques do not provide significant power reduction when the integrated circuit is in full operation. That is, the power savings of the integrated circuit is not obvious or is limited when intensive processing is occurring and/or all circuit units of the integrated circuit are in use. Accordingly, a need exists for improving the power consumption of clock trees.
SUMMARY OF INVENTION
[0006] It is therefore an objective of the claimed invention to provide a low power clock distribution apparatus and related method to solve the above-mentioned problems.
[0007] According to an exemplary embodiment of the present invention, a clock distribution apparatus for providing a local clock signal having a first voltage swing to a circuit unit is disclosed comprising: a global clock distribution network for generating and distributing a global clock signal having a second voltage swing being less than the first voltage swing; and a local clock converting unit electrically connected between the global clock distribution network and the circuit unit, the local clock converting unit comprising a level shifter for converting the global clock signal into the local clock signal. Wherein the clock distribution apparatus and the circuit unit are on a same substrate.
[0008] According to another exemplary embodiment of the present invention, a method for providing a local clock signal having a first voltage swing to a circuit unit is disclosed. The method comprises generating a global clock signal having a second voltage swing being less than the first voltage swing; distributing the global clock signal; and utilizing a level shifter to convert the global clock signal into the local clock signal.
[0009] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a block diagram of a clock distribution network according to a first embodiment of the present invention.
[0011] FIG. 2 is a simplified block diagram of a clock distribution network according to a second embodiment of the present invention.
[0012] FIG. 3 shows a layout diagram of a clock distribution network according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0013] Please refer to FIG. 1 , which shows a block diagram of a clock distribution network 100 according to a first embodiment of the present invention. As shown in FIG. 1 , the clock distribution network 100 comprises a global clock generator 120 , a distribution network 130 electrically connected to the global clock generator 120 , and two level shifters 142 and 144 electrically connected between the distribution network 130 and a high-voltage area 150 . In this embodiment, the high-voltage area 150 comprises at least two circuit units 152 and 154 . The two circuit units 152 and 154 operate at a first operating voltage VCCH and are electrically connected to the first level shifter 142 and the second level shifter 144 , respectively. The two circuit units 152 and 154 may be any IC component. Generally, all components of the clock distribution network 100 are on a same substrate.
[0014] The clock distribution network 100 reduces power consumption by lowering the voltage swing of clock signal to be distributed. Specifically, the global clock generator 120 receives an input clock signal SCLK and accordingly produces a global clock signal GCLK, wherein the voltage swing of GCLK is lower than the voltage swing of SCLK. In practical implementations, the input clock signal SCLK is generated by a clock source (not shown) such as a crystal oscillator, a DCO (digital controlled oscillator), etc. In this embodiment, the input clock signal SCLK has a first voltage swing, which is substantially from a ground voltage GND to the first operating voltage VCCH, while the global clock signal GCLK has a second voltage swing, which is substantially from the ground voltage GND to a second operating voltage VCCL lower than the first operating voltage VCCH. The operation and implementations of the global clock generator 120 are well known in the art and therefore are not described further herein. The global clock signal GCLK is then distributed through the distribution network 130 .
[0015] Depending on the circuit designs, the timing and/or phase of a global clock signal been transmitted to the first level shifter 142 may be differ to another global clock signal been transmitted to the second level shifter 144 . Accordingly, as shown in FIG. 1 , the global clock signal received by the first level shifter 142 is denoted as GCLK 1 while the global clock signal received by the second level shifter 144 is denoted as GCLK 2 . Generally, both the global clock signals GCLK 1 and GCLK 2 have the same voltage swing as the global clock signal GCLK produced from the global clock generator 120 . In other words, both the global clock signals GCLK 1 and GCLK 2 are low swing clock signals.
[0016] As shown in FIG. 1 , each of the level shifters 142 and 144 is coupled to both the first operating voltage VCCH and the second operating voltage VCCL. In this embodiment, for example, the second operating voltage VCCL is 1.6V while the first operating voltage VCCH is 1.8V. In this embodiment, the first level shifter 142 is used for converting the low swing global clock signal GCLK 1 into a full swing first local clock signal LCLK 1 . The second level shifter 144 is used for converting the low swing global clock signal GCLK 2 into a full swing second local clock signal LCLK 2 . Preferably, both the first local clock signal LCLK 1 and the second local clock signal LCLK 2 have the same voltage swing as the input clock signal SCLK, i.e., the voltage swing of the first and second local clock signals LCLK 1 and LCLK 2 are substantially from the ground voltage GND to the first operating voltage VCCH. Accordingly, the local clock signals LCLK 1 and LCLK 2 can drive the circuit units 152 and 154 , respectively. Depending on the circuit designs, the timing and/or phase of the first local clock signal LCLK 1 could differ to that of the second local clock signal LCLK 2 .
[0017] As mentioned above, the low swing global clock signal GCLK is distributed through the distribution network 130 . In order to achieve low power clock distribution, components of the distribution network 130 of this embodiment are designed to properly operate with the low swing global clock signal GCLK. In other words, all the components of the distribution network 130 are low-voltage components, which operate properly at the second operating voltage VCCL.
[0018] In the embodiment shown in FIG. 1 , the distribution network 130 comprises a plurality of low-voltage components 130 a ˜ 130 f. Each of the plurality of low-voltage components 130 a through 130 f may be a driving stage for re-driving the global clock signal GCLK, a delay unit for delaying the timing of the global clock signal GCLK, a logical operating unit for performing a logical operation, a clock gating unit for serving the function of logic clock gating, or a multiplexer. For example, in the shown embodiment of FIG. 1 , each of the low-voltage components 130 a through 130 c is a driving stage and could be implemented with a buffer. The low-voltage component 130 d is an inverter, and the low-voltage component 130 e is a delay unit, which could also be implemented with a buffer. The low-voltage component 130 f is a clock gating unit and is typically implemented with a AND gate. In this embodiment, the clock distribution network 100 further comprises a control unit (not shown) for providing a gate control signal GCS to control the clock gating unit 130 f. While the second circuit unit 154 is not in use, the transmission of the global clock signal GCLK generated by the clock gating unit 130 f to the second level shifter 144 could be stopped according to the gate control signal GCS. In other embodiments, the clock gating unit may be implemented with an OR gate. In practice, clock gating may be performed at any stage of the distribution network 130 .
[0019] As mentioned in the foregoing illustration, the global clock generator 120 is used for generating a low swing global clock signal GCLK and the distribution network 130 is used for distributing the low swing global clock signal GCLK. Thus, the combination of the global clock generator 120 and the distribution network 130 is regarded as a global clock distribution network. In addition, the disclosed techniques of the present invention could be used in conjunction with other known or future techniques for even further power reductions.
[0020] As is well known in the art, the level shifter could be integrated or embedded within other components (such as a logic gate, gating unit, buffer, etc.) in practical implementations.
[0021] FIG. 2 is a simplified block diagram of a clock distribution network 200 according to a second embodiment of the present invention. As shown, a distribution network 230 composed of low-voltage components operating at the second operating voltage VCCL distributes a low swing global clock signal GCLK to local clock converting units 242 and 244 . The distribution network 230 is substantially the same as the distribution network 130 shown in FIG. 1 , and a repeated description of its operation is therefore omitted here. In this embodiment, the first local clock converting unit 242 receives a low swing global clock signal GCLK 3 from the distribution network 230 and accordingly produces a full swing local clock signal LCLK 3 to a circuit unit 252 of a high-voltage area 250 . The second local clock converting unit 244 receives a low swing global clock signal GCLK 4 from the distribution network 230 and accordingly produces a full swing local clock signal LCLK 4 to a corresponding circuit unit 254 of the high-voltage area 250 . Similarly, the circuit units 252 and 254 operate at the first operating voltage VCCH while components of the distribution network 230 operate at the second operating voltage VCCL, which is lower than the first operating voltage VCCH.
[0022] In this embodiment, the first local clock converting unit 242 , which may be integrated or embedded in a buffer, a delay unit, or a logic gate, is a level shifter for converting the low swing global clock signal GCLK 3 into the full swing third local clock signal LCLK 3 . The second local clock converting unit 244 acts as a level shifter for converting the low swing global clock signal GCLK 4 into the full swing fourth local clock signal LCLK 4 and also acts as a clock enabling unit for enabling or disabling the clock signal based on an enabling signal ES. Typically, the enabling signal ES is controlled by a control unit (not shown) so as to disable the clock signal and avoid driving the second circuit unit 254 when the second circuit unit 254 is not in use. The second local clock converting unit 244 could be a clock gating unit comprising a level shifter. For example, the second local clock converting unit 244 could be with the integration of an AND gate and a level shifter.
[0023] Typically, employing a proper layout design could reduce the power consumption and chip area. As mentioned above, the distribution network composed of low-voltage components operating at the second voltage VCCL and the high-voltage area composed of high-voltage circuit units operating at the first voltage VCCH are generally on the same substrate. In other words, two different voltage supply lines are required in the same substrate.
[0024] FIG. 3 shows a layout diagram of a circuit layout 300 according to an exemplary embodiment of the present invention. In the circuit layout 300 , high-voltage areas composed of high-voltage components are labeled as H while low-voltage areas composed of low-voltage components are labeled as L. As shown in FIG. 3 , a dual-rail power mesh is employed for reducing the total length of voltage supply lines and signal lines. Due to the circuit layout 300 , any two neighboring voltage supply lines can share the same ground voltage line, and each of the high-voltage areas and low-voltage areas can be supplied with the required operating voltage in a shortest distance. As a result, the power consumption contributed on the clock distribution networks is further reduced.
[0025] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A clock distribution apparatus for providing a local clock signal having a first voltage swing to a circuit unit being on a same substrate includes a global clock distribution network for generating and distributing a global clock signal having a second voltage swing being less than the first voltage swing; and a local clock converting unit being electrically connected between the global clock distribution network and the circuit unit. The local clock converting unit includes a level shifter for converting the global clock signal into the local clock signal. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a theft preventative system, such as which is specifically associated with high resale value metals employed in heating, cooling and ventilation (HVAC) assemblies. More specifically, the present invention disclose a copper theft prevention system which, in a first embodiment, utilizes a transformer and relay arrangement creating a closed circuit through the lines of conductive copper pipe, and which is also hooked to an alarm of some type for notifying when the metal conductive circuit (e.g. the copper line or associated connecting wire) is opened, such as by sectioning. A second variant (additional or alternative to the primary) discloses incorporating at least one fluid pressure switch into each of the copper lines, for notifying when fluid pressure within the line decreases, this indicative of the normally fluid filled copper line being sectioned.
BACKGROUND OF THE INVENTION
[0002] The prior art is documented with examples of alarm related systems for protecting valuables. In each instance, the objective of such systems is to deter the theft of typically unattended valuables.
[0003] Kerr et al. (U.S. Pat. No. 7,274,289) teaches a pattern of conductors extending in spaced, isolated fashion across each surface of an object, and in order to define a tamper detection area. At least one sensor device is connected to the pattern of conductors and is capable of detecting a change in the continuity of pattern of the conductors. A communication circuit provides at least one signal indicative of a change in the continuity of the pattern of conductors.
[0004] Schnell (U.S. Pat. No. 7,178,663) teaches a conductor loop, such as embedded into a polymer, and including individual wires defining a component of a transport belt and which further includes a conductor loop with a support side, running side and embedded tensile support. U.S. Strader (U.S. Pat. No. 4,854,446) discloses a conveyor belt having an electrically conductive sensor or antenna embedded within and which, in the instance of a rip being detected in the belt, acts to interrupt a repeating sine wave created by the conductor. Finally, the Strelow (U.S. Pat. No. 5,631,634) and Gibbs (U.S. Pat. No. 6,895,941) references are directed to pressure sensor and liquid leak detection systems, respectively, each providing alarm notification in the event of a pipe rupture.
SUMMARY OF THE INVENTION
[0005] The present invention teaches a theft preventative system associated with protecting valuable metals, such as in particular copper lines incorporated into various HVAC applications, and which have been found to yield high scrap resale. As a result of this, incidences of copper theft have significantly risen, particularly in environments where such materials are loosely attended or completely unattended.
[0006] In a first embodiment, a transformer and relay arrangement is provided which creates a closed circuit through one or more lines of conductive copper pipe, such as extending between a first (interiorly) located piece of equipment, such as a furnace refrigeration coil, and a second (externally) located piece of equipment, such as a ground or rooftop mounted condensing unit. Wires extend from such as a 12 V DC transformer and contact locations associated with each of the copper lines. Owing to the electrically communicative/conductive nature of copper, the closed circuit thereby created extends throughout the entire length of all such lines communicated in this fashion.
[0007] An alarm is further communicated to a relay (such as a 12 V DC coil relay) and, upon detecting an open circuit condition indicative of a copper line being sectioned (such as during unauthorized theft removal) issues an alarm to such as a siren (and which is understood to include any or all of an audio output, a strobe light, and a remote notification of a theft in progres).
[0008] A second variant (additional or alternative to the primary electrically conductive version) incorporates one or more fluid pressure switches into each of the copper lines. As with the electrical lines associated with applying a conductive field to the copper lines, additional lines likewise communicate the fluid pressure switch to the transformer/relay. Upon the switch detecting a reduction or total loss of fluid pressure within a selected line, this indicative of the normally fluid filled copper line being sectioned, the flow sensor switch issues a signal for activating the alarm protocol as previously described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like references refer to like parts throughout the several views, and in which;
[0010] FIG. 1 is an environmental illustration in perspective of an electrical conductive circuit associated with copper lines as part of a theft preventative alarm system according to a first preferred embodiment of the present invention;
[0011] FIG. 2 is an environmental perspective according to an alternate preferred embodiment and in which substitutes a pressure flow sensor switch for notifying of an alarm situation resulting from cutting of one or more of the copper lines; and
[0012] FIG. 3 is a sectional view of an alarm control interface and exhibiting contact locations for both the circuit associated with the electrically conductive copper lines, as well as for the low pressure switch according to the present inventions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring now to FIGS. 1-3 , the present invention teaches a theft preventative system associated with protecting valuable metals, such as in particular copper lines incorporated into various HVAC applications. As previously explained, the present inventions are intended to provide an efficient and cost effective solution for addressing an alarm situation involving such as high resale valued copper used in existing HVAC applications. Another advantage of the present invention is the ability to incorporate the alarm capabilities for detecting copper theft into existing intrusion and smoke/fire alarms.
[0014] Referring again to FIG. 1 , an environmental illustration in perspective, at 10 , of an electrical conductive circuit associated a theft preventative alarm system communicated with copper lines 12 and 14 . A transformer 16 and relay arrangement 18 are collectively provided (each typically including a 12V DC power supply). A first contact wire 20 extends from a location associated with the first copper line 12 and branches to further contact (also pressure switch) locations 22 and 24 associated with the relay 18 . A second contract wire 26 extends from a further location associated with the second copper line 14 and branches to a contact location 24 associated with an opposite (+) pole of the relay coil 18 to transformer 16 interface.
[0015] The first 20 and second 26 wires extend from interior locations associated with the HVAC assembly, see wall 2 . A Third 30 and fourth 31 wires are further shown extending from an exterior location of line 12 , such as wire 30 extending in proximity to an exteriorly located condensing unit 4 , and connecting directly, at connection 32 , to the coil relay 18 , as well as wire 31 extending from connection 34 , to the negative pole interface of the transformer 16 .
[0016] The arrangement of the wires 20 , 26 [and] 30 and 31 (T1 wire) are such that they create a closed circuit (of sufficiently low voltage and current to avoid inadvertent electrocution or harm) through each of the lines of conductive copper pipe (e.g. again at 12 and 14 ), such as extending between a first (interiorly) located piece of equipment, such as a furnace as generally referenced at 6 and including a refrigeration coil 8 , and a second (externally) located piece of equipment, such as again a ground or rooftop mounted (air conditioning) condensing unit 4 . It is further understood and envisioned that the arrangement of the wires to the various copper lines takes into account the possibility of varied HVAC installation configurations, and which may include multiple numbers of copper lines being used, particularly in situations where multiple condenser units are specified for operating in a parallel arrangement. In such a configuration, additional pairs of wires would be employed and which would extend from such as the 12 V DC transformer 16 and contact locations associated with each of the copper lines.
[0017] Owing to the electrically communicative/conductive nature of copper, and upon providing 12V DC charge from the transformer to the various wires, the closed circuit thereby created extends throughout the entire length of all such lines communicated in this fashion. An alarm, represented by siren 36 , is further communicated to the relay. Upon detecting an open circuit condition, indicative of any of the electrically charged copper lines defining the closed circuit being sectioned (and such as during unauthorized theft removal), the alarm issues output to such as the siren 36 , and which is understood to collectively represent each or all of an audio output, a strobe light, and a remote notification of a theft in progress. As previously described, the copper theft detection system can be configured so as to be seamlessly and effectively incorporated into an existing alarm system and, in a suitable retrofit embodiment, can include such as a kit for installing the desired wires to the existing lines and routed to a relay interface engageable with the existing alarm unit control panel.
[0018] Referring now to FIG. 2 , an environmental perspective is shown of an alternate preferred embodiment and in which substitutes a pressure flow sensor switch 38 , for the transformer and relay arrangement of FIG. 1 , and for notifying of an alarm situation resulting from cutting of one or more of the copper lines 12 and 14 . Although not described in specific detail, it is understood that the pressure switch component associated with contact locations of the individual copper lines 12 and 14 contemplates installing a low pressure or micro switch sensor in contact with the fluidic interior of the copper fluid line, this occurring through any one of a number of different installation techniques. Identical features represented in the variant of FIG. 1 are similarly referenced here, a duplicate explanation of which is not necessary.
[0019] It is also understood that the secondary variant of pressure flow indicating switch can be provided as an additional or alternative to the primary electrically conductive version, and which incorporates one or more fluid pressure switches into each of the copper lines. In certain applications, an exclusively low flow pressure alarm can be substituted, such as in use with non-electrically conducting fluid lines such as constructed of PVC or the like.
[0020] As with the electrical lines associated with applying a conductive field to the copper lines, corresponding or additional lines (referenced at 20 ′, 26 ′ and 30 ′ for purposes of ease and consistency of illustration) likewise communicate the fluid pressure switch 38 to the transformer/relay arrangement (not shown). It is further understood that the pressure switch variant requires only two wires, as opposed to the arrangement illustrated in FIG. 1 as directed to the conductive arrangement of the initially disclosed variant. Upon the flow sensor switch 38 detecting a reduction or total loss of fluid pressure within a selected line, this indicative of the normally fluid filled copper line being sectioned, the flow sensor switch issues a signal for activating the alarm protocol (e.g. siren, retrofitted alarm panel, or the like) and according to a fashion as previously described.
[0021] Referring finally to FIG. 3 , a sectional view is provided of an alarm control interface 40 (representative of the transformer supplied relay arrangement referenced in FIG. 1 ) and exhibiting various contact locations for both the circuit associated with the electrically conductive copper lines, as well as for the low pressure switch. In one preferred application, the interlace 40 can be provided as a terminal strip for applying such as to an outside of a siren box or other existing alarm installation.
[0022] A representative copper line is again shown at 20 and from which respective pairs of connective wires (see by example at 26 and 20 in regards to the electrically communicating lines and further at 26 ′ and 20 ′ in regards to the low flow pressure sensing switches) extend. Also referenced at 41 is a low pressure switch 41 , this responding to a gradual or abrupt decrease in pressure in order to close and instruct the relay/transformer and alarm components. A 12 V DC power input is again referenced at 42 and additional features associated with the wiring, relay and siren are disclosed similar to that previously referenced in the description of FIG. 1 .
[0023] It is also understood that additional terminal strips can be incorporated into the assembly, as well as adding or substituting a likewise 12 V DC powered strobe light as an additional deterrent. It is further envisioned that the alarm can be wired with an APC chip in substitution for the relay.
[0024] Accordingly, the present invention discloses a novel assembly for protecting against theft valuable copper lines associated with existing HVAC applications. A secondary benefit associated with the present system is the ability to notify of problems associated with the copper fluid lines, not resulting from theft, and such as in instances where inadvertent damage, for example resulting from acts of nature, are inflicted upon the copper lines. In such a secondary application, the use of low flow pressure indicating (micro) switches is of particular value and in order to identify when fluid line integrity has been compromised. It is also envisioned that normally open pressure switches can be employed in another alternate variant.
[0025] Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without department from the scope of the appended claims | A theft preventative system, such as which is specifically associated with high resale value metals employed in heating, cooling and ventilation (HVAC) assemblies. A first embodiment utilizes a transformer and relay arrangement creating a closed circuit through the lines of conductive copper pipe, via interconnecting wires, and which is also hooked to an alarm for notifying when the metal conductive circuit to the copper line is opened, either by cutting the copper pipe or the wire connected to it. A second variant discloses incorporating a fluid pressure switch into each of the copper lines, for notifying when fluid pressure within the line decreases, this indicative of the normally fluid filled copper line being sectioned. | 6 |
[0001] The present application is a continuation-in-part application of parent application Ser. No. 10/269,046, filed Oct. 11, 2002, now abandoned, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention concerns a direct hydrogen peroxide fuel cell which utilizes a proton-donating fuel. In particular, a direct hydrogen peroxide/proton-donating-fuel fuel cell is provided for production of electric current by reduction of liquid hydrogen peroxide coupled with oxidation of liquid fuel by means of direct contact of same with a cathode coated with an electrocatalyst and an anode coated with an electrocatalyst, respectively, resulting in ion transfer across an ion-conducting polymer electrolyte without significant denaturing or decomposition of the electrocatalyst.
BACKGROUND OF THE INVENTION
[0003] In conventional fuel cells containing hydrogen peroxide as the oxidizing agent, a metal anode is oxidized along with reduction of the hydrogen peroxide solution, causing an electric current to flow from the anode to the cathode through the electrolyte, which is contained within the hydrogen peroxide solution. An alternate method for utilization of hydrogen peroxide involves the decomposition of hydrogen peroxide to water and oxygen, wherein oxygen then acts as an oxidant in conventional fuel/oxygen fuel cells, such as the popular hydrogen/oxygen fuel cell; this method can be referred to as indirect hydrogen peroxide reduction.
[0004] However, in conventional liquid fuel cells containing H 2 O 2 , the aluminum anode oxidizes to aluminum oxides during reduction of the H 2 O 2 , resulting in significant deterioration of the fuel cell's performance over time due to poisoning of the metal surface of the anode. Moreover, selection of the cathode material is difficult, as only certain cathode materials will effectively reduce H 2 O 2 at a desirable rate, i.e., at a rate of reduction which will produce sufficient current, but without undue H 2 O 2 decomposition. Additionally, the direct reduction of hydrogen peroxide to water on the cathode surface is the rate-limiting reaction in the production of electricity from hydrogen peroxide, and thus a catalyst is required to achieve sufficient power density. Utilization of noble metal catalysts in this manner facilitates hydrogen peroxide decomposition, releasing oxygen as waste, and thus a decrease in cell efficiency.
[0005] Conventionally, noble metals, such as palladium and platinum, have been used as catalysts. Palladium and platinum, like all noble metals, however, are catalysts, not electrocatalysts, and as such will decompose to oxygen rapidly when placed in contact with hydrogen peroxide. This decomposition generates a great amount of heat, resulting in a large loss of efficiency, and thus requiring significantly more hydrogen peroxide to flow through the system than would be otherwise needed, to compensate for the energy lost through heat.
[0006] For example, as disclosed in prior U.S. Pat. No. 6,554,877, fuel cells using methanol as a liquid fuel, with a cathode made using screen-printing methods of 20% platinum on activated carbon on waterproof paper, have been used. However, as noted therein, catalyst poisoning or cathode sintering is encountered.
[0007] In prior U.S. Pat. No. 6,294,281, a fuel cell is disclosed having an anode and a cathode comprised of an enzyme, such as a dehydrogenase, organic compounds or organometallic molecules, which operate using fuels from biological systems. The '281 fuel cell, for example, is implanted into a portion of an animal or plant, and utilizes biological fluid, such as blood or sap, as the fuel, or may utilize tissue or cellulose outside of the biological organism. The '281 fuel cell is capable of reducing hydrogen peroxide at the cathode, but must first form the hydrogen peroxide in a non-enzyme-catalyzed electrode reaction or in an enzyme-catalyzed reaction on or off the cathode. Thus, the '281 fuel cell necessitates additional steps in the power generation process, and cannot be manufactured in an extremely compact design.
[0008] In view of the deficiencies of the above-mentioned conventional direct hydrogen peroxide and liquid fuel cells, it is an object of the present invention to provide a direct hydrogen peroxide fuel cell having an electrocatalyst not susceptible to catalyst poisoning or sintering, or side reactions with the oxidant. It is a further object of the present invention to provide a direct hydrogen peroxide fuel cell capable of stable power generation over time, i.e., which does not experience degradation over time. It is yet a further object of the present invention to provide a direct hydrogen peroxide fuel cell capable of being manufactured in a compact design, and which can run on liquid fuel and oxidant.
SUMMARY OF THE INVENTION
[0009] The inventors of the present invention have earnestly conducted extensive research in order to achieve the objects of the present invention discussed above, and as such have discovered a novel direct hydrogen peroxide fuel cell cathode which provides closer to the thermodynamically expected efficiency of hydrogen peroxide. Reduction of hydrogen peroxide is carried out in a separate compartment, the anode and cathode comprise electrocatalysts, and ion transfer occurs through a polymer membrane electrolyte. Several embodiments of such direct methanol-direct hydrogen fuel cell of the present invention are provided as follows:
[0010] In a first embodiment of the present invention, a direct hydrogen peroxide fuel cell utilizing proton-donating fuel is provided, comprising:
a first compartment having a first end with at least one input orifice and at least one output orifice disposed therein, and a second open end; an anode disposed adjacent and in contact with the second open end of the first compartment, said anode coated with an electrocatalyst; a proton-conducting membrane disposed adjacent to and in contact with the anode; a cathode disposed adjacent to and in contact with the ion conducting membrane and in electrically connection with the anode, said cathode coated with a transition metal bio-mimic electrocatalyst, said electrocatalyst being reactive with hydrogen peroxide in an electrochemical system under current flow, and unreactive with hydrogen peroxide under direct contact conditions without current flow; and a second compartment having a first end with at least one input orifice and at least one output orifice disposed therein, and a second open end disposed adjacent to and in contact with the cathode.
[0016] In second embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, the first compartment additionally contains a proton-donating liquid fuel.
[0017] In a third embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the anode is comprised of a porous and electrically conductive substrate.
[0018] In a fourth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the third embodiment above is provided, wherein the anode further has an ion-conducting polymer impregnated therein.
[0019] In a fifth embodiment of the present invention, the direct hydrogen peroxide fuel cell according the first embodiment above is provided, wherein the ion conducting membrane is a perfluorinated polymer containing sulfonic or carboxylic ionic functional groups.
[0020] In a sixth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the cathode, anode, or both, further comprises a metal selected from the group consisting of ruthenium, rhodium, palladium, osmium, iridium and platinum, or a mixture thereof, to assist in catalyzing the reduction of hydrogen peroxide or the oxidation of fuel, respectively.
[0021] In a seventh embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the sixth embodiment described above is provided, wherein the cathode further comprises a conductive and porous substrate (for example, fritted or woven carbon and metallic species).
[0022] In an eighth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the seventh embodiment above is provided, wherein the cathode further comprises a conductive binder.
[0023] In a ninth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the eighth embodiment above is provided, wherein the binder is a porous, inert, and ion-conductive polymer.
[0024] In a tenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment described above is provided, wherein the electrocatalyst is a transition metal phthalocyanine.
[0025] In an eleventh embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the cathode further comprises a substrate attached to the electrocatalyst.
[0026] In a twelfth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the tenth embodiment above is provided, wherein the cathode further comprises a substrate attached to the electrocatalyst.
[0027] In an thirteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the fuel cell further contains a proton donor liquid reservoir flowably connected to the input orifice of the first compartment, for holding and supplying a proton donor liquid to the fuel cell via the input orifice.
[0028] In a fourteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the fuel cell further contains a proton acceptor liquid reservoir flowably connected to the input orifice of the second compartment, for holding and supplying a proton acceptor liquid to the fuel cell via the input orifice.
[0029] In a fifteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the fourteenth embodiment above is provided, wherein the proton acceptor liquid contains hydrogen peroxide.
[0030] In a sixteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the fuel cell further contains a receiving reservoir flowably connected to the output orifice of the first compartment.
[0031] In a seventeenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the first embodiment above is provided, wherein the fuel cell further contains a receiving reservoir flowably connected to the output orifice of the second compartment.
[0032] In an eighteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the fifteenth embodiment of the present invention is provided, wherein the proton acceptor liquid reservoir comprises a hydrogen peroxide concentration sensor.
[0033] In a nineteenth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the second embodiment above is provided, wherein the proton-donating fuel is comprised of water saturated hydrogen, methanol in water, sodium borohydride in water, hydroxylamine in water, and their analogues and combinations.
[0034] In a twentieth embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the second embodiment above is provided, wherein the second compartment additionally contains hydrogen peroxide and water.
[0035] In a twenty first embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the third embodiment above is provided, wherein the porous and electrically conductive substrate is selected from fritted carbon, carbon cloth, fritted metals or woven metals.
[0036] In a twenty second embodiment of the present invention, the direct hydrogen peroxide fuel cell according to the eighth embodiment above is provided, wherein the conductive binder is comprised of a substituted synthetic zeolite, or a conducting polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a cross sectional view of the direct hydrogen peroxide fuel cell of the present invention.
[0038] FIG. 2 is a block diagram of the fuel cell of the present invention.
[0039] FIG. 3 is a polarization curve illustrating voltage versus current for three 1 cm 2 fuel cells, the fuel cells having a conventional microperoxidase-11 cathode catalyst, a conventional palladium cathode catalyst, and an iron phthalocyanine cathode electrocatalyst of the present invention, respectively. Fuel is water saturated hydrogen; oxidant is 3M hydrogen peroxide. Flow rate for both streams is 1 ml/min (STP for hydrogen).
[0040] FIG. 4 is a polarization curve for a 50 cm 2 area fuel cell of the present invention having an iron phthalocyanine cathode electrocatalyst, illustrating voltage versus log of the current density when running 1M methanol in 0.1M sodium hydroxide as the fuel, and 3M hydrogen peroxide as the oxidant, with a flow rate for each stream of 8 ml/min.
[0041] FIG. 5 is a graph illustrating the stability of voltage over time for a 50 cm 2 area fuel cell of the present invention having an iron phthalocyanine cathode electrocatalyst, when running 1M methanol in 0.1M sodium hydroxide as the fuel, and 3M hydrogen peroxide as the oxidant, with a flow rate for each stream of 8 ml/min.
[0042] FIG. 6 is a fitted polarization curve for a 1 cm 2 area fuel cell of the present invention having an iron phthalocyanine cathode electrocatalyst, when running water saturated hydrogen as the fuel, and 3M hydrogen peroxide as the oxidant, with a flow rate for each stream of 1 ml/min (STP (standard temperature and pressure) for hydrogen).
[0043] FIG. 7 is a fitted polarization curve for a 50 cm 2 area fuel cell of the present invention having an iron phthalocyanine cathode electrocatalyst, when running 1M methanol in 0.1M sodium hydroxide as the fuel, and 3M hydrogen peroxide as the oxidant, with a flow rate for each stream of 8 m/min.
[0044] FIG. 8 is a fitted polarization curve for a 50 cm 2 area fuel cell of the present invention having an iron phthalocyanine cathode electrocatalyst, when running 0.1M sodium borohydride in 0.1M sodium hydroxide as the fuel, and 0.4M hydrogen peroxide as the oxidant, with a flow rate for each stream of 8 ml/min.
[0045] FIG. 9 is a graph illustrating the results of the measured voltage generated by the fuel cell of the present invention over time using Fuel I and Oxidant I, as described in Test Example I.
[0046] FIG. 10 is a graph illustrating the results of the measured voltage generated by a conventional fuel cell over time using Fuel II and Oxidant II, as described in Comparative Test Example I.
DETAILED DESCRIPTION OF THE INVENTION
[0047] Many conventional fuel cells using hydrogen peroxide are designed so that hydrogen peroxide comes into direct contact with the anode material, and reduces the anode material (usually a metal). Consequently, the liquid hydrogen peroxide constitutes an electrolytic species, and ions are conducted through the electrolyte to the cathode, the site of hydrogen peroxide reduction. Such conventional liquid fuel cells, containing hydrogen peroxide, have an anode and a cathode immersed in a diluted hydrogen peroxide solution.
[0048] Generally, the anode is made of a metal such as aluminum, which oxidizes to form aluminum oxides, and hydrogen peroxide (H 2 O 2 ) is reduced. However, as both the anode and the cathode are exposed to the hydrogen peroxide, excessive decomposition of the hydrogen peroxide occurs, and the anode quickly oxidizes through chemical reaction with hydrogen peroxide or its ions (as opposed to the electrochemical reaction), causing a decrease in performance relatively quickly over time. Further, difficulties arise in that only certain cathodes will reduce hydrogen peroxide in this environment, and satisfactory current production is difficult.
[0049] In contrast, the present invention provides a fuel cell 1 , as shown in FIG. 1 , wherein an electrolyte membrane 3 separates the proton donor (fuel) from the proton acceptor (hydrogen peroxide), resulting in the reduction of hydrogen peroxide at the cathode 5 and oxidation of the fuel at the anode 7 . Further, the cathode 5 of the present invention comprises a metal phthalocyanine electrocatalyst that will not heterogeneously decompose hydrogen peroxide, and will catalyze the reduction of hydrogen peroxide only under current flow.
[0050] The anode 7 may be formed of a porous conductive substrate, with a polymer impregnated therein, or coated thereon. Suitable polymers are, for example, perfluorinated polymers containing sulfonic or carboxylic ionic functional groups which allow the transfer of protons there through, such as NAFION. In addition, a polymer such as TEFLON may be impregnated therein or coated thereon to provide hydrophobicity to the anode 7 , for compatibility with nonpolar fuels. Alternatively, the anode 7 may be formed of dehydrogenases, substances that have similar structure-function relationships to dehydrogenases, or synthetic dehydrogenase-like enzymes, or be comprised of catalysts such as platinum, ruthenium, and palladium, or a mixture thereof.
[0051] As mentioned above, the hydrogen-peroxide reduction cathode 5 is comprised of a metallic phthalocyanine such as, for example, iron phthalocyanine, cobalt phthalocyanine, manganese phthalocyanine and copper phthalocyanine. As illustrated in FIGS. 3-8 , it was unexpectedly discovered that coating the cathode 5 with a metallic phthalocyanine, or forming the cathode partially or wholly of a metal phthalocyanine, provides a direct hydrogen peroxide fuel cell capable of efficient direct reduction of liquid hydrogen peroxide over time, minimal heat generation, stable voltage, while avoiding catalyst poisoning and/or sintering problems associated with conventional direct liquid hydrogen peroxide fuel cells.
[0052] In addition, as illustrated in FIG. 1 , the cathode 5 may include carbon paper, or a suitable conductive substrate, with porosity preferable to achieve sufficient surface area. An ion-conducting membrane 3 is placed between the anode 7 and the cathode 5 , and the anode 7 and cathode 5 pressed against the proton conducting membrane 3 to form an anode/cathode membrane which effectively divides the fuel cell 1 into separate compartments.
[0053] The block diagram shown in FIG. 2 illustrates the operation of fuel cell 1 . Specifically, hydrogen peroxide and water (as the oxidant) are added to the cathode side of the fuel cell 1 , and a fuel is added to the anode side of the fuel cell 1 , to produce electric current by the flow of protons, i.e., proton transfer, over the anode/cathode membrane. Fuel and hydrogen peroxide solutions must be added periodically to each of the anode and the cathode sides of the fuel cell 1 , respectively, usually by an automatic computer controlled system. Importantly, the concentrations of each of the solutions must be within a predetermined range, in order to achieve satisfactory operation of the fuel cell. Therefore, the concentration of the solutions must be monitored and adjusted before injection thereof into the fuel cells. The liquid fuel, dissolved in basic solution, may be methanol, sodium borohydride, hydroxylamine and the like. Preferred concentrations of the fuel component are 0.001M to 10M, and the most preferred concentrations are 0.01 to 5M in a basic solution whose concentration is 1/10 that of the fuel. For example, 0.1M sodium borohydride in 0.01M sodium hydroxide or 1M methanol in 0.1M sodium hydroxide. The hydrogen peroxide concentration is made to be stoichiometric with the fuel concentration. For example, 4M hydrogen peroxide with 1M sodium borohydride, or, 0.3M hydrogen peroxide with 0.1M methanol. Preferred concentrations are +/−50% of stoichiometric; most preferred are +/−10% of stoichiometric.
[0054] With regards to the fuel, water saturated hydrogen, as illustrated in FIG. 3 , may be used. However, methanol in water, sodium borohydride in water, hydroxylamine in water, and their analogues and combinations, as illustrated in FIGS. 4-5 , and 7 - 8 , are preferred. For example, the direct liquid hydrogen peroxide fuel cell of the present invention may be run on methanol/water and sodium borohydride/water fuel compositions.
[0055] In contrast to the fuel cell of the present invention, the '281 fuel cell does not have a cathode coated with a metallic phthalocyanine electrocatalyst for directly reducing hydrogen peroxide, wherein the electrocatalyst is reactive with hydrogen peroxide in an electrochemical system under current flow, and unreactive with hydrogen peroxide under direct contact conditions without current flow. Further, if the '281 fuel cell were to directly reduce hydrogen peroxide at the cathode using, for example, microperoxidase-11 as the electrocatalyst, the microperoxidase-11 would denature (oxidize) under high hydrogen peroxide concentrations. Thus, for applications requiring the use of high concentration hydrogen peroxide (such as in applications in which small fuel cell system size is desired), the '281 fuel cell is impractical.
TEST EXAMPLE I
[0056] A cathode electrocatalyst membrane was prepared containing iron phthalocyanine, and an anode electrocatalyst membrane containing platinum/ruthenium for the anode. A fuel cell was then constructed using these cathode electrocatalyst membranes and anode electrocatalyst membranes, as shown in FIG. 1 . Fuel I was then prepared by mixing 10.0% methanol in water by weight, and Oxidant I prepared by mixing as 10.4% hydrogen peroxide in water. The fuel cell was then run on the Fuel I and Oxidant I for 10 minutes, and the voltage measured continuously. The results of the measured voltage generated by the fuel cell using Fuel I and Oxidant I are shown FIG. 9 .
[0057] As illustrated in FIG. 9 , initial no-load voltage was very good, and then dropped rapidly after 3-4 minutes. The oxidizer effluent was tinted light brown, apparently losing some material. A final effluent concentration of fuel of 9.5%, and oxidizer concentration of 10.0%, was measured. The fuel cell was run for an additional 1 hour and 50 minutes. Effectively, 6.4 g of H 2 O 2 , and 8 g of methanol, were consumed during 2 hours of operation.
COMPARATIVE TEST EXAMPLE II
[0058] A conventional cathode electrocatalyst membrane comprised of platinum/ruthenium, and a conventional anode electrocatalyst membrane comprised of platinum/ruthenium, was prepared. Fuel II was then prepared by mixing 9.5% methanol in water by weight, and Oxidant II prepared by mixing as 10.0% hydrogen peroxide in water by weight. The fuel cell was then run on the Fuel II and Oxidant II for 2 hours and 10 minutes, and the voltage measured continuously. The results of the measured voltage generated by the fuel cell using Fuel II and Oxidant II are shown in FIG. 10 .
[0059] As illustrated in FIG. 10 , the no-load voltage was good. A final effluent concentration of fuel of 9.0%, and oxidizer of 3.3% was measured. However, unlike in the fuel cell in Test Example 1 above, significant heat generation on the cathode side was observed. Moreover, 107.2 g of H 2 O 2 , and 8 g of methanol, were consumed, illustrating that use of conventional catalysts necessitate significantly larger quantities of oxidant (i.e., it is necessary to “overdose” the fuel and oxidizer sides with higher replenishing flow rates to make up the energy lost to heat production) to produce the same effective energy as the electrocatalyst of the present invention. The cathode catalyst was also an effective decomposition catalyst, hence very low fuel cell efficiency was observed. | A direct hydrogen peroxide fuel cell for stable and efficient production of electric current by direct reduction of hydrogen peroxide via a cathode comprising a metal phthalocyanine electrocatalyst, coupled with oxidation of fuel by means of ion transfer across an ion-conducting polymer electrolyte, is provided. In addition, a hydrogen peroxide concentration meter is provided, which may be utilized, for example, for measuring the concentration of hydrogen peroxide in solutions that may contain strong electrolytes or in automated systems such as those to be used with the present fuel cell. | 7 |
PRIORITY
This is a continuation of Ser. No. 09/504,098 filed Feb. 15, 2000, allowed.
This application claims priority to provisional application Ser. No. 60/130,773 filed Apr. 23, 1999.
BACKGROUND
A well known commercial product in the laundry care industry is the fabric dryer sheet. In use, the consumer typically uses at least one sheet in the drying cycle of the laundering process. The sheets generally include a substrate material, such as a web, wherein the substrate carries one or more ingredients to impart desired benefits to the clothing. These ingredients can include, for example, perfumes, anti-static agents, dye transfer inhibitors, whitening agents, enzymes, stain repellents and wrinkle reducing agents.
Processes for fabricating these dryer sheets are also well known. In a typical process, a large role of the web material is guided at high speeds through various coating, smoothing and drying/cooling steps wherein one or more ingredients are applied to the web. An example of this process is shown in FIG. 1 .
With reference to FIG. 1, web 5 is preferably a polyester material and provided in rolls 2 . Rolls 2 are typically about 37 inches to about 85 inches in width and have a length between about 8,000 and about 13,000 yards. Web 5 passes through various rollers and rods wherein ingredients are applied to the web. As shown, web 5 is passed over guide roll 12 and onto applicator roll 14 . Applicator roll 14 transfers ingredients 17 from coating pan 15 onto the web. A holding tank (not shown) can be used to supply the ingredients to coating pan 15 . Preferably, automatic controls are used to ensure a proper level and temperature of ingredients 17 in pan 15 .
As known in the art, ingredients 17 can include perfume material in addition to other fabric treatment agents, particularly those that provide anti-static and fabric softening benefits. These fabric treatment agents can include, for example: cationic compounds, such as quartery ammonium compounds; nonionic surfactants, such as ethoxylated alcohols; fatty alcohols; fatty acids; alkali metal soaps of fatty acids; carboxylic acids and salts thereof; fatty acid esters; glycerides; waxes; anionic surfactants; water; optical brighteners; fluorescent agents; antioxidants; colorants; germacides; perfumes; bacteriocides; enzymes; dye transfer inhibitors; soil release polymers; skin care benefit agents; perfume carriers (e.g. starch, clyclodextrins); wrinkle reducing agents; and the like. Various preferred non-cationic formulations are disclosed in U.S. patent applications Ser. No. 08/832,887, filed Apr. 4, 1997, the contents of which is incorporated by reference. In prior art processes, perfume has been present from about 2 wt % to about 6 wt % based on total ingredients 17 .
In a preferred embodiment, the ingredients are maintained at approximately 140-190° F. in both the holding tank and coating pan 15 . At this temperature, one or more ingredients can be lost to the atmosphere due to their volatility or be adversely affected by means of thermal degradation. When the perfume is present, it is estimated that there is a loss of approximately 15 wt. % of the perfume to the atmosphere at this coating step.
Further on in the process of FIG. 1, after coated in the coating pan, coated web 5 ′ passes over smoothing rod 18 to guide roll 20 . From guide roll 20 , the web passes to heating drum 22 , travels to cooling drums 24 and 26 , which are preferably cooled to below about 100° F. by chilled water. Cooled web 5 ′ then passes to trimming station 28 , wherein the web is rolled and preferably cut into roles 2 ′. Roles 2 ′ are preferably about 12 inches in width. At this point in the process, the roles can be stored for later cutting and packaging. During the process shown in FIG. 1, the web can travel as fast as 1,000 feet per minute. It is estimated that the additional perfume lost after the step of coating can be in the range of approximately 20 wt. % to 30 wt. % from that which was originally present in pan 15 .
Turning to FIG. 2, final processing of coated web 5 ′ is carried out by passing one or more of the coated roles 2 ′ through a series of guide rollers 32 . The web is then folded by folders 34 , passed to conveyor 36 and cut by knife 38 . After cutting, the folded sheets are tamped down, stacked and accumulated for packaging.
During the above-described processes, it has been found that a significant amount of volatile agents can be lost prior to final packaging, particularly perfumes. This is generally due to the relatively high volatility of most perfume agents. For example, it has been found that up to 45% of the perfume added in a typical process can be lost by the time the dryer sheet is folded and packaged.
Therefore, there is a need for an improved fabric dryer sheet manufacturing process wherein the loss of volatile agents during the process of making the fabric sheets is minimized.
Perfume agents can be classified by their relative volatility. High volatile perfumes are known as “high notes” while relatively unvolatile perfumes are known as “low notes”. Due to their high volatility, high note perfumes are typically more perceptible by humans than low note perfumes. High note perfumes also have a wider range of odors and, therefore, allow for greater flexibility when selecting perfume agents. Unfortunately, when manufacturing dryer sheets, it is the desired high notes that can be lost during processing. This has resulted in a decreased amount of high note perfumes making it into the packaged product and alteration of the perfume profile. Use of high note perfumes have also been reduced or eliminated from perfume formulations due to the above-described process conditions.
Therefore, there is also a need for fabric sheet manufacturing techniques that would allow for increased usage of high note perfumes, wherein the highly volatile perfumes are retained on the fabric sheet so as to reach the consumer.
SUMMARY
For simplicity, “perfume” will be used herein to describe a fabric treatment agent that can volatilize or degrade from heat in an undesirable manner. It is within the scope of the present disclosure, however, that other volatile agents or heat sensitive agents can be advantageously applied by the presently disclosed process.
The present disclosure relates to a process that minimizes the loss of perfume and other volatile agents during the fabrication of dryer sheets. It has been found that it is possible to de-couple the addition of volatile or heat sensitive agents from one or more of the manufacturing process steps, particularly those portions that run at a high speed and/or high temperature.
In one preferred embodiment, the a selected agent or agents are applied during high speed web movement after high temperature application of other ingredients. In a second preferred embodiment, the selected agent or agents can be applied just prior to folding and packaging.
It has been found, for example, that by adding the perfume or other volatile agents closer to the step of packaging, i.e. after application of other ingredients in coating pan 15 , there is less loss of ingredients to the atmosphere during the dryer sheet process. In the case of perfumes, this new process has less affect on the perfume profile and, therefore, a wider variety of perfumes can be used. In addition, because ingredients are no longer lost or lost to a lesser extent, less of the ingredient is needed when practicing the present disclosure, resulting in raw material cost savings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a fabric sheet coating process that is known in the art;
FIG. 2 illustrates a fabric sheet cutting and folding process that is known in the art;
FIG. 3 illustrates a fabric sheet coating process that generally shows a preferred location of applying fabric treatment agents, subsequent to the main coating operation;
FIG. 4 illustrates a fabric sheet cutting and folding process that generally shows preferred locations of applying fabric treatment agents, subsequent to the main coating operation;
FIG. 5, illustrates a preferred method and apparatus for applying fabric treatment agents to a substrate material that can be used in the processes shown in FIGS. 3 and 4;
FIG. 6 illustrates an alternate, preferred method and apparatus for applying fabric treatment agents to a substrate material that can be used in the processes shown in FIGS. 3 and 4;
FIG. 7 illustrates a preferred method of transferring liquid agents to the apparatus of FIG. 6; and
FIG. 8 illustrates a fabric sheet cutting and folding process that shows the apparatus of FIG. 6 at preferred locations.
DETAILED DESCRIPTION
With reference to FIGS. 3 and 4, processes in accordance with the present disclosure are shown. FIG. 3 shows preferred fabric treatment agent application zone A, wherein ingredients can be added to web 5 ′ subsequent to the coating of ingredients 17 . Zone A is located after cooling drums 24 and 26 before cutting station 28 . By applying perfumes and/or other fabric treatment agents at or near zone A, the high temperatures associated with the upstream coating operation are avoided. In addition, because web 5 ′ is rolled-up at trimming station 28 shortly after application zone A, the fabric treatment ingredients become trapped as web 5 ′ winds about itself.
FIG. 4 shows an alternate, preferred application zones B. In this embodiment, the fabric treatment agents are applied in prior to final folding and cutting of the substrate. Several zones are shown because the preferred process performs several cutting and folding operations simultaneously. An advantage of waiting to apply certain fabric treatment agents just prior to cutting and folding is that roles 2 ′ can be generic across several brands. More specifically, for example, if the only difference between two or more brands of product is the type or quantity of perfume, rolled stock 2 ′ can be used for each brand as needed.
Turning to FIG. 5, a preferred apparatus for applying fabric treatment agents to web 5 ′ is shown. Spray assemblies 80 have controllers 81 and air flow modules 82 for controlling the flow and spray pattern of liquid spray 83 emitted from nozzles N. Spray assemblies 80 can be pressure spray assemblies or, more preferably, ultrasonic sprayers as shown. Preferred ultrasonic spray assemblies are available from Sono-Tek Corporation, Milton, N.Y. The Sono-Tek sprayers use ultrasonic power to atomize liquids. The flow of liquid from nozzles N and the flow of air from modules 82 are regulated by controllers 81 . Controllers 81 can be programmed to apply more or less liquid agent and can be coupled to web speed information so as to apply predetermined, uniform quantities of fabric treatment agent. While three spray assemblies or shown, one or more can be used, depending on the width of web 5 ′ and on the width of the spray. Spray assemblies can be used in zones A or B of FIGS. 3 and 4, respectively.
With reference to FIGS. 6 and 7, an alternate preferred apparatus for applying fabric treatment agents web 5 ′ is shown. In FIG. 6, the perfume applicator generally includes tubular member 50 having a plurality of micro holes 52 . Web 5 ′ is directed past the applicator by one or more guide rolls 54 . The number and configuration of guide rolls 54 is not critical and could even be eliminated.
Liquid fabric treatment agent is preferable pumped into applicator 50 by means of a metering pump 60 associated with tank 70 . As shown, the liquid passes through tube 58 , into one end of applicators 50 . Most preferably, the liquid is pumped into applicators 50 through a manifold (not shown) that directs the liquid into each end of the applicators 50 . Such a system can provide a more uniform pressure profile within applicator 50 . Applicators 50 are preferably fabricated from a low friction material that can apply the fabric treatment agents to the web as it contacts tubular member/applicator 50 and passes over the micro holes. While two rows of micro holes are shown, various combinations of holes, slits or other orifice that allow the liquid to exit the applicator can be used. Applicators 50 can be used in zones A or B of FIGS. 3 and 4, respectively. FIG. 8 shows several applicators similar to FIG. 6 in use prior to the steps of cutting and folding.
In a preferred process where one or more of the fabric treatment applicators are used to apply perfume, at least between about 50% to about 75% by weight of the total perfume in the final product is added after the high temperature coating operation. In a most preferred process about 95% to about 100% by weight of the total perfume in the final product is added after the high temperature coating operation.
By applying certain fabric treatment agents at either or both zone A and zone B, the need for changing and cleaning ingredients 17 in coat pan 15 can be eliminated, allowing for manufacturing efficiencies.
In practice it was unexpectedly found that the post-added perfume could absorb into the dryer sheet material that was processed as shown in FIG. 1 . By absorbing, the sheet remained “non-tacky”, and processing, such as cutting and packaging, were not hindered. See example 2, below.
EXAMPLE 1
An 11 inch by 6.75 inch polyester substrate was first coated with 1.392 grams of anti-static/softening agent on a bench-top coater. Subsequently, 0.058 grams of perfume (4% by weight, excluding the weight of the substrate) was sprayed onto the coated sheet. This sheet and a typical production sheet were analysed by a HeadSpace GC. The production sheet was produced using the process shown in FIGS. 1 and 2, i.e., without de-coupling the perfume from the coating step. The perfume level in ingredients 17 dosed into coat pan 15 was also initially 4% by weight. The analysis data is shown in the following table.
TABLE 1
Perfume added,
Perfume remaining,
Sample
g
g
Perfume Loss, %
Lab Sample
0.058
0.055
5.0
Production
0.058
0.033
42.5
sheet
The data indicates that the new process has improved the perfume retention. Therefore, for example, if the final product sold to the consumer only needs 0.033 g of perfume to deliver the expected perfume benefit, the methods disclosed herein allow for the addition of only 0.0347 g of perfume per sheet to deliver the same/expected amount—more than 40% reduction in perfume use.
EXAMPLE 2
An 11-inch wide dryer sheet roll was coated with anti-static/softening agent and perfume via the production process of FIG. 1 . The role was mounted on a pilot scale coater. An applicator device as shown in FIG. 6 was set to contact the web of dryer sheet between unwind and rewind rolls. The roll was unwound and rewound at the speed of 10 ft/min while a pump was pumping perfume with the flow rate of 1.03 g/min onto the coated web. The addition of perfume is equal to extra 4% of perfume added to the sheet. The sheets with the extra 4% perfume made by this method showed a minimum increase of tackiness. Thus, the process was demonstrated. | A process for applying relatively volatile or heat sensitive ingredients, such as perfume, to fabric dryer sheets minimizes the loss of the ingredients to the atmosphere or through degradation. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to scanning circuits of cathode ray tubes (CRTs) and more particularly to such circuits with a low power consumption at standby.
2. Discussion of the Related Art
FIG. 1 shows an exemplary CRT vertical scanning circuit together with control and supply circuits.
A power supply comprises a transformer 1 with a primary winding L 1 connected to an AC supply source and two secondary windings L 2 + and L 2 −. The secondary winding L 2 + is connected between the ground and the anode of a diode D+. A storage capacitor C+ is connected between the cathode of the diode D+ and the ground. The secondary winding L 2 − is connected between the ground and the cathode of a diode D−. A storage capacitor C− is connected between the anode of the diode D− and the ground. In operation, the cathode of the diode D+ is at a positive voltage, for example +12V, and is connected to a terminal of a switch S. The other terminal of the switch S is connected to a terminal Tup. The anode of the diode D− is at a negative voltage, for example −12V, and is connected to a terminal Tdown.
A typical vertical scanning circuit 2 comprises a differential amplifier 3 providing a control signal c to a power amplifier 4 . The output of the power amplifier 4 is connected to a first terminal of a deflection coil Ly. The second terminal of the deflection coil Ly is linked to the ground through a resistor R. Amplifiers 3 , 4 are supplied by connections to terminals Tdown and Tup. The differential amplifier 3 receives negative and positive input signals E+ and E− from a control circuit 6 supplied by connections to terminal Tup and to the ground. The intermediate node Z between the deflection coil Ly and the resistor R is connected to the control circuit 6 .
In operation, the switch S is closed. During the screen scanning, the deflection coil Ly current decreases linearly so that each scanned line is under the former one. Between two screen scannings, the current in deflection coil Ly increases very quickly, so that the spot is moved from the last line to the first one. The power amplifier 4 is in this example an inverting amplifier. When the difference voltage between input signals E+ and E− is positive, the current through the deflection coil Ly flows from the ground to terminal Tdown through “low-side” current paths of the power amplifier 4 . When the difference voltage between input signals E+ and E− is negative, the current through the deflection coil Ly goes from terminal Tup to the ground through “high-side” current paths of the power amplifier 4 .
So as to make sure that the current through the deflection coil Ly is correctly set by the vertical scanning circuit 2 , the control circuit 6 measures the current in the deflection coil Ly by analyzing the voltage of the node Z. The negative input signal E− produced by the control circuit 6 fluctuates according to the drift of the measured current compared to the expected current in the deflection coil Ly. The positive input signal E+ acts as a control signal. If the measured current is too high, the voltage difference between the positive input signal E+ and the negative input signal E− is lowered so as to decrease the current in the deflection coil and conversely.
In standby mode, power consumption must be minimized. The switch S is open to save power. The terminal Tup is no longer powered. The voltage of terminal Tup decreases as a current is drawn by the amplifiers 3 , 4 . However, when the control circuit 6 is an integrated circuit, there are diodes 7 whose anodes are connected to the ground and whose cathodes are connected to terminal Tup. Therefore it remains a current path for discharging capacitor C− and the active elements remain supplied substantially at one half of the normal supply voltage. This causes a low power consumption that is generally considered tolerable when compared to the drawbacks of using a second switch for disconnecting capacitor C−.
However, the inventor has noted that in about one vertical scanning circuit out of two, the power consumption in the standby state was much higher than expected.
Consequently, the purpose of this invention is to present a scanning circuit such that its power consumption is always minimal in standby mode.
SUMMARY OF THE INVENTION
To attain these purposes and others, the present invention provides a scanning circuit, comprising a power supply providing a negative voltage on a first terminal, an intermediate voltage on a second terminal and a positive voltage on a terminal of a switch, the other terminal of the switch being connected to a third terminal, a control circuit supplied by connections to the second and third terminals, a differential amplifier receiving a positive and a negative input signal provided by the control circuit, a power amplifier controlled by the differential amplifier, both amplifiers being supplied by connections to the first and third terminals, a deflection coil connected between the output of the power amplifier and the second terminal, biasing means setting, when the switch is open, the output of the differential amplifier so that the possible current paths through the power amplifier between the deflection coil and the first terminal are cut.
In one embodiment of such a scanning circuit, the differential amplifier comprises eight transistors, the third and fourth transistors being of NPN type, the other transistors of PNP type, the base of the first transistor receiving the negative input signal, the base of the second transistor receiving the positive input signal, the emitters of the first and second transistors being connected to the collector of the sixth transistor, the emitter of the sixth transistor being connected to the third terminal, the base of the sixth transistor being connected to the collector of the eighth transistor, the base of the eighth transistor being connected to its collector, the emitter of the eighth transistor being connected to the third terminal, the collector of the eighth transistor being connected to a current source, the collector of the first transistor being linked to the first terminal by a first resistor, the collector of the second transistor being linked to the first terminal by a second resistor, the bases of the fifth and seventh transistors being connected to the base of the sixth transistor, the emitters of the fifth and seventh transistors being connected to the third terminal, the collector of the fifth transistor being connected to the collector of the third transistor, the emitter of the third transistor being connected to the collector of the first transistor, the collector of the third transistor being connected to its base, the collector of the seventh transistor being connected to the collector of the fourth transistor, the emitter of the fourth transistor being connected to the collector of the second transistor, the base of the fourth transistor being connected to the base of the third transistor.
In one embodiment of such a scanning circuit, a comparator receives on a first input a fixed voltage equal to the voltage of third terminal minus the voltage of a reference supply, the other input of the comparator being connected to the collector of the sixth transistor, a reference current source controlled by the comparator being connected to the collector of the third transistor.
In one embodiment of such a scanning circuit, an auxiliary P-type zone is provided near the P-type zone forming the collector of the sixth transistor, the auxiliary P-type zone being connected to the collector of the third transistor.
In one embodiment of such a scanning circuit, a P-type zone forms the common emitters of the fifth, sixth and seventh transistors, a N-type zone surrounding the emitter forms the common base of the transistors, three P-type zones surrounding the common base form the collectors of the transistors, all collectors being separated by narrow N-type zones, the length of opposite outlines of the collectors of the fifth and sixth transistors being larger than the length of opposite outlines of the collectors of the seventh and sixth transistors.
In one embodiment of such a scanning circuit, the differential amplifier comprises an input transistor pair receiving the positive and the negative input signals, the input transistor pair forming a first amplifying stage coupled to a second amplifying stage, and wherein the sizes of the transistors of the input transistor pair are different and wherein the sizes of the components of the second amplifying stage are different to balance the transistor size difference of the input transistor pair when the switch is open.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and others purposes, features, aspects and advantages of the invention will become apparent from the following detailed description of embodiments, given by way of illustration and not limitation with reference to the accompanying drawings.
FIG. 1 is a circuit diagram, already described, of a vertical scanning circuit together with control and supply circuits;
FIG. 2 is a circuit diagram of a scanning circuit according to the present invention;
FIG. 3 shows an embodiment of a part of a scanning circuit according to the present invention;
FIG. 4 shows another embodiment of a part of a scanning circuit according to the present invention; and
FIG. 5 is a circuit diagram corresponding to the embodiment of FIG. 4 .
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The invention is based on an analysis of the operation of the circuit of FIG. 1 in standby mode.
In standby mode, it is commonly admitted that, as the control circuit does not provide any signal, the coil Ly is not supplied. However, due to the unavoidable dissymmetry of a practical circuit, one of the low- or high-side current paths of the power amplifier 4 is generally activated.
In the best case, when the control signal c is low, and equal to the voltage of Tdown (−12 V) in standby mode, only high-side current paths of the power amplifier 4 are conductive. Since terminal Tup is around the ground, both terminals of the deflection coil Ly are connected to the ground, and therefore no current is drawn.
In the worst case, when the control signal c is high, and equal to the ground in standby mode, there is a quite high current through the deflection coil Ly through the “low-side” current paths of the power amplifier 4 and the power consumption is high.
FIG. 2 shows an implementation of the vertical scanning circuit 2 of FIG. 1 to which have been added elements according to an embodiment of the present invention. The differential amplifier 3 comprises a differential pair of PNP transistors T 1 and T 2 . The base of transistor T 1 receives the negative input signal E − and the base of PNP transistor T 2 receives the positive input signal E + . Both emitters of transistors T 1 and T 2 are connected to the collector of a PNP transistor T 6 . The emitter of transistor T 6 is connected to terminal Tup. The base of transistor T 6 is connected to the collector of a PNP transistor T 8 connected as a diode, the base of transistor T 8 being connected to its collector. The emitter of transistor T 8 is connected to terminal Tup. The collector of transistor T 8 is connected to a current source Is. The collector of transistor T 1 is linked to terminal Tdown by a resistor R 1 . The collector of transistor T 2 is linked to terminal Tdown by a resistor R 2 . The bases of two PNP transistors T 5 and T 7 are connected to the base of transistor T 6 . The emitters of transistors T 5 and T 7 are connected to terminal Tup. The collector of transistor T 5 is connected to the collector of a NPN transistor T 3 whose emitter is connected to the collector of transistor T 1 . Transistor T 3 is connected as a diode, its collector being connected to its base. The collector of transistor T 7 is connected to the collector of a NPN transistor T 4 , whose emitter is connected to the collector of transistor T 2 . The base of transistor T 4 is connected to the base of transistor T 3 .
Transistors T 1 and T 2 are identical, as well as transistors T 3 and T 4 , transistors T 5 and T 7 , and resistors R 1 and R 2 .
During normal operation, when terminal Tup is at a positive voltage, +12 V, the differential amplifier 3 compares input signals E − and E + , at least one of the signals being at a lower voltage than the voltage of terminal Tup.
When the voltage of positive input signal E + is higher than the voltage of negative input signal E − , the current through transistor T 1 is higher than the current through transistor T 2 . Consequently, the voltage on the emitter of transistor T 3 is higher than the voltage on the emitter of transistor T 4 . As a result, the voltage difference between the base and the emitter of transistor T 4 is higher than the voltage difference between the base and the emitter of transistor T 3 . The currents delivered to transistors T 3 and T 4 are equal, as they are imposed by the current mirror constituted of transistors T 5 , T 6 and T 8 . As a result, the current drawn by transistor T 4 is higher than the current provided by transistor T 7 . As a consequence, the control signal c decreases. More precisely, the control signal c is lower than a common mode voltage V cm which corresponds to the voltage of control signal c when input signals E − and E + are equal and the current through the deflection coil Ly goes from terminal Tup to the ground through “high-side” current paths of the power amplifier 4 .
Conversely, when the voltage of negative input signal E− is higher than the voltage of positive input signal E+, the control signal c is higher than the common mode voltage V cm .
In standby mode, the voltage of terminal Tup is around zero as it is linked to the ground by the diodes 7 as described previously. The input signals E − and E + are around zero. As a consequence, the transistors T 1 and T 2 are both off. The currents through transistors T 3 and T 4 are equal and fixed by transistors T 5 and T 7 . As the matching of transistors T 3 and T 4 , resistors R 1 and R 2 and transistors T 5 and T 7 cannot be perfect, the control signal c cannot be predicted, and differs from a chip to another. If resistor R 2 is a little larger than resistor R 1 , or if transistor T 3 is larger than transistor T 4 , or if transistor T 7 is larger than transistor T 5 , the control signal c is high, near the ground in this case. Conversely, if resistor R 1 is larger than resistor R 2 , or if transistor T 4 is larger than transistor T 3 , or if transistor T 5 is larger than transistor T 7 , the control signal c is low, near the voltage of Tdown.
According to the present invention, a circuit 11 is provided to make sure that the control signal c is always low in standby mode, so that the above-mentioned low-side current paths are never activated in standby mode.
In circuit 11 , a comparator 12 receives on its negative input a fixed voltage equal to the voltage of terminal Tup minus the voltage of a reference supply source 13 . The positive input of comparator 12 is connected to the collector of transistor T 6 . A reference current source Iref, controlled by comparator 12 , is connected to the collector of transistor T 3 .
During normal operation, when terminal Tup is powered, the transistor T 6 is in active mode. The voltage of the collector of transistor T 6 depends on the voltage of input signals E− and E+ produced by circuit 6 , it is usually in the range 0–4 V when the voltage of terminal Tup is equal to +12 V. The voltage of the reference supply source 13 is chosen lower than the voltage between terminal Tup and the collector of transistor T 6 . Consequently, the output of comparator 12 is low and no current is provided by the reference current source Iref.
In standby mode, the voltage between the collector and the emitter of transistor T 6 decreases and transistor T 6 goes to saturation. The voltage between terminal Tup and the collector of transistor T 6 is lower than the voltage of the reference supply source 13 . The output of comparator 12 is high, and a reference current is provided to transistor T 3 . Thus, the current through transistor T 3 is higher than the current through transistor T 4 . Consequently, the voltage of control signal c is low and the output of power amplifier 4 is biased towards the voltage of terminal Tup. The power consumption is minimal.
FIG. 3 is a top view of transistor T 6 of the differential amplifier 3 together with added elements forming an embodiment of the present invention. P-type zones are hatched and N-type zones are white. In this example, the emitter is a small circular P-type zone 20 . The emitter is surrounded by a circular N-type zone 21 forming the base of the transistor. The base is surrounded by a P-type zone 22 forming the collector of the transistor. The external outline of the collector forms a square. A P-type zone 23 forming an auxiliary collector is near the right side of the collector of the transistor, both collectors being separated by a very small N-type zone 24 . The auxiliary collector is connected to the collector of transistor T 3 .
In standby mode, the transistor T 6 is saturated as described previously. Electrical carriers are injected from the collector of transistor T 6 to the auxiliary collector. An auxiliary current is created in the auxiliary collector. The auxiliary current provided to transistor T 3 unbalances the pair of transistors T 3 –T 4 and the control signal c is low.
During normal operation, the transistor T 6 is not saturated and no auxiliary current is provided, the differential amplifier operates normally.
By adding an auxiliary collector zone having a very small area compared to the global area of the differential amplifier 3 , it is possible to obtain the result sought for, i.e. to have a power consumption always minimal in standby.
FIG. 4 is a top view of transistors T 5 , T 6 and T 7 of the differential amplifier 3 of FIG. 2 according to another embodiment of the present invention. P-type zones are also hatched and N-type zones are white. The emitter common to all transistors is a small circular P-type zone 30 . The emitter is surrounded by a circular N-type zone 31 forming the common base of all transistors. All collectors are realized within a rectangular shaped zone surrounding the base. The bottom half part of the rectangular shape constitutes the collector C 6 of transistor T 6 . The top half part of the rectangular shape zone is divided into two unequal area zones, the smaller zone being the collector C 7 of transistor T 7 , the largest zone being the collector C 5 of transistor T 5 . Collectors C 5 , C 6 and C 7 are separated by narrow N-type zones. Though collectors C 5 and C 7 have different areas, the length of the outline of C 7 opposite to the outline of the emitter is equal to the length of the outline of C 5 opposite to the outline of the emitter. However, the length of the outline of C 5 opposite to the outline of C 6 is larger than the length of the outline of C 7 opposite to the outline of C 6 .
In standby mode, electrical carriers are emitted by collector C 6 and injected into collectors C 5 and C 7 . As the opposite outline lengths between collectors C 5 /C 6 and collectors C 7 /C 6 are different, the current created in collector C 5 is higher than the current created in collector C 7 .
FIG. 5 is an equivalent circuit of the differential amplifier 3 implemented with transistors T 5 , T 6 and T 7 realized as described previously in relation to FIG. 4 . In fact, two transistors T 9 and T 10 are added to the differential amplifier 3 . The collector of transistor T 8 is connected to the base of transistors T 9 and T 10 . The emitters of transistors T 9 and T 10 are connected to the collector of transistor T 6 . The sizes of transistors T 9 and T 10 are different, T 9 being larger than T 10 . The collector of transistor T 9 is connected to the collector of transistor T 3 . The collector of transistor T 10 is connected to the collector of transistor T 4 .
During normal operation, transistor T 6 is not saturated and the voltage of its collector is lower than the voltage of its base. Thus, the transistors T 9 and T 10 are off.
In standby mode, the collector voltage of transistor T 6 is higher than its base voltage. The transistors T 9 and T 10 are on. As transistor T 9 is larger than transistor T 10 , the current provided to transistor T 3 is higher than the current provided to transistor T 4 . Thus, the control signal c is low and the power consumption is minimal. According to another embodiment of a scanning circuit according to the invention, the pair of transistors T 1 /T 2 and either the pair of transistors T 3 /T 4 and/or the pair of transistors T 5 /T 7 and/or the resistors R 1 /R 2 are unbalanced. The differential amplifier 3 is such that when transistors T 1 and T 2 are off the control signal c is low. Transistor T 4 is then larger than transistor T 3 or/and transistor T 5 is larger than transistor T 7 or/and resistor R 1 is larger than resistor R 2 . To compensate the unbalanced pairs (T 4 /T 3 , T 5 /T 7 , R 1 /R 2 ) during normal operation, transistor T 2 is larger than transistor T 1 .
Having thus described three illustrative embodiments of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The invention is limited only as defined in the following claims and the equivalent thereto. | The invention concerns a scanning circuit, comprising a power supply providing a negative voltage on a first terminal (Tdown), an intermediate voltage on a second terminal (Gnd) and a positive voltage on a terminal of a switch (S), the other terminal of the switch being connected to a third terminal (Tup), a control circuit ( 6 ) supplied by connections to the second and third terminals, a differential amplifier receiving a positive and a negative input signal provided by the control circuit, a power amplifier controlled by the differential amplifier, both amplifiers being supplied by connections to the first and third terminals, a deflection coil (Ly) connected between the output of the power amplifier and the second terminal, biasing means setting, when the switch is open, the output of the differential amplifier so that the possible current paths through the power amplifier between the deflection coil and the first terminal are cut. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to building construction, and more particularly, to the use of thin subsurface wallboard panels to form a shear wall structure.
BACKGROUND OF THE INVENTION
[0002] Building codes today require that certain walls or, more commonly, sections of walls, of wood or steel framed houses or buildings, be formed to resist lateral (shear) loads due to anticipated seismic or wind conditions. Typically, ⅜″ to ⅝″ plywood sheets have been installed on the interior or exterior side of the framing studs to accept such lateral loads. It is common practice to install ½″ inch to ⅝″ thick wallboard panels (“drywall panels”), such as gypsum wallboards, on the interior sides of the framing studs and a ¾″ plaster (stucco) finish or other suitable material (with a water barrier) on the exterior side of the framing studs. Such interior and exterior finishing materials are typically installed over any plywood panels providing the lateral load resisting capacity. It is customary to install the plywood panels across an entire wall, requiring shear load resisting capacity, whether the plywood panels are located on the inside or outside of the framing studs, even when not needed in certain areas of the wall to avoid a drastic change in wall thickness.
[0003] For example, the interface between a ½″ drywall panel overlying a ½″ plywood panel and an adjacent sheet of ½″ or even a ⅝″ drywall panel would require considerable furring. By the same token, ½″ plywood paneling covering only a portion of an exterior framed wall would result in reducing the thickness of a typical exterior ⅞″ plaster finish by ½″. Such a thin layer of plaster is undesirable in that it will crack or break.
[0004] This current use of plywood to form a shear wall is wasteful of a limited natural resource. In addition, when subjected to reverse cyclical lateral forces (now required by the Uniform Building Code for shear wall structures) the openings in the plywood through which the fasteners (nails or screws) are placed tend to enlarge thereby tending to reduce the lateral load resisting capacity. In addition, plywood sheets are normally available in 4′ width and 8′, 9′ or 10′ lengths. An interior or exterior shear wall often requires a panel length that falls between such standard lengths, resulting in scrap end pieces.
[0005] As an alternative to using plywood sheets, steel straps have been installed in an “x” configuration to the wall framing studs, i.e., cross bracing, to provide shear resisting capacity. The interior drywall or exterior finishing material is then attached over the steel straps. Such straps generally require special plate brackets and are difficult to install without resulting in a sagging or loose fit. While the steel straps need only be employed in desired locations along a frame wall, if employed on the interior sides of the studs, there may be undesirable bumps or bulges in the inner wall surface. Further, such a wall structure is labor intensive to construct and requires higher design loads as specified by the building codes.
[0006] One solution to the above problem is disclosed in U.S. Pat. No. 5,768,841 (“'841 patent”) which issued to two of the co-inventors of this application. The '841 patent describes a composite wall board panel in which a thin sheet of high strength material, such as steel, is bonded to a wallboard panel made, for example, of gypsum. The overall thickness of the laminated panel, marketed as SURE-BOARD®Series 200 under the patent, is ½″ or ⅝″. SURE-BOARD is a trademark of Swartz and Kulpa Engineering. The 200 panel provides adequate lateral load protection for a section of a wall and eliminates a change in wall thickness when abutting a conventional drywall panel. While the 200 panel may be installed on steel studs as well as wood studs it is more readily attached with drywall screws which have a bugle head allowing the top surface of the screw to be set flush with the surface of the installed panel, therefore accommodating conventional taping.
[0007] Screws adapted to penetrate the steel sheet are generally hardened and when used to fasten the panels to wood studs may tend to break at the wood/steel sheet interface, e.g., by fatigue, when exposed to repeated shear forces thereby degrading the shear load protection. Such breakage may not be apparent without a partial destruction of the wall. In addition, the 200 panels are designed primarily for interior installation.
[0008] We have found an improved method of forming a shear wall structure in a stud framed building which is particularly adapted for wood framed structures and capable of forming a shear wall on the interior or exterior side of the framing studs. Our improvement includes the discovery of a novel, thin, subsurface, steel laminated, panel (hereinafter “subsurface shear panel” or “shear panel”), particularly useful in carrying out the method.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, a shear wall structure is formed on at least one building wall or section thereof designed to accommodate anticipated wind or seismic shear loads by initially securing at least one shear panel on the interior or exterior sides of the framing studs (wood or steel) designed to form the shear wall. Generally a plurality of such subsurface panels will be required.
[0010] The subsurface shear panels are formed with a thin steel sheet having a thickness within the range of about 0.015 to 0.060 inches laminated to a substantially rigid non-structural member or sheet with the overall thickness of the subsurface panel not exceeding about ¼″, exclusive, of the steel sheet. Preferably the shear panel thickness is within the range of about 1/16″ to 3/16″ and most preferably about ⅛″, excluding the steel sheet. The nonstructural members may be comprised of a medium density fiber board, plywood or other suitable material which allows the steel sheet to be easily handled and maintains the laminated panel substantially flat when positioned against the studs. While the subsurface shear panels may be secured to the framing stud by any suitable fastening devices, such as screws for steel studs and nails for wood studs, the steel sheet must sit directly against the studs.
[0011] Subsequently, the subsurface shear panels are covered with a conventional interior or exterior finishing material. Conventional wall board panels, e.g., ½″ or ⅝″ drywall may be used to cover interior subsurface shear panels with generally no furring being required. However, where a ½ drywall panels are used it may be desirable to place a thin shim stock such as cardboard on the interior side of the framing stud(s) adjacent the end(s) of the shear panel. A conventional exterior finishing material may be used to cover exterior placed shear panels with no furring or shimming.
[0012] Another aspect of the invention resides in the subsurface shear panel. While the face of the nonstructural member may serve as a building architectural finish, the shear panel is particularly useful as a subsurface panel to be covered by a more conventional interior or exterior finishing material. The combination of the nonstructural member, such as mdf, and the high strength sheet, such as steel, result in a highly water resistant panel. It is to be noted that a thin sheet of high strength material having a strength at least as great as the specified steel sheet can be substituted fro the steel sheet with the overall thickness of the shear panel falling within the above ranges.
[0013] The present invention may best be understood by reference to the following description taken in conjunction with the drawings wherein like members are identified by the same reference numeral.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the shear panel components before assembly thereof;
[0015] FIG. 2 is a partially broken way view of the assembled subsurface shear panel;
[0016] FIG. 3 is a perspective view partially broken away of a subsurface shear panel secured to the interior sides of framing studs to form a shear wall with conventional wall board (drywall) panels secured over the subsurface shear panel;
[0017] FIG. 4 is a broken away view showing one end of a subsurface shear panel nailed on the interior side of a wood framing stud with a conventional drywall panel mounted thereover;
[0018] FIG. 5 is a perspective view, partially broken away, of a subsurface shear panel secured to the exterior sides of framing studs to form a shear wall with conventional exterior cement/plaster placed over the subsurface panels; and
[0019] FIG. 6 is a partially broken away cross-section view of one end of a subsurface shear panel nailed to the exterior sides of the framing studs with a plaster finishing material as illustrated in FIG. 5 or exterior siding extending thereover.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawings, and more particularly to FIGS. 1 and 2 , the subsurface shear panel 10 ( FIG. 2 ) consists of a steel sheet 11 (preferably galvanized) laminated to a thin substantially rigid nonstructural member or sheet 12 via a suitable nonstructural adhesive 14 . The steel sheet 11 has a thickness t s within the range of about 0.015 to 0.060 inches and preferably within the range of about 0.0389″ to 0.0179″. We have found that a 22 gage sheet (i.e., 0.027 inches thick) provides superior shear load protection when installed in accordance with the method to be described. The nonstructural member 12 comprises a medium density fiber board (“mdf”), plywood or other suitable material which allows the steel sheet to be easily handled (including cutting to a desired length) and which maintains the laminated panel 10 substantially flat when positioned against the studs. A steel sheet of conventional wallboard dimensions, by itself, would not only be difficult to handle, but would tend to sag or dip between the framing studs when installed, thereby degrading the shear load protection.
[0021] The thin nonstructural member 12 has a thickness within the range of about 1/16″ to ¼″, preferably within the range of about 1/16″ to 3/16″ and most preferably about ⅛″. The shear panels may be formed in conventional widths and lengths, i.e., 4′ wide and a standard length of 8′, 9′, 10′, or 12′ or alternatively the panels may be formed to a desired length at the factory site where nonstandard interior 8′ ceilings are called for or where panels of a nonstandard length are to be used on the exterior framing studs and the precut panels may be delivered to a construction site. This eliminates a cutting operation, with its attendant scrap.
[0022] The subsurface shear panels 10 may be made by an automated process. The steel, if in a customary coil form, may be flattened and then trimmed to the desired width and length. The nonstructural members may be cut to the desired widths and lengths at the factory and applied with an adhesive. The metal sheet can then be laid on the adhesive side of the precut nonstructural members to provide a completed subsurface shear panel as is illustrated in the enlarged cross sectional view of FIG. 2 .
[0023] Referring now to FIG. 3 , a shear panel is secured to the interior sides of framing studs 16 a, b, c and d via suitable fasteners, i.e., nails or screws, to provide the specified shear resistance. As is illustrated, the shear panels are also secured to the head and bottom plates 18 and 20 . It should be noted that the number of subsurface shear panels required will depend upon a number of factors, such as building height, etc., as determined by the project's structural engineer.
[0024] Once the shear panel or panels have been secured to the studs, conventional drywall panels, e.g., ½″ or ⅝″ thick, are secured directly over the shear panel or panels as is illustrated in FIG. 3 . The use of ⅝″ drywall panels over ⅛″ nominal thickness shear wall panels should not require any furring. Where ½″ drywall is used it may be desirable to place shim stock in the form, for example, of a strip of cardboard on the interior side of the last stud, i.e., 16 e following the end of the subsurface shear wall panel, to reduce or eliminate any noticeable offset in the resulting interior wall. It should be noted that thee are an abundance of interior finishing materials which can be applied over the shear panels, such as gypsum plaster, cementous board and tile, stone veneer, etc.
[0025] FIG. 4 illustrates the end of the shear panel 10 secured to the framing stud 16 d via nails 24 with a drywall sheet 22 secured over the shear panel and fastened to studs 16 d and 16 e via screws (or nails) 26 . As discussed above, a thin strip of shim stock, such as cardboard, may be placed between the drywall sheet and the inner side 16 e ′ of the stud 16 e to provide a more gradual taper between the end of the shear panel and the remainder of the finished wall.
[0026] It should be noted that screws would normally be used to secure the shear panels to metal studs.
[0027] Referring now to FIG. 5 a subsurface shear wall panel 10 is secured to the exterior sides of framing studs 28 a - 28 d via nails 24 ( FIG. 6 ). A suitable water barrier material 30 , metal mesh 32 and plaster (stucco) 34 is then placed over the shear panel and over the remaining framing studs to complete the exterior wall in a conventional manner. It should be noted that while wood framing studs are illustrated in the several figures, the method of forming a shear wall structure is equally applicable to steel framing studs. The use of such shear panels on exterior walls has the beneficial result of maintaining a substantially consistent thickness of a plaster finish without furring. Wood, vinyl or metal siding may be used instead of plaster as the exterior finishing material.
[0028] The above described detailed description of a preferred embodiment describes the best mode contemplated by the inventors for carrying out the present invention at the time this application was filed and is offered by way of example and not by way of limitation. Accordingly, various modifications may be made to the above described preferred embodiment without departing from the scope of the invention. It should be understood that although the invention has been described and shown for a particular embodiment, nevertheless various changes and modifications obvious to a person of ordinary skill in the art to which the invention pertains are deemed to lie within the spirit and scope of the invention as set forth in the following claims. | A shear wall structure is formed on a building wall or section thereof designed to accommodate anticipated wind or seismic shear loads by initially securing one or more subsurface shear panels on the interior or exterior sides of the wood or steel framing studs. Each shear panel consists of a thin steel sheet (0.015″ to 0.060″ thick) laminated to a thin rigid sheet material such as medium density fiberboard ( 1/16″ to ¼″ thick). Subsequently, the shear panels are covered with a conventional interior (e.g., drywall panels) or exterior (e.g., plaster) finishing materials. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional Application 61/329,960 filed on Apr. 30, 2010.
BACKGROUND OF INVENTION
[0002] A variety of subsea control systems are employed for use in controlling subsea wells during, for example, emergency shutdowns. In many applications, the subsea systems may comprise a number of electrical lines that may be used to control a number of valves. During a specific valve operation, an operations engineer may issue a command via a human machine interface from a topside master controller station. The umbilical may be operationally connected to surface sources of power (e.g., electrical and hydraulic) in addition to electronics, communications, and power that may be provided via the topside master control station. For example, control signals may be sent down the umbilical to operate a number of solenoid valves and a subsea control module to actuate a number of directional control valves.
[0003] The umbilical spans the distance necessary to reach the various components of the subsea control systems, which may be located thousands of meters below the sea surface. Thus, the subsea electrical lines and components are difficult to reach while deployed subsea. Accordingly, there remains a need to easily diagnose the integrity of the subsea portions of the umbilical and other electrical lines used to control the various subsea components from the topside master controlled station to ensure the proper operation of, for example, the safety control features of the subsea control system.
SUMMARY OF INVENTION
[0004] In general, in one aspect, the invention relates to a ground fault detection circuit for detecting ground faults in electrical subsea conductor lines, including a first electrical conductor line, a second electrical conductor line, a first ground fault detection line, a second ground fault detection line, a voltage source, a first resistor operatively connected to the voltage source and the first ground fault detection line, a second resistor operatively connected to the voltage source and the second ground fault detection line, and a voltage detection device configured to detect the voltage at an output end of the first resistor to determine the presence of a ground fault in at least one of the first and second conductor lines.
[0005] In general, in one aspect, the invention relates to a ground fault detection system for detecting ground faults in electrical subsea conductor lines including a power supply unit, a ground fault detection circuit, a line enable switching module, and a voltage detection device. One or more embodiments of the ground fault detection system may include a power supply unit that is configured to supply power to the ground fault detection circuit and a subsea load.
[0006] In general, in one aspect, the invention relates to a method for detecting ground faults in electrical subsea conductor lines using a ground fault detection system, the method including operatively connecting a first resistor between a voltage source and a first ground fault detection line in a ground fault detection circuit, operatively connecting a second resistor between the voltage source and a second ground fault detection line the ground fault detection circuit, and detecting a voltage at an output end of the first resistor to determine the presence of a ground fault in at least one of the first and second conductor lines.
[0007] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 illustrates a subsea production well testing system in accordance with one or more embodiments of the invention.
[0009] FIG. 2A is a block diagram of a ground fault detection system in accordance with one or more embodiments of the invention.
[0010] FIGS. 2B-2C are block diagrams of ground fault detection circuits in accordance with one or more embodiments of the invention.
[0011] FIGS. 3A-3B are schematic diagrams of ground fault detection circuits in accordance with one or more embodiments of the invention.
DETAILED DESCRIPTION
[0012] Specific embodiments of the invention will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.
[0013] In the following detailed description of embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
[0014] In general, embodiments of the invention relate to an apparatus and method for detecting ground faults in a subsea control system. More specifically, embodiments of the invention provide an apparatus and method for detecting electrical line shorts to earth ground for electrical lines used to power various subsea well components, for example, test trees and their control systems, tubing hanger running tools, and subsea valves. In accordance with one or more embodiments of the invention, a ground fault detection apparatus may continuously monitor electrical subsea conductor lines for leakage to earth ground so as to provide an indication of a shorted electrical line. Under a ground fault condition, the attempted operation of a shorted electrical line may lead to tool failure and/or damage to sensitive electronics, e.g., the power supply units.
[0015] FIG. 1 illustrates a subsea production well testing system 100 which may be employed to test production characteristics of a well, in accordance with one or more embodiments of the invention. Subsea production well testing system 100 includes a vessel 102 which is positioned on a water surface 104 and a riser 106 which connects vessel 102 to a blowout preventer (“BOP”) stack 108 on seafloor 110 . A well 112 is drilled into seafloor 110 , and a tubing string 114 extends from vessel 102 through BOP stack 108 into well 112 . Tubing string 114 is provided with a bore 116 through which hydrocarbons or other formation fluids can be conducted from well 112 to the surface during production testing of the well.
[0016] Well testing system 100 includes a safety shut-in system 118 which provides automatic shut-in of well 112 when conditions on vessel 102 or in well 112 deviate from preset limits. Safety shut-in system 118 includes a subsea tree 120 (e.g., subsea test tree, “SSTT”), a subsea tree control system 10 , a topside master control station 5 and various subsea safety valves (“SV”) such as valve assembly 124 , and one or more blowout preventer stack rams.
[0017] Umbilical 136 includes conductor lines connecting a topside master control station 5 to subsea tree control system 10 . Furthermore, umbilical 136 is often required to extend to great length, for example 12,500 feet (3,810 m) or more. Umbilical 136 includes one or more conductor lines for transmitting signals from the surface to the subsea control system.
[0018] In the illustrated embodiment, subsea tree control system 10 is a modular unit that includes a subsea electronics module (“SEM”) 12 and a hydraulic valve and manifold pod 14 . Subsea tree control system 10 may include other elements such as hydraulic accumulators, electric power sources and the like. Subsea control system 10 is positioned below water surface 104 and proximate to tree 120 in this embodiment. Umbilical 136 may be operationally connected to surface sources of power (e.g., electrical, hydraulic) in addition to electronics, communications, and power that may be provided via topside master control station 5 . Subsea tree control safety system 10 may be positioned in various positions within riser 106 .
[0019] Ground faults may occur in subsea systems when, for example, any part of an electrical power line operatively connected to a subsea component makes electrical contact (or “shorts”) to any conductive part of the subsea production well testing system, for example, a subsea test tree. As described herein, a “ground fault” is a low impedance electrical path, or connection, to earth ground in one or more places along the electrical power line.
[0020] FIG. 2A is a block diagram of a ground fault detection system in accordance with one or more embodiments of the invention. According to this embodiment, the ground fault detection system 200 includes power supply unit 201 , ground fault detection circuit 203 , line enable relay module 205 , and load 207 . One of ordinary skill will appreciate that many different types of loads may be driven with the ground fault detection system 200 . For illustrative purposes only, load 207 is shown as a solenoid valve in FIG. 2A . In accordance with one or more embodiments, power supply unit 201 may be provided, for example, within a vessel as part of topside master control station as shown in FIG. 1 . Furthermore, fault detection circuit 203 and line enable relay module 205 , may both be provided as part of a subsea tree control safety system, or the like. The particular configuration of the individual components comprising the ground fault detection system 200 are shown as illustrative examples, only. Accordingly, one of ordinary skill will appreciate that any or all of the power supply units 209 and 201 , the fault detection circuit 203 , or the line enable relay module 205 may alternatively be located at any convenient subsea (e.g., at any location within the riser) or topside location without departing from the scope of the present invention.
[0021] Power supply unit 201 may include fault detection circuit power supply 209 and load power supply unit 211 . In accordance with one or more embodiments, load power supply unit 211 may be configured as a current source. Accordingly, load power supply unit 211 includes current source line 221 and current return line 223 . Furthermore, in accordance with one or more embodiments of the invention, fault detection circuit power supply 209 may be configured as a regulated DC power supply that includes ground fault detector lines 225 and 227 . In accordance with one or more embodiments, lines 221 , 223 , 225 , and 227 may be incorporated along with all the other necessary control, power, hydraulic, etc., lines into the umbilical 136 . One of ordinary skill will appreciate that the block diagram of power supply unit 201 , shown in FIG. 2A , is greatly simplified. Accordingly, many other known elements may be included within power supply unit 201 , depending on, for example, the particular type and number of subsea loads being driven, e.g., flapper valves, ball valves, solenoid valves, retainer valves, pipe ram seals, shear ram seals, etc. For example, in certain embodiments, dual polarity power may be required to operate the load, in which case, a polarity relay module may be included. Furthermore, various additional control electronics, such as multiplexors and demultiplexors may be implemented to allow for multiple load control and multiple line ground fault detection.
[0022] Line enable relay module 205 is configured to allow for switching between two configurations, a fault detect configuration and normal configuration (not shown). Under fault detect configuration, electrical subsea conductor lines 237 and 239 may be connected to ground fault detection lines 225 and 227 , respectively. Alternatively, under normal configuration, electrical subsea conductor lines 237 and 239 may be connected to current source line 221 and current return line 223 , respectively. In accordance with one or more embodiments of the invention, the line enable relay module 205 may be configured to default to the fault detect configuration, i.e., fault detect power lines 225 and 227 are wired to the normally closed terminals of their respective relays on the line enable relay module 205 . In accordance with one or more embodiments, the ground fault detection system may be configured to detect ground faults when in an idle state (i.e., when no subsea loads are being powered). One of ordinary skill will appreciate that the electrical subsea conductor lines 237 and 239 may be switched in a variety of ways using any switching device known in the art, e.g., by using solid state switches, mechanical relays, multiplex/demultiplexors, etc.
[0023] While FIG. 2A shows the ground fault detection system in the context of control lines for a solenoid valve, one of ordinary skill will appreciate that without departing from the scope of the present disclosure, the ground fault detection system may be used to detect ground faults in any electrical line, regardless of the specific type of equipment being employed.
[0024] FIG. 2B is a block diagram of a ground fault detection circuit in accordance with one or more embodiments of the invention. Ground fault detection circuit 203 includes resistors 229 and 231 , blocking diodes 233 and 235 , and fault detection nodes 217 and 219 . The values of resistors 229 and 231 are not critical to the operation of fault detection circuit 203 . In accordance with one or more embodiments, resistors 229 and 231 may be within a range of 1-10 kΩ or, alternatively, within a range of 1-20 MΩ. The voltage at fault detection nodes 217 and 219 may be independently monitored with any voltage monitor known in the art. For example, FIG. 2A-2C show the nodes being monitored via a programmable logic controller (“PLC”) digital input card. Preferably, the fault detection circuit 203 is deployed subsea along with the subsea electronics module. Thus, the PLC may also be deployed either subsea or topside. Furthermore, the fault detection circuit 203 may alternatively be deployed topside, in which case the PLC may also be deployed topside. Blocking diodes 233 and 235 are optional and serve to protect fault detection circuit power supply 209 and the voltage monitor.
[0025] During activation (configuration not shown) of the load 207 , load power supply unit 211 is operatively connected to load 207 , through relays 213 and 215 . Thus, under operational configuration, load power supply unit 211 may provide power to load 207 . In accordance with one or more embodiments of the invention, load power supply unit 211 may be configured as a current source that provides a constant current to solenoid valve 207 .
[0026] Under fault detect configuration, as shown in FIG. 2A , fault detection circuit power supply 209 may be electrically connected through relays 213 and 215 to load 207 . If a ground fault is not present anywhere in the circuit beginning at the fault detection circuit power supply 209 and terminating at the load 207 , all points in the circuit will be at the fault detection circuit power supply 209 voltage, or 24V in this example. Thus, any voltage detection devices placed at nodes 217 and 219 may read a voltage equivalent to the fault detection circuit power supply 209 voltage.
[0027] Under the conditions where a ground fault has occurred in one or both of lines 237 and 239 , the voltage at one of, or both, of the nodes 217 and 219 drops to a low value, nearly zero, in this example. The low voltage present at nodes 217 and 219 induced by the ground fault may be detected by any known voltage detection device and the output of the detection device may be used to, for example, inform an operator of the ground fault. Furthermore, the detection of a ground fault may trigger an automated response that initiates an appropriate safety protocol, for example, by diverting control to one or more backup valves and, in addition, by disabling any valves that may be electrically connected to the shorted control line or lines.
[0028] FIG. 2C shows a block diagram of a fault detection circuit in accordance with one or more embodiments of the invention. In FIG. 2C , FETs 241 and 243 are included to increase the reliability of the voltage detection made at the nodes 217 and 219 . The FETs 241 and 243 are configured in such a way as to have their respective gate terminals connected to nodes 217 and 219 , thereby isolating any voltage detection devices from the rest of the fault detection circuit through the high impedance gate-to-source path. In accordance with one or more embodiments, FETs 241 and 243 are P-channel MOSFETs, but other types of transistors may be used, for example, N-channel MOSFETs or bipolar junction transistors. Accordingly, under normal operating conditions (i.e., no ground fault present, 24V at nodes 217 and 219 ), the voltage measured by a voltage detection device (e.g., a PLC digital input card) at the FET drain terminals is in a low state. In the event of a ground fault, the voltage measured at the FET drain terminals will be in a high state.
[0029] While FIGS. 2B-2C show block diagrams of ground fault detection circuits that monitor only one set of electrical subsea conductor lines, the ground fault detection system disclosed herein need not be so limited. For example, using the same operational principles outlined about, the ground fault detection system may be extended to multi-component/multi-control line systems. FIGS. 3A and 3B show examples of a multi-line fault detection circuits, corresponding to FIGS. 2B and 2C , respectively, in accordance with one or more embodiments of the invention. FIGS. 3A-3B show examples of ground fault detection circuits with seven sub-units configured in a parallel configuration. Each sub-unit of the multi-component fault detection circuits shown in FIGS. 3A-3B operates in a substantially similar way to that described above for the single component examples.
[0030] FIG. 3A shows a multiple sub-unit parallel combination ground fault detection circuit with a sub-unit design that corresponds to that shown in FIG. 2B . Specifically, fault detection circuit power supply 309 corresponds to fault detection circuit power supply 209 and provides power to ground fault detection lines 325 a - 325 g . Likewise, outputs 337 a - 337 g may be connected to a number of corresponding electrical subsea conductor lines via, for example, a multichannel line enable relay module (not shown). In accordance with one or more embodiments, outputs 339 a - 339 g may be connected to the input channels of a multichannel voltage detection device, as described with reference to FIGS. 2A-2C (e.g., a PLC digital input card).
[0031] FIG. 3B shows a multiple sub-unit parallel combination ground fault detection circuit with a sub-unit design that corresponds to that shown in FIG. 2C . Specifically, fault detection circuit power supply 309 corresponds to fault detection circuit power supply 209 and provides power to ground fault detection lines 325 a - 325 g . Likewise, outputs 337 a - 337 g may be connected to a number of corresponding electrical subsea conductor lines via, for example, a multichannel line enable relay module (not shown). In accordance with one or more embodiments, outputs 339 a - 339 g may be connected to the input channels of a multichannel voltage detection device, as described with reference to FIGS. 2A-2C (e.g., a PLC digital input card). P-channel MOSFETS 341 a - 341 g may be used to increase the input impedance to the voltage detection device, as described above with reference to FIG. 2C . In addition, by incorporating two resistors into ground fault detection lines 325 a - 325 g , as shown, the gate voltage to the P-channel MOSFET may be set appropriately. Optionally, for increased reliability, Zener diodes may be wired from gate to source to protect P-channel MOSFETS 341 a - 341 g from high transient voltage spikes (e.g., from electrostatic discharge, or inductive kick back from a switching solenoid valve). One of ordinary skill will appreciate that many different types of transistors and resistors may be used without departing from the scope of the present disclosure. In addition, the appropriate choice of resistance values for the resistors depends on many factors, including but not limited to, the type of transistor used and value of DC voltage provided by the fault detection circuit power supply 309 .
[0032] Additional circuitry may be implemented in conjunction with the circuits shown in FIGS. 3A-3B . For example, corresponding multiplexing circuitry and/or multi-channel line enable relay modules may allow for the system to monitor several different sets of subsea conductor lines for driving a number of loads. One of ordinary skill will appreciate that, with the appropriate choice of power supply unit, and monitoring equipment, any number of lines may be monitored without departing from the scope of the present disclosure. Furthermore, as with FIGS. 2B-2C , blocking diodes in line with ground fault detection lines 325 a - 325 g are optional and serve to protect the ground fault detection circuit power supply and PLC digital input card.
[0033] 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 ground fault detection circuit for detecting ground faults in electrical subsea conductor lines including a first electrical conductor line, a second electrical conductor line, a first ground fault detection line, and a second ground fault detection line. The ground fault detection circuit further includes a first resistor operatively connected to a voltage source and the first ground fault detection line, a second resistor operatively connected to the voltage source and the second ground fault detection line, and a voltage detection device configured to detect the voltage at an output end of the first resistor to determine the presence of a ground fault in at least one of the first and second conductor lines. | 6 |
[0001] This application is a continuation of U.S. patent application Ser. No. 13/160,579, filed Jun. 15, 2011, which is a continuation of U.S. patent application Ser. No. 11/850,585, filed Dec. 5, 2007 which issued to U.S. Pat. No. 8,005,368 on Aug. 23, 2011 the entire contents of both applications are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to high-speed optical communications networks, and in particular to a signal equalizer in a coherent optical receiver.
BACKGROUND OF THE INVENTION
[0003] Optical signals received through conventional optical links are typically distorted by significant amounts of chromatic dispersion (CD) and polarization dependent impairments such as Polarization Mode Dispersion (PMD), polarization angle changes and polarization dependent loss (PDL). Chromatic dispersion (CD) on the order of 30,000 ps/nm, and polarisation rotation transients at rates of 10 6 Hz are commonly encountered. Various methods and systems intended to address some of these limitations are known in the art.
[0004] FIG. 1 schematically illustrates a representative coherent optical receiver capable of implementing the methods of Applicant's U.S. Pat. No. 7,555,227 issued Jun. 30, 2009 and entitled “Polarization Compensation In A Coherent Optical Receiver”; U.S. Pat. No. 7,606,498 issued Oct. 20. 2009 and entitled “Carrier Recovery in A Coherent Optical Receiver”; and U.S. Pat. No. 7,635,525 issued Dec. 22, 2009 and entitled “Signal Acquisition in A Coherent Optical Receiver”, the content, of ail of which are hereby incorporated herein by reference.
[0005] As may be seen in FIG. 1 , an inbound optical signal is received through an optical link 2 , split into orthogonal received polarizations by a Polarization Beam Splitter 4 , and then mixed with a Local Oscillator (LO) signal 8 by a conventional 90° optical hybrid 8 . The composite optical signals emerging from the optical hybrid 8 are supplied to respective photodetectors 10 , which generate corresponding analog electrical signals. The photodetector signals are sampled by respective Analog-to-Digital (A/D) converters 12 to yield raw multi-bit digital signals I X , Q X and I Y , Q Y corresponding to in-phase (I) and Quadrature (Q) components of each of the received polarizations.
[0006] Preferably, the raw multi-bit digital signals have resolution of n=5 or 6 bits which has been found to provides satisfactory performance at an acceptable cost. In the above-noted U.S. patent applications: the sample rate of the A/D converters 12 is selected to satisfy the Nyquist criterion for the highest anticipated symbol rate of the received optical signal. Thus, for example, in the case of an optical network link 2 having a line rate of 10 GBaud, the sample rate of the A/D converters 12 will he approximately 20 GHz.
[0007] From the A/D converter 12 block, the respective n-bit signals I X , Q X and I Y , Q Y of each received polarization are supplied to s respective dispersion compensator 14 , which operates on the raw digital signals to at least partially compensate chromatic dispersion of the received optical signal. The dispersion compensators 14 may be configured to operate as described in Applicant's co-pending U.S. patent application Ser. No. 11/550.042 filed Oct. 17, 2006, and summarized below with reference to FIGS. 2 a and 2 b.
[0008] As may he seen in FIG. 2 a ; each dispersion compensator (CD-COMP) 14 is provided as a high speed digital signal processor (or, equivalently, either an Application Specific Integrated Circuit, ASIC, or a Field Programmable Gate Array, FPGA) which is capable of implementing a variety of processing functions in the illustrated embodiment, two substantially identical CD-COMPs 14 are provided, each of which is connected to receive and process raw in-phase and Quadrature digital signals of a respective received polarization. For simplicity only the X-polarization CD-COMP 14 , is illustrated in FIG. 2 a , if being understood that the Y-polarization CD-COMP 14 y will be substantially identical.
[0009] In the embodiment of FIG. 2 a , the CO-COMP 14 generally comprises a pipelined series of functional blocks, including a deserializer 24 , a Fast Fourier Transform (FFT) filter 26 , a frequency domain processor (FDP) 28 and an Inverse Fast Fourier Transform (IFFT) filter 30 .
[0010] The deserializer 24 operates to accumulate successive n-bit words of the in-phase and Quadrature digital signals I X and Q X from the X-polarization A/D converters 12 IX and 12 QX during a predetermined clock period. The accumulated n-bit words are then latched into the FFT 28 as a parallel input vector {r 1 X +jr Q X }. Preferably, each of the real and imaginary components of the parallel vector {r 1 X +jr Q X } have the same resolution (n=5 or 6 hits, for example) as the raw digital signals. In general, the width (m), in words, of the input vector {r 1 X +jr Q X } is selected to be half the width (M) of the FFT 26 . In some embodiments, the FFT 26 has a width of M=256 taps, which implies an input vector width of m=128 complex values. However, a different FFT width may be selected, as desired, in practice, the FFT width is selected based on a compromise between circuit size and the amount of dispersion compensation desired.
[0011] The input vector {r 1 X +jr Q X } is augmented with a null vector {0, 0, 0, . . . 0} 32 which provides a zero data fill to the remaining input taps of the FFT 26 .
[0012] The FFT filter 26 performs a conventional FFT operation to generate an array {R A X } representing the frequency domain spectrum of the input vector {r 1 X +jr Q X }. The FDP 28 can then implement any of a variety of frequency domain processing functions, as will be described in greater detail below, to yield a modified array {V A X }, which is supplied to the IFFT filter 30 .
[0013] The IFFT filter 30 performs a conventional Inverse Fast Fourier Transform operation to yield time domain data 34 . In the form of a complex valued vector having a width equal to the IFFT 30 , which. In the illustrated embodiment is M taps. In the embodiment of FIG. 2 a , the IFFT output data 34 is divided Into two blocks and {V Q X }, of which {v 1 X } is delayed by one clock cycle (at 36 ) and added to {v Q X } (at 38 ) to yield the CD-COMP output 16 in the form of a complex valued vector {v 1 X +jv Q X } encompassing m(=128) complex values.
[0014] In the system of FIGS. 2 a and 2 b , the FDP 28 Implements a transpose-and-add function, along with dispersion compensation. In general, the transpose-and-add function operates to add the FFT output vector {R A X } to a transposed version of itself with respective different compensation vectors, implementing the transpose-and-add operation between the complex FFT and IFFT filters has the effect of emulating a pair of parallel real-FFT and IFFT functions through the CD-COMP 14 , without requiring the additional circuits needed for parallel real FFT and IFFT filters. The transpose-and-add function can foe conveniently implemented in hardware, by providing a pair of parallel paths between the FFT output and a vector addition block 40 . One of these paths may be referred to as a direct path 42 , in which the tap-order of the FFT output {R A X } Is retained. The other path, which may be referred to as a transpose path 44 , includes a transposition block 46 which operates to reverse the tap-order of the FFT output upstream of the vector addition block 40 . In this respect, it will be recognised that the transposition block 48 can be readily Implemented in hardware, which provides an advantage in that the transposition step does not incur a significant propagation delay penalty.
[0015] Preferably, the direct and transpose paths 42 and 44 are provided with a respective multiplication block 48 , which enables various filter functions to be implemented by the FDP 28 . For example, in the embodiment of FIG. 2 b , a pair of compensation vectors {C 0 X } and {C T X } 50 are applied to the direct and transpose paths, 42 and 44 respectively. Each of the compensation vectors {C Q X } and {C T X } is composed of a respective set of coefficients which are calculated to apply a desired function, in the frequency-domain, to the digital signals. For example, {C Q X } and {C T X } may be calculated to apply a first-order dispersive function to at least partially compensate chromatic dispersion of the optical link. {C Q X } and {C T X } may also incorporate a transform of a differential delay function, so as to compensate residual sample phase errors In the I and Q digital signals. When both of these functions are implemented by the compensation vectors {C Q X } and {C T X }, the CD-COMP output 16 will represent a dispersion-compensated and phase-error corrected version of the raw I X and O X digital Signals received from the A/D converters 12 .
[0016] Returning to FIG. 1 , the dispersion-compensated digital signals 16 appearing at the output of the dispersion compensators 14 are then supplied to a polarisation compensator 18 which operates to compensate polarization effects, and thereby de-convolve transmitted symbols from the complex signals 16 output from the dispersion compensators 14 . If desired, the polarization compensator 18 may operate as described in Applicant's U.S. Pat. No. 7,565,227 issued Jun. 30, 2009 and U.S. Pat. No. 7,806,498 issued Oct. 20, 2009. The output of the polarization compensator 18 is a pair of multi-bit estimates X′(n) and Y′(n), 20 of the symbols encoded on each transmitted polarization. The symbol estimates X′(n), Y′(n) appearing at the output of the polarization compensator 18 are then supplied to a carrier recovery block 22 for LO frequency control, symbol detection and data recovery, such as described in Applicant's U.S. Pat. No. 7,806,498 issued Oct. 20, 2009.
[0017] In the above described system, the dispersion compensators 14 operates across a large number of successive samples (e.g. 126 samples), which permits compensation of relatively severe chromatic dispersion, but at a cost of a relatively slow response to changing dispersion. This slow response is acceptable, because of the known slow rate of change of dispersion in real-world optical links. The polarization compensator 18 , in contrast, is comparatively very narrow (e.g. on the order of about 5 samples), to enable a rapid update frequency, which is necessary to track observed high-speed polarisation transients.
[0018] The above-described system provides reliable signal acquisition, compensation of dispersion and polarization effects, carrier recovery and data recovery even in the presence of moderate-to-severe optical impairments. This, in turn, enables the deployment of a coherent optical receiver in real-world optical networks, with highly attractive signal reach and line rate characteristics. For example, a receiver implementing the above methods has demonstrated a signal reach of 1500 km at a line rate of 10 Gbaud (i.e. 10 9 symbols/second). It is noteworthy that this performance has been measured with real-time continuous processing, not just burst data acquisition followed by off-line processing or simulation The system described above with reference to FIGS. 1 and 2 is the only coherent optical receiver known to the applicants to have achieved such real-time performance.
[0019] With increasing demand for link band-width. It would be desirable to increase the line rate beyond 10 Gbaud. For example, lines rates of 35 GBaud and higher have been proposed. However, as the symbol rate is increased, the amount of distortion compensation that is required in order to obtain the same signal reach also increases. For example, the required amount of dispersion compensation increases proportional to the square of the symbol rate, while the required amount of compensation for polarization effects increases proportional to the symbol rate. These increases in distortion compensation can be met, using the system described above, but at a cost of increased size and/or complexity of the dispersion and polarization compensation blocks.
[0020] At the same time, increasing the line rate also necessitates an increase In the sample rate of the A/D converters and downstream digital circuits, in order to maintain Nyquist sampling,
[0021] It will be appreciated that both increased circuit size and increased sample rate imply that the power consumption of the receiver must necessarily also increase, as will the heat generated by the circuits during run-time. This can Impose an effective “thermal barrier” to increasing the line rate, as higher temperatures degrade system reliability.
[0022] Accordingly, methods and techniques that enable reliable operation of a coherent optical receiver at line rates above 10 Gbaud are highly desirable.
SUMMARY OF THE INVENTION
[0023] The present invention addresses the above-noted problems by providing a signal equalizer capable of compensating both dispersion and polarization, but which Is nevertheless agile enough to track high-speed polarization transients.
[0024] Thus, an aspect of the present invention provides a signal equalizer for compensating impairments of an optical signal received through a link of a high speed optical communications network. At least one set of compensation vectors are computed for compensating at least two distinct types of impairments. A frequency domain processor is coupled to receive respective raw multi-bit in-phase (I) and quadrature (Q) sample streams of each received polarization of the optical signal. The frequency domain processor operates to digitally process the multi-bit sample streams, using the compensation vectors, to generate multi-bit estimates of symbols modulated onto each transmitted polarization of the optical signal. The frequency domain processor exhibits respective different responses to each one of the at least two distinct types of impairments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
[0026] FIG. 1 is a block diagram schematically illustrating principal elements and operations of a coherent optical receiver known from Applicant's U.S. Pat. Nos. 7,556,227: 7,827,252; 7,532,322: 7,806,498; and 7,635,525;
[0027] FIGS. 2 a and 2 b are a block diagram schematically illustrating principal elements and operations of the dispersion compensation block of FIG. 1 , known from Applicant's U.S. Pat. No. 7,894,728:
[0028] FIG. 3 Is a block diagram schematically illustrating principal elements and operations of a coherent optical receiver in accordance with an embodiment of the present invention:
[0029] FIG. 4 is a block diagram schematically illustrating principal elements and operations of the equalizer of FIG. 3 ;
[0030] FIGS. 5 a and 5 b illustrate representative LMS loops for computing polarization compensation vectors in accordance with a first embodiment of the present invention;
[0031] FIG. 6 illustrates a representative LMS loop for computing polarization compensation vectors in accordance with a second embodiment of the present invention; and
[0032] FIGS. 7 a and 7 b Illustrate representative frequency domain filters usable in the LMS loop of FIG. 8 .
[0033] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention provides an agile signal equalizer for compensating dispersion and polarization impairments in a coherent optical receiver of a high speed optical network. Embodiments of the present invention are described below, by way of example only, with reference to FIGS. 3-7 .
[0035] FIG. 3 illustrates principle elements of a coherent optical receiver which incorporates an agile signal equalizer 52 in accordance with the present invention. As may be seen in FIG. 3 , the agile signal equalizer 52 combines the functionality of the dispersion compensation and polarization compensation blocks 14 and 18 of the system of FIG. 1 Thus, the agile signal equalizer 52 is capable of correcting timing errors between I and Q sample streams of each received polarization, compensating moderate to severe chromatic dispersion, and compensating polarization effects to thereby de-convolve symbols modulated onto each of the transmitted polarizations from the received signals.
[0036] As described in Applicant's U.S. Pat. No. 7,555,227 issued Jun. 30, 2009, separating the dispersion and polarization compensation blocks, in the manner described above in respect of FIGS. 1 and 2 , has the advantage of enabling different compensation response times for each compensation block. Thus, the dispersion compensation block 14 is very wide to enable compensation of moderate to severe dispersion, and the associated slow response (for recalculating the compensation coefficients C X and C Y ) is acceptable because dispersion is typically a slowly changing phenomenon. Conversely, the polarization compensation block 18 is, by comparison, very narrow, to facilitate a rapid response to polarization rotation transients. Combining both dispersion and polarization compensation into a common equaliser would be beneficial because it reduces the total number of gates required by the compensation circuitry, thereby reducing power consumption and associated heat dissipation problems. However; these potential advantages come at a cost of reductions in either or both of dispersion compensation performance and responsiveness to polarization transients.
[0037] The present invention overcomes this difficulty by providing an agile signal equalizer 52 which has sufficient width to enable compensation of moderate-to-severe dispersion. A high-speed Least Mean Squares (LMS) update block 54 provides recalculation of compensation coefficients at a sufficiently high speed to enable tracking of polarization transients. A representative coherent optical receiver incorporating the signal equalizer is described below with reference to FIG. 3 . A representative embodiment of the signal equalizer 52 is illustrated in FIG. 4 . Representative embodiments of the LMS update block 54 are described below with reference to FIGS. 5-7 .
[0038] As may be seen in FIG. 3 , a coherent optical receiver incorporating the signal equalizer 52 of the present invention generally comprises a Polarization Beam Splitter 4 ; 90° optical hybrid 8 ; photodetectors 10 ; and A/D converters 12 , all of which may operate as described above With reference to FIG. 1 . The raw digital sample streams I X , Q X , and I Y , Q Y generated by the A/D converters 12 are then supplied to the signal equalizer 52 . If desired, timing control methods described in Applicant's co-pending U.S. patent application Ser. No. 11/550,042 filed Oct. 17, 2008, including the use of elastic stores (not shown in FIG. 3 ) between the A/D converters 12 and the equalizer 52 may be used to ensure at least coarse phase alignment between samples at the equalizer input.
[0039] In general, the equalizer 52 operates to compensate chromatic dispersion and polarization rotation impairments. Consequently, the compensated signals 20 output from the equalizer 52 represent multi-bit estimates X′(n) and Y′(n) of the symbols encoded on each transmitted polarization of the received optical signal. The symbol estimates 20 X′(n), Y′(n), are supplied to a carrier recovery block 22 for LO frequency control, symbol detection and data recovery, such as described in Applicants U.S. Pat. No. 7,806,498 issued Oct. 20, 2009.
[0040] In the embodiment of FIG. 4 , the equalizer 52 generally follows the construction of the dispersion compensators 14 described above with reference to FIGS. 1 and 2 . Thus, the raw digital sample streams I X , Q X , and I Y , Q Y generated by the A/D converters 12 are deserialized (at 24 ) and the resulting m-word Input vectors {r 1 X +jr Q X } and {r 1 Y +jr Q Y } latched into /the respective X- and Y-polarization FFT blocks 28 . The arrays {R A X } and {R A Y } output by the FFT blocks 28 are then supplied to a Frequency Domain Processor (FDP) 56 , as will be described below.
[0041] The modified arrays {V A X } and {V A Y } output by the FDP 56 are supplied to respective IFFT blocks 30 , and the resulting lime domain data 34 processed using respective overlap-and-add as described above with reference to FIG. 2 a , to yield the equalizer output 20 in the form of complex valued vectors {v 1 x +jv Q x } and {v 1 Y +jv Q Y }, each of which encompasses m complex valued estimates X′(n) and Y′(n) of the transmitted symbols.
[0042] In the embodiment of FIG. 4 , the FDP 58 comprises a respective transpose-and-add functional block 58 for each polarization, and a cross-compensation block. The transpose-and-add block 58 operates in generally the same manner as described above with reference to FIG. 2 b . Thus, the X-polarization transpose-and-add block 58 x operates to add the FFT output array {R A X } to a transposed version of itself { R Y A }, with respective different compensation vectors {C 0 x } and {C T X }, to yield intermediate array ΔT A X }. As described above, compensation vectors {C 0 X } and {C T X } can be computed to at least partially compensate chromatic dispersion of the optical link and/or to compensate residual sample phase errors in the raw digital signals generated by the A/D converters 12 . Of course, the Y-polarization transpose-and-add block 58 x will operate in an exactly analogous manner.
[0043] The cross-compensation block 80 applies X-polarization vectors H XX , H XY to the X-polarization intermediate array {T A x }, and Y-polarization vectors H YY , H YX to the Y-polarization intermediate array {T A Y }. The multiplication results are then added together to generate modified vectors {V A X } and ΔV A Y }: as may be seen in FIG. 4 The X- and Y-polarization vectors H XX , H XY . H YY and H YX are preferably computed using a transform of the total distortion at the output of the equalizer 52 , as will be described In greater detail below. At a minimum, the X- and Y-polarization vectors H XX , H XY , H YY and H YX impose a phase rotation which compensates polarization impairments of the optical signal, and so de-convolve the transmitted symbols from the raw digital sample streams I X , G X , and I Y , Q Y generated by the A/D converters 12 . Those of ordinary skill in the art will recognise that the illustrated cross-compensation block 60 implements an inverse-Jones matrix transfer function, which compensates the polarization effects, in this formulation, the vectors H XX , H XY , H YY and H YX are provided as the coefficients of the inverse-Jones matrix. The width of the inverse-Jones matrix is equal to that of the intermediate arrays {T A X } and {T A Y } and so is based on the expected maximum dispersion of the received optical signal to be compensated by the equalizer 52 .
[0044] Preferably, the X- and Y-polarization vectors H XX , H XY , H YY and H YX are computed at sufficient speed to enable tracking, and thus compensation, of high-speed polarization rotation transients. This may be accomplished using the Least Mean Squares (LMS) update loop illustrated in FIG. 4 , and described in greater detail below with reference to FIGS. 5 and 6 .
[0045] FIG. 5 a shows an LMS update loop, according to one embodiment of the Invention, for calculating polarization vectors H XX and H YX . A directly analogous LMS loop for calculating the polarization vectors H XY and H YY is shown in FIG. 5 b , in the embodiment of FIGS. 5 a and 5 b , the carrier recovery block 22 operates as described in Applicant's U.S. Pat. No. 7,808,498 issued Oct. 20, 2009. Thus, the carrier recovery block 22 is divided into two parallel processing paths 80 (only the X-polarization path 60 x is shown in FIG, 5 a , and the Y-polarization path 60 y is shown in FIG. 5 b ),each of which includes a decision circuit 62 and a carrier recovery loop comprising a carrier phase detector 64 and a phase rotator 68 . In general, the phase rotators 68 use a carrier phase estimate generated by the respective carrier phase detector 64 to compute and apply a phase rotation K(n) to the symbol estimates X′(n) and Y′(n) received from the signal equalizer 52 . The decision circuits 62 use the phase-rotated symbol estimates X′(n)e −jk(n) and Y′(n)e −jk(n) to generate recovered symbol values X(n) and Y(n), and the phase detectors 84 operate to detect respective phase errors Δφ between the rotated symbol estimates X′(n)e −jk(n) and Y′(n)e −jk(n) and the corresponding recovered symbol values X(n) and Y(n),
[0046] Referring to FIG, 5 a , the H XX LMS update loop receives the phase error Δφ X (n) of each successive symbol estimate X′(n), which is calculated by the phase detector 64 as described in Applicant's U.S. Pat. No. 7,808,498 issued Oct. 20, 2009. In addition, the rotated symbol estimate X′(n)e −jk(n) and its corresponding decision value X(n) are also received from the earner recovery block 22 , and compared (at 88 ) to obtain a complex symbol error value e x ; which is indicative of residual distortion of the symbol estimate X′(n). In some embodiments it is desirable to format the optical signal into data bursts comprising a plurality of data symbols separated by a SYNC burst having a known symbol sequence. In such cases, a selector can be used to supply a selected one of the decision values X(n) and the known SYNC symbols to the comparator 68 . With this arrangement, the selector can be controlled to supply the known SYNC symbol sequence to the comparator during each SYNC burst, so that the error value e x is computed using the known SYNC symbols rather than the (possibly erroneous) decision values X(n).
[0047] In order minimize calculation complexity through the LMS update loop, the resolution of the complex symbol error e x is preferably lower than that of the symbol estimate X′(n). For example, in an embodiment in which the symbol estimate X′(n) has a resolution of 7 bits for each of the real and imaginary parts (denoted herein as “7+7 bits”), the complex symbol error e x may have a resolution of, for example, 3+3 bits. It will be noted, however, that the present invention Is not limited to these resolution values.
[0048] The phase error Δφ X (n) is processed, for example using a Look-up-Table (LUT) 70 , to generate a corresponding complex value φ X having a unit amplitude arid the same phase as Δφ X (n) with a desired resolution (e.g. 3+3 bits) matching that of the symbol error e X . This allows the phase error φ X and symbol error e X to be multiplied together (at 72 ) to obtain a complex vector d x indicative of the total residual distortion of the symbol estimate X′(n).
[0049] Applicant's U.S. Pat. No. 7,835,525 issued Dec. 22, 2009 describes methods and systems for signal acquisition in a coherent optical receiver. As described in U.S. Pat. No. 7,635,525, during a start-up operation of the receiver (or during recovery from a “loss-of frame” condition), LO frequency control, clock recovery, dispersion compensation and polarization compensation loops implement venous methods to acquire signal, and stabilize to steady-state operation. During this “acquisitions period”, the rotated symbol estimates X′(n)e −jk(n) and their corresponding decision values X(n) are probably erroneous. Accordingly, in the embodiment illustrated in FIGS. 5 a and 5 b , a window select line may be used to zero out those values of the distortion vector d x which are computed from non-sync symbols, Values of the distortion vector d X , which are computed from the known SYNC symbols are likely to be valid, even during signal acquisition, and thus are left unchanged.
[0050] In the illustrated embodiments, values of the distortion vector d x are generated at the symbol timing, in the case of Nyquist sampling, this is half the sample rate of the raw digital sample streams I X , Q X , and I Y , Q Y generated by the A/D converters 12 , and it is therefore necessary to adjust the timing of the error values d x to match the sample timing. In the case of T/2 sampling (that is, the sample period is one/half the symbol period T, which satisfies the Nyquist criterion), retiming of the error values d x can be accomplished by inserting one zero between each successive error value, if desired, Interpolation or other filtering can be performed upon the retimed stream of error values to enhance the loop stability and performance.
[0051] The resulting T/2 sampled symbol distortion vector is then input to a Fast Fourier Transform (FFT) block 74 , which calculates the frequency domain spectrum of the symbol distortion vector d x .
[0052] Preferably, the width of the FFT block 74 corresponds with that of the intermediate array {T A X }. With this arrangement, each value of the intermediate array {T A X } can be truncated at 76 to match the resolution of the FFT block output (e,g. 3+3 bits), and then a conjugate of the truncated array multiplied with the FFT output army (at 78 ), to compute a low-resolution correlation between {T A X } and the FFT output This correlation vector Is then scaled (at 80 ) to obtain an update vector {u xx }, which is accumulated (at 82 ) to obtain a vector representation of the total distortion of the Intermediate array {T A X }. Truncating the total distortion vector, for example by taking the 7+7 most significant bits, yields the cross-compensation vector H XX .
[0053] As noted above, directly analogous methods can be used to compute each of the other cross-compensation vectors H XY , H YY and H YX , which are therefore not described herein in detail,
[0054] In embodiments in which the compensation vectors {C 0 X }, {C T X }, {C 0 Y } and {C T Y } are computed to compensate only, residual sample phase errors in the raw digital sample streams I X , Q X , and I Y , Q Y , the symbol error e x will contain substantially ail of the dispersion of the received optical signal 2 . In this case, the dispersion will propagate through the LMS update loop(s) and the resulting cross compensation vectors H XX , H XY , H YY and H YX will provide at least partial compensation of the dispersion, in addition to applying a phase rotation to de-convolve the symbols modulated onto each polarization of the transmitted optical signal, from the raw digital sample streams I X , Q X , and I Y , Q Y .
[0055] In embodiments in which the compensation vectors {C 0 X }, {C T X }, {C 0 Y } and {C T Y } are computed to compensate both residual sample phase errors and chromatic dispersion, the symbol error e x will contain only a residual portion of the dispersion. In these embodiments, the cross-compensation vectors H XX , H XY , H YY and H YX will provide little or no additional dispersion compensation, but will still apply the needed phase rotation to de-convolve the symbols modulated onto the transmitted polarizations.
[0056] A limitation of the embodiment of FIG. 5 is that noise tends to increase as the speed of the tracking of polarization rotation transients increases, e.g. to 50 kHz it would be preferable to provide low noise, accurate, compensation, while at the same time enabling close tracking of polarization rotation transients of 50kHz or more. FIG. 6 illustrates a modification of the LMS update loop of FIG. 5 , in which this issue is addressed.
[0057] In the embodiment of FIG. 6 , the H XX LMS update loop of FIG. 5 a is modified by the addition of a “supercharger” block 84 , which is inserted into the LMS loop between the scaling function 80 and the accumulator 82 . In this embodiment, it is assumed that the compensation vectors {C 0 X }, {C T X }, {C 0 Y } and {C T Y } are computed to compensate at least the majority of the chromatic dispersion, as described above. In this case, the inventors have observed that as the polarization rotation rate tend towards zero, the intermediate arrays {T K X } and {T A Y } become highly de-correlated with the output of the respective LMS loop FFTs 74 , and the resulting update vectors have very low magnitudes. Conversely, as the polarization rotation rate increases, the intermediate arrays and {T A X } and {T A Y } become significantly correlated with their respective FFT outputs, and this is reflected In an increasing magnitude of the update vectors.
[0058] The Inventors have further observed that under these conditions the time duration of the majority of a time domain version of the update vector {u xx } is relatively short. This limited time duration occurs because of the limited memory inherent in optical polarization effects. The long memory effects of chromatic dispersion have already been substantially compensated, as noted above. Any residual dispersion or other long memory effects generally only need slow tracking.
[0059] The supercharger block 84 exploits these observations by implementing an arrangement in which; 1) portions of the update vector {u xx } that lie outside the time duration of a polarization effect are suppressed; 2) fully detailed updates are allowed to slowly accumulate, enabling the slow tracking of long memory effects such as chromatic dispersion and line filtering; and 3) the magnitude of the enhanced update vector {u′ xx } supplied to the accumulator 82 is scaled in proportion to the polarization rotation rate.
[0060] The suppression of portions of the update vector {u xx } lying outside the time duration of a polarization effect reduces the noise contribution from those portions, and so allows a higher LMS tracking speed without excessive added noise. However, since this suppression Is incomplete, fully detailed updates are allowed to slowly accumulate, thereby enabling accurate tracking of slowly-changing impairments such as chromatic dispersion and line filtering, indeed, rather than suppressing, the illustrated embodiment actually enhances the magnitude of the relevant time domain portions of the update vector. Finally, scaling the magnitude of the update vector {u xx } in proportion to the polarization rotation rate effectively increases the update step size of the important aspects of the update vectors during high speed transients, substantially without affecting the ability of the LMS update loop to provide accurate compensation (via a small update step size) during periods of low-speed polarization rotation.
[0061] As may be appreciated, there are various ways in which the Supercharger function may be implemented, in the embodiment of FIG. 6 : the supercharger 84 is implemented as a frequency-domain digital filter 86 which receives the update vector {u xx } and a summation block 88 for adding the filter output vector {s xx } to the update vector {u xx } to yield the enhanced update vector {u′ xx }.
[0062] If desired, a threshold block 90 can be inserted at the output of the digital filter 86 , as shown in dashed line in FIG. 8 . The threshold block 90 can implement any of a variety of suitable linear and/or nonlinear functions to improve loop performance. A low gate-count embodiment is to implement a zeroing function. In which the “raw” filter output {s xx } from the digital filter 88 is multiplied by zero whenever the magnitude of {s xx } is less than a predetermined threshold. This can be done individually for each term of {s xx }, or by making one decision for the whole vector based upon a vector magnitude metric, such as peak absolute value or sum of the squared magnitude of each of the vector terms.
[0063] As may be appreciated, the frequency domain filter 86 may be implemented in various ways. FIG. 7 a illustrates a low-gate-count embodiment in which the frequency domain filter 86 is implemented as a cascade of summation blocks. Thus, for example, consider an embodiment in which the update vector {u xx } has a width of N=128 taps. These 128 taps can be separated into K=16 groups of 8 taps each. Within each group, the complex values on each tap are summed {at 92 }, to yield a corresponding group sum B(k). A respective weighted summation value S(k) is then computed (at 94 ) for each group, using the group sum values B(k) of the group, and those of the three nearest neighbouring groups. In the embodiment of FIG. 6 , for each group k, the weighted summation value S(k) is computed using the equation
[0000]
S
(
k
)
=
∑
i
=
k
-
3
k
+
3
w
(
i
)
·
B
(
i
)
,
[0000] where the weighting factor w(i)=2 −|k−1| , and modular arithmetic on the i provides the desirable circular wrap around characteristic.
[0064] For example, consider group k=8. The group sum B(k=8) will he the sum of the complex values on taps i=64 . . . 71 of the update vector. The weighted summation value S(k) will be computed as a weighted sum of the respective group sums B(i), i=5 . . . 11. The respective weighting factor w(i) applied to each group sum B(i) will be w(i)=2 5 =1 for j=k, and then descending by powers of two for each of the three neighbouring groups. Thus, w(i)=2 −1 for i=k±1; w(i)=2 −2 for j=k±2; and w(i)= −3 for i=k±3.
[0065] The filter output vector {s xx }, comprising the weighted summation value S(k) for each group, is optionally processed by the threshold block 90 , and then added (at 88 ) to each of the group tap values of the update vector{u xx } to yield the enhanced update vector {u′ xx }. Thus, continuing the above example, the weighted summation value S(k=8) will be added back to each of the complex values on taps i=64 . . . 71 of the update vector {u xx }.
[0066] With this arrangement, the value of S(k) will depend on the degree of correlation between the X-Polarization intermediate array {T A X } and the FFT output vector. When the X-Polarization intermediate array {T A X } and the FFT output vector are highly correlated, S(k) will have relatively large magnitude (in embodiments in which the threshold block 90 is used, S(k) will often be larger than the threshold), and so will have a strong effect on the enhanced update vector {u′ xx }, thereby improving the ability of the LMS update loop to track a rapidly changing polarization angle.
[0067] Conversely, when the X-Polarization intermediate array {T A X } and the FFT output vector are highly uncorrected (that is, when the polarisation angle of the received optical signal is not significantly changing), S(k) will have a very low magnitude (in embodiments in which the threshold block 90 is used, S(k) will usually be lower then the threshold, and thus forced to zero), and so will have little or no effect upon the enhanced update vector {u′ xx }, thereby keeping the added noise to a small level.
[0068] FIG. 7 b illustrates an alternative embodiment In which the frequency domain filter 88 is Implemented as an IFFT 98 , Time-domain filter (TDF) 98 and FFT 100 blocks in sequence, in this case, the IFFT block 98 converts the update vector {u xx } to the time-domain, so that the TDF 98 can implement a windowing function that suppresses portions of the update vector {u xx } lying outside an expected duration of the polarization effect. The thus “windowed” time-domain update vector is then converted back Into the frequency domain by the FFT block 100 , to yield the output vector {s x }. Various other time-domain filter functions may also be implemented by the TDF 98 (either m addition to or instead of the windowing function) as desired.
[0069] The above description uses frequency domain LMS. Other adaptive methods can be used. Zero-forcing is a well known alternative algorithm, which suffers from less than optimal noise filtering. Time domain versions of LMS or other algorithms could be used. This frequency domain version of LMS has the advantage of a small gate-count and relatively fast convergence.
[0070] The configuration of FIG. 4 can be simplified by omitting the multiplication of the arrays {R A X } and {R A Y } by the compensation vectors {C 0 X } and {C 0 Y }. Mathematical equivalence, to yield identical modified vectors {V A X } and {V A Y }, can be obtained by dividing the transpose compensation vectors {C T X } and {C T Y } by {C 0 X } and {C 0 Y }, respectively, and multiplying cross compensation vectors H XX and H XY by {C 0 X }, and multiplying H YY and H YX by {C 0 Y }. In a simple implementation, the {C 0 X } and {C 0 Y } multiplication blocks in the embodiment of FIG. 4 are omitted. The compensation vectors {C T X } and {C T Y } and cross compensation vectors H XX , H XY , H YY and H YX are then computed using the techniques described above, which will yield the appropriate values.
[0071] Other ways may be used for separating the response to slow long memory effects from the response to more rapid short memory effects. Pattern matching, transient speed measurement, time moments, error rates, nonlinear equalization, Jones Matrix calculations, and parameter estimations, are examples of methods that may be used, with varying gate-count requirements. Some of the slower parts of functions could be Implemented in firmware.
[0072] Power based scaling or other scaling methods can be used to enhance the speed of the LMS tracking of the slower frequency components.
[0073] The embodiments of the invention described above are intended to be Illustrative only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims. | A signal equaliser for compensating impairments of an optical signal received through a link of a high speed optical communications network. At least one set of compensation vectors are computed for compensating at least two distinct types of impairments. A frequency domain processor is coupled to receive respective raw multi-bit in-phase (I) and quadrature (Q) sample streams of each received polarization of the optical signal. The frequency domain processor operates to digitally process the multi-bit sample streams, using the compensation vectors, to generate multi-bit estimates of symbols modulated onto each transmitted polarization of the optical signal. The frequency domain processor exhibits respective different responses to each one of the at least two distinct types of impairments. | 7 |
FIELD OF THE INVENTION
[0001] The proposed utility is a cat scratching device with the replaceable fabric-covered pads and a universal base capable of attaching to various surfaces via a selection of different mounting components. Its design is fundamentally different from the traditional construction of this well-known utility. It offers better solution for protecting household surfaces from the claws of cats and kittens and at the same time providing animals with more comfortable habitat. Certain design features turn this combined scratching device into the best versatile utility for animal's motor activity development. Overall, proposed device owns the following distinctive design features: interchangeable pads, removable utility components and design elements and a series of standardized mounts for various interior surfaces of the dwellings.
BACKGROUND OF THE INVENTION
[0002] It is well known that cats need to sharpen their claws and that they do it by scratching various objects, mostly wooden or upholstered furniture. This process is largely unavoidable because it is a natural instinct that helps animals to stay healthy. Selecting a location of a scratching are by animals depends on the nature, temperament, age and gender of the pet, as well as on the interior of the room where it lives. Sometimes, a cat may select several places to sharpen its claws. And more often than not, the place where the cat sharpens its claws is not at all the place where the pet owner would like it to be. Traditional stationary scratching devices rarely help with such a problem. A cat chooses a place for clawing intuitively, instinctively, and it is very difficult to train it to use a scratching device if it has already chosen a location to sharpen its claws, for example, over the furniture or a door jamb. In such cases it is advisable to put a scratching device of the appropriate shape and size at the location “chosen” by the pet; that may protect the surface from the damage and also help to avoid the pet's forced migration to a different location. This was the main reason for designing this unique combined scratching device that offers multiple mounting methods for a variety of surfaces. Its major advantage is utilization of removable pads for scratching which can be easily and conveniently replaced once they become unusable. The design of this combined scratching device allows it to be blended into the interior of any room. With the use of a natural manila or Mexican fiber rope as the cover material of scratching pads they will be made light-weight and look attractive decoratively. An option of having the post installed on practically any surface this device should be enjoyed by both cats and their owners. Finally, the device has an option of replacing the clawing pads with variety of other components such as climbing runs, shelves, nests etc. An easy on a fly modification would convert the scratching post into an animal activity and play station.
SUMMARY OF THE INVENTION
[0003] The combined scratching device solves two major problems:
1. Creation of a comfortable habitat for cats by getting rid of the need for the owners to force their pets out from their chosen clawing locations. 2. Protection of virtually all household interior surfaces from clawing damage.
[0006] Structurally, the combined scratching device consists of two detachable parts: the clawing pad and the mounting base. The clawing pad is a rectangular plate made of a rigid material and wrapped with manila or Mexican-fiber rope or another durable material. At the ends of the clawing pad, plugs from a rigid material are mounted that prevent slippage of the rope; these plugs also perform a decorative function. In addition, the plugs cover the space from the clawing pad of the scratching posts to the fastening surface, which creates a perception of the integrity of the set design (the design decision). In addition to these functions, the plugs prevent rocking of the clawing pad on the mounting base by resting on the fastening surface. The backside of the clawing pad, which is attached to the mounting base, features attachment protrusions (screws with larger round head) with heads projecting over the upper edge of the clawing material to the thickness of the coupling bracket, which is made of metal or hard polymer, for engagement and for provision of the necessary contact of the clawing pad and the mounting base. The shape of the pad plate can be rectangular, triangular or of another geometric shape. Various shapes of pads provide freedom of choice for creating the most comfortable habitat for cats and more opportunities for surface protection. All types of clawing pads have unified mounting and are compatible with all types of mounting bases. A special type of connector has been designed for each type of a surface. The original design of the connector of the mounting base and upholstered parts of the furniture is allowing installation of the combined scratching device on any part of the upholstered parts of the furniture by pinning without damaging the surface. The fastening method is based on piercing of a material attached to the mounting base of the device to a fabric of the surface of upholstered furniture. It is being done with the use of a steel needle/pin with a spherical head, which prevents sliding of the needle after fixing the mounting base of the proposed device to the fastening surface. Connecting flaps of the material are fixed at opposite ends of the mounting base to provide reliable fastening to the surface. Two or more piercing needle/pins are being set per side. Clawing pads of variable geometric shapes are available for installing on a mounting base of the device. Mounting base can be made flat or L-shaped, which allows mounting of this scratching device on edges of the walls or furniture items. The L-shaped mounting bases are equipped with the same fastening connectors as the flat version. For door trims and other similar protruding surfaces, mounting bases can be attached using the surface connectors with the short angled brackets. In terms of crimping action, the door trim fastener is subdivided into the following two types: 1—with a tension spring, 2—without a tension spring. Fasteners with a tension spring have their clamping force produced by the tension spring mounted between the opposite brackets with the clamped surface being placed in between. Fasteners without a tension spring use the clamping method of tilting of one of the brackets to the chute using a special screw. At least four mounting base brackets minimum are needed for a reliable connection on the rung, i.e. is two brackets per side. The mounting base is equipped with any clawing pads selected from the above-mentioned options. A mounting base with a special crimping connector is offered for angular protruding surfaces (e.g. U-shaped walls). In this case, an L-shaped mounting base is used. An adjustable connector is attached to one edge of the mounting base with a screw; this connector is made either of metal or of a rigid material and is shaped as an elongated bracket (attached at an angle of 90°). The bend of the elongated bracket is made parallel to the adjacent edge of the mounting base. The flexible connection of the elongated bracket with the mounting base is necessary to eliminate inconsistencies of linear dimensions in the course of installation of the scratching device. A clamping device is installed on the edge of the mounting base that is opposite to the bending of the elongated bracket. The clamping device has retractable screws that are screwed into the edge of the mounting base. In order to prevent damage to the fastening surface, a movable protective spacer plate is installed against the ends of the screws, through which the screw ends are resting on the fastening surface and thus creating the clamping force. A clamped 3-way projection is placed between one edge of the mounting base with the clamping device and the curved elongated bracket. On the mounting base, provision is made for at least 2 brackets for secure mounting that are used as a connecting device. For flat surfaces, the mounting base with a connecting device in the shape of a 2-sided sticky tape (duct tape) is used. This type of fastening is used in those cases where it is difficult to use other types of fasteners. The mounting base with a connecting device is quickly and easily installed onto any type of smooth hard surfaces. A variety of devices for cats' development and creation of a favourable habitat can also be used instead of clawing pads. These devices can be shelf-like nests, climbing rungs, and other developing structures. All mounting bases and foundations of clawing pads and their plugs are to be made of hard wood or of hard plastic. Clutching brackets are to be made of metal or of rigid polymer. Brackets are to be made of metal.
BRIEF DESCRIPTION OF THE FIGURES
[0007] FIG. 1 General Diagram of Use of Combined Scratching Devices with Various Surfaces
[0008] FIG. 2 General Diagram of Mounting Bases of Combined Scratching Devices in Conjunction with a Variety of Additional Devices
[0009] FIG. 3 Schematic Design of Fastener of the Clawing Pads to the Mounting Base of Combined Scratching Devices
[0010] FIG. 4 Installation of the Clutching Bracket of the Mounting Base and the Catching Device for the Clawing Pads of Combined Scratching Devices
[0011] FIG. 5 Design of the Plug for the Clawing Pads of Combined Scratching Devices
[0012] FIG. 6 Types of Connecting Devices for Mounting Bases of Combined Scratching Devices
[0013] FIG. 7 Design of the Special Connecting Device for Upholstered Furniture Pieces with the Use of Pinning of Base-Connected Material with Needle/pins to Upholstered Surfaces
[0014] FIG. 8 Design of the Special Connecting Device with Elongated Crimping Brackets for Wide Rectangular Protruding Surfaces such as Jambs etc.
[0015] FIG. 9 Design of the Special Connecting Device with Crimping Short Brackets with a Tension Spring for Narrow Rectangular Protruding Surfaces, such as Door Trims etc.
[0016] FIG. 10 Design of the Special Connecting Device with Crimping Short Brackets with a Tension Screw for Narrow Rectangular Protruding Surfaces, such as Door Trims etc.
[0017] FIG. 11 Design of the Special Connecting Device for Rough Non-Flat Surfaces with the Use of Duct Tape.
[0018] FIG. 12 Some Shapes of Fastened Clawing Pads and Devices for the Comfort of Cats
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 shows the general diagram of the use of standard options of the combined scratching device and its fastening to a variety of household surfaces. The clawing pads 1 of the combined scratching device (for example, straight and triangular) of an arbitrarily admissible geometric shape, linear dimensions, and material for clawing are united by a common universal mounting type and can be installed onto any universal mounting base. All types of mounting bases 8 , 9 , 10 , 11 , 12 have a standardized fastening for connection to pads 1 of any shape. The combined scratching device assembly is a clawing pad 1 installed on one of the mounting bases 8 , 9 , 10 , 11 , and 12 . Mounting bases differ through connecting devices for the fastening surface, linear dimensions, and shape: straight and angled. They must be manufactured of a rigid material: wood, plastic etc. The mounting base 8 is used for fastening of the post to flat smooth surfaces 3 (furniture walls, door units etc.) with the use of a double-sided adhesive tape. The L-shaped mounting base 9 is used to fasten the scratching device to angled wall projections or other similar engineering structures 4 . In this case, the connecting device consists of elongated crimping brackets. The L-shaped mounting base 10 can also be fitted with a connecting device with adhesive tape and can be used for installation on furniture legs 5 or other angled surfaces. The mounting base 11 is designed to fasten it to the upholstered part. The connecting accessories here are the scraps of material at the ends of the plate of the mounting base that are pinned to the surface of the upholstered parts of furniture with needle/pins 6 . The mounting base 12 is designed for mounting on narrow and low rectangular protrusions (door trims etc.). 7 , with the use of short crimping brackets.
[0020] FIG. 2 shows, on the basis of a sample cat nest complete with a climbing rung 1 , the use of the mounting base of the combined scratching device in connection with the devices for improvement of living conditions and development of motor activity of cats. The device 1 can be installed onto the following types of mounting bases of the combined scratching device: 2 —the mounting base with a connecting device with elongated brackets, 3 —the mounting base with a connecting device with a double-sided adhesive tape, 4 —the mounting base with a connecting device with short brackets. View 10 —cat nest 7 complete with a climbing rung 8 mounted on the mounting base with elongated brackets 2 and fastened to the wall protrusion 5 . View 11 —cat nest 7 complete with a climbing rung 8 is mounted on the mounting base with the double-sided adhesive tape 3 and fastened onto the furniture wall 6 . View 12 —cat nest 7 complete with a climbing rung 8 mounted on the mounting base with short brackets 4 and fastened to the door trim 9 . The connecting device for improvement of the habitat and development of motor activity of cats that is fastened to the bottom of the mounting base must be equipped with the corresponding connecting protrusions, as do the clawing pads (see FIG. 3 ).
[0021] FIG. 3 shows the design of fastening of clawing pads and other possible accessories to the bottom of the mounting base of the combined scratching device on the basis of fastening of a sample straight mounting base and the connecting device (a double-sided adhesive tape). All other types have a similar standardized mounting base for fastening of the clawing pads. 1 —View of the clawing pad installed onto the mounting base, from the front of the clawing section. 2 —View of the back of the clawing pad of the scratching device from the side of the fastening protrusions. The design of the combined scratching device consists of two assembled parts: the clawing pad 1 (Rear View 2 ) or another device for cats and the mounting base 5 . All clawing pads 1 (Rear View 2 ), possible accessories for cats 3 (Side View 4 ), and the mounting bases 5 have the same universal type of fastening for connection with each other. With the use of a catching device (the connecting projections 6 ) the pad of the combined scratching device or another device for cats engages with the clutching brackets 7 serially mounted on the plate of the mounting base 5 vertically. The standardized mounting base options that are reviewed herein contain strictly vertical clutching brackets 7 . In terms of the shape, the mounting base 5 is made in the shape of a rectangular plate (other arbitrary shapes of the plates that are not considered here are also allowed) made of a rigid material with anchoring clutching brackets 7 , screws 8 , or other suitable fasteners on one side of the plate, and a connecting device for fastening to the surface on the other side of the plate. The clutching bracket 7 on the bar of the mounting base 5 is installed in the quantity of at least 2 pcs. All of them must be installed at a fixed distance on the universal mounting base in accordance with the location of attachment projections 6 on the clawing pads or in other devices for cats. Clawing pad 1 (Rear View 2 ) features plugs 9 at the ends of its length, which prevent the clawing material 10 from slipping; the clawing material can be manila or Mexican-fiber rope as well as other durable material. At the ends of the plugs 9 , the spacers 11 are installed that are made of soft material and that serve to prevent damage to the fastening surface. A more detailed design of the clutching bracket 7 is provided in FIG. 4 .
[0022] FIG. 4 shows the design of the clutching bracket and the catching device for the clawing pads. View 1 shows the clawing pad of the combined scratching device in conjunction with clutching brackets 3 from the mounting base of the combined scratching device. In View 2 , the round head of the attachment protrusion 5 of the catching device on the clawing pad 1 is extended above the surface of the material of the clawing pad 1 to the thickness of the clutching bracket 3 . View 4 —the fastening protrusion 5 of the clawing pad 1 at the moment of engagement with the clutching bracket 3 . The clutching bracket 3 of the mounting base is made of a rigid sheet material (presumably metal). The catching protrusion 5 of the clawing pad 1 enters the central opening 6 (View 3 ) between the two longitudinal slots 7 of the clutching bracket 3 , which can structurally be a screw with an increased flat head. For engagement with the clutching bracket 3 , the clawing pad 1 moves with the use of connecting projections 5 inside the slots 7 in either direction depending on the position of the mounting base until it clicks as shown in the View 1 . The enlarged View 4 also shows the principle of fastening the clawing pad to the clutching bracket 3 with the use of fastening protrusions 5 (at the moment of entry into the bracket). Holes 8 on the clutching bracket are used to connect it to the combined scratching device with the use of the fasteners 9 . The fit and the clamping force of the clawing pad to the mounting base can be adjusted through the height of the fastening protrusion 5 from the adhesive material of the clawing pad. The spacer 10 is provided in order to mitigate the vibration of the clawing pad and to prevent damage to the adjacent surface. The design of the clutching bracket 3 provides for its symmetrical installation, thereby the mounting base of the combined scratching device has no fixed up or down position.
[0023] FIG. 5 shows the design of the end plug of the clawing pad of the combined scratching device. View 1 shows the connection of the combined scratching device to the furniture wall surface using a double-side adhesion tape connecting device as an example. All major peculiar properties of the design of the plug 3 of the clawing pad that are described herein are used in all types of clawing pads 8 of combined scratching device. View 2 shows an enlarged view of the plug 3 mounted onto the combined scratching device attached to the fastening surface. As can be seen from View 1 and 2 , the end plug 3 of the clawing pad 8 is extended for the thickness of the elongated plate of the mounting base 4 so that when attached to the adjacent surface 5 , the scratching post assembly with the clawing pad 8 abuts against the plugs 3 fitted with spacers 6 made of soft material (in order to prevent damage to the fastening surface) in the fastening surface 5 at the same level 7 as the plate of the mounting base 4 . Thus the combined scratching device assembly rests against the fastening surface with all parts of its design when attached to the surface with all its planes, which prevents additional rocking and vibration of the pad while clawing.
[0024] FIG. 6 provides a general description of the types of the used connecting devices for the mounting base of the combined scratching device to be fastened to the fastening surface. A detailed review of each of the connecting devices is summarized in the corresponding sketches. 1 and 4 —the connecting device with the double-sided adhesive tape 5 , the bands of which are mounted onto the mounting base 6 . The types of connecting devices 1 and 4 are used for attachment to flat smooth surfaces. Type 1 is intended for angle-shaped surfaces only. Type 4 is designed for all forms of flat surfaces (for details, see FIG. 11 ). Type 2 and 5 of the connecting device are used to fasten the scratching device to upholstered parts of furniture and to fabric-covered surfaces. General design of the connecting device consists of the connecting device 7 , which is attached to the plate of the mounting base 6 . The connecting device 7 can be used both with the straight plate 5 of the mounting base and with the angular plate 2 of the mounting base. The connecting device consists of the original fixtures based on the method of pinning of flaps of material from the plate of the mounting base 6 to the fastening surface by means of needle/pins (for details, see FIG. 7 ). The corner mounting base with a connecting device with elongated brackets (View 3 ) is used to fasten to wide rectangular projections of walls and similar 3-way structures. The connecting device 8 consists of elongated brackets and clamping devices on one side of the mounting base (for details, see FIG. 8 ). The connecting device (View 6 ) is designed to fasten the mounting base to low-protruding narrow rectangular surfaces, such as door trims etc. The connecting device 9 consists of short clamping brackets that clasp the protrusion of the surface and are mounted on the plate of the mounting base 6 . The method of compression of brackets can be based on a tension spring or on a clamping screw (for details, see FIG. 9 , FIG. 10 ). The connecting device of this type is used with both flat and L-shaped mounting bases.
[0025] FIG. 7 describes the principle of action of the original connecting device of the mounting base of the combined scratching device to upholstered parts of furniture. View 1 —the mounting base with the connecting device attached to the surface. View 2 —enlarged front view of one side of the mounting base with a connecting device; View 3 —enlarged reverse view of one side of the mounting base with a connecting device. View 4 —Needle/pin. The connecting device consists of two flaps of material 5 on opposite sides of the plate of the mounting base 6 , needle/pins 7 , and the auxiliary ring of the opening 8 . The design of the needle/pin 7 provides for the round opening 7 and the head 9 with a larger diameter than the inner diameter of the opening of the ring 8 . The head plays a role of the stop in the ring 8 that prevents rupture of the material under load in the course of clawing. The length of the needle/pin is not regulated; however, it needs to be sufficient for secure fastening. The needle/pins must be manufactured of metal. The upper edge of the flaps of material 5 that is opposite from the plate of the mounting base 6 , features the rings 8 with the holes according to the diameter of the needle/pin 7 , which are mounted on the same horizontal level. Each flap, at the top edge, has at least two punched ringed holes 8 in order to provide for secure fastening. The flap of the material 5 is attached to the mounting base plate 6 by means of fastening screws 10 or punch-down brackets. For fastening to the surface of the upholstered part of furniture 11 , the plate of the mounting base 6 is set against the surface with the use of straightened flaps 5 to the sides along the entire length. Needle/pins 7 are inserted into ringed holes 8 in the direction of the plate of the mounting base 6 so that the tip of the needle/pin pierces throughout the length of the connecting material 11 when passing through the ring 8 and the spherical surface of the head 9 of the needle/pin 7 comes into contact with the ring of the hole 8 . To ensure secure fastening, the plate of the mounting base 6 is fitted with two vertical connecting devices—at the top and at the bottom.
[0026] FIG. 8 describes the principle of action of the connecting device of the mounting base of the combined scratching device with the use of long brackets for fastening to three-way rectangular protrusions of walls, furniture and other engineering structures. View 1 (from the inside)—the angled mounting base equipped with a connecting device with elongated brackets. View 2 —a fragmentary sectional view of the clamping screw 5 complete with the nut 6 . View 3 —the end view of the section of the mounting base fastened to the surface. View 4 —the mounting base fitted with a connecting device with elongated brackets (Front View). The connecting device consists of principal parts: the elongated brackets 7 and the clamping device, which in turn consists of the installation plate 8 , the guide pins 9 , the nuts 6 and the bolts 5 . The mounting base 10 in this option has an L-shape. The plates of the mounting bases are connected into an angled shape 10 with the use of screws 18 as seen from the View 4 . From inside of the angle, elongated brackets 7 are attached to one of the plates of the mounting base of the angled mounting base 10 ; and a clamping device is installed on the adjacent plate. The brackets are installed in slots 11 that have a depth equal to the thickness of the bracket 7 so that the inner plane of the bracket and the plane of the plate 10 of the mounting base are at the same level, which provides uniform contact with the fastening surface. The elongated bracket 7 is attached to the plate of the angled of the mounting base 10 by means of fastening screws 12 , which are placed in slots 13 and which have a small longitudinal shift for pressure adjustment during the installation of the mounting base onto the fastening surface. At one end, the elongated bracket 7 has a bend 14 of 90° to cover one side of the fastening surface. The inner side of the bend 14 of the bracket 7 features a spacer 15 made of soft material in order to prevent damage to the fastening surface. The fastening surface 16 is placed between the bends 14 of the brackets 7 and the cramping device on the plate of the mounting base 10 . The clamping device is composed of the nuts 6 in recessed slots 17 flush with the plate of the mounting base 10 . A clamping screw 5 in recessed grooves 19 flush with the plate of the mounting base 10 (2 pcs) is screwed into the nut and pushes its ends into the spacer plate 8 placed in front of them thus creating clamping force toward the fastening surface 16 . The spacer plate 8 is mounted on movable guide pins 9 (2 pcs) that are installed into the corresponding slots 18 on the mounting plate 10 and that serve to protect against damage of the fastening surface caused by screws. The spacer must be made of sheet metal or plastic. To ensure secure fastening, the plate of the mounting base 6 is vertically fitted with at least two elongated brackets 7 . The length of the bracket is selected on the basis of the width of the protrusion.
[0027] FIG. 9 describes the principle of action of the connecting device of the mounting base of combined scratching device using short brackets with the tension spring for fastening to low-protruding narrow rectangular surfaces such as door trims. View 1 —the front part of the mounting base from the side of the attachment of the clawing pads. Views 2 and 3 are showing the rear part of the assembly plate of the mounting base with a connecting device with a tension spring. View 4 —the end view of the section of the mounting base fastened to the surface. The connecting device consists of the following principal parts: short movable ( 5 ) and stationary ( 6 ) brackets, which are arranged pairwise opposite each other horizontally and which tighten the spring 7 attached to the respective opposite horizontal brackets; screws for mounting and stroke adjustment 8 ; mounting screws for stationary brackets 9 . Screws for mounting and stroke adjustment 8 are screwed into the threaded socket 10 and fasten a vertical part of the pairs of brackets 5 in a sliding way to the plate of the mounting base 11 ; moving along the horizontal slot 12 , they allow for horizontal movement of the respective bracket 5 to stretch the spring and to create the clamping force on the fastened surface 13 . The opposite vertical part of the pair of brackets 6 is attached fast to the plate 11 with the use of the screw 9 . The clamping force is developed by the tension spring 7 , which is attached to opposite brackets 5 and 6 mounted on the same horizontal level; this provides for uniform clamping of the mounting base 11 to the fastening surface with all of its 13 brackets. The maximum width of the surface depends on the maximum width of the plate of the mounting base 11 .
[0028] FIG. 10 describes the principle of action of the original connecting device of the mounting base of combined scratching device using short brackets with the tension screw for fastening to low-protruding narrow rectangular surfaces such as door trims. View 1 —the front part of the mounting base from the side of the attachment of clawing pads. Views 2 and 3 —are showing the shape of the plate of the mounting base from the side of the connecting device assembly. View 4 —edge view of the plate of the mounting base in section along the brackets of the connecting device. View 5 —the end view of the section of the mounting base fastened to the surface. The connecting device consists of the following principal parts: short mobile ( 6 ) and stationary ( 7 ) brackets, which are arranged pairwise opposite each other horizontally, tension screws for mounting and stroke adjustment 8 ; mounting screws 9 for stationary brackets that are screwed into the threaded holes 10 of stationary brackets 7 . Movable side brackets 6 that are crimped with the use of the screw 8 possess a design feature. On the plane of its base adjacent to the plate of the mounting base 11 , the movable bracket 6 has a narrow projection 12 , which serves as a stop during the clamping of the bracket 6 to an inclined surface 13 in order to prevent slippage and displacement. In each horizontal pair of brackets, one bracket 7 is attached fast to the plate 11 with the use of the screw 9 . The tightening screws for mounting and stroke adjustment 8 move in the slot 14 and attach one bracket 6 in a sliding way to the plate of the mounting base 11 in each pair of horizontal brackets, which allows for the movement and tilting of the movable bracket on the horizontal slope slot 13 in order to create clamping force on the fastened surface 15 . The clamping force is developed by the tension screw 8 , which presses the movable bracket 6 of each horizontal pair of brackets along the special sloping slot 13 on the plate 11 of the mounting base. As it is screwed into the threaded socket 16 of the base of the bracket 6 , the clamping screw 8 tilts it along the slope 13 . Horizontal tilt of the bracket 6 in the direction W depends on the distance Q of the angle deviation value 13 and is selected empirically. The clamped surface 15 is located between the opposite brackets 6 and 7 of each horizontal pair of brackets. At least, two vertical pairs of brackets are expected. The maximum girth of the fastening surface depends on the maximum width of the plate of the mounting base 11 .
[0029] FIG. 11 describes the principle of action of the connecting device of the mounting base of combined scratching device using double-sided adhesive tape for fastening to flat smooth surfaces (such as cabinets, drawers, kitchen furniture etc.). View 1 —a composite view of the mounting base of the combined scratching device as fastened to the fastening surface 6 . Views 2 and 3 —show the mounting base; the view is from the side of the connecting device. The connecting device consists of a double-sided adhesive tape 4 along the length of the plate 5 of the mounting base. If the plate of the mounting base has a substantial width, the use of multiple strips of adhesive tape 4 is allowed (View 3 ).
[0030] FIG. 12 . The combined scratching device is fitted with clawing pads of any geometric shape but with the required catching devices as shown in FIG. 4 for a tight connection to the plane of the mounting base. The sketch shows some options of the preferred shapes: the triangular shape 1 and the rectangular shape 2 . A device for development of the cat's physical activity and improvement of the habitat is the nest 3 complete with a climbing rung. All clawing pads of the scratching device and accessories are equipped with standardized catching devices as indicated in FIG. 4 to connect with all types of mounting bases of the scratching device. | The proposed utility is a cat scratching device with the replaceable clawing pads covered with fabric and a universal base capable of attaching to various surfaces via a selection of different mounting components. A key feature of the device is its interchangeable clawing pads that don't need any tooling for their replacement. Another key feature is the selection of various non-damaging mounts. The mounts are designed to safely attach the device to different pieces of furniture or directly to the walls. These two features are the main advantages of the device which guarantees the protection of furniture and dwelling surfaces from cat claw damage. The device can be easily relocated and can be applied to a scratching spot already chosen by the pet thereby creating a comfortable habitat for the animal. In addition, various devices for cat development can be installed on standardized mounting base converting the scratching post into an animal activity and play station. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 62/240,622, filed 13 Oct. 2015.
BACKGROUND OF THE INVENTION
[0002] The invention disclosed herein relates to an apparatus and methods for forming disposable products such as diapers at very high speeds, while automatically scheduling certain aspects of production, including material loading, splicing, reloading. While the description provided relates to diaper manufacturing, the apparatus and method are easily adaptable to other applications.
[0003] In particular, the present invention relates to material unwind systems. Turret unwind systems, which automatically splice an expiring roll of material with a waiting roll of material are disclosed, the turret unwind systems provided with a recovery system for recovering end portions of the material carried by the expiring roll, and automatically separating an expiring roll core from the expiring material. Two waste streams are created—each of a single material, making recycling and downstream handling of the expiring roll cores and expiring material simpler and more efficient.
[0004] Generally, diapers comprise an absorbent insert or patch and a chassis, which, when the diaper is worn, supports the insert proximate a wearer's body. Additionally, diapers may include other various patches, such as tape tab patches, reusable fasteners and the like. The raw materials used in forming a representative insert are typically cellulose pulp, tissue paper, poly, nonwoven web, acquisition, and elastic, although application specific materials are sometimes utilized. Usually, most of the insert raw materials are provided in roll form, and unwound and applied in continuously fed fashion.
[0005] In the creation of a diaper, multiple roll-fed web processes are typically utilized. To create an absorbent insert, the cellulose pulp is unwound from the provided raw material roll and de-bonded by a pulp mill. Discrete pulp cores are created using a vacuum forming assembly and placed on a continuous tissue web. Optionally, super-absorbent powder may be added to the pulp core. The tissue web is wrapped around the pulp core. The wrapped core is debulked by proceeding through a calendar unit, which at least partially compresses the core, thereby increasing its density and structural integrity. After debuIking, the tissue-wrapped core is passed through a segregation or knife unit, where individual wrapped cores are cut. The cut cores are conveyed, at the proper pitch, or spacing, to a boundary compression unit.
[0006] While the insert cores are being formed, other insert components are being prepared to be presented to the boundary compression unit. For instance, the poly sheet is prepared to receive a cut core. Like the cellulose pulp, poly sheet material is usually provided in roll form. The poly sheet is fed through a splicer and accumulator, coated with an adhesive in a predetermined pattern, and then presented to the boundary compression unit. In addition to the poly sheet, which may form the bottom of the insert, a two-ply top sheet may also be formed in parallel to the core formation. Representative plies are an acquisition layer web material and a nonwoven web material, both of which are fed from material parent rolls, through a splicer and accumulator. The plies are coated with adhesive, adhered together, cut to size, and presented to the boundary compression unit. Therefore, at the boundary compression unit, three components are provided for assembly: the poly bottom sheet, the core, and the two-ply top sheet.
[0007] A representative boundary compression unit includes a profiled die roller and a smooth platen roller. When all three insert components are provided to the boundary compression unit, the nip of the rollers properly compresses the boundary of the insert. Thus, provided at the output of the boundary compression unit is a string of interconnected diaper inserts. The diaper inserts are then separated by an insert knife assembly and properly oriented, such as disclosed in related U.S. Application No. 61/426,891, owned by the assignee of the present invention and incorporated herein by reference. At this point, the completed insert is ready for placement on a diaper chassis.
[0008] A representative diaper chassis comprises nonwoven web material and support structure. The diaper support structure is generally elastic and may include leg elastic, waistband elastic and belly band elastic. The support structure is usually sandwiched between layers of the nonwoven web material, which is fed from material rolls, through splices and accumulators. The chassis may also be provided with several patches, besides the absorbent insert. Representative patches include adhesive tape tabs and resealable closures.
[0009] The process utilizes two main carrier webs; a nonwoven web which forms an inner liner web, and an outer web that forms an outwardly facing layer in the finished diaper. In a representative chassis process, the nonwoven web is slit at a slitter station by rotary knives along three lines, thereby forming four webs. One of the lines is on approximately the centerline of the web and the other two lines are parallel to and spaced a short distance from the centerline. The effect of such slitting is twofold; first, to separate the nonwoven web into two inner diaper liners. One liner will become the inside of the front of the diaper, and the second liner will become the inside of the back of that garment. Second, two separate, relatively narrow strips are formed that may be subsequently used to cover and entrap portions of the leg-hole elastics. The strips can be separated physically by an angularly disposed spreader roll and aligned laterally with their downstream target positions on the inner edges of the formed liners. This is also done with turn bars upon entrance to the process.
[0010] After the nonwoven web is slit, an adhesive is applied to the liners in a predetermined pattern in preparation to receive leg-hole elastic. The leg-hole elastic is applied to the liners and then covered with the narrow strips previously separated from the nonwoven web. Adhesive is applied to the outer web, which is then combined with the assembled inner webs having elastic thereon, thereby forming the diaper chassis. Next, after the elastic members have been sandwiched between the inner and outer webs, an adhesive is applied to the chassis. The chassis is now ready to receive an insert.
[0011] In diapers it is preferable to contain elastics around the leg region in a cuff to contain exudates for securely within the diaper. Typically, strands of elastic are held by a nonwoven layer that is folded over itself and contains the elastics within the overlap of the nonwoven material. The nonwoven is typically folded by use of a plow system which captures the elastics within a pocket, which is then sealed to ensure that the elastics remain in the cuff.
[0012] Most products require some longitudinal folding. It can be combined with elastic strands to make a cuff. It can be used to overwrap a stiff edge to soften the feel of the product. It can also be used to convert the final product into a smaller form to improve the packaging.
[0013] To assemble the final diaper product, the insert must be combined with the chassis. The placement of the insert onto the chassis occurs on a placement drum or at a patch applicator. The inserts are provided to the chassis on the placement drum at a desired pitch or spacing. The generally flat chassis/insert combination is then folded so that the inner webs face each other, and the combination is trimmed. A sealer bonds the webs at appropriate locations prior to individual diapers being cut from the folded and sealed webs.
[0014] Roll-fed web processes typically use splicers and accumulators to assist in providing continuous webs during web processing operations. A first web is fed from a supply wheel (the expiring roll) into the manufacturing process. As the material from the expiring roll is depleted, it is necessary to splice the leading edge of a second web from a standby roll to the first web on the expiring roll in a manner that will not cause interruption of the web supply to a web consuming or utilizing device.
[0015] In a splicing system, a web accumulation dancer system may be employed, in which an accumulator collects a substantial length of the first web. By using an accumulator, the material being fed into the process can continue, yet the trailing end of the material can be stopped or slowed for a short time interval so that it can be spliced to leading edge of the new supply roll. The leading portion of the expiring roll remains supplied continuously to the web-utilizing device. The accumulator continues to feed the web utilization process while the expiring roll is stopped and the new web on a standby roll can be spliced to the end of the expiring roll.
[0016] In this manner, the device has a constant web supply being paid out from the accumulator, while the stopped web material in the accumulator can be spliced to the standby roll. Examples of web accumulators include that disclosed in U.S. patent application Ser. No. 11/110,616, which is commonly owned by the assignee of the present application, and incorporated herein by reference.
[0017] As in many manufacturing operations, waste minimization is a goal in web processing applications, as products having spliced raw materials cannot be sold to consumers. Indeed, due to the rate at which web processing machines run, even minimal waste can cause inefficiencies of scale. In present systems, waste materials are recycled. However, the act of harvesting recyclable materials from defective product is intensive. That is, recyclable materials are harvested only after an identification of a reject product at or near the end of a process. The result is that recyclable materials are commingled, and harvesting requires the extra step of separating waste components. Therefore, the art of web processing would benefit from systems and methods that identify potentially defective product prior to product assembly, thereby eliminating effort during recyclable material harvesting.
[0018] Furthermore, to improve quality and production levels by eliminating some potentially defective product, the art of web processing would benefit from systems and methods that ensure higher product yield and less machine downtime.
[0019] Some diaper forming techniques are disclosed in co-pending U.S. application Ser. No. 12/925,033 which is incorporated herein by reference. As described therein, a process wherein a rotary knife or die, with one or more cutting edges, turns against and in coordination with a corresponding cylinder to create preferably trapezoidal ears. Ear material is slit into two lanes, one for a left side of a diaper and the other for a right side of a diaper. Fastening tapes are applied to both the right and the left ear webs. The ear material is then die cut with a nested pattern on a synchronized vacuum anvil.
[0020] The resulting discrete ear pieces however, due to the trapezoidal pattern of the ears, alternate between a correct orientation and an incorrect (reversed) orientation. The reversed ear is required to be rotated 180° into the correct orientation such that the ears and associated tape present a left ear and a right ear on the diaper.
[0021] To accomplish the reversal of the ear pattern, discrete ear pieces are picked up at the nested ear pitch by an ear turner assembly that will expand to a pitch large enough for ears to be unnested and allow clearance for every other ear to be rotated. The rotated ears are then unnested and into the correct orientation.
[0022] Two ear turner assemblies can be provided, to rotate every other ear applied to the right side of the product, and every other ear applied to the left side of the product. In this manner, for a single product, one of the two ears will have been rotated 180°.
[0023] Ear application to a chassis web can be by a bump method (described later) with intermittent adhesive applied to the chassis web, or can be by vacuum transfer.
[0024] The present invention also allows for two side panel assemblies, including fastening mechanisms, to be attached to two ears, the side panel assemblies attached in a pre-folded condition. Two more ears can coupled to a chassis web to create a front panel to wear about the waist of a user.
[0025] The present invention also allows for chips of material to be removed from the ears to provide a diaper with contoured leg openings. In one embodiment, the chips may be removed from the ears before the ears are attached to the chassis web. In an additional embodiment the chips may be removed from the ears after the ears are attached to the chassis web. In an additional embodiment the chips may be removed from the ears and a portion of the chassis web removed after the ears are attached to the chassis web.
[0026] The invention disclosed herein also relates to apparatus and methods for waste reduction, such as disclosed in related U.S. Application Ser. No. 61/400,318, also incorporated herein by reference. Generally, diapers comprise an absorbent insert or patch and a chassis, which, when the diaper is worn, supports the insert proximate a wearer's body. Additionally, diapers may include other various patches, such as tape tab patches, reusable fasteners and the like. The raw materials used in forming a representative insert are typically cellulose pulp, tissue paper, poly, nonwoven web, acquisition, and elastic, although application specific materials are sometimes utilized. Usually, most of the insert raw materials are provided in roll form, and unwound and applied in assembly line fashion. As in many manufacturing operations, waste minimization is a goal in web processing applications, as products having spliced raw materials cannot be sold to consumers. Indeed, due to the rate at which web processing machines run, even minimal waste can cause inefficiencies of scale.
[0027] In present systems, waste materials are recycled. However, the act of harvesting recyclable materials from defective product is intensive. That is, recyclable materials are harvested only after an identification of a reject product at or near the end of a process. The result is that recyclable materials are commingled, and harvesting requires the extra step of separating waste components. Therefore, it is beneficial to use up all of incoming rolls, so that a portion of the incoming rolls do not become waste. That objective is accomplished with the present invention
[0028] When manufacturing hygiene products, such as baby diapers, adult diapers, disposable undergarments, incontinence devices, sanitary napkins and the like, a common method of applying discrete pieces of one web to another is by use of a slip-and-cut applicator. A slip-and-cut applicator is typically comprised of a cylindrical rotating vacuum anvil, a rotating knife roll, and a transfer device. In typical applications, an incoming web is fed at a relatively low speed along the vacuum face of the rotating anvil, which is moving at a relatively higher surface speed and upon which the incoming web is allowed to “slip”. A knife-edge, mounted on the rotating knife roll, cuts a off a segment of the incoming web against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the anvil's surface. Once cut, the web segment is held by vacuum drawn through holes on the anvil's face as it is carried at the anvil's speed downstream to the transfer point where the web segment is transferred to the traveling web.
[0029] Continual improvements and competitive pressures have incrementally increased the operational speeds of disposable diaper converters. As speeds increased, the mechanical integrity and operational capabilities of the applicators had to be improved accordingly.
[0030] Decreasing the footprint required by the manufacturing equipment is also desirable, as is increased automation, decreased system downtime, and increased manufacturing speeds. In typical disposable products manufacturing techniques, raw materials are fed into the manufacturing system at ground level, generally from the sides (and often perpendicular on the ground level) relative to the main machine direction on the ground.
[0031] The raw material supply system can also be done manually. A forklift operator is typically required to constantly monitor supplies of raw materials, such as the nonwoven materials, elastics, pulp, SAP, tape, poly, etc. and drive the forklift from a storage area containing these materials, and deposit those materials onto the system, where typically splicing systems are used to provide for continuous operation. In prior art systems, an operator would typically use a utility knife to slice layers of web material remaining on an almost empty core, in order to separate the core from the remaining web material carried by the core. By using an automated material supply system, along with a system described in U.S. Application No. 62/206,394, there is no longer a need for manual separation of the last layers of web material from the core.
SUMMARY OF THE INVENTION
[0032] Provided are methods and apparatus for minimizing waste and improving quality and production in web processing operations in a high speed, small footprint environment.
[0033] Disclosed is an Automatic Roll Loading System (ARLS). Specifically, the machine of the present invention anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run.
[0034] Once all material unwinds have the size of material rolls loaded and splices set up, splices can by manually or automatically triggered to splice in the new material rolls and use the running machine process to pull all the new materials through the process. This saves considerable time compared to loading each unwind manually and then manually rethreading each material process throughout the machine. The result is a significant reduction in change-over times and the present technique can be employed for any machine process requiring input of multiple material rolls when different materials (size, weight, color, etc.) are required for different products codes or sizes.
[0035] When employing the technique described herein, splicing in different width materials and pulling them through a running machine process will not result in the immediate making of acceptable products. The present method results in intentionally pulling in material widths different than what the current product code being run is setup for, so certain details will result in unacceptable product; for instance, glue applicator patterns may exceed the new material width and therefore glue applicators are turned off for the duration of this material pull through technique. For the same reason, web with detectors are temporarily disable or ignored, and web guides put into a non-responsive mode so they do not try and respond to material widths not compatible with their current setup. Those machine capabilities are restored prior to starting the next good product run, but by pulling in new materials through web processes by using the old materials already threaded through web processes, good-product to good-product changeover is greatly sped.
[0036] An ARLS Scheduler monitors machine speed, consumption of raw materials, materials remaining on each turret unwind, progress on case count of current product code run, schedule of next product code run, materials available at machine, materials remaining on each material loading cart, and optionally, materials in warehouse, and general position of robot carts in motion.
[0037] First, the ARLS Scheduler determines which turret unwind should be loaded next. It also determines when material rolls specific to the NEXT product, code to be run should be loaded onto the associated turret unwinds. This is part of the preparation to conduct the special splice event as part of the current product code run shutdown, Once new materials are pulled through the machine process (auto-threaded) by the expiring materials, the machine can be full shut down in preparation for other, non-material related changeover activities to set the machine up for the next product code run.
[0038] The ARLS Scheduler may also keep track of the changeover parts, assemblies, and set-ups needed for each specific changeover to assist the machine operators and technicians in their outside time preparations for the changeover as well as during the inside time changeover activities when in progress.
[0039] The basic roll loading decision is informed by information queries such as: material remaining on each cart; status of a turret unwind as ready to load; and the time remaining or product, pitches remaining to end of roll on the turret unwind. The decision could be located in the turret unwind control routine, the ARLS PLC, or the machine control PLC depending on size, complexity, or configuration of machine.
[0040] A vertical reciprocating conveyor or a robot is used to carry waiting new material rolls from a main processing level to the material unwinding level. A robotic assembly obtains an expiring roll and discards the roll in a waste chute. Once on the material unwinding level, the waiting new material rolls are staged at a material address dedicated to that particular material. A robotic assembly acquires a material roll from one of said material addresses and transports and places the material roll onto its appropriate auto-fed material unwinding system.
[0041] Turret unwind systems, which automatically splice an expiring roll of material with a waiting roll of material are disclosed, the turret unwind systems provided with a recovery system for recovering end portions of the material carried by the expiring roll, and automatically separating an expiring roll core from the expiring material. Two waste streams are created—each of a single material, making recycling and downstream handling of the expiring roll cores and expiring material simpler and more efficient.
[0042] The material supply techniques and product layouts disclosed can be used to produce pant-type diapers, brief-type diapers, baby diapers, adult diapers, or any other types of disposable products using web processing machinery.
[0043] A system for manufacturing disposable products is disclosed, the system comprising a production machine for producing a first configuration of disposable products and a second configuration of disposable products; a first set of material rolls configured to produce said first configuration of disposable products; a second set of material rolls configured to produce said second configuration of disposable products; a controller communicatively coupled to said production machine, said controller receiving a plurality of input signals, and, based upon said input signals, generating an output signal controlling whether said first configuration or said second configuration of disposable products is produced by said production machine; said controller selectively coupling at least one of said first set of material rolls and said second set of material rolls with said production machine based upon at least one of said input and output signals, to selectively produce said first and said second configurations of disposable products.
[0044] Input signals can comprise at least one of scheduling input, sales and marketing input, purchasing input, receiving input, warehousing input, production input, maintenance input, shipping input, and accounting input, and based on those inputs, arrive at an output decision. In a preferred embodiment, the scheduling input is reactive to at least one of sales and marketing input and purchasing input.
[0045] The system is capable of producing different disposable products, for instance by supplying new material rolls having a first roll width, and said second set of material rolls comprising a plurality of new material rolls having a second roll width, said second roll width larger than said first roll width. In this manner, the disposable products themselves can be characterized as having a first product width, said second configuration of disposable products comprising disposable products having a second product width, said second product width larger than said first product width.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIGS. 1A and 1B are a schematic of a representative web processing system;
[0047] FIG. 2 is a top view of a floorplan layout of the web processing system of the present invention;
[0048] FIG. 3 is a top view of a floorplan layout of the web processing system of the present invention;
[0049] FIG. 4 is a side view of the ground level and mezzanine levels of the web processing system of the present invention;
[0050] FIG. 5 is a side view of an extension panel construction section of the present invention;
[0051] FIG. 6 is a side view of a back ear final construction section of the present invention;
[0052] FIG. 7 is a side view of a soft backsheet lamination section of the present invention.
[0053] FIG. 8 is a perspective view of a mezzanine and floor level of a web processing system of the present invention used to create a pant-type product;
[0054] FIG. 9 is a perspective view of an alternate mezzanine and floor level of a web processing system of the present invention used to create a brief-type product;
[0055] FIG. 10 is a perspective view of a loaded material roll supply cart of the present invention;
[0056] FIG. 11 is a perspective view of a gantry crane system carrying a material roll used in the present invention, shown in a retracted position;
[0057] FIG. 12 is a perspective view of a gantry crane system carrying a material roll used in the present invention, shown in an extended position;
[0058] FIG. 13 is a side view of a turret unwind and splicing system for carrying expiring material rolls and waiting new material rolls.
[0059] FIGS. 14-22 are views of a splicing and material recovery sequence.
[0060] FIG. 23 is a side view of an alternate embodiment of a bump and severing mechanism for bumping an expiring roll to a splice tape on a waiting material roll, and severing the expiring roll.
[0061] FIG. 24 is a schematic view of a disposable product producing facility, and attendant communications system.
[0062] FIG. 25 is a schematic view of a disposable product producing facility with multiple production machines, and attendant communications system.
[0063] FIG. 26 is a decision tree for material supply.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0064] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0065] It is noted that the present waste minimization techniques and apparatus are described herein with respect to products such as diapers, but as previously mentioned, can be applied to a wide variety of processes in which discrete components are applied sequentially.
[0066] Referring to FIGS. 1A and 1B , a two-level disposable product manufacturing process is disclosed. Portions of the disposable product are formed on a floor level, and other portions are formed on an upper or mezzanine level.
[0067] On the floor level, the web processing operation starts with incorporating raw materials such as paper pulp and super absorbent polymer (SAP) in a pulp mill. The mixture is sent to a core forming drum, where cores are formed for retaining liquids. A core can be placed on a tissue and processed as shown. Eventually, an additional tissue layer can be applied to sandwich the core. In the illustrated embodiment, two independent cores can be formed and joined together at a compression unit.
[0068] Simultaneously formed on the upper level are back ear and front ear portions of the disposable product, which can be formed with methods and apparatus such as those disclosed in the simultaneously pending U.S. patent application Ser. No. 12/925,033, incorporated herein by reference, and described in the schematic as the “NOSE unit.”
[0069] As disclosed therein, discrete preferably trapezoidal ear pieces are initially cut alternating between a correct orientation and an incorrect (reversed) orientation. The reversed ear is required to be rotated 180° into the correct orientation such that the ears and associated tape present a left ear and a right ear on the diaper.
[0070] To accomplish the reversal of the ear pattern, discrete ear pieces are picked up at the nested ear pitch by an ear turner assembly that will expand to a pitch large enough for ears to be unnested and allow clearance for every other ear to be rotated. The rotated ears are then unnested and into the correct orientation.
[0071] Two ear turner assemblies can be provided, to rotate every other ear applied to the right side of the product, and every other ear applied to the left side of the product. In this manner, for a single product, one of the two ears will have been rotated 180°.
[0072] Ear application to a chassis web can be by a bump method with intermittent adhesive applied to the chassis web, or can be by vacuum transfer.
[0073] Still on the upper level, a cuff portion of the diaper can be supplied from the upper level, the top sheet can be stored and unwound, an acquisition layer can be stored and unwound, and a nonwoven backsheet/poly laminate can be stored, formed and unwound. All of the stored materials on the upper level can be retrieved automatically and mechanically to restock as the rolls are used up. Eventually the upper level materials, which generally overly the floor level machinery, are supplied down to the floor level for use in the diaper manufacturing process.
[0074] Together on the floor level, the back ear, front ear, cuff (now including cuff elastic), top sheet, acquisition layer, and backsheet/poly laminate are preferably simultaneously placed and coupled together and coupled with the previously formed core. The web can undergo folding, extraction and trimming of excess material, and application of material to tighten the diaper about the waist. Eventually, the product is folded and packaged.
[0075] Referring now to FIGS. 2 and 4 , a preferred floor plan of the present invention is shown both from a top view ( FIG. 2 ) and a side view ( FIG. 4 ). As indicated, pulp rolls 200 feed raw pulp into a pulp mill 204 , where the pulp is de-bonded. Super absorbent polymer is added from station 12 . The SAP/pulp mixture, or pulp/SAP blend, or pulp and SAP is fed onto core forming drum 14 , The pulp/SAP mixture is introduced to a core forming apparatus. Cores are made by conveying the pulp/SAP mixture through a duct and into a vacuum forming drum. Cores from core forming drum 14 are conveyed by conveyor 18 and core accelerator 20 downline. A secondary core forming drum 16 is likewise employed if a secondary core is desired, and the secondary core is passed through the debulking unit 22 , and onto the core accelerator 20 and placed atop the primary core. A compression conveyor 23 keeps control of the core to pass it through to the introduction of poly laminate backsheet. A backsheet laminate is comprised preferably of a continuous nonwoven layer (for soft, cloth like feel), along with a moisture barrier layer, generally made from polypropylene or polyethylene film. This layer can be glued, ultrasonically bonded over the length of the backsheet, or applied as a patch with glue using a slip/cut process.
[0076] Referring to FIG. 7 , the formation of the soft backsheet lamination is shown in side view, A nonwoven backsheet roll is carried on the upper level along with its backup roll to be spliced in as inventories deplete (see FIG. 3 ) and laminated together at station 110 .
[0077] Referring to FIGS. 4 and 7 , it can be seen that a process interface module 110 is carried between said unwind level and said main processing level, said main level containing splice preparation equipment 110 located between the unwind level and the main process system level, for instance by hanging a process interface module 110 from a supplied I-beam. The process interface module can achieve many functions, such as slitting, laminating, and splice preparation. After being transported vertically, the poly laminated backsheet is introduced to the fed from the bottom, at station 25 (see FIGS. 3, 7 ). A nonwoven topsheet assembly, including a lycra and cuff portion and an absorbent distribution layer, enters the system prior to the boundary compression unit. Still referring to FIG. 3 , it is noted that actual raw materials and the locations of those materials could vary in floor plan, but it is preferred that the materials remain on the vertical levels shown.
[0078] Referring back to FIG. 4 , this poly laminate and core combination is passed to boundary compression unit 29 . It is at unit 29 that other diaper elements are introduced in pre-formed fashion, from the upper level components on FIG. 1B . Also, lycra unwind unit 27 introduces lycra, in addition to the pre-formed upper level diaper components, at this point.
[0079] Referring to FIG. 2 , the upper level components comprise the front ear nonwoven supply unit 24 , to supply the front ears, the acquisition layer provided from unwind unit 26 , the top sheet supplied from the supply and unwind station 28 , and the cuff components supplied from the cuff supply unit 30 to supply the cuff material for lower level slitting/spreading and introduction of lycra, and foldover of the lycra to form the cuff. These materials are fed in the pathways shown, and introduced to the boundary compression unit 29 , in the sequence shown in FIGS. 1A and 1B .
[0080] Still referring to FIG. 2 , on the upper level, the back ear and extension panel are formed at station 60 . The back ear section is formed as shown in FIG. 6 , using the methods and apparatus formed in U.S. application Ser. No. 12/925,033, disclosed herein by reference. The extension panel section is formed as shown in FIG. 5 . In particular, the depiction and description shown in FIG. 19A-26 of U.S. application Ser. No. 12/925,033 results in the back ear/extension panel formation depicted in FIGS. 5 and 6 . Ultimately the back ear/extension panel construction is transported as depicted, downwards toward the nested zero waste ear rotation unit 27 as shown on FIG. 4 , also described in detail in U.S. application Ser. No. 12/925,033, for instance at FIG. 8A of that application.
[0081] Still referring to FIG. 4 , front, ears are formed at unit 24 using preferably nonwoven material, and are placed onto the chassis web preferably by slip-cut technique after being conveyed circuitously and downwardly towards the boundary compression unit 29 .
[0082] Cuff unit 30 conveys, from the upper level, cuff material to the lower level where right and left cuffs are formed by passing the cuff material first through slitter 42 , spreader 44 . Lycra unwind unit 27 feeds strands of lycra onto the cuff material, and then a bonding/foldover unit 46 seals the lycra strands within a foldover portion of the nonwoven material to create the cuff.
[0083] An additional bonding unit 48 couples the previously created cuff with the incoming topsheet material 28 , fed from the upper level downwardly. The cuff/topsheet combination is fed toward incoming acquisition layer 26 for acquisition placement at station 50 and that combination is then fed toward the NOSE unit 32 , where the previously formed materials will be joined with the cuff/topsheet/acquisition combination. After the NOSE unit, all of the materials are then joined at the boundary compression unit, including the nonwoven topsheet assembly, including an absorbent distribution layer, lycra and cuff portion, which have entered the system prior to the boundary compression unit.
[0084] Now moving right to left on FIG. 4 , the formed diaper can be subjected to folding plows 52 to fold over front ear and back ear/extension panels, passed through a die cut unit 56 to sever individual products from the previously continuous web, and then past tucker blades 54 to fold the products at the crotch region or elsewhere desired for packaging and bagging operations at station 00 .
[0085] Referring now to FIG. 5 , the extension panel construction is shown. The formation of side panel assemblies begins with an nonwoven web material 318 , supplied in primary and backup roll fashion, with splicer 320 and accumulator 322 used to provide a continuous web, which is slit and spread into discrete nonwoven web portions (see FIG. 2 ), each of the nonwoven web portions also preferably being cut in the cross-machine direction into the preferred size.
[0086] To each of the discrete nonwoven web portions, one or more fastening mechanisms are applied. Fastening mechanisms can be tape tabs, covered tape tabs, strips of hook and loop material, continuous hook and loop material, patches of hook and loop material, etc. The fastening mechanisms will be unfastened and refastened about the waist of the user to tighten the disposable garment about the waist.
[0087] The fastening mechanisms are supplied by incoming web 62 , slit and spread by units 64 and applied via slip cut unit 324 onto the nonwoven 318 .
[0088] Next, the nonwoven webs 318 carrying fastening mechanisms 322 are folded over, creating a folded web 318 and folded-over fastening mechanisms. This causes the combination of the nonwoven web 318 and the fastening mechanisms to be narrower than the discrete nonwoven web portions. It is noted that the folded fastening mechanisms of web portions 318 a and 318 b will have opposing fastening mechanisms 322 ′ as they will become the right and left hip waist fastening mechanisms, respectively, once placed about the waist of a user (shown later in the process).
[0089] Referring now to FIG. 6 , the back ear final construction is shown, a cross sectional view of the designated view of FIG. 2 . This process is disclosed, e.g., in FIGS. 20-22 of simultaneously pending U.S. patent application Ser. No. 12/925,033, incorporated herein by reference.
[0090] The back ear final construction receives where indicated the partially completed extension panel assembly where indicated, which first pass through additional folding units 342 . A back ear web 28 is provided upon which to attach the previously formed extension panel. This too can be slit and spread into discrete stretch laminate web portions.
[0091] Next, the nonwoven web portions, including their respective fastening mechanisms, are slip/cut and bonded to stretch laminate web portions in a staggered relationship, forming the side panel assemblies in four different lanes. The nonwoven web portions can be bonded to the stretch laminate web portions in any fashion, such as by ultrasonic bonding.
[0092] The stretch laminate portions can also be folded if desired, or the stretch laminate portions in combination with the nonwoven web portions can all be folded together and again, by plows 52 . The back ear/extension panel construction assembly is then conveyed to the floor level NOSE unit 32 , ultimately for placement with the other components and the boundary compression unit 29 .
[0093] Referring now to FIG. 8 , a perspective view of a mezzanine (or material unwinding) level 480 and floor (or main processing) level 482 of a web processing system used to create a pant-type product of the present invention is shown. The material unwinding level 480 is a human-free zone, intended for no human occupation during machine operation in areas accessible by a gantry crane 500 .
[0094] On the floor level, a series of ground floor material access doors 464 are provided. These access doors 464 are each preferably dedicated to a single material. For example in a preferred embodiment, door address 416 is for transporting inner nonwoven material from the ground level to the mezzanine level. Address 414 is for outer nonwoven, address 412 for non-woven backsheet material, address 410 for non-woven topsheet material, address 408 for poly backsheet material, address 406 for acquisition layer material, and address 404 for tissue material. A vertical reciprocating conveyor (VRC) operates behind each access door 464 to lift a full rack of waiting new material rolls ( FIG. 10 ) supplied into the addresses in magazines to the mezzanine level. Alternatively, descending robots can be used in place of the VRCs.
[0095] Preferably, when an access door 464 is open, a corresponding access door on the mezzanine level is closed, and vice versa.
[0096] On the material unwinding level 480 , unmanned, auto-fed material unwinding systems are provided corresponding to the materials supplied to addresses above. In a preferred layout, turret unwind 424 is for a tissue unwind, corresponding to address 404 on the ground and mezzanine levels (turret unwind detail provided in FIG. 13 ). An acquisition layer unwind station 426 (corresponding to station 406 ) is provided, as are turret unwinds for poly backsheet unwind 428 (corresponding to station 408 ), nonwoven topsheet layer 430 (corresponding to station 410 ), nonwoven backsheet layer 422 (corresponding to station 412 ), outer chassis nonwoven unwind 434 (corresponding to station 414 ), and inner chassis nonwoven unwind 436 (corresponding to station 416 ).
[0097] As material is unwound from the unwinds 424 , 426 , 428 , 430 , 432 , 434 , and 436 , material is fed through material supply slots 462 in the floor of the mezzanine level, downward to the ground level 482 . There, the materials are fed into and used by the system, as shown in FIGS. 1A and 1B, 2, and 4-7 .
[0098] As a connected material roll feeds material from the mezzanine level through an opening 462 in the floor of the mezzanine level to the floor level, the material roll will eventually expire.
[0099] During machine operation, those portions of the mezzanine level accessible by a gantry crane system 500 are designed to operate without human occupation. This not only provides an added measure of safety, but an added measure of automation for the machine. A gantry crane system 500 operates robotically on an overhead system that allows movement across a horizontal plane. The present invention uses the gantry crane 500 for horizontal movement, and a robotic arm 502 capable of vertical movement and rotation, and equipped with a camera operated location system (see FIGS. 11 and 12 ) to detect the position of the core of waiting new material rolls for pickup, and to deposit precisely a core of a replacement waiting new material roll onto arms of turret unwinds for use in the system.
[0100] Gantry robots 500 are preferred for this pick and place applications because of positioning accuracy, aided by vision systems. Positional programming is done in reference to an X, Y, Z coordinate system.
[0101] Although humans can access the mezzanine level 480 by stairs 460 for equipment service, no human occupation during operation is intended. Humans can also access the mezzanine level 480 behind access door 452 , this portion of the mezzanine level 480 is physically separated from the human-free zone of the other portions of the mezzanine level 480 . Access door 452 is used to access physically divided power station and control station 450 . This station is for control panels, ultrasonic bonder control, and drive controls.
[0102] Also evident on FIG. 8 are pulp rolls 402 supplying pump mill 400 at the beginning of the processing on the main floor, and a final knife unit 466 , an ear folding and horizontal pad turner 468 , and lastly a cross-folder 470 which discharges the diapers to product packaging downstream.
[0103] This unique machine layout has achieved significant machine length decrease. Exemplary prior art diaper making machines for a pant process are approximately 44 meters, and this new machine layout can be achieved in less than 34 meters, a 23% shorter overall machine length from the beginning of the pulp unwind to the end of cross-folder 470 . A range of 20-35% decrease in machine length can be achieved.
[0104] Referring now to FIG. 9 , a perspective view of an alternate mezzanine and floor level of a web processing system of the present invention used to create a brief-type product is shown.
[0105] In this embodiment, carts of materials are staged initially on the ground floor. In an exemplary embodiment, loading carts are position at stations 510 (upper tissue), 512 (lower tissue), 514 (poly backsheet), 516 (nonwoven backsheet), 518 (back ear), 520 (acquisition layer), 521 (front ear), 522 (nonwoven topsheet), 524 (extension panel), and 526 (cuff). These materials are transported to and placed behind VRC door 464 and transported by VRC 550 to the mezzanine level 480 . A similar demand/replacement system is employed in the brief-type product floor layout as in the pant-type product layout described in FIG. 8 . Namely, expiring materials are fed through slots in the floor of the mezzanine level, a splicing sequence is initiated, and a material replacement sequence is initiated, whereby a material roll is acquired by crane/robot combination 500 / 502 and transported to and placed on the turret unwind systems.
[0106] In the pictured embodiment, a lower tissue turret unwind 532 is provided as are turret unwind stations for upper tissue ( 530 ), poly backsheet ( 534 ), nonwoven backsheet ( 536 ), back ear ( 538 ), acquisition layer ( 540 ), front ear ( 541 ), inner top-sheet nonwoven extension panel ( 544 ), cuff ( 546 ). These materials are all fed downward to be used in a brief-type diaper.
[0107] This unique machine layout has achieved significant machine length decrease. Exemplary prior art diaper making machines for a brief process are approximately 41 meters, and this new machine layout can be achieved in less than 29 meters, a 30% shorter overall machine length from the beginning of the pulp unwind to the end of cross-folder 470 . A range of 20-35% decrease in machine length can be achieved. A power station and control station 592 is provided. Additionally, certain components can be fed at the ground level, for instance an offline stretch material unwind 590 .
[0108] Referring now to FIG. 10 , a perspective view of a loaded material roll supply cart 600 or magazine of the present invention is shown. A material staging magazine 600 is provided to carry waiting new material rolls 602 from a ground level to a mezzanine level 480 , the mezzanine level 480 carrying a series of turret unwind systems for dispensing materials from the mezzanine level back to the ground level. The material staging magazines 600 contain a series of individual roll stabilization features 604 which prevent waiting new material rolls 604 from tipping during material transport and unloading. The cart 600 is filled on the ground level, and rolled into the appropriate ground level addresses 404 , 406 , 408 , 410 , 412 , 414 , and 416 , for transport to mezzanine level addresses 404 , 406 , 408 , 410 , 412 , 414 , and 416 . The rolls are then summoned as described above.
[0109] Referring now to FIG. 11 , a perspective view of a roll transfer device 700 comprising a gantry crane 500 system carrying a material roll 602 used in the present invention is shown in a retracted position. A camera 612 is used to detect the position of a core of a waiting new material roll during pickup of a waiting new material roll by the robot off of a cart 600 , and also to detect the position of the shaft 616 on the turret unwind systems ( FIG. 13 ) upon which to push the material roll 602 with roll bumper 610 . Lasers, radar, or ultrasonics can also be used to measure distance and position, either in addition to or instead of camera 612 .
[0110] In an alternate embodiment (not shown), an automated cart is provided. A powered and programmed cart is provided to retrieve material rolls from an initial storage location, and then to return to the material address to be called upon to provide new material rolls to the system. Once emptied of one or more waiting new material rolls, the powered and programmed cart returns to retrieve material rolls from the initial storage location.
[0111] FIG. 12 is a perspective view of a gantry crane 500 carrying a material roll 602 used in the present invention, the robotic arm 502 shown in an extended position.
[0112] Referring now to FIG. 13 , a side view of a turret unwind and splicing system for carrying expiring material rolls 602 ′ and waiting new material rolls 602 is shown. In a preferred embodiment, an expiring material roll 602 ′ is positioned in an expiring material roll position at the top of turret arm 622 , and waiting new material rolls 602 are positioned in a waiting roll position at the bottom of turret arm 622 . Of course alternate configurations are possible for the positions of expiring material roll position and the waiting roll position,
[0113] Turret unwinds are described for exemplary purposes in U.S. Pat. Nos. 6,701,992, 3,655,143, 3,306,546, 3,460,775, which are incorporated herein by reference.
[0114] When the system detects that one of the expiring material rolls 602 ′ in the top position on unwinds 424 , 426 , 428 , 430 , 432 , 434 , and 436 is set to expire of material 642 , a splice sequence is initiated between the expiring material roll 602 ′ and the waiting new material roll 602 . In a preferable embodiment, a running or expiring roll 602 ′ is at a top position of the turret unwind of FIG. 13 , with a waiting new material roll 602 placed by the gantry crane system located at a bottom position of the turret unwind on shaft 616 . The web 642 of expiring roll 602 ′ is guided to the hot wire splicer arm 624 structure by a guide roller 640 .
[0115] A splice and material recovery sequence is shown with reference to FIGS. 14-22 . Referring first to FIGS. 14 and 15 , when vision system 650 detects that, the expiring roll 602 ′ traveling at velocity V 1 is coming close to expiration (compare the size of expiring roll 602 ′ from FIG. 14 to FIG. 15 ), the waiting new material roll 602 traveling at velocity V 2 is driven up to velocity V 1 .
[0116] Referring to FIG. 14A , the expiring roll 602 ′ carried by rotating shaft 616 has a core 602 a, around which is wrapped material 642 .
[0117] Referring now to FIG. 16 , hot wire splicer arm 624 moves in adjacent to the waiting new material roll 602 , bringing in the running web 642 into close proximity to the waiting new material roll 602 . Vision system 650 a (or a photo eye) identifies the location of splice tape 644 , and then the waiting new material roll 602 is driven by its controlled motor so that at the moment of splice, a bump of the expiring roll material 642 towards splice tape 644 by arm 624 bonds the expiring roll material 642 to material 644 of the waiting roll 602 . A bump arm of the hot wire structure 624 bumps the expiring web 602 ′ to the waiting new material roll, and at the precise moment of contact, splice tape 644 is introduced to splice the web 644 of waiting new material roll 602 and the expiring roll 602 ′ together. At the same time as the bump, the hot wire arm 624 severs the running web with a hot wire. In this manner, the expiring web material 642 is instantly taped to the leading edge of the new roll material 644 , as depicted in FIG. 18A .
[0118] Referring now to FIG. 17 , at the moment that the web 642 is severed, a free end 643 of web 642 is created. Just prior to or when web 642 is severed, a vacuum is initiated and drawn by vacuum structure 646 which is coupled to a source of negative pressure (not shown), and the vacuum structure 646 is situated in close proximity to web 642 . At this point, web 644 is paid out and is supplied to the process, and there is no longer any use for the expiring roll 602 ′ comprising the web 642 and the core 602 a. Material recovery system or vacuum structure 646 recovers free end 643 of web 642 , and the remainder of web 642 is paid out by rotation of shaft 616 . Web 642 is paid out by shaft 616 until the entirety of the web 642 becomes separated from core 602 a as shown in FIG. 19 . At this point, point shaft 616 is no longer required to rotate until called upon to begin rotation of the next web of material.
[0119] Material recovery system 646 thus automatically separates an expiring roll core 602 a from the expiring material 642 . Two single material waste streams are created, one of the expiring roll core 602 a , and the other of the expiring material 642 , which makes recycling and downstream handling of the expiring roll cores 602 a and expiring material 642 simpler and more efficient because the waste streams are not required to be handled manually.
[0120] Next referring to FIG. 20 , the rotating turret arm 622 rotates clockwise to place the waiting new material roll 602 into the expiring roll position (because the material roll 602 will now be an expiring roll 602 ′), preferably at the top vertical position of rotating turret arm 622 . Clockwise rotation of the turret arm 622 also places the shaft 616 (still carrying core 602 a ) in the waiting roll position in order to automatically receive a new waiting roll 624 . Also at this time, splicer arm 624 swings away. During rotation of the rotating turret arm 622 , it is desirable to vary V 2 during rotation of the new material roll 602 from the waiting position to the expiring roll position, in order to maintain constant tension and supply rate of web 644 to the downstream processing operations.
[0121] Referring now to FIG. 21 , rotating turret arm 622 causes the newly expiring roll 602 to reach the expiring roll position, and eventually splicer arm 624 swings back to its ready position for the next bump sequence.
[0122] Referring now to FIG. 22 , a kicker ring 620 next bumps the core 602 a off of shaft 616 for discard, and kicker ring 620 then reverts back to its position proximal to the rotating turret arm 622 to allow shaft 616 to receive the next waiting roll 602 , for instance from the unit configured in FIG. 12 .
[0123] Next, the system demands a replacement waiting new material roll to place upon the shaft 616 at the bottom position of the turret unwind.
[0124] At the mezzanine level addresses 404 , 406 , 408 , 410 , 412 , 414 , and 416 , magazines of waiting new material roll ( FIG. 10 ) are received from the ground level, and wait for demand. The gantry crane 500 is summoned to pick up a material roll from a cart ( FIG. 10 ) stationed at the dedicated VRC stations, and transport the full material roll to a turret unwind system dedicated to that particular material. The system detects which waiting new material roll requires replacement after its predecessor has been spliced and turned into an expiring roll, and then travels the crane/robot combination 500 / 502 to the appropriate mezzanine level address 404 , 406 , 408 , 410 , 412 , 414 , and 416 and obtains a replacement waiting new material roll.
[0125] The gantry robot is programmed to discard the remainder of the expiring roll (the now empty core 602 a ) into a waste chute (not shown) on the mezzanine level or to container 660 ( FIG. 22 ), and then to obtain a replacement waiting new material roll from the dedicated VRC from which the appropriate material is located on the cart. When the system detects that all rolls of waiting new material roll are used from a supply cart ( FIG. 10 ), the VRC containing the empty cart is automatically transported to the floor level for replacement of all of the waiting new material rolls.
[0126] Referring now to FIG. 23 , a side view of an alternate embodiment of a bump and severing mechanism for bumping expiring roll 602 ′ to splice tape 644 on the waiting material roll 602 , and severing the expiring roll 602 ′ is shown. In this embodiment, a sliding bump/sever mechanism 668 is engaged when called upon, to bump via roller 672 the expiring web material 642 against splice tape 644 . In preferred embodiments, the linear sliding bump/sever mechanism 668 can be fired by an air cylinder, simplifying setup of the pivot arm 624 previously described, or the sliding bump/sever mechanism 668 could be servo motor driven. When called upon, for instance when vision system 650 senses material 602 ′ is running out, the splicing/severing sequence begins. The bump/sever mechanism 668 linearly approaches the web 642 to bump the web 642 into contact with splice tape 644 , and momentarily thereafter, a hot wire 670 severs expiring web material 642 , allowing newly expiring roll material to be used in the process as shown in FIG. 18 a.
[0127] Referring now to FIG. 24 , a schematic view of a disposable product producing facility, and attendant communications system is shown. As can be seen, this schematic can be used to plan an inventive production facility of the present invention.
[0128] At the conceptual center of the facility is a front office, where communications take place (receiving and sending information) between the front office and a machine equipment platform, an incoming warehouse and storage section, an outgoing packages section, and a case packaging section. The machine equipment platform is where disposable products are products, e.g., a machine to make diapers. The incoming warehouse/storage section is where raw materials are delivered to the facility, and stored until called upon for introduction into the machine equipment platform or the case packaging platform. The outgoing packages portion of the facility if where formed product in packages and cases, is stored for distribution outside of the facility. The front office will receive information and send information from the different segments to inform of material requirements, inventory, and scheduling.
[0129] Referring now to FIG. 25 , a schematic view of a disposable product producing facility with multiple production machines, and attendant communications system is shown. Disclosed is an Automatic Roll Loading System (ARLS). A plurality of ARLS schedulers (S 1 , S 2 , and S 3 ) for example, communicate with each other, and with their dedicated production machines (Production Machines 1 , 2 , and 3 , respectively). Specifically, the ARLS scheduler(s) of the present invention anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. Those decisions are informed by, with respect to ARLS scheduler S 1 but equally applicable to the schedulers S 2 and S 3 , sales and marketing input/output A 1 , purchasing input/output A 2 , and scheduling input/output A 3 . Sales and marketing input/output A 1 contains information related to the desired output quantity of certain disposable products, e.g., SKUs (stock keeping units of a particular product that allows it to be tracked for inventory purposes). A specific material requirement schedule for each of the certain disposable products is necessary, and purchasing input/output A 2 reacts with the scheduler S 1 to ensure that required materials are on hand at the incoming warehouse storage of FIG. 24 . Scheduling input/output A 3 reacts with sales and marketing input/output A 1 , and purchasing input/output A 2 , as well as the ARLS scheduler S 1 to control when ARLS scheduler S 1 commands production machine M 1 to manufacture a specific product.
[0130] ARLS scheduler S 1 commands production machine M 1 to manufacture a specific product, and when informed by receiving/purchasing/scheduling input/outputs A 1 /A 2 /A 3 to command machine M 1 to manufacture a different specific product, raw material used by production machine M 1 may require changeover, e.g., for a size dependent material change such as a chassis web of a different width. Once all material unwinds of machine M 1 (e.g., any one of upstairs unwinds of FIG. 9 ) have the size of material rolls loaded and splices set up, splices can by manually or automatically triggered to splice in the new material rolls and use the running machine process to pull all the new materials through the process. This saves considerable time compared to loading each unwind manually and then manually rethreading each material process throughout the machine. The result is a significant reduction in change-over times and the present technique can be employed for any machine process requiring input of multiple material rolls when different materials (size, weight, color, etc.) are required for different products codes or sizes.
[0131] When employing the technique described herein, splicing in different width materials and pulling them through a running machine process will not result in the immediate making of acceptable products. The present method results in intentionally pulling in material widths different than what the current product code being run is setup for, so certain details will result in unacceptable product; for instance, glue applicator patterns may exceed the new material width and therefore glue applicators are turned off for the duration of this material pull through technique. For the same reason, web with detectors are temporarily disable or ignored, and web guides put into a non-responsive mode so they do not try and respond to material widths not compatible with their current setup. Those machine capabilities are restored prior to starting the next good product run, but by pulling in new materials through web processes by using the old materials already threaded through web processes, good-product to good-product changeover is greatly sped.
[0132] An ARLS Scheduler monitors machine speed, consumption of raw materials, materials remaining on each turret unwind, progress on case count of current product code run, schedule of next product code run, materials available at machine, materials remaining on each material loading cart, and optionally, materials in warehouse, and general position of robot carts in motion.
[0133] Referring now to FIG. 26 , a decision tree for material supply is shown. First, the ARLS Scheduler determines which turret unwind should be loaded next. It also determines when material rolls specific to the NEXT product code to be run should be loaded onto the associated turret unwinds. This is part of the preparation to conduct the special splice event as part of the current product code run shutdown. Once new materials are pulled through the machine process (auto-threaded) by the expiring materials, the machine can be full shut down in preparation for other, non-material related changeover activities to set the machine up for the next product code run.
[0134] The ARLS Scheduler may also keep track of the changeover parts, assemblies, and set-ups needed for each specific changeover to assist the machine operators and technicians in their outside time preparations for the changeover as well as during the inside time changeover activities when in progress.
[0135] The basic roll loading decision is informed by information queries such as: material remaining on each cart; status of a turret unwind as ready to load; and the time remaining or product pitches remaining to end of roll on the turret unwind. The decision could be located in the turret unwind control routine, the ARLS PLC, or the machine control PLC depending on size, complexity, or configuration of machine.
[0136] As described with respect to FIGS. 1-23 , a vertical reciprocating conveyor or a robot is used to carry waiting new material rolls from a main processing level to the material unwinding level. A robotic assembly obtains an expiring roll and discards the roll in a waste chute. Once on the material unwinding level, the waiting new material rolls are staged at a material address dedicated to that particular material. A robotic assembly acquires a material roll from one of said material addresses and transports and places the material roll onto its appropriate auto-fed material unwinding system.
[0137] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, 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. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. | A machine for producing disposable products anticipates when a current run of a product size is coming to an end, and therefore begins loading of material rolls intended for the next product size or code that will be run. An integrated production facility layout automatically orders and stocks raw material based on production plans, and commands a production machine to produce specific products of differing configurations, and automatically loads appropriately sized raw materials into the process. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a squeeze roller retraction assembly, for use with an electrophotographic copying machine of the type in which a latent image is subjected to a wet developing step and the resulting visual image is transferred onto a record sheet, for facilitating the dismounting or mounting of a photosensitive drum from or onto the machine.
In the known copying process in which an electrostatic latent image is formed on the surface of a photosensitive drum and is converted into a visual image with a developing solution and then the visual image is transfered onto a record sheet, the removal of an excess amount of developing solution which wets the surface of the drum before the visual image is transferred onto the record sheet is essential in order to assure a successful transfer. A squeeze roller is usually employed and is effective to remove such excess amount of developing solution. Referring to FIG. 1 for a brief description of the process involved, there is shown a photosensitive member 1 in the form of a drum, and a squeeze roller 2 is disposed closely thereto at a position intermediate a developing station and a transfer station. The roller 2 is shown as mounted on a rotary shaft 20, which is driven at a rotational speed, determined by the peripheral speed of the drum 1, in a direction which is usually opposite from the direction of rotation of the drum, but which may be the same therewith, in order to remove an excess amount of developing solution from the drum surface. The squeeze roller 2 is urged toward the drum surface, and a pair of bearings 21, 22 rotatably disposed on the opposite ends of the squeeze roller 2 function as spacers to maintain a constant spacing, between the surface 23 of the roller and the drum 1, which corresponds to the difference in diameter between the roller surface 23 and the bearings, by abutting against the opposite ends of the drum surface.
When dismounting or mounting the drum 1 from or onto the copying machine, the squeeze roller 2 must be retracted from the drum surface since otherwise the surface of the drum which is displaced axially may be scratched by the bearings 21, 22 which are maintained in abutting engagement therewith to thereby cause damage to the drum surface or to interfere with the dismounting or mounting operation. Heretofore, the squeeze roller has been retracted by a separate operation from the mounting or withdrawal of the drum, with the result that inadvertent errors have been involved in dismounting the drum without retracting the squeeze roller to cause damage to the drum surface, forgetting to replace the squeeze roller to its operative position after the drum has been mounted, thereby wetting the record sheet too much to provide a good copy.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the invention to provide a squeeze roller retraction assembly which provides an automatic retraction of the squeeze roller when the photosensitive drum is dismounted and which provides an automatic replacement of the squeeze roller when the drum has been mounted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the positional relationship between a squeeze roller and a photosensitive drum;
FIG. 2 is a schematic front view of one embodiment of the invention;
FIG. 3 is an axial section of the photosensitive drum;
FIG. 4 is a fragmentary side elevation of the embodiment shown in FIG. 2;
FIG. 5 is a perspective view of the coverplate shown in FIG. 3;
FIG. 6 is a side elevation, partly in section, of a mechanism which transmits a drive to the squeeze roller;
FIG. 7 is a perspective view of another example of the mechanism which transmits a drive to the squeeze roller;
FIG. 8 is a perspective of a further example of the mechanism which transmits a drive to the squeeze roller;
FIG. 9 is a perspective view of an additional example of the mechanism which transmits a drive to the squeeze roller;
FIG. 10 is a fragmentary front view of the squeeze roller and the blade;
FIG. 11 a schematic view showing the positional relationship between the sequeeze roller and the blade when mounting the latter on the former; and
FIG. 12 is a perspective view of a slantwise notched blade which prevents damage or bending thereof when mounting it on the squeeze roller.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIG. 2, there is shown one embodiment of the squeeze roller retraction assembly according to the invention. The assembly includes a coverplate 4 which is mounted to cover an opening 3 formed in the sidewall of the casing of the copying machine so as to permit a passage of the photosensitive drum 1 therethrough. Another sideplate 7 is formed with a bearing, as is the coverplate 4, for supporting a shaft 10 on which the drum 1 is mounted. A support member 5 is pivotally mounted on a stationary pin 51 for journaling the rotary shaft 20 on which the squeeze roller 2 is mounted. A tension spring 53 extends between the free end of the support 5 and a stationary point to bias support 5 for a clockwise rotation, as viewed in FIG. 2. The bias is effective to urge the squeeze roller 2 toward the drum 1, whereby the bearings 21, 22 (shown in FIG. 1) are brought into abutment against the opposite ends of the drum surface. The support member 5 fixedly carries a pin 52 intermediate its length. A release lever 6 is pivotally mounted on a shaft 61, and has its one end engaged by a tension spring 64 the other end of which is anchored to a stationary point, whereby the lever 6 is biased for a clockwise rotation about the shaft 61. As shown in FIG. 4, the shaft 61 extends through the sideplate 8, and a pin 62 is fixedly mounted thereon on the opposite side of the sideplate 8 from the lever 6 for engagement with the pin 52 on the support member 5. At its other end, the release lever 6 fixedly carries a detent pin 63. The coverplate 4 is formed with a detent piece 41, which, as shown in FIG. 5, extends in a plane parallel to, but spaced from the plane of the coverplate 4. The detent pin 63 is engaged by the detent piece 41 to limit the extent of the angular movement of the release lever 6 which takes place under the bias of spring 64 (see FIGS. 2 and 4).
When dismounting the drum 1 from the machine, set screws 42, 43 etc., (see FIG. 2) which secure the coverplate 4 in place, are removed to permit an axial movement of the drum 1 through the opening 3. As the coverplate 4 is removed, the detent pin 63 on the release lever 6 is disengaged from the detent piece 41, whereby the lever 6 rotates clockwise under the bias of the spring 64. Thereupon, the pin 62, which is fixedly mounted on the shaft 61 engages the pin 52. The bias of the spring 64 is so chosen that a sufficient torque is applied to the release lever 6 to cause a counterclockwise rotation of the support member 5 through the engagement between the pins 62, 52 to thereby retract the squeeze roller 2 away from the drum surface. After the squeeze roller 2 is retracted from the drum surface, the drum 1 is axially moved through the opening 3 to the exterior thereof. The squeeze roller 2 is retracted until a clockwise rotation of the release lever 6 is interrupted by its abutment against a pin 9 which is fixedly mounted on the sideplate 8. At this time, the detent pin 63 will assume a position which the detent piece 41 previously occupied.
When replacing the drum 1 into the machine, the procedure is opposite to that described above. To close the opening 3 with the coverplate 4, the coverplate 4 is secured to the sideplate 8 by means of the screws 42, 43, ect., after locating it by fitting locating apertures 46, 47 formed in a pair of projections 44, 45 of the coverplate 4 over a pair of positioning pins 11, 12 which are fixedly mounted on the sideplate 8. In the course of such assembly, the detent pin 63 on the release lever 6 is engaged by the detent piece 41 integral with the coverplate 4 to thereby rotate the lever 6 in the counterclockwise direction. Thus, the coverplate 4 cannot be secured to the sideplate 8 unless the detent pin 63 is engaged by the detent piece 41. When the coverplate 4 is secured to the sideplate 8 in this manner, the torque applied to the release lever 6 is no longer transmitted to the support member 5, which is therefore allowed to rotate clockwise under the bias of the spring 53 to bring the squeeze roller 2 into its operative position again. Thus the engagement and release of the lever 6 with or from the detent piece 41 of the coverplate 4 is automatically achieved when dismounting or mounting the drum 1, thereby eliminating the disadvantages mentioned above.
With the present retraction assembly, the squeeze roller 2 is displaced as the drum 1 is dismounted or mounted. Since a drive is transmitted to the squeeze roller 2 to rotate it, the transmission mechanism must be capable of allowing such a displacement of the squeeze roller 2. Such a mechanism may comprise a flexible means such as spring 25 shown in FIG. 6 which transmits a drive from a drive gear 24 to the rotary shaft 20. Alternatively, as shown in FIG. 7, the mechanism may comprise a driven gear 26 fixedly mounted on the rotary shaft 20 and meshing with a drive gear 27, the shaft 271 of which rotatably carries a lever 28 on which the shaft 20 is carried, for permitting a displacement of the squeeze roller 2 as the lever 28 rocks. As a further alternative, FIG. 8 shows a drive mechanism comprising a drive pulley 29 and a driven pulley 31 which is fixedly mounted on the rotary shaft 20 and which is driven by the pulley 29 through a transmission belt 30, thus enabling a displacement of the squeeze roller 2. As an additional alternative, FIG. 9 shows a lever 32 carrying the rotary shaft 20 and pivotally mounted on a shaft 321 for rocking motion thereabout so that a displacement of the squeeze roller 2 may be permitted, while moving the driven gear 26 into and out of engagement with the drive gear 27 so that the drive is transmitted to the roller only when the both gears 26, 27 are in meshing engagement with each other.
As shown in FIG. 10, a blade 13 is maintained in abutment against the periphery of the roller surface 23 of the squeeze roller 2 so as to clean the surface thereof. The blade 13 is a thin sheet of a resilient material such as Mylar film, and is usually fixedly mounted on the tank 15 of the developing unit by means of a support 14. When dismounting and mounting the tank 15 from or onto the machine, the blade is frequently damaged or bent by abutment against the end face of the squeeze roller 2 since it is configured, in its free position, to lie within the space occupied by the squeeze roller 2, as shown in FIG. 11. To prevent damage or bending of the blade 13 by abutment against the end face of the squeeze roller 2 as the tank is either dismounted or mounted, it may be bevelled at its corner which is located nearer the squeeze roller 2 as the tank is mounted, as shown in FIG. 12. When the tank is mounted together with the blade, the bevelled portion of the blade 13 initially engages the edge of the bearing 21, which flexes the blade 13 radially of the roller 2, thus avoiding damage thereto. | A squeeze roller retraction assembly for use with electrophotographic copying machines of the type in which a photosensitive drum is removable from the machine, for inspection or other purposes, through an opening formed in a sidewall which opening is normally covered by a coverplate. A squeeze roller which normally engages with the peripheral drum surface has its engagement therewith automatically released once the coverplate has been dismounted from the sidewall, and also is returned to its operative position as the coverplate is remounted, to thereby prevent damage of the drum as well as a wrong usage of the machine which may be caused by forgetting to replace the squeeze roller to the operative position. | 6 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/213,696 filed Mar. 14, 2014, now U.S. Pat. No. 9,470,226 issued Oct. 18, 2016, which claimed the benefit of U.S. Provisional Application No. 61/785,246 filed Mar. 14, 2013, the disclosures of which are hereby incorporated herein by reference in their entirety.
TECHNICAL FIELD OF INVENTION
[0002] The present invention relates to a valve assembly for use in reciprocating, positive displacement pumps, such as mud pumps, well service pumps, and other industrial applications. More particularly, the present invention is especially suitable for use in a fracking pump for subterranean production services. More specifically, the present invention relates to a multi-part valve assembly of various materials constructed in a novel manner that replaces conventional two and three part welded valves.
BACKGROUND OF THE INVENTION
[0003] Valves have been the subject of engineering design efforts for many years, and millions of them have been used. The engineering development of valves has stagnated in this crowded and mature field of technology. Improvements have been elusive in recent years, even as the cost of materials and manufacturing has continued to climb.
[0004] The basic valve structure is present in several U.S. patent publications. Some of these describe conventional methods of building a valve, and others describe methods that have been rejected by industry. Fewer disclosures teach multiple component valves, as valves having multiple components have heretofore been disfavored for a number of reasons. Primarily, they are viewed as more costly to manufacture. Multiple components require multiple manufacturing steps, assembly steps, and fit-tolerances requirements that valves having fewer parts do not have. Secondly, each assembly and connection is deemed a potential failure point, so these valves are again, disfavored.
[0005] Fracking valves are a particular valve used to pump hard material into a production wellbore for the purpose of fracturing the reservoir containing formations to increase fluid flow into the wellbore. Such pumps are reciprocating, positive displacement pumps in which the valves are held closed by springs and open and close by differential pressure. The pumps deliver clear fluids or slurries through simple poppet valves that are activated (opened and closed) by the fluid pressure differential generated when the mechanical energy of the pump is converted into fluid pressure.
[0006] In oil and gas exploration, there are two common reciprocating, positive displacement applications; mud pumps and well service pumps. This invention is also appropriate in both of these categories as well as other, general industrial reciprocating, positive displacement applications. Pump valves in these applications must be guided as they move back and forth about an axis parallel to the fluid flow. The guides may be “stems” or “wings” and these may be on either side or both sides of the valve. They must remain an inseparable part of the pump valve during its useful life.
[0007] Due to the hardness of the material being pumped, valves include a soft seating material, such as a urethane insert, such that a seal can be obtained that would be prevented with a metal-to-metal valve seating. The softer insert component necessitates at least some assembly in frack valves. Other than the inclusion of the insert, conventional manufacturing practice has been to minimize the number of components in a valve assembly.
[0008] Conventional pump valves are thus made from a pair of near net shape pieces of low carbon alloy steel that are welded together and then carburized to produce a hard, wear resistant surface. The process of manufacturing such near net shapes is expensive. Alternatively, pump valves are made from high carbon, low alloy steels of one expensive piece that requires detailed finishing, as these alloys are generally not welded.
[0009] One form of convention valve manufacturing includes making the components of the valve of high alloy steel such as 8620 or 4130. These are expensive grades of steel for manufacturing a limited life product. Additionally, conventional manufacturing techniques generate waste.
[0010] Conventional valve guides are manufactured by investment casting. It is common practice to forge a one-piece valve and top stem of low carbon alloy steel. The two pieces are welded together and carburized as a single piece.
[0011] An alternative known method of making valves is to make a single investment casting of the entire valve for assembly with only the insert. As with the other method, the entire part is then carburized to harden it.
[0012] An alternative known method of making valves is to make a single piece forging from a high carbon alloy steel. Areas that require hardened surfaces are induction or flame hardened. However, the only areas of the valve that require hardened surfaces are relatively small and include the face of the valve and the outer edges of the guides.
[0013] The present invention replaces expensive raw material forms with a combination of inexpensive pieces and allows the most productive selective hardening processes to be used.
SUMMARY OF THE INVENTION
[0014] The present invention provides a method of manufacturing and assembling a pump valve that allows the use of materials usually considered unsuitable for multiple components welded together to be constructed as a weldment.
[0015] This present invention provides for the use of high carbon or high carbon alloy steel that can be induction or flame hardened and a collection of inexpensive pieces to be assembled and captured as a finished unit at the time of welding. The weld can be a solid state inertia or friction weld or any appropriate melt fusion technique. The assembly includes a retaining pin, a guide, a valve, an insert, a retainer, and a retainer cap. The retainer cap is welded to an end of the retaining pin to compress the other elements into an assembly.
[0016] One embodiment of the present invention provides for the assembly of several components of simpler geometry that would not generally be considered candidates for welding because of their composition.
[0017] In another embodiment, a valve assembly is provided comprising a retaining pin, a wing guide located on the retaining pin, and a valve located on the retaining pin above the guide. An insert is located on the valve. An insert retainer is located on the retaining pin above the insert. A retainer cap is welded to the retaining pin to hold the collective assembly together.
[0018] In another embodiment, the top stem, retainer, wing guide stem, and wing guide are comprised of a low carbon, or low alloy steel material, and the valve is comprised of a steel that is higher in carbon content than that of the retaining pin, guide, retainer, and retainer cap.
[0019] In another embodiment, the weld between the retainer cap and the retaining pin is an inertia weld.
[0020] In another embodiment, the retainer cap has a nonagon configuration.
[0021] In another embodiment, the guide has a top portion and three legs extending downward from the top portion. A footer extends outward from each leg. Three stabilizers extend downward from the top portion, one each between the downwardly extending legs.
[0022] In another embodiment, a plurality of tabs extends outward from the top portion. The tabs engage the internal circumference of a circular recess in the valve to center the guide concentrically with the valve.
[0023] In another embodiment, the retaining pin has a generally triangular head for fitted engagement with the underside of the guide.
[0024] A primary advantage of the present invention is that many of the parts may be made of material that is easy to machine, such that these components can be made less expensively.
[0025] Another advantage of the present invention is that many of the components need not be heat treated, eliminating a costly process step that is applied to the entirety of conventional valve assemblies.
[0026] Another advantage of the present invention is that it is unnecessary to selectively and manually apply and remove expensive compounds needed to prevent carburization of several surfaces to which hardening is undesirable.
[0027] The advantages and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is an isometric view of the valve assembly shown in accordance with certain embodiments of the present invention, as viewed from the top of the valve.
[0029] FIG. 2 is an isometric view of the valve assembly of FIG. 1 as viewed from the bottom of the valve.
[0030] FIG. 3 is an isometric exploded view of the valve assembly of FIGS. 1-2 shown in accordance with certain embodiments of the present invention.
[0031] FIG. 4 is a bottom view of the valve assembly embodiment of FIGS. 1-3 , illustrating a section line A-A through this view of the valve assembly.
[0032] FIG. 5 is a sectional view of the valve assembly embodiment of FIGS. 1-4 sectioned at A-A as illustrated in FIG. 4 .
[0033] FIG. 6 is an isometric view of the retaining pin component of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0034] FIG. 7 is a bottom view of an in-process guide component of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0035] FIG. 8 is a bottom view of the guide component of FIG. 7 after a forming step.
[0036] FIG. 9 is an isometric view of the guide component of FIG. 8 .
[0037] FIG. 10 is a cross-sectional side view of the valve component of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0038] FIG. 11 is a cross-sectional side view of the insert component of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0039] FIG. 12 is a cross-sectional side view of the retainer component of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0040] FIG. 13 is a bottom view of the retainer cap of the valve assembly embodiment illustrated in FIGS. 1-3 .
[0041] FIG. 14 is a sectional view of the retainer cap of the valve assembly embodiment illustrated in FIGS. 1-3 sectioned at B-B as illustrated in FIG. 13 .
[0042] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0044] FIG. 1 is an isometric view of an embodiment of a valve assembly 10 of the present invention as viewed generally from the top of valve assembly 10 . FIG. 2 is an isometric view of this embodiment of valve assembly 10 as viewed generally from the bottom of valve assembly 10 .
[0045] FIG. 3 is an isometric exploded view of an embodiment of valve assembly 10 , illustrating the multiple components of this embodiment. Valve assembly 10 comprises a retaining pin 20 . A guide 30 is positioned on retaining pin 20 . A valve 50 is positioned on retaining pin 20 above guide 30 . An insert 60 is positioned on and in engagement with valve 50 . A retainer 70 is positioned on retaining pin 20 above and engaging insert 60 and valve 50 . A retainer cap 80 is welded to retaining pin 20 and optionally to retainer 70 .
[0046] FIG. 4 is a bottom view of the embodiment of valve assembly 10 illustrated in FIGS. 1-3 , and providing a section line A-A through this view of valve assembly 10 .
[0047] FIG. 5 is a sectional view of the valve assembly embodiment of FIGS. 1-4 sectioned at A-A as illustrated in FIG. 4 . Valve assembly 10 is illustrated inside a cylinder 100 . As shown, guide 30 centers valve assembly 10 inside cylinder 100 . Valve 50 engages cylinder 100 in normal operation, as does insert 60 . Retainer 70 compresses insert 60 , valve 50 , and guide 30 between retaining pin 20 and retainer cap 80 . Retainer cap 80 is welded at 90 to retaining pin 20 to form a secure valve assembly 10 in which the component parts do not rotate relative to each other. In an optional embodiment illustrated, retainer cap 80 is also welded at 92 to retainer 70 . In a preferred embodiment, retainer cap 80 is friction, or inertia welded at 90 to retainer pin 20 and/or friction or inertia welded at 92 to retainer 70 .
[0048] FIG. 6 is an isometric view of an embodiment of the retaining pin 20 component of the illustrated embodiment of valve assembly 10 . In the embodiment illustrated, retaining pin 20 has a triangular shaped base 22 . Referring back to FIG. 4 , it is seen that a substantially triangular head 22 of retaining pin 20 provides an increased contact surface area to better secure the generally triangular configuration of guide 30 into valve assembly 10 .
[0049] A pin shaft 24 extends upwards from the center of base 22 . An end face 26 is formed on the end of pin shaft 24 opposite to base 22 . In the disclosed assembly, retaining pin 20 may be made of low carbon steel, such as 1018 or other suitable material. In this embodiment, heat treatment of retaining pin 20 is advantageously not required.
[0050] FIG. 7 is a bottom view of an embodiment of guide 30 of valve assembly 10 , shown in process. Among the several unique features of the present invention is the inclusion of a flat stock guide component 30 , shown here after stamping and prior to forming. Optionally, guide 30 may be formed by laser cutting. Guide 30 has an aperture 32 for positioning guide 30 over retaining pin 20 . At this stage, guide 30 has a substantially flat central portion 40 .
[0051] Referring to FIG. 7 , dashed lines A, B and C, illustrate nine separate folds of the flat stock of guide 30 that are required to create the final part illustrated in this embodiment. Folds ‘A’ create three footers 38 . Folds ‘B’ create three legs 36 , which include footers 38 . Folds ‘C’ create three stabilizers 34 . Of these components, only footers 38 may come into contact with cylinder 100 ( FIG. 4 ). Footers 38 may have hardfacing or other treatment applied to enhance their wear resistance without the need to heat treat the entire valve assembly.
[0052] FIG. 8 is a bottom view of guide 30 of FIG. 7 after a forming step which includes the bending of folds A, B and C. FIG. 9 is an isometric view of the embodiment of guide 30 illustrated in FIG. 8 . As best seen in FIG. 9 , folds A have created footers 38 which extend substantially perpendicular, one each, in relation to legs 36 . Folds B have created legs 36 which extend downward and substantially perpendicular in relation to top surface 34 . Folds C have created stabilizers 34 , which also extend downward and substantially perpendicular in relation to top surface 40 .
[0053] In a preferred embodiment illustrated in FIGS. 8 and 9 , the folds at B and C can be advantageously formed such that contiguous stabilizers 34 and legs 36 provide a singular substantially continuous structure. In this manner, stabilizers 34 and legs 36 provide mutual support and strengthen the structure of guide 30 .
[0054] As best seen in FIGS. 7 and 9 , a plurality of tabs 42 is provided that extends outward from central portion 40 . Tabs 42 may be used to provide locating structures for accurate bending of folds A, B, and C. Referring back to FIG. 4 , tabs 42 further provide triangulated positioning of guide 30 inside a recess 57 (see FIG. 10 ) of valve 50 of valve assembly 10 . In this manner, a more accurate concentric alignment of the guide 30 and footers 38 can be achieved with regard to the center of valve 50 . It is understood that such concentricity between these structures is critical to the life and performance of valve assembly 10 . It is further understood that direct three-point alignment between valve 50 and guide 30 is superior to the inevitable accumulated tolerances realized in aligning all components on a third body, such as retaining pin 20 .
[0055] As described, the unique configuration and process for manufacturing guide 30 may be advantageously made of an inexpensive low carbon, or low carbon alloy sheet steel, or other affordable material. Guide 30 may also be made of high carbon steel. It may only be necessary to heat treat or otherwise surface treat legs 36 of guide 30 . Legs 36 and/or guide 30 may be readily heat treated by various means, including, but not limited to, induction or laser heat treating, spot welding, or conventional hardfacing.
[0056] FIG. 10 is a cross-sectional side view of an embodiment of valve 50 of valve assembly 10 . In this embodiment, valve 50 has an aperture 52 for location of valve 50 onto retaining pin 20 . Valve 50 has a recess 57 on bottom surface 54 and an opposite top surface 55 connected at their centers by aperture 52 . Valve 50 has a valve face 56 . A tongue and groove 58 is provided between valve face 56 and top surface 55 . Recess 57 of bottom surface 54 engages central portion 40 of guide 30 when assembled on retaining pin 20 . Tabs 42 of guide 30 position guide 30 centrally by engaging the inner circumference of recessed surface 54 .
[0057] Valve face 56 is commonly angled between 30 and 45 degrees relative to recessed bottom surface 54 . Valve 50 may be made of suitable steel such as 4150 or other relatively hard steel. In one embodiment, valve 50 may be hardened by induction hardening or other appropriate heat treating method. Advantageously, valve 50 may be heat treated without the requirement to heat treat the entire valve assembly 10 .
[0058] FIG. 11 is a cross-sectional side view of an embodiment of insert 60 of valve assembly 10 . Insert 60 has an aperture 62 . Insert 60 has a top surface 68 and a face 66 . A tongue and groove 64 is provided between aperture 62 and face 66 . Tongue and groove 64 is configured for complementary engagement with tongue and groove 58 of valve 50 . Aperture 62 fits over valve 50 to engage insert 60 with valve 50 .
[0059] Insert face 66 is commonly angled between 30 and 45 degrees relative to insert top surface 68 , such that when insert 60 is located onto valve 50 , insert face 66 and valve face 56 form a semi-continuous surface for engaging cylinder 100 , as best seen in FIG. 5 .
[0060] Insert 60 may be made of urethane or other suitable material that is used to manufacture inserts for conventional valve designs. Insert 60 operates to provide a seal with cylinder 100 when debris common to operations such as fracking prevents a metal-to-metal seal. In a preferred embodiment, insert 60 is compressively fit over valve 50 , thereby enhancing the wear performance of the elastomeric insert 60 .
[0061] FIG. 12 is a cross-sectional side view of an embodiment of retainer 70 of valve assembly 10 . Retainer 70 has an aperture 72 for location onto retaining pin 20 . Retainer 70 has a bottom surface 74 and a top surface 76 . Bottom surface 74 engages top surface 62 of insert 60 when assembled on retaining pin 20 . Retainer 70 may be advantageously made of low carbon steel such as 1020 steel or other suitable material. In the embodiment illustrated, heat treatment is optional, and not required.
[0062] In the embodiment illustrated, a first circular recess 78 is located in top surface 76 . In an optional embodiment, a second circular recess 79 is located on top surface 76 .
[0063] FIG. 13 is a bottom view of an embodiment of retainer cap 80 of the valve assembly 10 embodiment illustrated in FIGS. 1-3 . FIG. 14 is a sectional view of the embodiment of retainer cap 80 sectioned at B-B as illustrated in FIG. 13 . Referring to FIGS. 13 and 14 , retainer cap 80 has a head portion 82 on top of a stem portion 84 . A substantially flat base 86 is located at the end of stem 84 . A flash trap 88 is formed on the underside of head portion 82 , adjacent stem 84 , to facilitate welding.
[0064] In the embodiment illustrated, as best seen in FIG. 13 , the exterior of head portion 82 is configured to have nine symmetrical sides. The nonagon exterior perimeter generates contiguous sides having an angle ‘A’ of about 40 degrees between them. Other shapes may be used. Retainer cap 80 may be made of a low alloy, or low carbon steel. Heat treatment of retainer cap 80 is optional, and is not required.
[0065] In the assembly of valve assembly 10 , guide 30 , valve 50 , insert 60 , and retainer 70 are stacked on stem 24 of retaining pin 20 . Force is applied between head 22 and retainer cap 80 to compress the assembly. Base 86 of retainer cap 80 is welded to end face 26 of retaining pin 20 . This weld can be a solid state inertia or friction weld or any appropriate meld fusion technique. In another embodiment illustrated, cap 80 may optionally be welded directly to retainer 70 on top surface 76 between first recess 78 and second recess 79 .
[0066] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | The present invention discloses a multi-component valve system for use in pumps such as fracking pumps for use in subterranean resource production. The assembly includes a retaining pin, a guide on the retaining pin, a valve on the retaining pin, an insert on the retaining pin, a retainer above the insert on the retaining pin, and a retainer cap inertia welded to the end of the retaining pin. In a particular embodiment, the guide component is stamped and folded to create the desired shape. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from the U.S. provisional patent application entitled Golf Bag with Compressive Pockets, filed Jan. 22, 2002, and given Serial No. 60/351,160.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to sporting equipment, and in particular, to golf bags.
[0003] Current golf bags often include large pockets for storage of tees, golf balls, rain gear, water bottles, etc. When these pockets are loaded with bulky or heavy items, they often bulge out from the bag, or sag under the heavy weight. As the golfer picks up and carriers the bag, the weight of the items is often placed far from the golfers body, making the bag feel heavy to the golfer. In some pockets, loose items may flop from side to side as the golfer walks down the course, producing an undesirable sound, and further making the bag difficult to carry. For golfers that prefer to carry their clubs rather than use carts, this uneven distribution of weight may become particularly tiresome over an entire round of golf. For elderly or other less sure-footed golfers, this uneven weight distribution may even be unsafe.
SUMMARY OF THE INVENTION
[0004] The present invention is a golf bag with compressive pockets. Pockets that compress may bring the weight of items being carried in the bag closer to the bag and may make it easier to carry and maneuver the golf bag. Furthermore, compressive packets may make the items carried more secure and decrease weight shifts do to item movement in the bag. The closer the weight of the golf accessories to a golf bag, the easier it may be to carry and maneuver the golf bag. Furthermore, the less the items carried in a golf bag pockets move around, this may improve balance, stability and safety when carrying or moving the bag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a top view of a golf bag with a compression element according to one embodiment of the present invention, shown in a compressed configuration.
[0006] [0006]FIG. 2 depicts the golf bag of FIG. 1 with the compression element shown in an expanded configuration.
[0007] [0007]FIG. 3 is a top view of a golf bag with a compression element according to another embodiment of the present invention, shown in a compressed configuration.
[0008] [0008]FIG. 4 depicts the golf bag of FIG. 3 with the compression element shown in an expanded configuration.
[0009] [0009]FIG. 5 is yet another embodiment of the present invention, illustrating a lower, side view of a golf bag with a compression element.
[0010] [0010]FIG. 6 is a view of the compressive element of FIG. 5 with the pocket in a compressed position.
[0011] [0011]FIG. 7 is a top view of still another embodiment of the present invention with more than one compressive element shown in a compressed configuration.
[0012] [0012]FIG. 8 depicts the compression elements of FIG. 7 in an expanded configuration
[0013] [0013]FIG. 9 is a side view of a golf bag with a compression element according to one embodiment of the present invention.
[0014] [0014]FIG. 10 is a rear view of the golf bag shown in FIG. 9.
[0015] [0015]FIG. 11 is another side view of the golf bag shown in FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
[0016] [0016]FIGS. 1 and 2 illustrates a top view of a golf bag 10 with a pocket 12 on the left side. Pocket 12 is shown in compressed (FIG. 1) and uncompressed (FIG. 2) positions. Pocket 12 is compressed towards the golf bag 10 by compressive element 14 . In this embodiment compressive element 14 , extends from golf bag 10 horizontally around the outside of pocket 12 and can be tightened to compress pocket 12 . Compressive element 14 may be elastic, fabric, or any other material suitable to be used as a compressive element. Pocket 12 may be solid fabric or other suitable, lightweight, flexible and durable material or materials.
[0017] Another embodiment of the present invention is illustrated in FIGS. 3 and 4. Golf bag 110 may have a pocket 112 that may be compressed toward golf bag 110 by compressive element 114 . Again, pocket 112 is shown in compressed (FIG. 3) and uncompressed (FIG. 4 ) positions. In this embodiment, compressive member 114 extends vertically from golf bag 110 to compress pocket 112 toward golf bag 110 . As shown, there may be more than one compressive element 114 that may be used to compress pocket 112 towards golf bag 110 .
[0018] [0018]FIGS. 5 and 6 illustrate yet another embodiment of the present invention. As shown in FIG. 6, Golf bag 210 may have a back 220 . Golf bag 210 may have pocket 212 and compressive element 214 that compresses pocket 212 towards back 220 of golf bag 210 . Compressive element 214 may connect to back 220 and extend over pocket 212 and connect to back 220 on the opposite side of pocket 212 , thereby compressing pocket 212 toward back 220 of golf bag 210 . Pocket 212 is illustrated here as rectangular in shape. It will be appreciated that pocket 212 may be any suitable shape. Pocket 212 may have a panel 216 and a gusset 218 as illustrated in FIG. 3. Panel 216 may be molded plastic, reinforced fabric or other suitable, lightweight and durable material. Gusset 218 may be elastic, fabric, or other lightweight, flexible and durable material that would allow panel 216 to be compressed toward back 220 of golf bag 210 .
[0019] [0019]FIG. 6 illustrates the golf bag 210 and pocket 212 from FIG. 6 in a compressed position. Panel 216 is shown compressed closer toward golf bag 210 by compressive element 214 . Compressive element 214 may connect to back 220 and extend over pocket 212 and connect to back 220 on the opposite side of pocket 212 , thereby compressing pocket 212 toward back 220 of golf bag 210 . Compressive element 214 may attach to golf bag 210 by any Velcro, buckle or any other suitable connection technique. Compressive element 214 may be a strap, lever or any other device suitable to be used as a compressive element.
[0020] [0020]FIGS. 7 and 8 illustrate a top view of a golf bag 310 having a different pocket configuration in still another embodiment of the present invention. Golf bag 310 may have a first pocket 312 connectably related to a back 320 of golf bag 310 . Golf bag 310 may also have a second pocket 322 connetably related to first pocket 312 . Pockets 312 and 322 are shown in compressed (FIG. 7) and uncompressed (FIG. 8) positions. First pocket 312 and second pocket 322 may be made of an elastic material that may compress pockets 312 , 322 towards back 320 of golf bag 310 . Pockets 312 , 322 may be made entirely of an elastic material or may have a configuration similar to that in FIGS. 1 - 6 with a panel, gusset and compressing element. Alternatively, pockets 312 , 322 may be made entirely of a compressive element or may include a gusset made of a compressive element.
[0021] [0021]FIG. 9 is a right side view of golf bag 410 illustrating various pockets 412 a , 412 b , 412 c , 412 d , and 412 e . As shown, pocket 412 a includes compressive gusset or side panel 414 a , which serves as a compression element. Gusset 414 a may be made of elastic or another suitable material.
[0022] Pockets 412 a , 412 b , 412 c , 412 d , and 412 e may be adapted to include specialized contents. For example, golf bag 410 may include a ball pocket, a valuables pocket, a utility pocket, a water bottle pocket, or the like. For example, a ball pocket may hold golf balls and may be compressed towards golf bag. A valuables pocket may hold car keys, billfold, etc. A utility pocket may be used to hold spare golf gloves or other devices or materials. A water bottle pocket may hold a water bottle or other drink container or other devices or materials. Any of the pockets may be associated with each other similar to pockets illustrated in FIG. 6 wherein the outside portion of one pocket may serve as the inside portion of another pocket or pockets. The pockets may be elastic, molded plastic, fabric, mesh or other suitable, lightweight, flexible and durable material, and any or all of the pockets may include any of the compression elements described above, or a combination thereof.
[0023] Golf bag 410 may further include one or more of a handle 430 , a padded region 440 , and a retractable stand 450 .
[0024] [0024]FIG. 10 is a view of the back of golf bag 410 depicted in FIG. 9. In addition to the pockets shown in FIG. 9, golf bag 410 may further include pocket 412 f , which may also include a compressive gusset 414 f.
[0025] [0025]FIG. 11 is a front view of golf bag 410 in the embodiment of the present invention depicted in FIGS. 8 and 9. FIG. 11 illustrates a view of the pockets on the right and left side of the golf bag that may have compressive members.
[0026] It should be noted that while in the examples above the pockets and compressive members are shown as compressing inward towards the outer surface of the golf bag, it should be appreciated that the pockets and compressive members may be configured such that the interior compartment of the pockets expand outwards towards the exterior portion of the pocket. In this embodiment, the exterior portion of the pocket may be fixed or static.
[0027] It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. | The present invention provides a golf bag having compressive pockets. The compressive pockets are adapted to minimize alteration of the profile created by the presence of contents within the pocket and/or minimize shifting of the center of mass of the contents away from the surface of the body as the bag is moved. | 0 |
BACKGROUND OF THE INVENTION
1. Field of The Invention
The subject invention relates to the frequency response of loudspeakers when mounted in a recessed baffle arrangement.
In television receivers, it is desirable to have loudspeakers strategically mounted in the cabinet so that the user may hear a pleasing rendition of the audio portion of television programs being displayed. However, due to the esthetic designs of the cabinet and the available location(s) for the speakers, the shortened tunnel that results in such locations causes the frequency response of the loudspeaker to be perturbed in a relatively predictable manner.
In general, the mid-range response in the 1 kHz to 2 kHz range tends to be augmented, while the response in the 3 kHz to 6 kHz range tends to be decreased.
2. Description of The Related Art
U.S. Pat. No. 4,709,391 discloses an arrangement for converting an electric signal into an acoustic signal or vice versa and a non-linear network for reducing distortion in the output signal of the arrangement, the distortion being caused by the electro-acoustic conversion performed by an electro-acoustic transducer in the arrangement. In particular, the non-linear network is arranged for reducing non-linear distortion by compensating for at least a second or higher order distortion component in the output signal of the arrangement.
While this arrangement effectively reduces the distortions in the output signal based on the predicted distortions of the process of electro-acoustic transducing, this solution does not address the effects that the mounting environment may have on the output signal of the transducer.
SUMMARY OF THE INVENTION
An object of the invention is to provide an equalizing circuit for compensating frequency response perturbations in a loudspeaker caused by a recessed mounting of the loudspeaker.
In particular, it is an object of the invention to provide an equalizing circuit for compensating the augmented and decreased portions of the frequency response of a loudspeaker in a recessed mounting.
This object is achieved in an equalizing circuit comprising an input for receiving an audio signal; a peaking network coupled to said input for augmenting the audio signal in a first frequency range; a dipping network coupled to said input for attenuating the audio signal in a second frequency range; and means for combining an output of said peaking network to an output of said dipping network, an output of said combining means carrying a compensated audio signal for application to said loudspeaker.
Alternatively, the object is achieved in an equalizing circuit comprising an input for receiving an audio signal; a peaking network coupled to said input for augmenting the audio signal in a first frequency range; and a dipping network coupled to an output of said peaking network for attenuating the audio signal in a second frequency range, an output of said dipping network carrying a compensated audio signal for application to said loudspeaker.
Applicant has found that by combining a peaking network with a dipping network, the overall acoustic response of loudspeakers installed in many television cabinet designs can be restored to a flattened condition. The placement of the tuned frequencies of the peaking and dipping networks may be adjusted to match each particular cabinet design by simply modifying the values of the components in the networks.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and additional objects and advantages in mind as will hereinafter appear, the invention will be described with reference to the accompanying drawings, in which:
FIG. 1 shows a block diagram of a typical television receiver;
FIG. 2 shows a perspective view of a cabinet within which the television receiver of FIG. 1 may be mounted;
FIG. 3A shows a first embodiment of the invention, FIG. 3B shows a second embodiment of the invention, and FIG. 3C shows a third embodiment of the invention;
FIG. 4 shows schematic diagram of a stereo implementation of the second embodiment of the invention, as shown in FIG. 3B, in which the dipping network uses passive components;
FIG. 5A shows a response curve of a loudspeaker in a television cabinet without the equalizing circuit of the subject invention, while FIG. 5B shows a response curve of the same loudspeaker in the same television cabinet with the equalizing circuit; and
FIG. 6 shows a stereo implementation of the second embodiment of the invention, as in FIG. 3B, in which the dipping network uses active components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a circuit block diagram of a television receiver. Television signals are received by an antenna 1 and applied to a tuner 3. Alternatively, the television signals may be applied to the tuner 3 by a cable connection, a video cassette recorder, etc. An output from the tuner 3 carrying the video signal is applied to a video signal processing circuit 5 for generating color signals (R, G, B) which are applied to a display, shown as CRT 7. In addition, the video signal from the tuner 3 is applied to synchronization circuits 9 for generating horizontal and vertical synchronizing signals for the CRT 7.
A second output from the tuner 3 carries audio signals for application to an audio signal processing circuit 11. In the case of stereo, the audio signal processing circuit 11 forms a left channel signal, applied to a left audio amplifier 13, and a right channel signal, applied to a right audio amplifier 15. A left channel speaker 17 is connected to outputs from the left audio amplifier 13 while a right channel speaker 19 is connected to outputs from the right audio amplifier 15.
FIG. 2 shows a perspective drawing of a portion of the inside of a cabinet 20 into which the components of the television receiver of FIG. 1 may be mounted. In particular, the cabinet 20 includes an opening 22 into which the CRT 7 is be mounted, and an area 24 where the right speaker 19 is to be mounted. The cabinet 20 further includes a corresponding area (not shown) where the left speaker 17 is to be mounted. Due to the configuration of the cabinet 20 in the area 24, a shortened tunnel results which has an adverse effect on the performance of the speaker 19 (and similarly with speaker 17) mounted therein. Notably, the shortened tunnel configuration causes the mid-range response of the speakers 17 and 19 in the 1 kHz to 2 kHz range to be augmented, and the response of the speakers 17 and 19 in the 2 kHz to 6 kHz range to be decreased.
The purpose of the subject invention is to compensate for these perturbations of the frequency response. To that end, the subject invention provides an equalizing circuit for insertion into the audio signal line of the television receiver as shown in FIG. 1. This may be between the audio signal processing circuit 11 and the left and right audio amplifiers 13 and 15, or between the left and right audio amplifiers 13 and 15 and the left and right speakers 17 and 19, respectively.
FIG. 3A shows a block diagram of a first embodiment of the invention in which an audio signal is applied to an input of a peaking network 30 and to an input of a dipping network 32. The peaking network 30 is dimensioned such that it operates on a first frequency range of the audio signal to augment (or boost) the frequency response of the audio signal in that frequency range. This first frequency range is the same frequency range within which the audio signal is decreased due to the perturbations to the frequency response caused by the mounting position in the television receiver cabinet 20. It has been found, in practice, that the first frequency range is approximately 3 kHz to 6 kHz.
The dipping network 32, on the other hand, is dimensioned such that it operates on a second frequency range of the audio signal to decrease the frequency response of the audio signal in that frequency range. This second frequency range is the same frequency range within which the audio signal is augmented due to the perturbations to the frequency response caused by the mounting position in the television receiver cabinet 20. It has been found that the second frequency range is approximately 1 kHz to 2 kHz.
Outputs from the peaking network 30 and the dipping network 32 are applied to respective inputs of a combining circuit shown in FIG. 3A as an adder 34. An output from the adder 34 carries the equalized audio signal for application to a loudspeaker.
FIG. 3B shows a second embodiment of the invention in which the audio signal is applied directly to the peaking network 30. Since the first and second frequency ranges do not overlap, the output from the peaking network 30 is applied directly to the input of the dipping network 32, and the adder 34 may be eliminated. As such, the output from the dipping network 32 forms the output from the equalizing circuit.
FIG. 3C shows a third embodiment of the invention which is substantially similar to the second embodiment with the exception that the positions of the peaking network 30 and the dipping network 32 are interchanged.
FIG. 4 shows a schematic diagram of a first stereo implementation of the second embodiment of the equalizing circuit. A left audio signal is applied to an input terminal L IN which is connected to ground by a resistor R1. The input terminal L IN is also connected to an inverting input of operational amplifier (OP-AMP) A1 through a series arrangement of a capacitor C1, a resistor R2 and a capacitor C2. A resistor R3 further connects the junction between capacitor C1 and resistor R2 to the inverting input of OP-AMP A1. The output from OP-AMP A1 is fed back to its inverting input through the series arrangement of a capacitor C3 and a resistor R4, in which the junction between capacitor C3 and resistor R4 is connected to ground through a series arrangement of a resistor R5 and a capacitor C4. The output from OP-AMP A1 is further connected to the junction between resistor R5 and capacitor C4 through a resistor R6.
Similarly, a right audio signal is applied to an input terminal R IN which is connected to ground by a resistor R7. The input terminal R IN is also connected to an inverting input of operational amplifier (OP-AMP) A2 through a series arrangement of a capacitor C5, a resistor R8 and a capacitor C6. A resistor R9 further connects the junction between capacitor C5 and resistor R8 to the inverting input of OP-AMP A2. The output from OP-AMP A2 is fed back to its inverting input through the series arrangement of a capacitor C7 and a resistor R10, in which the junction between capacitor C7 and resistor R10 is connected to ground through a series arrangement of a resistor R11 and a capacitor C8. The output from OP-AMP A2 is further connected to the junction between resistor R11 and capacitor C8 through a resistor R12. The non-inverting inputs of OP-AMP's A1 and a2 are interconnected and connected to ground through the parallel combination of resistor R13 and capacitor C9.
The components thus far discussed form separate peaking networks for the left and right channels, respectively.
The left channel dipping network is formed by a series arrangement of capacitors C10 and C11 connected between the output of OP-AMP A1 and an output terminal L OUT . The input terminal of capacitor C10 is further connected to ground through the series combination of a resistor R14 and a capacitor C12. The junction between capacitors C10 and C11 is connected to the junction between resistor R14 and capacitor C12 by a resistor R15. Finally, the output terminal L OUT is connected to ground by resistor R16.
Similarly, the right channel dipping network is formed by a series arrangement of capacitors C13 and C14 connected between the output of OP-AMP A2 and an output terminal R OUT . The input terminal of capacitor C13 is further connected to ground through the series combination of a resistor R17 and a capacitor C15. The junction between capacitors C13 and C14 is connected to the junction between resistor R17 and capacitor C15 by a resistor R18. Finally, the output terminal R OUT is connected to ground by resistor R19.
In this implementation, the components may have the following values:
______________________________________RESISTORSR1, R2, R7, R8, R16, R19 100 kohmsR3, R9 27 kohmsR4, R10 24 kohmsR5, R6, R11, R12 2 kohmsR13 1 kohmsR14, R15, R17, R18 1.4 kohmsCAPACITORSC1, C5 2 μFC2, C6 1000 pFC3, C7 .01 μFC4, C8 .047 μFC9 100 μFC10, C13 .022 μFC11, C14 5 μFC12, C15 .15 μF______________________________________
FIG. 5A shows the frequency response of a loudspeaker mounted the television cabinet 20. In examining the frequency response curve, one should note the augmented portion thereof at approximately 2 kHz, as well as the attenuated portion at approximately 8 kHz. In contrast therewith, FIG. 5B shows the frequency response of the same loudspeaker in the same television cabinet 20 which has been equalized using the above implementation of the equalizing circuit. One should note that the frequency response curve is substantially flat from 1 kHz to the upper limits of the loudspeaker.
FIG. 6 shows a second stereo implementation of the second embodiment of the equalizing circuit of the subject invention, in which the same parts carry the same reference numbers. In particular, the peaking networks remain the same. However, the dipping networks are effected by active circuits. The output from OP-AMP A1 is now connect through a capacitor C16 to ground through a series arrangement of resistors R20 and R21. The junction between resistors R20 and R21, which is connected to output terminal L OUT , is also connected to one end of a capacitor C17. The other end of capacitor C17 is connected to the inverting input of OP-AMP A3 through a resistor R22, and to the non-inverting input through a capacitor C18. The output of OP-AMP A3 is connected to its inverting input. A resistor R23 connects the non-inverting input of OP-AMP A3 to the non-inverting input of OP-AMP A1. Connected as such, OP-AMP A3, along with capacitors C17 and C18 and resistors R22 and R23, forms a resonant circuit.
Similarly, the output from OP-AMP A3 is now connect through a capacitor C19 to ground through a series arrangement of resistors R24 and R25. The junction between resistors R24 and R25, which is connected to output terminal R OUT , is also connected to one end of a capacitor C20. The other end of capacitor C20 is connected to the inverting input of OP-AMP A4 through a resistor R26, and to the non-inverting input through a capacitor C21. The output of OP-AMP A4 is connected to its inverting input. A resistor R27 connects the non-inverting input of OP-AMP A4 to the non-inverting input of OP-AMP A2. Connected as such, OP-AMP A4, along with capacitors C20 and C21 and resistors R26 and R27, forms as a resonant circuit.
In this implementation, the components may have the following values:
______________________________________RESISTORSR1, R7 100 kohmsR2, R8 47 kohmsR3, R9 22 kohmsR4, R10 33 kohmsR5, R6, R11, R12 10 kohmsR13 1 kohmsR20, R24 39 kohmsR21, R25 27 kohmsR22, R26 3.3 kohmsR23, R27 130 kohmsCAPACITORSC1, C5 2 μFC2, C6 1000 pFC3, C7 .0022 μFC4, C8 .0068 μFC9 100 μFC16, C19 5 μFC17, C18, C20, C21 .0047 μF______________________________________
Numerous alterations and modifications of the structure herein disclosed will present themselves to those skilled in the art. However, it is to be understood that the above described embodiments are for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | An equalizing circuit, for compensating frequency response perturbations in a loudspeaker caused by a recessed mounting of the loudspeaker, includes an input for receiving an audio signal, a peaking network coupled to the input for augmenting the audio signal in a first frequency range, a dipping network also coupled to the input for attenuating the audio signal in a second frequency range, and a combiner for combining an output of the peaking network to an output of the dipping network, an output of the combiner carrying a compensated audio signal for application to the loudspeaker. | 7 |
This is a Continuation of application Ser. No. 063,228, filed Jun. 17, 1987 U.S. Pat. No. 5,006,289.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel method for producing an elongated sintered article, particularly relates to a method for producing elongated sintered articles in a form of wire, strand, tape, sheet, rod or the like from powder materials.
The method of the present invention is advantageously applicable to production of wire or rod of ceramics, particularly so called new ceramics or fine ceramics, sintered alloys or their combination, which are difficult of shaping or moulding by conventional process such as wiredrawing, rolling or extrusion of powder material and are difficult of machining or processing after the powder material is sintered.
2. Description of the Related Art
Since new ceramics or fine ceramics and sintered alloys show a wide variety of functions, their application is spreading over a variety of industrial fields. These new or fine ceramics and sintered alloys are utilized in machine parts due to their higher hardness, heat-resistance and dimensional stability, in optical parts due to their high transparency or unique electromagnetic functions, in biological or chemical field such as artificial bone or catalyst because of their superior histocompatibility or chemical-resistance, in electronics or electric parts owing to their improved or unique properties such as electroconductivity or insulative property, and so on.
The term of ceramics and sintered alloys imply any sintered article made by sintering process of inorganic powder material and/or metal powder material. Ceramics are classified into two types of oxide-type and nonoxide type. The oxide type ceramics are divided into simple oxides such as alumina (Al 2 O 3 ), zirconia (ZrO 2 ), beryllia (BeO) etc. and compound oxides such as ferrites (MO.Fe 2 O 3 ), PLZT ((Pb,La)(Zr,Ti)O 3 ) or the like. In the nonoxide type ceramics, we can mention a variety of compounds such as nitrides such as Si 3 N 4 , AlN, carbide such as SiC, WC, boron carbide (B 4 C), partially stabilized zirconia etc. Sintered alloys such as carbide precipitating type cobalt-based alloy are made mainly of transition metals but are also called as a kind of ceramics.
Ceramics such as tungstencarbide and so called cemented carbides in which carbides of transition metals are bonded with a binder metal such as cobalt show higher hardness and superior tenacity and hence are widely used in a variety of applications such as cutting tools, abrasion resisting parts or the like. It has become more popular to use twistdrills made of this ceramics in the field of the cutting tool and printer head rods for dot-matriprinters as a abrasion resisting part.
Ceramics such as tungstencarbide, alumina or the like posses extremely higher hardness and higher abrasion resistance and are attracting wide public interest. They are used widely in a variety of industries as a ceramic shaft, a ceramic reed or the like.
Ceramics such as siliconcarbide, alumina or the like posses higher strength at high temperatures and improved abrasion resistance and hence are widely used in a variety of applications such as parts which are used at a higher temperature range. Particularly, demand for ceramics parts having an elongated rod-like shape is much increasing in the field of a shaft for engine parts, conveyer rollers which are used at high temperatures, electrodes for automatic welding machines or the like.
Recently, alumina is widely used in the field of electronics as packaging material or substrates or the like.
Carbide precipitating reinforced type cobalt-based alloy consists of 20 to 35 wt % of Cr, 3 to 20 wt % of W, 0.5 to 3 wt % of C and balance of Co and have superior heat-resistance, corrosion-resistance and abrasion-resistance and hence is usually used under high-temperature or corrosive atmosphere. Recently, the carbide precipitating reinforced type cobalt-based alloy has been used in the field of shafts of jet-engines, electrodes for welder, jet-spraying rod etc. and hence demand for elongated wire or elongated rods (hereinafter referred as fine wire) is increasing.
Although ceramics or sintered alloys are used in every industrial field, machining or processing of the sintered body is very difficult to perform because one of their important properties is their harness. That is, sintered body can not be machined or shaped by ordinary cutting tools and so they have been machined only by electro spark machining or diamond cutting techniques. Still more, powder material for these ceramics and sintered alloys are difficult to be shaped or moulded into an elongated article by conventional techniques such as extrusion, rolling or wire-drawing.
Therefore, heretofore, when an elongated article is produced, the powder material is moulded or shaped into an elongated configuration and then sintered in order to minimize after-treatment or after-processing of the sintered article. In this method, it is difficult to produce an elongated article of high quality.
In another technique for producing a rod such as a shaft, a block or billet is preformed by a press and then is machined by cutting into the final shape. This process, however, has not high productivity as well as produce very large amount of loss of expensive powder material. In this process, it is also impossible to produce a long wire or rod because the ratio of longitudinal dimension to cross sectional dimension can not be increased and continuous operation can not be adopted.
In still another prior art, a mixture of powder material and binder of organic compound is extruded into an elongated article or coated onto a supporting belt, and after the organic binder is eliminated in a preliminary sintering stage, final sintering is carried out. It is very difficult in practice to remove the organic binder completely during the preliminary or intermediate sintering step because a large volume of organic binder is added to the powder material and hence a part of carbon remain in the final sintered product, resulting in cause of defects such as cavities or voids which will lower the strength of the final sintered products or deteriorate characteristics of the sintered product whose contents of carbon must be controlled precisely. Still more, it takes long time such as several hours to perform the preliminary sintering for removal of carbon, resulting in lowering productivity.
Therefore, it has been very difficult to produce an elongated article of high quality from powder materials for ceramics.
In case of carbide precipitating type cobalt-based alloy, there are several other techniques which can be applicable to produce an elongated article such as (1) centrifugal Casting, (2) Rotary Spinning in water and (3) metal plating. However,
(1) Although centrifugal casting process is one of rather easier techniques, it is difficult to produce elongated fine articles. The maximum length of the fine wire produced by this technique was about 20 to 30 cm in case of a diameter of 2 mm. There is problem of defects such as cavity which is apt to be produced at the center of the fine wire and microsegregation due to casting operation, resulting in that it is difficult to produce a fine wire having a high quality in strength.
(2) The rotary spinning in water can produce fine elongated wire products but it is very difficult to adjust or control its diameter. Still more, the diameter of the wire is limited to less than 1 mm.
(3) In the metal plating, a carbon fiber is coated with a plating layer of Co, W, Cr or the like which is then diffused to produce an alloy. However, the plating of W is extremely difficult to practice and productivity is also low.
Therefore, there still remain problems to be solved in this field of technology. Particularly, a novel process which is practicable in the field of wire manufacturing or rod manufacturing is strongly requested.
Accordingly, an object of the present invention is to provide a novel method for producing an elongated sintered article of higher quality with the higher productivity and with reduced loss of expensive powder material.
SUMMARY OF THE INVENTION
According to the present invention, method for producing an elongated sintered article is characterized by the steps including filling powder material in a pipe, carrying out plastic deformation of the pipe filled with the powder material, and heating the pipe filled with the powder material to burn and/or sinter the powder material.
In a preferred embodiment, the pipe is made of metal, the metal may be made of at least one of metals selected from a group consisting of Fe, Cu, Ni and Co and alloys containing the same. The term of "pipe" implies any kind of elongated hollow bodies, such as pipe, tube or cylinder. The cross section of the pipe is not limited to a circle but can be any other polygonal shape such as rectangular.
The powder materials to which the present invention is applicable may be any kind of powder material including metal powder which is difficult of moulding and machining, hard metal or cemented carbide, carbide precipitating reinforced cobalt-based alloy and a variety of ceramics powder. According to the present invention, the powder material does no contain binder of organic compounds.
According to the preferred embodiment, the powder material can be pelletized before the powder material is filled in the pipe. It is also preferable to seal at least one of ends of the pipe before the step of plastic deformation of the pipe filled with the powder material and before the step of burning and/or sintering.
The plastic deformation is preferably performed by wire-drawing or rolling. And it is also preferable to perform annealing or tempering of the pipe filled with the powder material in the stage of plastic deformation of the pipe filled with the powder material, and preferably the plastic deformation is carried out in a temperature range in which the powder material is not sintered. The heating temperature in the plastic deformation stage is preferably 10° to 100° C. lower than the sintering temperature of powder material. Therefore, preferably the pipe filled with the powder material is heated at a temperature which is higher than the anneal temperature or tempering temperature, in the plastic deformation stage.
The wire-drawing may be carried out by means of any one of die, roller die, roller, swagging machine or extruder. It is also possible to repeat a plural times of the plastic deformation and also possible to use different kinds of the plastic deformation processes in the plastic deformation stage.
The burning and/or sintering step may include preliminary or intermediate sintering operation and the preliminary sintering is preferably performed at a temperature which is from 10° to 100° C. lower than the melting point of the powder material.
According to another preferred embodiment, an elongated core body extending through the pipe can be placed in the pipe together with the powder material. This elongated core body is removed after the plastic deformation step or the burning and/or sintering step. Particularly, the elongated core body may be made of wood.
According to another embodiment of the present invention, at least a part of the plastic deformation step and at least a part of the burning and/or sintering step can be carried out simultaneously. Or it is also possible to perform the burning and/or sintering stage before or after the plastic deformation stage.
Finally, it is possible to remove the outer pipe from the final product. But, in special use such as a wire electrode for automated welding machines, it is preferable to leave the outer metal pipe or sheath on the sintered body without removing the metal pipe. The pipe may be removed after the plastic deformation stage or the burn and/or sintering stage. After the outer metal pipe is removed, the burnt and/or sintered body can be further heat-treated. In this case, the heat-treatment may be carried out at a temperature which is higher than the sintering temperature of the powder material.
The resulting product obtained by the process according to the present invention can have the longitudinal dimension of the final product which is more than 100 times longer than the cross sectional dimension.
According to the first preferred embodiment of the present invention, the method for producing an elongated article which is difficult of machining is characterized by filling powder material containing material or materials which are difficult of processing in a metal pipe, by extruding, rolling or wire-drawing the pipe filled with the powder above an annealing temperature of the metal pipe but below such a temperature at which the powder is sintered so that the metal pipe is shaped into the final configuration of the product, if necessary by repeating the shaping step, by sintering the shaped powder filled in the metal pipe, and then by removing the metal pipe.
According to the second preferred embodiment of the present invention, an elongated rod made of high-strength sintered cemented carbide is provided. This rod has a deflective strength of more than 350 Kg/mm 2 and the dimension of the rod along an elongated direction is more than 100 times longer than the cross sectional dimension thereof.
According to the second preferred embodiment of the present invention, the method for producing the high-strength elongated rod of sintered cemented carbide is characterized by filling powder material of cemented carbide in a pipe of metal, sealing the pipe, wire-drawing the sealed pipe filled with the powder at the dimension reduction ratio of more than 10% but less than 90%, carrying out a preliminary sintering of the sealed pipe at a temperature between 700° and 1200° C., removing the outer metallic pipe from an inner preliminarily sintered body, and then sintering the inner preliminarily sintered body at a temperature between 1280° and 1500° C.
In this embodiment, the pipe is made of at least one of metals of copper, nickel and cobalt or alloys including them as a base metal.
According to the third preferred embodiment of the present invention, the method for producing a composite which is difficult of machining is characterized by filling powder material containing material or materials which are difficult of processing in a metal pipe, by carrying out at least one of hot-workings comprising extruding, rolling or wire-drawing to give the pipe filled with the powder material to the final configuration of the product at a temperature which is higher than an annealing temperature of the metal pipe but is lower than the sintering temperature of the powder, and then by sintering the powder material in the metal pipe.
According to the fourth preferred embodiment of the prsent invention, the method for producing an elongated rod of ceramics is characterized by filling powder material of ceramics in a pipe of metal, by performing wire-drawing of the pipe filled with the powder material at the dimensional reduction ratio of more than 20% but less than 90%, by carrying out a preliminary sintering of the drawn pipe at a temperature between 1000° and 1300° C., removing the outer metallic body from a preliminarily sintered body, and then sintering the preliminarily sintered body at a temperature between 1600° and 2100° C.
In this embodiment, the pipe of metal is preferably made of metals of copper, nickel or cobalt or their alloys containing of at least one of the metals as a base metal.
According to the fifth preferred embodiment of the present invention, an elongated sintered hollow rod made of cemented carbide is provided. The rod has the longitudinal dimension which is more than 10 times longer than the cross sectional dimension and has a hole along the longitudinal direction. The deflective strength of the rod is more than 350 Kg/mm 2 .
According to the fifth preferred embodiment of this invention, the method for producing the sintered elongated hollow rod of cemented carbide is characterized by placing an elongated core inside a pipe of metal along its axial direction, by filling powder material of cemented carbide containing no organic binder in an annular space between the pipe and the core, by performing wire-drawing of the pipe filled with the powder material at the dimensional reduction ratio of more than 10% but less than 90%, by carrying out a preliminary sintering of the drawn pipe at a temperature between 500° and 1200° C., removing both of the core and the outer metallic body from a preliminarily sintered hollow body, and then sintering the preliminarily sintered body at a temperature between 1280° and 1500° C.
In this embodiment, the elongated core is preferably made of wood and the pipe of metal is preferably made of copper, nickel or cobalt or one of alloys including at least one of these metals as a base metal.
According to the sixth preferred embodiment of the present invention, the method for producing a fine wire of cobalt-based alloy of carbide precipitating reinforced type is characterized by filling powder material of carbide precipitating reinforced type cobalt-based alloy in a pipe of copper, by performing wire-drawing of the copper pipe filled with the powder material at the dimensional reduction ratio of more than 20% but less than 90%, by carrying out a preliminary sintering of the drawn pipe at a temperature between 800° and 1000° C., removing the outer copper pope from a preliminarily sintered body, and then sintering the preliminarily sintered body at a temperature which is from 10° C. to 100° C. lower than the melting point of the alloy.
In this embodiment, the wire-drawing is preferably repeated and, before each wire-drawing, the pipe of copper which has been subjected to wire-drawing is annealed or tempered at least one time at a temperature of 400° to 700° C.
According to the seventh preferred embodiment of the present invention, the method for producing a fine wire of carbide precipitating reinforced type cobalt-based alloy is characterized by filling powder material of carbide precipitating reinforced type cobalt-based alloy in a pipe of cobalt, by performing wire-drawing of the cobalt pipe filled with the powder material at the dimensional reduction ratio of more than 20% but less than 90%, and then performing sintering at a temperature which is from 10° C. to 100° C. lower than the melting point of the alloy.
According to a variation of abovementioned seventh embodiment of the present invention, the method for producing a fine wire of carbide precipitating reinforced type cobalt-based alloy is characterized by filling powder material of carbide precipitating reinforced type cobalt-based alloy in a pipe of metal, by performing wire-drawing of the metal pipe filled with the powder material at the dimensional reduction ratio of more than 20% but less than 90%, and then performing sintering at a temperature which is from 10° C. to 100° C. lower than the melting point of the alloy and the pipe is preferably made of iron, nickel or cobalt.
Now, we will describe the present invention in more details by preferred embodiments of the present invention with reference to attached drawings, but the scope of the present invention should not be limited to the embodiments but must be understand from the definition of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 (a) to 1 (h) are an illustrative drawings showing successive steps of the process for producing an elongated article according to the present invention and FIGS. 1 (i) and 1 (j) are perspective views of the final products; and
FIGS. 2 (a) to 2 (h) are another illustrative drawings which are similar to FIGS. 1 (a) to 1 (j), but in the FIG. 2, a core body is used for producing an elongated hollow article.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 (a), a pipe or sheath 1 has an outer diameter of L and an inner diameter of 1. Powder material 2 is filled or charged in the pipe 1 (FIG. 1 (b)).
Then, the pipe or sheath 2 in which the powder material is filled is subjected to wire-drawing. In FIG. 1 (c), the wire-drawing is performed by a pair of roller dies 3. The wire-drawing can be carried out by passing the pipe 1 through one or plurality of die plates 4 shown in FIG. 1 (d). In the other embodiments, the wire-drawing can be performed by means of a swagging rollers 5 (FIG. 1 (e)) or an extruder 6 (FIG. 1 (f)). Still more, when the pipe has a rectangular cross section, the pipe can be laminated by means of rollers 7 (FIG. 1 (g)). At each operation of the wire-drawing, the metal pipe or sheath filled with powder material can be annealed or tempered so as to perform the wire-drawing smoothly. It is preferable to seal one or both ends of the pipe before the wire-drawing starts to prevent powder material from escaping, as is shown in FIG. 1 (h).
FIGS. 1 (i) and 1 (j) show two types of the product manufactured according to the process of the present invention. A product of a wire or rod shown in FIG. 1 (i) has the outer layer of the pipe or sheath 1 on the inner sintered body 2, while another product shown in FIG. 1 (h) has not the outer layer which is removed.
Now we will refer to FIG. 2 which illustrates another embodiment of the present invention for producing an elongated hollow sintered article. In FIG. 2, the same parts or material have the same reference numbers as FIG. 1.
In this embodiment, a core body or core member 1a is used for producing a hollow wire or rod. Namely, an elongated core body 1a is placed inside the pipe 1 (FIG. 2 (a)) and then powder material 2 is filled in an annular space between the pipe 1 and the core body 1a. Then, wire-drawing is performed by the same techniques as are shown in FIG. 1, that is by roller die 3 (FIG. 2 (c)), by a series of die plates 4 (FIG. 2 (d)), by swagging rollers 5 (FIG. 2 (e)), and by an extruder 6 (FIG. 2 (f)). The pipe 1 is reduced in diameter by abovementioned wire-drawing operation as is shown in FIG. 2 (g) wherein the core body 1a has a reduced diameter 1' while the pipe 1 has a reduced diameter L'. Under this condition, the composite of the core 1a, powder material 2 and the outer pipe 1 is subjected to preliminary sintering during which the core body 1a may be burnt if the core 1a is made of combustible material.
As is the FIG. 1, in this embodiment also, it is possible to remove the counter layer 1 off the inner body 2 which is then sintered to produce a hollow sintered article as is shown in FIG. 2 (h).
It is apparent from the description abovementioned that the method for producing an elongated article of sintered powder according to the present invention is completely different from conventional process in which binder of organic compounds is used. Still more, in the present invention, a long wire or rod having a higher value of dimension ratio of longitudinal dimension to transversal dimensional can be produced continuously if the powder material is fed continuously during the pipe is manufactured or shaped from a flat sheet. Furthermore, since the powder material is filled in and supported in the pipe during the plastic deformation stage, the powder material can take any form such as a coil.
Now, we will describe the present invention for producing an elongated sintered articles which are produced with a variety of powder materials with referring the following Examples.
EXAMPLE 1
The First Embodiment
In a pipe made of pure nickel having an outer diameter of 12.0 mm and a wall thickness of 3 mm, the following two kinds of powder materials (a) and (b) were filled:
(a) WC containing 2 wt % of Co
(b) Al 2 O 3 containing 29.5 wt % of TiC, 2.0 wt % of TiO 2 , 0.1 wt % of MgO, 0.1 wt % of Cr 2 O 3 and 1.5 wt % of NiO
The first pipe filled with the powder material (a) was wire-drawn by a hot-swagging unit at 700° C. to reduce its outer diameter to 10.0 mm (this pipe is called Sample 1a hereinafter).
The second pipe filled with the powder material (b) was wire-draw as the same manner as above (this pipe is called Sample 1b).
The third and fourth pipes filled with the powder materials (a) and (b) respectively were wire-drawn by a hot-swagging unit at 1250° C. which is above sintering temperatures of the powder materials (a) and (b) to reduce their outer diameter to 10.0 mm (there pipes are called Sample 2a and 2b respectively).
The fifth and sixth pipes filled with the powder materials (a) and (b) respectively were wire-drawn by a pair of dies in place of by the hot-swagging unit to reduce its outer diameter to 10.0 mm (these pipes are called Samples 3a and 3b respectively).
All of the Samples were then wire-drawn by a pair of dies to reduce their outer diameters to 8.5 mm. The result showed that Samples 1a, 1b, 3a and 3b could be wire-drawn without damage, while Samples 2a broke at the first die and Sample 2b broke at the second die. These breakage occurred not at the outer metal pipe but at the inner powder due to shear-stress.
Samples 1a, 1b, 3a and 3b were annealed at 600° C. for 20 min. and then were wire-drawn through a die to reduce their outer diameter to 6.0 mm with no breakage. The resulting pipes having the outer diameter of 6.0 mm of Samples 1a, 1b, 3a and 3b were then sintered at 1300° C. for 1 hr. and then their outer pipes of pure nickel were removed by washing them with nitric acid. Samples 1a and 1b were further sintered at 1800° C. for 1 hr.
The resulting wires obtained from Samples 1a, 1b, 3a and 3b showed the following Vickers hardness (under a load of 50 Kg):
______________________________________ Sample 1a 1520 Sample 1b 1910 Sample 3a 1470 Sample 3b 1820______________________________________
These values of hardness reveal such fact that these samples have good properties as abrasion-resistant products.
In the other experiments in which Samples 1a, 1b, 3a and 3b were annealed at 1250° C. for 20 min. in place of abovementioned 600° C. for 20 min., the resulting pipes broke at the first die when their outer diameter was reduced to 8.0 mm.
EXAMPLE 2
The Second Embodiment
75 wt % of commercially available WC powder having an average particle size of 0.8 microns, 5 wt % of commercially available WC powder and 20 wt % of commercially available Co powder were mixed in wet in an attriter and dried. After passing through a 100 mesh sieve, the resulting powder was filled in a pipe made of copper tube having an outer diameter of 6 mm, an inner diameter of 5 mm and a length of 300 mm and opposite ends of the tube was sealed.
The tube filled with the powder material was wire-drawn to reduce its outer diameter to 2 mm and then preliminary sintering was carried out at 950° C. for 30 min. under vacuum. Then, the copper outer tube was removed by cutting operation. The resulting preliminary sintered body was sintered at 1325° C. under vacuum to obtain a rod of cemented carbide having a diameter of 1.44 mm and a length of 228 mm.
The rod was then reduced on its outer periphery by cutting operation to gain an outer diameter of 1.4 mm and then the deflective strength was measured by the three-point bending breakage test. The result showed 495 Kg/mm 2 of the deflective strength.
In a comparative example, a rod of the same size was produced with the same proportion of powder materials and by the same procedure as abovementioned Example 2 except that a conventional binder of organic compound was added to the powder material which was then extruded and sintered the result showed the deflective strength of 295 Kg/mm 2 . In this comparative example, it was necessary to mix 45 volume % of paraffin as a binder with the powder material to facilitate extrusion process.
In the other experiments wherein a rectangular billet having a cross section of 3.0×3.0 mm and a length of 40 mm was prepared by a press and was shaped into a rod having a diameter of 1.5 mm and a length of 35 mm by cutting operation. The rod was then sintered and tested in the same manner as abovementioned. The result showed the deflective strength of 285 Kg/mm 2 . In this technique, it was impossible to produce a longer rod of more than 50 mm long measured at the sintered final product.
EXAMPLE 3
The Second Embodiment
The same powder material as Example 2 was filled in two copper tube each having an outer diameter of 5 mm, an inner diameter of 4 mm and a length of 800 mm. After the tubes were sealed, wire-drawing was carried out for the tubes at a dimensional reduction ratio of 7% and 15% respectively, and then the tubes were subjected to preliminary sintering under the same condition as Example 2.
In the case of dimensional reduction ration of 7%, powder was not sintered sufficiently and slipped out of the tube in a form of course powder. Complete sintering was done in the case of dimensional reduction ratio of 15% and a sintered body could be removed out of the tube due to shrinkage of the sintered powder so that it was not necessary to use additional operation for removing the outer tube such as cutting or washing with acidic liquid.
The resulting preliminary sintered body was then sintered under the same condition as Example 2 to produce a rod of cemented carbide having a diameter of 2.9 mm and a length of 700 mm.
EXAMPLE 4
The Second Embodiment
The same powder material as Example 2 was filled in three nickel tubes each having an outer diameter of 6 mm, an inner diameter of 5 mm and a length of 500 mm. Wire-drawing was carried out for the tubes at a dimensional reduction ratio of 95%, 80% and 50% respectively, and then the tubes were subjected to preliminary sintering and final sintering under the same condition as Example 2 to produce rods of cemented carbide. The result showed that the rod of dimensional reduction ratio of 95% broke into three parts while other two rods did not break.
Then, the rod of dimensional reduction ratio of 80% was subjected to preliminary sintering at 600° C., 1000° C. and 1400° C. respectively and then the outer tube was removed with nitric acid. The result showed that the first rod which was sintered at 600° C. could not maintain its shape and broke into smaller pieces, the second rod which was sintered at 1400° C. broke into 6 pieces, while the third rod which was sintered at 1000° C. did not break.
EXAMPLE 5
The Third Embodiment
In a pipe made of pure nickel having an outer diameter of 12.0 mm and a wall thickness of 3 mm, a powder of WC containing 5 wt % of Co was charged. This pipe filled with the powder material was wire-drawn by a hot-stage at 700° C. to reduce its outer diameter to 10.0 mm. Then, the resulting wire-drawn pipe was annealed at 700° C. for 30 min. and then was passed through six dies so that the outer diameter of the pipe was reduced to 6.0 mm. This reduced pipe was then sintered at 1300° C. for 1 hr.
The resulting composite which was difficult of machining was an elongated wire consisting of a core of sintered alloy and a uniform surface metal layer of nickel having a thickness of 1.8 mm. This wire showed the Young' modulus of 27,500 Kg/mm 2 and the tensile strength of 285 Kg/mm 2 . For a comparative example, the same powder material as abovementioned was charged in the same nickel pipe as above Example 5, but the pipe was passed through the hot-stage at 1800° C. which is a sintering temperature of the powder. In this case, the pipe could not be processed or deformed because of breakage of inner sintered powder body. Another sample of a composite pipe which was prepared in the same manner as the abovementioned Example 5 was annealed at 1300° C. for 1 hr. after the pipe was passed through the hotstage at 700° C. We tried to perform wire-drawing on this sample by a die to reduce its cross section at 20%, but it was impossible to draw the composite because of breakage thereof.
EXAMPLE 6
The Fourth Embodiment
95 wt % of commercially available Si 3 N 4 powder having an average particle size of 0.8 microns and 5 wt % of commercially available MgO powder were mixed in wet condition in an attriter and dried. After passing through a 100 mesh sieve, the resulting powder was filled in a tube made of nickel having an outer diameter of 10 mm, an inner diameter of 8 mm and a length of 150 mm and opposite ends of the tube were sealed.
The tube filled with the powder material was subjected to wire-drawing operation to reduce its outer diameter to 4 mm and then preliminary sintering was carried out at 1200° C. for 1 hour under vacuum. After the preliminary sintering operation, the outer tube of nickel was removed by cutting operation. The resulting preliminarily sintered body maintained its shape completely. The resulting preliminarily sintered body was then finally sintered at 1750° C. under the pressure of 2 atm. to obtain a rod of Si 3 N 4 having a diameter of 2.54 mm and a length of 700 mm. Outer periphery of the resulting rod was then reduced by cutting operation to gain an outer diameter of 2.5 mm and then the deflective strength was measured by the three-points bending test between a span of 20 mm. The resulting deflective strength was 73 Kg/mm 2 .
In a comparative example, a rod having the same shape as abovementioned was produced with the same proportion of powder materials and by the same procedure as abovementioned Example 6 except that a known binder of organic compound was added to the powder material. In this case, the resulting deflective strength was mere 36 Kg/mm 2 and it was necessary to add 45 volume % of organic compound as a binder to the powder material of ceramics in order to perform extrusion technique.
EXAMPLE 7
The Fourth Embodiment
94 wt % of commercially availabler Al 2 O 3 powder having an average particle size of 0.5 microns, 4 wt % of commercially available SiO 2 powder and 2 wt % of commercially available MgO powder were mixed in wet condition in an attriter and dried.
After passing through a 100 mesh sieve, the resulting powder was filled in a tube made of nickel having an outer diameter of 6 mm, an inner diameter of 5 mm and a length of 300 mm. The tube filled with the powder material was subjected to wire-drawing operation to reduce its oute diameter with the dimensional reduction ratio of 95%, 80% and 50% respectively and then preliminary sintering was carried out at 1000° C. for 1 hour under vacuum. After the preliminary sintering operation, the outer tube of nickel was removed by cutting operation. The resulting preliminarily sintered body was then sintered finally at 1800° C. under vacuum. The result showed that the rod which was produced under the dimensional reduction ratio of 95% broke into six portions, while the others were not damaged.
Preliminary sintering was performed to rods which were produced at the dimensional reduction ratio of 80% under respective temperatures of 800° C., 1000° C. and 1400° C. After the nickel tube was removed by dissolution thereof, the result revealed that a rod which was sintered at 800° C. could not maintain its shape and a rod which was sintered at 1400° C. broke into five pieces, but a rod which was sintered at 1000° C. did not damaged at all.
EXAMPLE 8
The Fourth Embodiment
99 wt % of commercially availabler SiC powder having an average particle size of 0.5 microns, 0.5 wt % of B powder and 0.5 wt % of commercially available SiO 2 powder and 2 wt % of commercially available C powder were mixed in wet condition in an attriter and dried.
After passing through a 100 mesh sieve, the resulting powder was filled in a tube made of nickel having an outer diameter of 5 mm, an inner diameter of 4 mm and a length of 400 mm. The tube filled with the powder material was subjected to wire-drawing operation to reduce its oute diameter with the dimensional reduction ratio of 13% and 24% respectively and then preliminary sintering was carried out at 1300° C. for 1 hour under vacuum. After the preliminary sintering operation, the outer tube of nickel was removed by cutting operation. A rod which was produced at the dimensional reduction ratio of 13% could not maintain its shape.
Another rod which was produced at the dimensional reduction ratio of 24% and which was not damaged was then sintered at 2050° C. under argon gas atmosphere of 500 Torr. The resulting rod was an elongated rod of SiC having a diameter of 2.7 mm and a length of 380 mm.
EXAMPLE 9
The Fifth Embodiment
80 wt % of commercially available WC powder having an average particle size of 0.8 micron, 2 wt % of commercially available WC powder and 18 wt % of commercially available Co powder were mixed in a solvent of ethylalcohol in an attriter and dried. After passing through a 200 mesh sieve, the resulting powders was filled in a tube made of copper having an outer diameter of 14 mm, an inner diameter of 12 mm and a length of 300 mm, wherein an elongated core made of wood having an outer diameter of 1.2 mm being placed in the tube previously, and then opposite ends of the tube was sealed.
The tube filled with the powder material was wire-drawn to reduce its outer diameter to 9 mm and then preliminary sintering was carried out at 900° C. for 30 min. under vacuum. After the preliminary sintering operation, the copper outer tube can be pealed off without difficulty because of shrinkage of the sintered inner cemented carbide. The wood core also could be removed easily because of the core is dehydrated and shrank. The resulting preliminarily sintered body was sintered at 1325° C. for 1 hour under vacuum to obtain a rod of cemented carbide having a diameter of 6.2 mm and an inner diameter of 0.9 mm.
In a comparative example, a rod having the same shape as abovementioned was produced with the same proportion of powder materials and by the same procedure as abovementioned Example 9 except that a known binder of organic compound was added to the powder material. In this case, it was necessary to add 55 volume % of organic compound as a binder to the powder material and was necessary to perform preliminary sintering at 450° C. for 48 hours under 25 Torr in hydrogen gas stream to eliminate the binder.
Outer periphery of the rods of Example 9 and comparative example was then reduced by cutting operation to gain a rod having an outer diameter of 6 mm and then the deflective strength was measured by the four-point bending test. The result deflective strength of Example 9 was 385 Kg/mm 2 , while that of the comparative Example was mere 165 Kg/mm 2 .
EXAMPLE 10
THE FIFTH EMBODIMENT
The same powder material as Example 9 was filled in to copper tube each having an outer diameter of 15 mm, an inner diameter of 12 mm and a length of 800 mm, a fine core of wood having a diameter of 2.0 mm being placed in the center of the tube previously. Then, wire-drawing was carried out for the tubes at a dimensional reduction ratio of 7% and 15% respectively, and then the tubes were subjected to preliminary sintering under the same condition as Example 9.
In the case of dimensional reduction ratio of 7%, powder was not sintered sufficiently and slipped out of the tube in a form of course powder. Complete sintering was done in the case of dimensional reduction ratio of 15% and a sintered body and the core could be removed out of the tube due to shrinkage of the sintered powder.
EXAMPLE 11
THE FIFTH EMBODIMENT
The same powder material as Example 9 was filled in three nickel tube each having an outer diameter of 20 mm, an inner diameter of 18 mm and a length of 500 mm, a fine core of wood having a diameter of 1.5 mm being placed in the center of the tube previously. Then, wire-drawing was carried out for the tubes at a dimensional reduction ratio of 95%, 80% and 50% respectively, and then the tubes were subjected to preliminary sintering and the final sintering under the same condition as Example 9 to produce rods of cemented carbide. The result showed that the rod of dimensional reduction ratio of 95% broke into three parts while other two rods did not break.
Then, the rod of dimensional reduction ratio of 80% was subjected to preliminary sintering at 400° C., 100° C. and 1400° C. respectively and then the outer tube was removed with nitric acid. The result showed that the first rod which was sintered at 400° C. could not maintain its shape and broke into smaller pieces, the second rod which was sintered at 1400° C. broke into 6 pieces, while the third rod which was sintered at 1000° C. did not break.
EXAMPLE 12
THE SIXTH EMBODIMENT
29.5 wt % of Cr powder, 3.9 wt % of W powder, 1.1 wt % of C powder and the balance of Co powder (all the powders were commercially available ones and were passed through a sieve of 150 mesh) were mixed and then filled in a tube made of copper having an outer diameter of 20 mm, an inner diameter of 17 mm and a length of 600 mm and then opposite ends of the tube was closed.
The tube filled with the powder material was then subjected to several times of wire-drawing operations. At each operation of wire-drawing, the tube was reduced with the dimensional reduction ratio of 70% and annealed at 500° C. before entering next wire-drawing operation. Finally, the tube had an outer diameter of 1.9 mm and an inner diameter of 1.6 mm and then preliminary sintering was carried out at 950° C. for 1 hour.
At the end of the preliminary sintering operation, the copper outer tube was removed and the inner preliminarily sintered body was then sintered finally at 1250° C. to obtain a fine wire of carbide precipitating type cobalt alloy having a diameter of 1.6 mm and a length of 67 mm. This fine wire was used as an electrode in an automatic welding machine and showed good result.
EXAMPLE 13
THE SIXTH EMBODIMENT
The same powder material as Example 12 was filled in a copper tube having an outer diameter of 50 mm, an inner diameter of 6 mm and a length of 500 mm and opposite ends were sealed.
The tube filled with the powder material was then subjected to wire-drawing at the dimensional reduction ration of 95%, 90%, 85%, 25%, 20% and 15% respectively and then the tubes were subjected to preliminary sintering at 95° C. for 1 hour. When the outer copper sheaths were removed by cutting process, it was found that the first one of the preliminarily sintered bodies whose dimensional reduction ratio was 95% broke and the last one whose dimensional reduction ratio was 15% cracked, while the others were not damaged.
Then, the preliminarily sintered body whose dimensional reduction ratio was 85% was subjected to the final sintering operation at temperatures of 10° C., 30° C., 100° C. and 150° C. lower than the melting point of the alloy respectively. The result showed that the first rod which was sintered at the difference in temperature of 10° C. did not maintain its shape because of lack of strength and the fourth one which was sintered at the difference in temperature of 150° C. could not be sintered completely, while the others were sintered satisfactorily.
EXAMPLE 14 (THE SEVENTH EMBODIMENT)
28.4 wt % of Cr powder, 4.1 wt % of W powder, 1.1 wt % of C powder and the balance of Co powder (all the powders were commercially available ones and were passed through a sieve of 150 mesh) were mixed and then filled in a tube made of iron having an outer diameter of 7 mm, an inner diameter of 5 mm and a length of 600 mm and then opposite ends of the tube was closed.
The iron tube filled with the powder material was wire-drawn at the dimensional reduction ratio of 90% to obtain a wire having an outer diameter of 2.2 mm, an inner diameter of 1.6 mm and a length of 6 m. Then, the powder material in the tube was sintered at 1240° C. for 1 hour and then iron sheath was removed by dipping the tube in hydrochrolic acid to obtain a fine wire of carbide precipitating reinforced type cobalt-based alloy.
The resulting fine wire of carbide precipitating reinforced type cobalt-based alloy having a diameter of 1.6 mm and a length of 60 mm was used as an electrode in an automatic welding machine and good quality of welding was observed.
EXAMPLE 15 (THE SEVENTH EMBODIMENT)
30.5 wt % of Cr powder, 17.1 wt % of W powder, 2.1 wt % of C powder and the balance of Co powder (all the powders were commercially available ones and were passed through a sieve of 150 mesh) were mixed and then filled in a tube made of nickel having an outer diameter of 8 mm, an inner diameter of 6 mm and a length of 500 mm and then opposite ends of the tube was closed.
The nickel tube filled with the powder material was then subjected to wire-drawing at the dimensional reduction ration of 95%, 90%, 85%, 25%, 20% and 15% respectively and then the tubes were subjected to sintering at 1200° C. for 1 hour. When the outer nickel sheaths were removed by cutting process, it was found that the first one of the sintered bodies whose dimensional reduction ratio was 95% broke and the last one whose dimensional reduction ratio was 15% cracked, while the others were not damaged.
Then, the sintered body whose dimensional reduction ratio was 85% was subjected to the final sintering operation at temperatures of 10° C., 30° C., 100° C. and 150° C. lower than the melting point of the alloy respectively. When the nickel sheath was removed, the result showed that the first rod which was sintered at the difference in temperature of 10° C. showed diffusion of nickel which reacted with a surface of the sintered body and the fourth one which was sintered at the difference in temperature of 150° C. could not be sintered completely, while the others were sintered satisfactorily.
EXAMPLE 16 (THE SEVENTH EMBODIMENT)
53.5 wt % of Cr powder, 7.2 wt % of W powder, 1.7 wt % of C powder and the balance of Co powder (all the powders were commercially available ones and were passed through a sieve of 150 mesh) were mixed and then filled in a tube made of cobalt having an outer diameter of 5 mm, an inner diameter of 4 mm and a length of 600 mm and then opposite ends of the tube was closed.
The nickel tube filled with the powder material was then subjected to wire-drawing at the dimensional reduction ration of 90% to obtain an elongated wire having an outer diameter of 1.6 mm, an inner diameter of 1.3 mm and a length of 6 m and then the tube was subjected to sintering at 1250° C. for 1 hour to obtain a wire of Co based alloy.
The wire of the Co based alloy having a diameter of 1.6 mm and a length of 6 mm has a surface layer of cobalt of 0.15 mm thick. The wire has as a whole such a composition as 28.2 wt % of Co--3.8 wt % of Cr--0.9 wt % of C. This wire was used as an electrode for an automatic welding machine with good result. | Method for producing an elongated sintered article, characterized by the steps including filling powder material in a pipe, carrying out plastic deformation of the pipe filled with the powder material, and heating the pipe filled with the powder material to burn and/or sinter the powder material.
The method of the present invention is advantageously applicable to production of wire or rod of ceramics, particularly so called new ceramics or fine ceramics, sintered alloys or their combination, which are difficult of shaping or moulding by conventional process such as wire-drawings, rolling or extrusion of powder material and are difficult of machining or processing after the powder material is sintered. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on Provisional Application No. 60/851,657 filed Oct. 13, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK
[0003] Not Applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to a process for the production of chlorates and derivative chemicals from ammonium perchlorate as a starting material. Ammonia is produced in a first step wherein a metal hydroxide is reacted with ammonium perchlorate to produce ammonia and a metal perchlorate. If the metal hydroxide used is sodium hydroxide, sodium perchlorate is formed. The ammonia generated is recovered and sent to a reformer to produce hydrogen which is used to fuel a fuel cell that generates water and electrical energy to run an electrochemical reactor where the metal perchlorate is converted to a metal chlorate and derivative chemicals.
[0007] 2. Description of Related Art
[0008] The perchlorate anion (ClO 4 − ) has been found in water supplies throughout the southwestern United States. The primary source of this perchlorate is from the release of ammonium perchlorate to the environment. The primary use of ammonium perchlorate is as a propellant which generates controlled propulsion of a rocket or projectile during flight. Ammonium perchlorate, as a solid fuel for rocket motors, is ideal for military applications since it is stable, can be stored almost indefinitely, and is denser than liquid fuels yielding more compact systems. In fact, the space shuttle is the largest consumer of ammonium perchlorate in which each set of space shuttle solid rocket motors use approximately 1.7 million pounds of the propellant. The other large user of ammonium perchlorate is the U.S. military in which the propellant is used in virtually every solid-fueled tactical and strategic missile in the inventory. In 1998, the EPA added perchlorate to the Contaminated Candidate List for drinking water. Currently the EPA is overseeing the clean-up of a variety of contaminated sites in states such as Nevada, California, Arizona, and Texas. From a health standpoint the perchlorate ion, which is similar in size to the iodide ion, can be taken up by the mammalian thyroid gland. As a result, the perchlorate ion can disrupt the production of thyroid hormones and hence disrupt metabolism. Therefore, there is a need for processes that are able to reduce the amount of perchlorate introduced into the environment.
[0009] This invention addresses the perchlorate problem from a demilitarization standpoint. The United States Department of Defense maintains that there are no feasible technologies available to completely address the perchlorate problem through the chemical processing of ammonium perchlorate. Current demilitarization practices only recover and reuse the perchlorate without any attempt to convert it to any other chemical moiety. This invention relates to a chemical process by which ammonium perchlorate, recovered from weapons systems, can be chemically converted to commodity chemicals and used commercially. This approach completes the life cycle of a weapons systems in which an environmentally unfriendly chemical is converted to chemicals that have significant commercial value.
SUMMARY OF THE INVENTION
[0010] In accordance with the present invention there is provided a process for producing chlorates and derivative chemicals from ammonium perchlorate, which process comprises:
[0011] a) introducing an effective amount of an aqueous solution of ammonium perchlorate and an effective amount of an aqueous caustic solution into a reaction zone, which caustic is represented by MOH, wherein M is selected from the group consisting of Li, Na and K;
[0012] b) reacting said ammonium perchlorate and MOH in said reaction zone at effective reaction conditions to produce an ammonia product stream and a product stream containing M-perchlorate;
[0013] c) reforming the ammonia in a reforming zone to produce a hydrogen-containing product stream;
[0014] d) introducing at least a portion of said hydrogen-containing product stream in said reforming zone to a fuel cell, wherein the electrical energy generated by the fuel cell is used to power an electrochemical reaction zone containing a cathode and an anode;
[0015] e) reacting the M-perchlorate in said electrochemical reaction zone to produce oxygen at the anode and at the cathode a product stream containing M-chlorate and at least on other product selected from the group consisting of M-chlorite, M-hypochlorite, and M-chloride; and
[0016] f) collecting the M-chlorate and derivate chemicals produced in said electrochemical reaction zone.
[0017] In a preferred embodiment the caustic is NaOH.
[0018] In another preferred embodiment at least a portion of the oxygen produced in the electrochemical reaction zone is conducted to said fuel cell.
BRIEF DESCRIPTION OF THE FIGURE
[0019] The sole FIGURE hereof is a simplified flow scheme of a preferred embodiment of the present invention for producing a metal chlorate from ammonium perchlorate by a three step process.
DETAILED DESCRIPTION OF THE INVENTION
[0020] As previously mentioned, the perchlorate ion is a harmful contaminant in the environment. It is typically released into the environment primarily by way of improper disposal of ammonium perchlorate that is used as a solid propellant for such things as rockets, missiles and fireworks. Conventional demilitarization processes are not able to achieve the destruction efficiencies to meet perchlorate levels adopted by EPA of 24 ppb in drinking water. The process of the present invention is capable of meeting those levels as well as generating energy.
[0021] The FIGURE hereof is a simplified representation of a preferred process scheme for practicing the present invention. Ammonium perchlorate is conducted into a reaction zone RZ via line 10 . It is preferred that the ammonium perchlorate be used as an aqueous solution of suitable molarity and that the ratio of caustic to ammonium perchlorate in reaction zone RZ be from about stoichiometric to excess caustic, more preferably about stoichimetric. Effective molarities of aqueous ammonium perchlorate range from 0.01 to 10 mol/L, preferably from about 0.1 to 3.0 mol/L, depending upon temperature. Effective temperatures range from about 0° to 100° C., preferably from about 0° to about 60° C. An effective amount of caustic (MOH, where M is selected from Li, Na, and K) is also conducted into reaction zone RZ via line 12 where hydrolysis takes. The caustic converts the ammonium ion from the ammonium perchlorate to ammonia gas. Also, the M cation that is introduced into reaction zone RZ via the caustic takes the place of the ammonium ion in solution with the formation of M-perchlorate. Aqueous or solid caustic can be introduced to reaction zone RZ. The reaction zone RZ may be heated to enhance the rate of ammonia gas generation and recovery. As a result, the addition of solid caustic to reaction zone RZ is beneficial in that the exothermic heat of solution can be used to heat the reactor of reaction zone RZ.
[0022] In this invention, the processing of 45.4 kilograms of ammonium perchlorate, requires 15.4 kilograms of sodium hydroxide for the generation of a stoichiometric mixture in reaction zone RZ. The hydrolysis reactor generates about 6.8 kilograms of additional water, about 6.8 kilograms of ammonia, and about 47.2 kilograms of sodium perchlorate. Next, the recovered ammonia is used to produce hydrogen.
[0023] As previously mentioned, reaction zone RZ is one in which hydrolysis of ammonium perchlorate in the presence of a caustic generates a product stream comprised of gaseous ammonia and a product stream comprised of M-perchlorate. The ammonia gas product stream is conducted, via line 16 , and an oxygen-containing gas, preferably air via line 18 , to reformer REF where a hydrogen product stream is produced, which hydrogen product stream is conduced to fuel cell FC via line 20 . Reformer REF is preferably one wherein the autothermal ammonia reformation occurs. Conducting the ammonia decomposition reaction under such autothermic conditions leads to higher conversions of ammonia and to higher hydrogen selectivities. An autothermic state is achieved in which no heat need be added to the reaction system. Performance can further be enhanced through the independent supply of heat to the reaction system or recovery and reuse of heat generated within the reactor. Any catalyst can be used that is capable of decomposing ammonia to produce a hydrogen Preferred catalysts include the transition metals, such as those selected from the group consisting of Groups IIIA (Sc, Y, La), IVA (Ti, Zr, Hf), VA (V, Nb, Ta), VIA (Cr, Mo, W), VIIA (Mn, Re), VIIIA (Fe, Co, Ni, etc.), IB (Cu, Ag, Au), and IIB (Zn, Cd, Hg) of the Periodic Table of the Elements, inclusive of mixtures and alloys thereof. Preferred are the metals from Groups VIA, VIIA, and VIIIA, particularly Fe, Ni, Co, Cr, Mn, Pt, Pd, and Ru. Also included as suitable ammonia decomposition catalysts are those disclosed in U.S. Pat. No. 5,976,723, which is incorporated herein by reference. The catalysts of U.S. Pat. No. 5,976,723 are comprised of: a) alloys having the general formula Zr 1-x Ti x M 1 M 2 wherein M 1 and M 2 are selected independently from the group consisting of chromium, manganese, iron, cobalt, and nickel and x is in the range from about 0.0 to 1.0 inclusive, and b) between about 20% by weight and about 50 by weight of aluminum.
[0024] The ammonia decomposition catalyst used in the practice of the present invention may be either supported and non-supported. A preferred non-supported catalyst would be a pure metallic woven mesh, more preferably a nickel woven mesh. It is preferred that the catalyst be supported on any suitable support. Preferred support structures include monoliths, fiber mats, and refractory inorganic particles. The supports will preferably be comprised of carbon or a metal oxide, such as alumina, silica, silica-alumina, titania, magnesia, aluminum metasilicates, and the like. The second type of preferred material for the catalyst support structures suitable for use herein are the heat- and oxidation-resistant metals, such as stainless steel or the like. Also suitable are materials known as Fecralloys that can withstand high temperatures, can be wash-coated, and can also form an alumina layer (oxide layer) on its surface that can be used to not only support a metal catalyst but that also can act as a thermal insulating material.
[0025] Autothermal ammonia decomposition provides an especially effective way to supply hydrogen for use in the proton exchange membrane (PEM) fuel cell system. This technique combines endothermic heterogeneous ammonia decomposition reaction, into hydrogen and nitrogen on a supported catalyst, with the exothermic homogenous oxidation of ammonia (into nitrogen and water) in the gas phase. This direct coupling of ammonia dissociation and oxidation within the same reactor greatly improves heat transfer and process energetics. It is preferred that the reformer approach adiabatic operation with cooling of the reactor effluent via feed gas preheat in a suitable heat exchanger. The reformer will be operated at a temperature of about 200° C. to about 2000° C., preferably from about 400° C. to about 1500° C. and at ammonia to oxygen mol ratios of about 3 to 20, preferably from about 4 to 10, more preferably from about 7 to 8. The resulting observed ammonia conversions are in excess of 99%.
[0026] The product from the ammonia reformer is hydrogen, nitrogen, and water. At least a portion of the hydrogen and optionally at least a portion of the nitrogen are conducted to proton exchange membrane (PEM) fuel cell FC via line 20 . At least a portion of nitrogen can also be vented to the atmosphere via line 22 and water removed from the reformer via line 24 . It will be understood that before entering the fuel cell FC the hydrogen-containing stream 20 will need to be cooled to the operating temperature range of the fuel cell. Residual amounts (ppm levels) of ammonia may be present in the hydrogen/nitrogen product stream. A scrubber (not shown) can be used upstream of fuel cell FC to reduce the amount of residual ammonia to acceptable levels for the PEM fuel cell.
[0027] For a fuel cell, such as a PEM fuel cell, with an overall energy density based on the mass of ammonia of 1.5 Watt hours per gram, the processing of the 6.8 kilograms of ammonia generates 35,000 kilojoules of electrical energy of which a portion is used to electrochemically reduce the perchlorate anion is the next step.
[0028] At least a portion of the M-perchlorate product stream from the reaction zone RZ will be conducted to electrochemical reactor ER, via line 26 , wherein M-perchlorate is reduced to M-chlorate and derivate chemicals with the generation of oxygen in an aqueous solution. The M-chlorate is collected via line 28 and a portion of the oxygen is optionally conducted via line 30 to the fuel cell FC which generates an electrical current and water as a by-product, which can be discharged via line 32 .
[0029] The perchlorate anion reduction process takes the chlorine atom from the +7 oxidation state to +5 when reduced to chlorate. The standard reduction potential is 1.194 Volts and occurs at the cathode of the electrochemical reactor. The oxidation of water occurs at the anode of the electrochemical reactor; this half-cell reaction has a standard potential of −1.229 Volts. As a result, the overall cell potential is −0.035 Volts. Since the cell potentials are related to the Gibbs free energy of formation by Faraday's Laws of Electrolysis, the Gibbs free energy change is 6.76 kiloJoules/mol. Therefore, 2,600 kilojoules of energy are required to electrochemically reduce the perchlorate from 47.2 kilograms of sodium perchlorate. However, 35,000 kilojoules of electrical energy is generated in the fuel cell FC through the processing of the 6.8 kilograms of ammonia generated in reaction zone RZ. During the course of the electrochemical reduction process, the 47.2 kilograms of sodium perchlorate, for example, yields 6.4 kilograms of oxygen and 40.8 kilograms of sodium chlorate. This invention utilizes the internal energy of ammonia obtained by autothermally reforming ammonia and powering a fuel cell, to provide the energy needed to power electrochemical reactor ER where the reduction of perchlorate occurs.
[0030] The electrochemical reactor ER will preferably not be operated at standard conditions since concentrations of perchlorate are typically not at 1 mol/L. Effective molarities of the aqueous ammonium perchlorate range from about 0.1 to 10 mol/L depending upon temperature which as previously mentioned is in the range of about 0° to 100° C. Since electrochemical reactor ER does not operate at standard conditions, a significant overpotential is required when powering electrochemical reactor ER. Fortunately, fuel cell FC can generate a great excess of energy that meets overpotential requirements. In addition, any excess electrical energy from fuel cell FC can be used to power other equipment in the process such as pumps.
[0031] The perchlorate anion is reduced in the electrochemical reaction zone. The perchlorate anion is comprised of a tetrahedral array of oxygen atoms bonded to a central chlorine atom. Since the chlorine atom is in the +7 oxidation state, the perchlorate anion is a strong oxidizing agent. In addition, the reduction of perchlorate (ClO 4 − ) in electrochemical reactor ER can further reduce the oxidation state of the chlorine from +7 to not only +5, but also to +3, +1, and −1. As a result, other derivative chemicals aside from chlorate (ClO 3 − ) are produced. Such other derivative chemicals include chlorite (ClO 2 − ), hypochlorite (ClO − ), and chloride (Cl − ). The production of these derivative chemicals requires additional energy of which some or all can be provided by fuel cell FC.
[0032] Perchlorate reduction is non-labile and exhibits low reactivity. These properties of perchlorate led to its extensive use as a propellant. Fortunately, the nonliable and low reactive nature of perchlorate is due to kinetic effects since the reduction process is thermodynamically favored. As a result, catalytic materials are used to reduce the rather large activation energy associated with perchlorate reduction. The use of catalytic materials can take the form of electrode materials used in electrochemical reactor ER or the addition of metal particles to the aqueous solution in the electrochemical reactor itself. These materials can include any materials used in traditional electrochemical reactors. These materials include, but are not limited to, platinum, tin, ruthenium, iridium, vanadium, titanium, and graphite.
[0033] Overall, this invention describes a process in which the controlled chemical conversion of ammonium perchlorate to derivative chemicals is achieved. When ammonium perchlorate is used as a propellant, the perchlorate ion rapidly oxidizes the ammonium ion releasing large amounts of energy in an uncontrolled fashion. In this invention, the ammonium ion is recovered from ammonium perchlorate through a hydrolysis reaction conducted in reaction zone RZ. This ammonia is then oxidized in a controlled fashion in reformer REF to generate hydrogen for fuel cell FC. This fuel cell then powers the electrochemical reactor ER where the controlled reduction of perchlorate occurs. | A process for the production of chlorates and derivative chemicals from ammonium perchlorate as a starting material. Ammonia is produced in a first step wherein a metal hydroxide is reacted with ammonium perchlorate to produce ammonia and a metal perchlorate. If the metal hydroxide used is sodium hydroxide, sodium perchlorate is formed. The ammonia generated is recovered and sent to a reformer to produce hydrogen which is used to fuel a fuel cell that generates water and electrical energy to run an electrochemical reactor where the metal perchlorate is converted to a metal chlorate and derivative chemicals. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a sheet paper attracting system for use in a sheet paper feeding system of a copying machine, a facsimile system, a printing machine, etc.
The present invention relates, more particularly, to a piled feeding preventing system in a sheet paper feeding system.
Various types of sheet paper feeding systems have been developed for supplying a paper sheet from a storing section wherein a plurality of sheets are stacked. In such a system it must be ensured that one sheet of paper is transferred at a desired time. It is not desirable that the transferred paper includes more than one sheet piled up.
To prevent piled feeding, one of the conventional systems includes a catch for separating the paper sheets at one corner thereof. This mechanism does not work well when the attracting force between the sheets is considerably strong. Furthermore, the catch may damage the surface of the paper sheet. Another conventional system includes a separating roller which rotates in the reverse direction. This type of system does not work well when the frictional condition of the separating roller varies during a long usage time. Furthermore, an accurate adjustment is required depending on the thickness of the paper sheet. Moreover, it is clear that the separating roller may damage the surface of the paper sheet.
Accordingly, an object of the present invention is to provide a novel paper feeding system which prevents the piled feeding of the paper sheets.
Another object of the present invention is to provide a paper sheet attracting system which ensures an accurate feeding without damaging the surface of the paper sheeet.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
To achieve the above objects, pursuant to an embodiment of the present invention, a paper sheet attracting system is provided for attracting a paper sheet through the use of a suction air force. A piled feeding preventing system is provided in a manner that the piled feeding preventing system confronts the paper sheet attracting system when the paper sheet attracting system attracts the paper sheet. The piled feeding preventing system functions to attract the paper sheet attracted by the paper sheet attracting system through the use of a section air force.
In a preferred form, the attracting force created by the piled feeding preventing system is selected lower than the attracting force created by the paper sheet attracting system, and the attracting force created by the piled feeding preventing system is selected greater than the attracting force formed between the adjacent two paper sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein:
FIG. 1 is a schematic side view of an embodiment of a piled sheet feeding preventing system of the present invention;
FIG. 2 is a schematic front view of the piled sheet feeding preventing system of FIG. 1;
FIGS. 3, 4, 5 and 6 are schematic side view of a paper feeding system including the piled sheet feeding preventing system of FIG. 1 for explaining an operational mode of the piled sheet feeding preventing system of FIG. 1; and
FIG. 7 is a schematic block diagram of a control system for activating the piled sheet feeding preventing system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The piled sheet feeding preventing system of the present invention is constructed to cooperate with a sheet paper attracting system such as disclosed in my copending application, SHEET PAPER ATTRACTING SYSTEM, U.S. application Ser. No. 464,377 which claims priority based on Japanese patent application No. 57-20467 which was filed in Japan on Feb. 10, 1982.
The piled sheet feeding preventing system of the present invention includes a suction air casing 1 having a pressure chamber 2 formed therein. Air intake openings 3 are formed at desired sections in the suction air casing 1. A rotating shaft supporting plate 4 is secured to the bottom surface of the suction air casing 1, and a rotating shaft 5 is fixed to the rotating shaft supporting plate 4. The rotating shaft 5 is rotatably supported by a bearing member 6 which is provided on a drive table 7. Accordingly, the suction air casing 1 is rotatable about the rotating shaft 5 as shown by an arrow A in FIG. 1. Stopper members (not shown) are provided for determining the rotating angle of the suction air casing 1 about the rotating shaft 5.
The above-mentioned unit is slidably (in the direction shown by an arrow B) mounted on a slide shaft 9. More specifically, a slider 8 is secured to the drive table 7. The slider 8 is mounted on the slide shaft 9 which is secured to a slide shaft supporting plate 10. A motor 11 is secured to the drive table 7 via a motor securing plate 14 for driving the unit including the suction air casing 1.
The above-mentioned rotating operation of the suction air casing 1 is controlled by an ON/OFF operation of a solenoid 16. The solenoid 16 is secured to a solenoid supporting plate 17 and is connected, via a latch 19, to a latch angle 18 which is fixed to the bottom surface of the suction air casing 1. The above-mentioned sliding operation is driven by the motor 11 via gears 15 supported by a gear supporting plate 13. The suction air casing 1 is communicated with a suction blower (not shown) through a duct 20.
An operational mode of the piled sheet feeding preventing system of FIGS. 1 and 2 will be described with reference to FIGS. 3, 4, 5 and 6.
As already discussed above, the piled sheet feeding preventing system of the present invention cooperates with a paper sheet attracting system 21. An example of the paper sheet attracting system is disclosed in my copending application, "SHEET PAPER ATTRACTING SYSTEM" which claims the priority from a Japanese patent application No. 57-20467 (Our Reference 2010-US,GER-T).
When a paper sheet feed initiation is instructed, a paper sheet supporting table 23 is driven to shift upward in the direction shown by an arrow C in FIG. 3 so that an uppermost sheet 25' in paper sheets 25 stacked on the paper sheet supporting table 23 contacts the paper sheet attracting system 21. At this moment, the piled sheet feeding preventing system is held at a stand-by position and the suction operation is not performed by the piled sheet feeding preventing system.
Then, the suction operation of the paper sheet attracting system 21 is initiated to attract the uppermost sheet 25'. The paper sheet attracting system 21 is rotated as shown in FIG. 4. At this moment, the suction operation of the piled sheet feeding preventing system is initiated, and the piled sheet feeding preventing system is moved to a position near the rear surface of the uppermost sheet 25'. Thereafter, the piled sheet feeding preventing system is driven backward to a preselected position as shown by the solid line in FIG. 4. The forward and backward movement of the piled sheet feeding preventing system is controlled by a position control circuit 71 shown in FIG. 7. When the piled sheet feeding preventing system is held as shown by the solid line in FIG. 4, a determination is carried out as to whether any sheets are attracted by the piled sheet feeding preventing system. This determination is conducted by a sheet attract detection circuit 72 through the use of a detection of the variation of the load current of the suction blower.
The attracting force created by the piled sheet feeding preventing system is selected slightly lower than that of the paper sheet attracting system 21. Therefore, the uppermost sheet 25' caught by the paper sheet attracting system 21 will not be separated from the paper sheet attracting system 21. If the paper sheet is not attracted by the piled sheet feeding preventing system, only one sheet (the uppermost sheet 25') has been correctly attracted by the paper sheet attracting system 21. At this moment, the piled sheet feeding preventing system is rotated to depress the following sheets as shown in FIG. 6.
When more than one sheet has been attracted by the paper system attracting system 21, the next sheet (sheets) 25" is attracted by the piled sheet feeding preventing system as shown in FIG. 4. That is, the attracting force of the piled sheet feeding preventing system is selected greater than the attracting force created between adjacent two sheets. When the sheet attract detection circuit 72 detects that the piled sheet feeding preventing system attracts one or more sheets, the suction operation is interrupted, and the piled sheet feeding preventing system is returned to the initial stand-by position as shown by the dotted line in FIG. 5, thereby allowing the sheets to return to the paper sheet supporting table 23. After a predetermined time has passed, the above-mentioned operation is repeated to again attract the piled sheets 25" if any.
When the sheet attract detection circuit 72 does not develop a signal indicating that the paper sheet is not attracted by the piled sheet feeding preventing system, because the paper sheet attracted by the piled sheet feeding preventing system is again attracted by the uppermost sheet 25', even when the above-mentioned operation is repeated by several times, an attracting force control circuit 73 is enabled to increase the attracting force created by the piled sheet feeding preventing system. When the next sheets 25" can not be removed at all, the system operation is interrupted and an alarm device is enabled.
With the above-mentioned operation, when only the uppermost sheet 25' is attracted by the paper sheet attracting system 21, a sheet feeding mechanism 22 is enabled as shown in FIGS. 5 and 6 to transfer the uppermost sheet 25' along a guide 24 in the direction shown by an arrow E. While the sheet feeding operation is conducted, the piled sheet feeding preventing system depresses the paper sheets 25 stacked on the paper sheet supporting table 23. When the sheet feeding operation is completed, the piled sheet feeding preventing system is returned to the initial stand-by position as shown in FIG. 3.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims. | A paper sheet supplying system including a paper sheet attracting unit for attracting a paper sheet for feeding purposes, and a piled sheet feeding prevention unit which confronts the paper sheet attracting unit at a preselected position. When more than one sheet is attracted by the paper sheet attracting unit, the piled sheet feeding preventing unit removes the paper sheet or sheets from the sheet attracted by the paper sheet attracting unit so that only one sheet is accurately fed. | 1 |
The present invention relates to improvements in cleaning the cavities of soap molding machines.
A well known type of molding machine comprises a multicavity mold which is incrementally rotated to successively register sets of mold cavities with a loading station, molding or pressing station, an unloading station and a cleaning station. The present invention is concerned with the cleaning station of this turret type machine.
In this type of soap molding machine, the mold cavities are in the nature of straight sided passageways, usually having a generally rectangular outline. Soap bar preforms are trimmed and inserted into the cavities at the loading station. The mold then rotates to bring these cavities to the pressing station, where they are compressed to a desired density and, in the usual case, a trademark identification is embossed therein. The next incremental rotation of the mold brings these cavities to the unloading station where the compressed bars of soap are displaced from the cavities for further processing. The empty cavities are then rotated to the cleaning station.
After the compressed bars of soap are unloaded from the mold cavities, there will be soap residue adhering to the walls of the cavities. Additionally, there can be loose scraps of soap in this cavity. It has long been recognized that the mold cavities must be free of soap residue when preforms are loaded thereon. If any such residue is present, it will cause disfiguration of soap bars subsequently compressed therein. These scraps and the adhering residue are removed at the cleaning station.
In prior art machines, a felt pad has been employed to obtain this cleaning function. Typically a felt pad, having a thickness of approximately 3/8 inch, is clamped between a pair of plates which have an outline slightly less than that of the die cavity. The felt pad is formed with an outline matching that of the die opening. The felt pad, so mounted, is reciprocated into and out of the die opening. The side surfaces of the felt pad wipe the die cavity surface, thereby removing soap residue and soap scraps.
This approach has been effective in providing the required cleaning function. However, it has a serious drawback in that the wiping surfaces of the pads become matted and lose their effectiveness as a cleaning mechanism, in a relatively short period of time. Thus there is not only the inconvenience of frequent replacement of the felt pads, typically on a weekly basis, but also the loss of production involved in the shutting down the machine in order to replace felt pads.
It is also to be noted that the referenced soap molding machines are highly automated and operate at high production rates. Thus, when a felt pad loses its effectiveness, there can be a large number of defective soap bars produced before the need to replace the felt pads is recognized. This further contributes to the losses incident to the relatively short working life of the felt pads.
Accordingly, the object of the present invention is to provide more effective and reliable means for cleaning the mold cavities of a soap molding machine.
A further and related object of the present invention is to minimized the down time of soap molding machines, incident to replacing the cleaning means for these mold cavities.
Yet another object of the present invention is to attain the foregoing ends in a manner requiring a minimum modification of existing soap molding machines.
These means are broadly attained by substituting a brush for the cleaner plates previously employed in the referenced type of soap molding machine.
More specifically, the invention comprises a mold cleaning mechanism comprising a mold having a cavity extending therethrough. A mold cleaning element is registered with this cavity and is reciprocated between a rest position spaced from said mold and an extended position in which at least a portion of the mold cleaning element is extended through said cavity.
The mold cleaning element is a brush having bristles projecting from a mounting block. Preferably the brush comprises a block and a plurality of bristle plugs inserted into and projecting from said block. These bristles have an outline greater than the outline of the cavity. Thus, the bristles of the brush will be flexed to effectively clean soap residue from the cavity surface, when the brush is reciprocated between its rest and extended positions.
Further, it is preferred, in accordance with more specific aspects of the invention to form each plug of approximately 60 bristles, with the individual bristles being #14 nylon.
In accordance with further specific aspects of the invention, where the mold cavity outline has a width of approximately 21/4 inches and a height of approximately 31/2 inches, the brush outline has a width of approximately 25/8 and a height of approximately 41/8 inches. With this configuration, the interference between the bristles and the cavity outline is between approximately 30% and 50% of the length of the bristles.
Another aspect of the invention is found in that the brush, in its extended position, is projected at least partially through and beyond the mold cavity. Additionally, at least a portion of the bristles are extended to an unflexed position, in the extended position of the brush, so that bristles will be flexed in an opposite direction when the brush is reciprocated back to its rest position.
The above and other related objects and features of the invention will be apparent from a reading of the following description of a preferred embodiment, with reference to the accompanying drawings, and the novelty thereof pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, with certain elements in exploded relation, of the portions of a soap molding machine pertinent to an understanding of the present invention;
FIG. 2 is a perspective view, on an enlarged scale, of a brush support member seen in FIG. 1;
FIG. 3 is an elevation, on a further enlarged scale, of a brush unit seen in FIGS. 1 and 2;
FIG. 4 is a section taken on line 4--4 in FIG. 3;
FIG. 5 is a side view, on an enlarged scale and partially in section, of actuating mechanism seen in FIG. 1;
FIG. 6 is a side view similar to FIG. 5 illustrating the actuating mechanism in an alternate position;
FIG. 7 is a section taken on line 7--7 in FIG. 5.
FIG. 8 is a view, on an enlarged scale of the ends of bristle plugs employed in the present brush; and
FIG. 9 is a view similar to FIG. 3 illustrating the relationship between the brush outline and the outline of a mold cavity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is illustrated as a modification of an existing soap molding machine, also known as a soap press, which is generally identified by reference character 10 in FIG. 1. The molding machine 10 comprises a frame structure 12 on which a mold 14 is mounted for rotation about a horizontal axis. The mold 14 has four sets of mold cavities 16 which, as illustrated, may simply be straight sided passageways through the mold 14. Each set of mold cavities, in turn, comprises four cavities 16.
The mold 14 is rotated in 90 deg. increments to successively bring each set of mold cavities to a loading station 18, a pressing station 20, an unloading station 22 and a cavity cleaning station 24.
Operation of the machine is in turret fashion. At the loading station 18, soap preforms, or slugs, P are automatically positioned in lateral registration with the cavities 16 and then trimmed and loaded into those cavities by means which include trimmers 26. At the pressing station 20, the previously loaded preforms are compressed by dies 28 (there would be a second set of similar dies on the opposite side of the mold 14). At the unloading station 22, the compressed bars of soap are displaced from the cavities 16 by pushers 30 and gripped by suction cups 32 which then transfer the bars to other mechanism for further processing. At the cleaning station 22, brushes 34 brushes remove any soap scraps or residue from the mold cavities 16.
The mechanisms employed at the loading station 18, the pressing station 20 and the unloading station 22 are well known in the prior art, being the mechanisms provided in an existing machine available from Company G. Mazzoni, S.P.A., Busto Arsizio, Italy.
The present invention is directed to improvements embodied in the cleaning station 24 and more particularly to the brushes 34. Each brush comprises a central block 36 (See also FIGS. 2 and 5) which is secured by screws 38 to a stem 40 projecting from a support bar 42. The support bar 42 is mounted on a slide 44 is reciprocably mounted in a guideway 46, secured to the frame 12. A roller 48 is mounted on the slide 44 and received in a closed cam slot 50 formed in a cam plate 52 (Additional reference is made to FIG. 7). The cam plate 52 is mounted on a shaft 54 which is journaled on the frame structure 12. A lever 56 is also secured to the shaft 54 and connected by a link 58 (FIG. 1) and a further lever 59 to a shaft 60.
The components sequentially described from the stems 40 through the shaft 60 are likewise components found in said existing machine. The shaft 60 oscillates in proper timed relation to incremental rotation of the mold 14 to reciprocate the brushes 34 to provide an improved cleaning function, all in a manner now to be specifically described.
At the start of each cycle of incremental rotation of the mold 14, the brushes 34 are in a rest position, spaced rearwardly of the mold 14, as illustrated in FIG. 5. When this cycle is initiated, the shaft 60 rotates in a counterclockwise direction, causing the cam plate 52 to likewise rotate in a clockwise direction (FIG. 1). The cam 50 has a dwell portion so that the slide 44 remains stationary during the initial rotation of the cam plate 52. After this initial rotation is completed, the cam 50 displaces the slide 44 and, thus, the brushes 34 outwardly. The brushes 34 are respectively registered with the set of cavities 16 at the cleaning station 22. The brushes 34 are thus projected through this set of cavities 16 to the position illustrated in FIG. 6, which position is at the extreme of counterclockwise movement of the cam plate 52. Thereafter, the shaft oscillates to rotate in a clockwise direction, causing the cam plate 52 to also rotate in a clockwise direction and retract the brushes to the rest position of FIG. 5.
The brushes 34 provide a superior means of cleaning the surfaces of the mold cavities 16. The brushes 34 have a wear life greatly exceeding that of the prior felt wiper pads. Thus, while there is a need to periodically replace the brushes 34, the frequency is much less than with felt pads and, consequently down time and production losses are greatly minimized.
These superior results are further attributable to the characteristics of the brushes 34 and the features now to be described.
It will be first noted that each brush 34 comprises a plurality of plugs 62 comprising bristles 64 (FIGS. 3, 4 and 8). A preferred bristle material is a #14 white level nylon. It has been found that a bush formed with plugs 62 comprising approximately 60 bristles 64 of #14 white level nylon provides an effective cleaning action. These plugs are inserted into holes 66 having a preferred diameter of approximately 1/8 in. Preferably the plugs 62 are drawn into the block by #302-18 gauge stainless steel wire.
There is a natural tendency for the bristles of a plug to angle outwardly from the hole into which it inserted. This is illustrated in FIG. 8, where the broken line circles 70 identify the areas covered by the outer ends of the bristles 64 of each plug 62. It will be seen that the circles 70 overlap so that, across the width of the brush, on its outer surface, there will be bristle ends which engage the surface of a mold cavity, to effect a cleaning action. It will also be noted that the ends of the bristles of one plug are preferable spaced from the bristle ends of adjacent plugs, as illustrated by the spacing between adjacent, broken circles 70.
Reference is next made to FIG. 9, in which the front elevation of the outer ends of the bristles 64 is indicated by a broken line 72. The outline of the unflexed, brush bristles is in its registered relation with a die cavity 16. It will be seen that the outline of the brush, in all directions extends beyond the outline of the cavity, so that the bristles will have to be deflected when the brush is inserted into the cavity. This is also illustrated in FIG. 6. As will be seen, where the outline of the cavity 16 is generally rectangular, the bristles 64, at the corners of the brush will have a length somewhat longer than bristles defining its side surfaces.
There is, thus, an interference between the bristles and the die cavity. This interference should be at least sufficient to flex the bristle ends so that they provide a scrubbing action on the die cavity surface. Preferably, the interference, i.e., the difference between the brush outline and the cavity outline, should be limited to a dimension that permits some of the bristles to spring to an unflexed position, when the brush is in its fully projected position, as seen in FIG. 6.
It has been found, for purposes of the present invention, for a cavity outline having a width of approximately 21/4 inches and a height of approximately 31/2 inches, a brush outline having a width of approximately 25/8 and a height of approximately 41/8 inches provides an effective scrubbing action. This effective cleaning action is further derived with the use of bristle plugs 62, as above characterized. Additionally, the length of the bristles is approximately 5/8 inch along the side surfaces of the brush and approximately 7/8 inch at the corners.
Characterized in a different fashion, the interference between the bristles 64 and the adjacent outline of the cavity opening may vary between approximately 30% and 50%.
Variations in the described embodiment will occur to those skilled in the art within the spirit of the present inventive concepts, and are to be included within the scope of the following claims. | A turret type soap molding machine has a cleaning station at which soap residue is removed from mold cavities. The cleaning station includes reciprocating brushes for cleaning the surfaces of the mold cavities. | 1 |
FIELD
The present embodiments relate, generally, to self-contained systems and methods for improving production of a well using a gas.
BACKGROUND
When producing a well, hydrocarbons or other fluids to be recovered are provided with a natural lift due to dissolved gasses within the fluid, which facilitates recovery of the fluid. However, during production, this natural lift diminishes and eventually ceases, requiring other methods to be undertaken to continue producing from a reservoir.
To simulate the lifting effect of natural gasses, one or more compressed gasses, known as lift gasses, can be injected into a well to reduce the density of the hydrocarbon fluid, or other fluid to be recovered. Typically, a substantially non-combustible, non-condensible, inert gas that will not react with, corrode, or degrade well equipment or compounds within the well, and will not support significant microbial growth, such as nitrogen, is utilized.
The equipment required to generate, compress, inject, and recover lift gas, is expensive and bulky, which can be a significant drawback when space on or proximate to a well is limited. Further, the fuel reservoirs or other power sources necessary to utilize such equipment are also expensive and cumbersome.
It is often economically disadvantageous to produce a well using a lift gas. Frequently, the value of the fuel required to generate and compress the lift gas exceeds that of the product recovered from the well. A significant quantity of energy is required to compress enough nitrogen, or another gas, to extract product from a well. The energy costs, coupled with the costs required to transport fuel to the well to power the lift gas operation, can cause a production operation to become prohibitively expensive.
A separator can be used to separate lift gas from the extracted product, enabling the lift gas to be recycled and recompressed. However, even when recycled lift gas is used, a significant percent of the initial lift gas, such as fifteen percent, or more, is normally lost and must be regenerated, and a significant amount of recompression of the recycled gas is usually required.
When producing a hydrocarbon well using a lift gas, it is common for natural gas from the well to become mixed with the lift gas, and remain entrained with the lift gas after the produced fluid hydrocarbons have been separated.
A need exists for a system and method that can selectively separate the natural gas from the lift gas, and depending on the economic viability of each alternative, can selectively: 1) recycle and compress the gas, thereby conserving the costs associated with the production and compression of lift gas; 2) collect the natural gas for sale; or 3) use the natural gas to provide power for compressing the lift gas, thereby conserving costs related to fuel use, storage, and transport.
A further need exists for a system and method that can seamlessly and intelligently alternate between each aforementioned alternative, depending on changes in both the practical and economic viability of each alternative.
The present embodiments meet these needs.
SUMMARY
In an embodiment, the present system can include a gas generator for supplying a lift gas to a well, to obtain a production stream. The gas generator can include a low pressure, self-generating nitrogen generator. However, in addition to nitrogen, other gasses are also usable, such as natural gas, helium, hydrogen, krypton, argon, or other similar gasses. Preferably, a non-corrosive, non-condensible, oxygen-free gas can be used, to prevent damage or degradation to any well equipment or compounds from the well and to prevent microbial growth.
In an embodiment, the lift gas can initially include nitrogen or a similar gas produced by the gas generator at start-up, however, after the system has been in operation, at least a portion of the lift gas can be obtained from recycled gas separated from the production stream from the well.
A compressor can pressurize the lift gas prior to providing the lift gas to the well. In an embodiment, the lift gas can be compressed to a pressure ranging from 1500 pounds per square inch to 4300 pounds per square inch.
In an embodiment, dual compressors can be used, a first compressor compressing the atmosphere and communicating the nitrogen from the atmosphere to the second compressor, while the second compressor raises the pressure of the nitrogen prior to injection into the well. The first compressor can remain idle much of the time to conserve energy, and can be activated only when the volume of nitrogen in the system has become depleted.
A power source, such as a diesel fuel reservoir or similar source of energy, can be used to provide power to the gas generator, the compressor, or combinations thereof. In an embodiment, the power source can be used to drive the compressor initially, at start-up, but after the system has been in operation, at least a portion of the power for the compressor can be obtained from natural gas that has been recycled from the production stream from the well.
A first separator can be used to receive and separate the production stream from the well. In an embodiment, the first separator can be a three-phase separator, which can include a retention vessel that uses gravity to separate the production stream, forming a waste stream, which can include water and other waste materials, a product, such as a hydrocarbon fluid, and a recycle gas stream, which can include recycled lift gas entrained with natural gasses from the well.
While the recycled gas can be communicated directly to the compressor for re-injection into the well, thereby conserving lift gas and the energy required to create the lift gas, the recycled gas can also be selectively communicated to a second separator. In an embodiment, the second separator can be a pressure swing absorption separator.
The pressure swing absorption separator can mechanically separate mixtures of pressurized gases using one or more permeable membranes configured to remove nitrogen, or another gas used as the initial lift gas, from the recycle gas stream. In addition to or in lieu of a three-phase separator and/or a pressure swing absorption separator, one or more other separation apparatuses or techniques can be used.
The second separator can separate the recycle gas stream to form a power stream, which can include natural gas, and a lift gas stream, which can include nitrogen or another gas used as the initial lift gas. The lift gas stream can be communicated to the compressor for re-injection into the well, while the power stream can be selectively manipulated depending on a variety of factors.
One or more measuring devices can be used to determine the contents and/or the volume of the lift gas stream, the recycle gas stream, the power stream, or combinations thereof. For example, if it is determined that the power stream does not contain saleable, 900 btu per cubic foot natural gas, or if it is determined that the cost of producing and compressing additional lift gas exceeds the value of the amount of natural gas contained in the power stream, the power stream can be communicated to the compressor for re-injection into the well as lift gas.
Conversely, if it is determined that the power stream contains saleable natural gas, and it is economically viable to collect, store, and/or transport the natural gas for sale, given the cost to compress additional lift gas, the power stream can be collected for sale.
Alternatively, if it is determined that the cost of power for the compressor exceeds the value of the natural gas, both as a saleable product and as a lift gas, the natural gas can be used as an alternate power source for the compressor to conserve fuel costs. If a sufficient amount of natural gas is continuously extracted from the well, the present system can become entirely self-contained, such that little or no external energy is required to provide power to the compressor outside of that obtained from the natural gas. Further, if a sufficient amount of natural gas is obtained, the need for the generation of additional lift gas can also be minimized or eliminated.
In an embodiment, the present system can include a controller usable to selectively actuate a plurality of valves disposed between the gas generator, compressor, power source, separators, and one or more measuring devices. The controller can include a processor in communication with computer software usable to automatically actuate one or more of the valves, or to prompt manual actuation of the valves through the provision of notices and/or information.
Specifically, the controller is usable to selectively actuate valves to provide power to the gas generator, to direct the lift gas to the well, to divert the lift gas to a collector, to remove the waste stream from the system, to direct the product to a collector, to direct the recycle gas stream to the compressor, to direct the recycle gas stream to the second separator, to divert the recycle gas stream to a collector, to direct the power stream to the compressor for use as power, to direct the power stream to the compressor for use as lift gas, to divert the power stream to a collector, or combinations thereof.
Through use of an intelligent controller, the present system is usable to calculate the economic viability of each possible alternative use of the lift gas, the recycle gas stream, the power stream, or combinations thereof, by obtaining measurements from the measuring devices and comparing the measurements with predetermined or continuously monitored and/or changing parameters.
In an embodiment, the present system can include one or more transportable members, such as skids, which contain the gas generator, compressor, power source, separators, measuring devices, or combinations thereof. Use of transportable members enables the present system to be efficiently and conveniently transported between wells and other destination sites, and rapidly installed or disassembled, as needed. Through use of transportable members, the present system can be transported using one to two trucks and/or trailers.
The present embodiments also relate to a self-contained method for producing a well using a gas. The method can include providing a compressed lift gas to a well to obtain a production stream, and separating the production stream to form a product and a recycle gas stream.
The recycle gas stream can be separated to form a power stream and a lift gas stream. At least a portion of the power stream can be used to provide power for compressing the lift gas stream to form the compressed lift gas for provision to the well.
In an embodiment, the contents and/or volume of the compressed lift gas, the recycle gas stream, the power stream, or combinations thereof, can be measured, and the measured gas stream can be selectively diverted based on the measurement.
The present system and method thereby provide a self-contained means by which a well can be produced using a lift gas, while depleted lift gas and/or the power requirements of the system can be supplemented using natural gas obtained from the well during production.
BRIEF DESCRIPTION OF THE DRAWINGS
In the detailed description of the embodiments presented below, reference is made to the accompanying drawings, in which:
FIG. 1 depicts a diagram of an embodiment of the present system for improving production of a well.
FIG. 2 depicts a diagram of an embodiment of the present method for improving production of a well.
The present embodiments are detailed below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular descriptions and that the embodiments can be practiced or carried out in various ways.
Referring now to FIG. 1 , a diagram of an embodiment of the present system is depicted. FIG. 1 illustrates one embodiment of a gas lift system, the primary components including a lift gas source ( 10 ), a compressor ( 20 ), a three-phase separator ( 36 ), and a pressure swing absorption separator ( 64 ), which can be connected using a plurality of lines or similar conduits, with a plurality of three-way valves ( 14 , 26 , 50 , 56 , 72 ) for directing gas flows throughout the system.
FIG. 1 shows the lift gas source ( 10 ), such as a nitrogen generator, for producing and flowing a generated gas stream ( 12 ) to the compressor ( 20 ). In an embodiment, the lift gas source ( 10 ) can be a diesel-powered, low pressure, self-generating nitrogen generator, capable of producing 200,000 SCF/day, or more, of nitrogen gas at 150 psig. Other gasses are also usable, however it is preferable to use a generally inert, non-condensible, oxygen-free gas that will not react with, corrode, degrade, or otherwise negatively affect any system equipment or well compounds, and will not support microbial growth.
The lift gas source ( 10 ) can be powered by a power source ( 82 ), such as a diesel fuel tank or similar source of fuel. A first fuel valve ( 84 ) is shown disposed between the power source ( 82 ) and the lift gas source ( 10 ), for selectively providing fuel to the lift gas source ( 10 ).
A first three-way valve ( 14 ) is shown disposed between the lift gas source ( 10 ) and the compressor ( 20 ). The first three-way valve ( 14 ) is usable to selectively direct the generated gas stream ( 12 ) to the compressor ( 20 ).
A pressure transducer ( 18 ) or similar measuring device can also be disposed between the lift gas source ( 10 ) and the compressor ( 20 ) for determining the current pressure within the system, and thereby the current demand for additional lift gas. The lift gas source ( 10 ) can be selectively actuated to generate more gas for addition to the generated gas stream ( 12 ) based on the measurement indicated by the pressure transducer ( 18 ). The pressure transducer ( 18 ) can be used to ensure that the pressure within the system does not decrease, due to lost gas, to a degree that could damage any of the system components.
The compressor ( 20 ) can compress received gasses to a pressure of 1500 psig, or more, depending on the operations to be undertaken. For some applications, the pressure of the received gasses can be increased to 4000 to 4300 psig. In an embodiment, the compressor ( 20 ) can be a bi-fuel capable diesel driven booster compressor system, that can be powered using diesel fuel, natural gas, or combinations thereof, with a capacity of 2000 MCF per day, or more, at a pressure of 1500 psig, or more.
FIG. 1 depicts the power source ( 82 ) in communication with the compressor ( 20 ), with a second fuel valve ( 86 ) disposed therebetween, for selectively providing fuel to the compressor ( 20 ).
In an embodiment, the compressor ( 20 ) can be integral with the lift gas source ( 10 ). In another embodiment, the compressor ( 20 ) can include dual compressors, a first compressor usable to compress the atmosphere and communicate the nitrogen from the compressed atmosphere to a second compressor, which compresses the nitrogen to the desired pressure.
A compressed lift gas stream ( 22 ) is flowed from the compressor ( 20 ) through a first high pressure gas flow meter ( 24 ), which monitors the discharge rate of the compressed lift gas stream ( 22 ) from the compressor ( 20 ). A second three-way valve ( 26 ) can selectively direct the compressed lift gas stream ( 22 ) toward the well ( 32 ), or can divert the compressed lift gas stream ( 22 ) for collection.
For example, if it is determined that the compressed lift gas stream ( 22 ) contains a saleable quantity of natural gas, the second three-way valve ( 26 ) can permit a diverted compressed lift gas stream ( 28 ) to flow past a second high pressure gas flow meter ( 29 ), which monitors the flow of the diverted compressed lift gas stream ( 28 ), to a high pressure gas sales line or collector.
If not diverted for sale, the compressed lift gas stream ( 22 ) is flowed through the second three-way valve ( 26 ) to the well ( 32 ). FIG. 1 depicts an adjustable choke ( 30 ) disposed between the second three-way valve ( 26 ) and the well ( 32 ) for controlling the pressure of the compressed lift gas stream ( 22 ), depending on the needed pressure for producing the well ( 32 ).
The well ( 32 ) can include any sundry manner of gas lift systems, gas lift equipment, and/or production equipment known in the art, depending on the nature of the production operations undertaken.
The injection of the compressed lift gas stream ( 22 ) into the well ( 32 ) enables the extraction of a production stream ( 34 ) from the well ( 32 ). The production stream ( 34 ) can contain any combination of the lift gas, a hydrocarbon fluid product, natural gas from the well ( 32 ), and one or more waste products, such as water.
FIG. 1 depicts the production stream ( 34 ) communicated from the well ( 32 ) to a three-phase separator ( 36 ), which, in an embodiment, can be a retention time-based separator that uses gravity to separate the production stream ( 34 ) into a waste stream ( 38 ), a hydrocarbon fluid product ( 42 ), and a recycle gas stream ( 46 ).
The waste stream ( 38 ), which can include primarily water and any other heavy wastes, solids, or similar impurities, is flowed from the three-phase separator ( 36 ) through a first low pressure flow meter ( 40 ), which monitors the flow of waste water and other components of the waste stream ( 38 ) to a collector, a waste line or system, or a similar appropriate location for deposition of waste water and/or other waste.
The hydrocarbon fluid product ( 42 ) is flowed from the three-phase separator ( 36 ) through a second low pressure flow meter ( 44 ), which monitors the flow of the hydrocarbon fluid product ( 42 ), to a sales line, a collector, or a similar destination for collection and/or sale.
The recycle gas stream ( 46 ) can include recovered lift gas, as well as one or more gasses from the well ( 32 ), including usable natural gas. The recycle gas stream ( 46 ) is flowed from the three-phase separator ( 36 ) through a first low pressure gas flow meter ( 48 ), which obtains measurements usable to direct the flow of the recycle gas stream ( 46 ).
A third three-way valve ( 50 ) is usable to divert the recycle gas stream ( 46 ) for sale or collection, such as when it is determined that the recycle gas stream ( 46 ) contains a saleable quantity and quality of natural gas. The third three-way valve ( 50 ) can permit a diverted recycle gas stream ( 52 ) to flow through a second low pressure gas flow meter ( 54 ), which monitors the flow of the diverted recycle gas stream ( 52 ) to a low pressure gas sales line or collector.
If the recycle gas stream ( 46 ) is not diverted for collection or sale, the third three-way valve ( 50 ) can direct the recycle gas stream ( 46 ) to a fourth three-way valve ( 56 ), which can in turn direct the recycle gas stream ( 46 ) based on the measurement obtained by the first low pressure gas flow meter ( 48 ).
For example, if it is determined that the recycle gas stream ( 46 ) does not contain a significant amount of natural gas, or if the value of the natural gas does not exceed the value of the fuel required to produce additional lift gas, the fourth three-way valve ( 56 ) can direct the recycle gas stream ( 46 ) toward the first three-way valve ( 14 ) as a recycled lift gas stream ( 58 ).
The recycled lift gas stream ( 58 ) can be combined with the generated gas stream ( 12 ) from the lift gas source ( 10 ), as it flows through the first three-way valve ( 14 ), as a lift gas stream ( 16 ), to the compressor ( 20 ).
Alternatively, the fourth three-way valve ( 56 ) can direct the recycle stream ( 46 ) through a third low pressure gas flow meter ( 62 ), which monitors the flow of the directed recycle gas stream ( 60 ), to a pressure swing absorption separator ( 64 ).
In an embodiment, the pressure swing absorption separator ( 64 ) can be a membrane-based separator that accelerates the directed recycle gas stream ( 60 ) while using a membrane to separate nitrogen, or another initial lift gas, from the natural gas and/or other gasses obtained from the well ( 32 ). The directed recycle gas stream ( 60 ) can be separated to form a recovered lift gas stream ( 66 ) and a separated well gas stream ( 68 ).
The recovered lift gas stream ( 66 ) is directed from the pressure swing absorption separator ( 64 ) to the compressor ( 20 ), during which the recovered lift gas stream ( 66 ) can combine with the generated gas stream ( 12 ) and/or recycled lift gas stream ( 58 ). The separated well gas stream ( 68 ) is directed through a gas BTU value analyzer ( 70 ) or similar measuring device, which monitors the output of the separated well gas stream ( 68 ) and determines the BTU value of any natural gas contained therein.
Based on the measurement obtained by the BTU value analyzer, the separated well gas stream ( 68 ) can be directed by a fifth three-way valve ( 72 ). The fifth three-way valve ( 72 ) can direct the separated well gas stream ( 68 ) toward the compressor ( 20 ) as a recycled well gas stream ( 74 ), where the recycled well gas stream ( 74 ) can combine with the generated gas stream ( 12 ), the recycled lift gas stream ( 58 ), and/or the recovered lift gas stream ( 66 ) prior to compression, thereby conserving the fuel and lift gas required to produce additional generated gas using the lift gas source ( 10 ). Additionally, the separated well gas stream ( 68 ) directed toward the compressor ( 20 ) can be diverted for sale or collection after passing through the second three-way valve ( 26 ), which can direct the gas toward a high pressure gas sales line or collector, as described previously.
Alternatively, if it is determined that the value of the fuel required to power the compressor ( 20 ) exceeds the value of the separated well gas stream ( 68 ), the fifth three-way valve ( 72 ) can divert the separated well gas stream ( 68 ) toward the compressor ( 20 ) as a power stream ( 80 ). The power stream ( 80 ) passes through one or more pressure-reducing valves ( 78 ), which reduce the pressure of the power stream ( 80 ) to accommodate the requirements of a power input of the compressor ( 20 ). The power stream ( 80 ) is then fed into the compressor ( 20 ) as fuel, thereby conserving the diesel fuel or other fuel from the power source ( 82 ) required to power the compressor ( 20 ).
The present system can thereby utilize recovered natural gas from the well ( 32 ) for a variety of purposes, each of which enable the present system to become self-contained shortly after start-up. Natural gas can be directed for sale or collection following separation from the hydrocarbon product, using the third three-way valve ( 50 ). The natural gas can be recirculated for use as lift gas using the fourth three-way valve ( 56 ), the fifth three-way valve ( 72 ), or combinations thereof. Recirculated lift gas can be diverted for sale or collection using the second three-way valve ( 26 ). Alternatively, the natural gas can be used as power for the compressor ( 20 ).
The present system can thereby enable lift gas and the fuel required to power the lift gas source ( 10 ) to be conserved through recycling of gas from the well ( 32 ) for use as lift gas. The present system can further enable the fuel required to power the compressor ( 20 ) to be conserved through use of gas from the well ( 32 ) as a power source for the compressor ( 20 ). The present system can further collect and transport gas from the well ( 32 ) for sale.
As the economic viability of each of these alternative uses for gas recovered from the well ( 32 ) changes, the present system can seamlessly select among the alternative uses through automatic or manual manipulation of the three-way valves ( 14 , 26 , 50 , 56 , 72 ). If a sufficient quantity of natural gas is recovered from the well ( 32 ), both the need for externally generated lift gas from the lift gas source ( 10 ) and the need for external power for the compressor ( 20 ) from the power source ( 82 ) can be reduced or eliminated, creating a self-contained system. Due to the costs inherent in the transport and sale of natural gas, use of the natural gas to create a self-contained system is often a more economically viable use for the recovered gas. In situations where the collection and/or sale of the natural gas becomes a more economical alternative, the gas can instead be sold.
In an embodiment, each of the three way valves ( 14 , 26 , 50 , 56 , 72 ) can be automatically actuated, such as through use of a processor-driven controller, which can be programmed with preset values and thresholds and/or programmed to monitor the real-time economic viability of each use of the obtained natural gas, and compare these values with measurements obtained from one or more of the measuring devices ( 18 , 24 , 29 , 40 , 44 , 48 , 54 , 62 , 70 ). Based on the obtained measurements and the preset and/or real time values, the present system can automatically undertake the most practical or economically viable activity.
Referring now to FIG. 2 , a flow diagram of an embodiment of a self-contained method usable to improve production of a well is depicted.
At Step 102 , compressed lift gas is provided into a well. The compressed lift gas can include nitrogen or another externally produced lift gas, and/or a combination of recovered and recycled streams from the well. At start-up, the compressed lift gas can consist entirely of externally generated gas, however after the present method has been performed for a period of time, a quantity of gas could be recovered from the well that is sufficient to reduce or eliminate the need for external sources of lift gas.
After providing the compressed lift gas to the well, Step 104 includes obtaining a production stream from the well. The well can be produced using any sundry manner of lift gas system known in the art, depending on the type of well and the nature of the operations undertaken. The production stream can include a desired product, such as a liquid hydrocarbon, at least a portion of the lift gas provided into the well, natural gas from the well, and one or more solid or liquid waste products and/or other gasses.
At Step 106 , the production stream from the well is separated to form a product and a recycle stream. At Step 108 , the product is transported and/or collected for sale.
Step 110 illustrates that regarding the recycle stream, a determination can be made. The recycle stream can contain a quantity of natural gas, entrained with at least a portion of the lift gas provided to the well. If it is determined that the value of the natural gas in the recycle stream does not exceed the cost of producing and compressing additional lift gas, then Step 112 can be performed, and the recycle stream can be compressed for use as lift gas.
At Step 114 , the pressure of the system can be measured to determine whether the system requires additional lift gas. If additional lift gas is required, Step 116 can be performed, and additional lift gas can be produced and compressed for provision to the well. If no additional lift gas is required, Step 102 can be repeated using recycled lift gas from the well. Recycled lift gas from the well, in combination with recovered natural gasses from the well, is thereby usable to reduce or eliminate the need for externally produced lift gas.
If it is determined that the value of natural gas in the recycle stream may exceed the cost to produce and compress additional lift gas, Step 118 can be performed, and the recycle stream can be separated to form a power stream and a lift gas stream. It should be noted that if a sufficient quantity of gas is recovered from the well, a first portion of the recovered gas could be compressed and recycled for use as lift gas, in Step 112 , while a second portion of the recovered gas could be separated as indicated at Step 118 .
At step 120 , the lift gas stream obtained at Step 118 is compressed for use as lift gas. If additional lift gas is required by the system, as indicated at Step 114 , Step 116 can be performed to produce and compress additional lift gas. If no additional lift gas is required, the lift gas stream and/or a portion of the recycle stream can be provided to the well without generating additional gas, as indicated at Step 102 .
At step 122 , a determination regarding the power stream can be made. If the value of the natural gas in the power stream as a saleable commodity exceeds the cost of producing and compressing additional lift gas, and exceeds the cost of providing fuel to the compressor, the natural gas can be transported and/or collected for sale at Step 126 .
If the value of the natural gas in the power stream as fuel for the compressor exceeds the value of the natural gas as a saleable commodity, and exceeds the cost of producing and compressing additional lift gas, the natural gas can be used as fuel for the compressor at Step 128 .
If the cost of producing and compressing additional lift gas exceeds the cost of providing fuel to the compressor, and exceeds the value of the natural gas as a saleable commodity, Step 124 can be performed, and the power stream can be compressed for use as lift gas. A determination can then be made regarding whether additional lift gas is needed by the system, as indicated by Step 114 . The compressed power stream can be combined with the compressed lift gas stream at Step 120 , the recycle stream from Step 112 , and/or produced lift gas from Step 116 .
The present method is thereby usable to determine the most economically and practically viable use for the gas recovered from the well, and seamlessly select among the alternative uses. If a sufficient quantity of natural gas is recovered from the well, both the need for externally generated lift gas at Step 116 , and the need for fuel for compression of the gas streams can be reduced or eliminated, creating a self-contained method. In situations where the collection and/or sale of the natural gas is a more economical or practical alternative, the gas can instead be sold.
While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein. | Systems and methods for producing a well using a gas are disclosed herein. A compressed lift gas can be provided to a well to obtain a production stream. The production stream can be separated to obtain the product and a recycle gas stream. The recycle gas stream can be immediately recompressed for use as lift gas, or separated to form a lift gas stream, and a power stream containing natural gasses from the well. The lift gas stream is recycled for use as lift gas, while the power stream can be transported and/or collected for sale, recycled for use as lift gas, or consumed as power for the compressor, based on measurements obtained throughout the system, coupled with practical and economic variables. By supplementing or replacing generated lift gas and/or an external power source with natural gas from the well, the present systems and methods can become self-contained after start-up. | 4 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to communication networks. In particular this invention relates to methods and devices that monitor data network responsiveness and act to limit adverse effects of a data or communication network overload.
BACKGROUND OF THE INVENTION
In data communication networks like the internet, there are time delays between the issuance of a command or data packet from one computer and the receipt of a response to the command or responsive data packet from another computer in the network. Logging onto a web site for instance typically causes the data files that comprise images of the web site to be sent from one computer to another.
Inter-computer communications in a data network comprise commands and data packets, among other things, issued by one computer addressed to one or more other computers. When a command, or data packet response is received by a computer to which it is addressed, the addressed computer typically issues a response to the computer issuing the command in some way. In the case of one computer “logging on” to a web site computer for example, what actually happens is that a host computer that stores files comprising the web site, sends a file or files to a client computer. When the client receives the file or files from the host, the client displays the web site content. To access (or log onto) a web site it can be said that the client issues a command to the host, which responds by sending data files to the client.
In all data communications networks there is a measurable time between issuance of any command by a computer and the receipt of a response to the command from another computer.
The delay between a command and a response is a function of several factors including network traffic load, traversed network node capacity, data transmission rates, communication link design, electrical and physical distance between computers and the number of data network users. In general, delay time is inversely proportional to the amount of data that the network is tasked to handle. Stated alternatively, as the number of data network users increases, and as the amount of data through a network increases, the more time it will take the network to process all of the data exchanges.
In many instances, delays between issuance of a command or data packet and receipt of a response thereto can become so great that a computer waiting for a response will adversely affect other processes dependent upon the computer that is waiting for a response. Many computers will use timers to set an upper limit on the amount of time that a computer will wait for a response to a command. Using a timer prevents a computer from effectively locking up and impeding other processing tasks. If a response to a command is not received when the time-out timer expires, the computer can ignore the process that was waiting for a response, which might never come.
Using a time-out timer in a data communications network has some limitations however. Many times a data network becomes so overloaded with traffic that virtually all communication transactions thereon require long times to complete. Fixed-value timers do not take operational software differences or transmission network difference into account and can expire before any communications transactions are completed. A method and apparatus for use of a computer in a data network that reduces time-out communications failures, which in turn cause communications delays on a varying basis would be an improvement over the prior art.
SUMMARY OF THE INVENTION
In a data communications network, including packet networks using packet data communications protocols, packet delay timers are used in network computers to prevent a computer from waiting for unnecessarily long times for a response. The invention disclosed herein dynamically re-sets so-called watch-dog or time-out timers which helps insure that a computer not become locked up waiting indefinitely for a response but prevents a computer from pre-maturely aborting communications sessions that require more time.
The improved method measures the time required to receive a response to a command over a data communications network to obtain a first round trip delay time. This actual round-trip delay time for a response to come back from a command, a data packet or a message fragment is compared periodically to some baseline expected round trip delay time value to yield a round trip delay time difference. If the measured round-trip delay time differs from the expected baseline value by a pre-defined amount, the baseline expected value is adjusted, up or down by some predetermined incremental amount to yield a new baseline value. The newly calculated baseline round-trip delay time is thereafter used to determine the time that the computer will wait for responses.
Dynamically adjusting time-out timers in a communication network helps insure that the maximum communication session wait time reflects actual network conditions. As the actual round-trip delay times change, they are used to adjust the baseline value by an incremental amount. The newly calculated round-trip delay time is used to limit the maximum length of time that a computer will wait for responses to commands or packets it issues. Re-calculating timer values based upon actual delay time experience reflecting actual network responsiveness avoids rigid application of a fixed timer value which might abort communications if network responsiveness falls for any reason. Network sluggishness, increased network path length, increased network traffic load or other network-originated delays can unexpectedly increase response delays. During heavy traffic periods, network delays might become so lengthy that virtually every communication session might be aborted using fixed time-out values.
The recalculated timer values can automatically be implemented in a switching system software such as the Lucent Technologies No. 5 ESS™.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a simplified block diagram of a data communications network contemplated by the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a simplified block diagram of a data communications network comprised of three client computers 102 , 104 , 106 coupled to the internet 108 , which as shown is comprised of three server computers 110 , 112 and 113 . The client and server computers both might include single-user personal computers or work stations but might also include data switches or switching systems, as those skilled in the art will recognize. The server computers 110 , 112 and 113 are coupled together through some appropriate media 114 , 116 so that the servers 110 , 112 and 113 can communicate with each other. The data carried between computers might include synchronous data, asynchronous data, isochronous (synchronous transmission within an asynchronous frame) and packet data, which might be carried over a variety of pathways including but not limited to, wire, microwave radio or optical fiber. The client computers 102 , 104 and 106 are coupled to the server computers 110 , 112 , 113 through media that would in part be comprised of one or more switching systems such as Lucent Technologies No. 5 ESS switching system or other switching system (not shown) including for instance ATM (asynchronous transfer mode) switches and also including optical switching systems as well.
Each of the computers shown 102 , 104 , 106 , 110 , 112 and 113 carry communications to and from each other. As is shown in FIG. 1, the client computers 102 , 104 , and 106 do not communicate directly with each other in command-response transactions nor do the server computers 110 , 112 , and 114 communicate with each other in command-response transactions. In the course of exchanging data, one of the computers will issue a command or other output requiring or causing a response to be generated by another computer.
The time required for one computer to issue a command and for some other to issue a response thereto will normally be some expected amount. The expected amount of time to exchange messages between the computers 102 , 104 , 106 , 110 , 112 and 113 will depend upon the transmission path length, network congestion, CPU operating speed, or the necessity of message retries due to poor signal quality. Path length delay time is usually affected by the physical path length, i.e. geographic distance between the network computers as well as the number of intervening nodes through which a message passes. The command-response time of a physically longer path 114 will usually be longer than the command-response time of physically shorter path 116 if all other elements of the paths are identical. In some instances however, one path ( 114 through computer 113 for instance) might be physically longer than another path ( 116 ) yet have a shorter response time between computers 110 and 112 if the equipment or transmission technology used in the shorter path ( 116 ) is slower than that used on the physically longer path ( 114 ).
It is well known that propagation delay along any transmission line increases as the transmission line length increases. It is also well known that as data is routed through intermediate connection nodes and switches, transmission delay times also increase. Asynchronous data can sometimes be queued in one or more asynchronous transfer mode switches, adversely affecting delay time.
By way of example, if computer 102 wishes to receive a file or files from a distant computer 104 , the first computer will request a copy of the pertinent files from the distant computer. The data request traverses the internet 108 in some well-known fashion, including but not limited to synchronous data over the public switched telephone network, asynchronous transfer mode through a proprietary data network, or other network. Regardless of the data architecture or data communications protocol or format, some time will always be required to exchange data between the two computers.
At least some of the computers of the network shown in FIG. 1 employ communication time-out timers, sometimes referred to as watch dog timers, the expiration of which tells the computer that too much time has elapsed for a communication transaction. Upon the expiration of the time out timer, the communication will be aborted if an expected response to a previous message has not been received. Aborting the communication is done on the assumption that the other computer from which a response is awaited is either failed, out of service, or otherwise inaccessible because a response was not timely received.
As set forth above, as the amount of data being carried through the internet 108 increases, the computers comprising the internet 110 , 112 , 113 require more and more time to respond to each data transaction. Alternatively, data transmissions might be routed along a different path, from 116 to 114 for instance changing propagation delay time. As the amount of transaction response time increases, communication time out timer expiration becomes more commonplace and in many instances, communications sessions are prematurely terminated.
Within each computer using a communication time out timer, there is a timer initialized with a baseline time out value. Such a timer might be a hardware device such as a counter timer chip or even a suitably programmed microprocessor the only function of which is to calculate elapsed times. Alternatively, communication time-out timers might be implemented entirely in software executed on one or more processors of the computers shown in FIG. 1 .
Expiration of a communication time-out timer prevents a computer from waiting beyond an acceptable length of time for an expected response. Dynamically adjusting communication time-out timers allows the computers 102 , 104 , 106 , 110 , 112 and 113 to continue to communicate but without the risk that one or more of them will become lost to other tasks because of intolerably long communication delay times on the network. The method of the invention still retains timer limits beyond which a computer will not wait so as to insure some limit on the time that a computer will wait for a response. Baseline timer values are not adjusted without limit; user specified upper and lower values of the timer insures that the timer re-calculation does not undo the purpose of the communication response timer.
The baseline timer value used to decide when to abort a data communication session is adjusted to reflect actual communication network conditions. It is well known that data network responsiveness varies with network loading or use. At times when a network is heavily loaded, the network will require more time to process data communications between computers. At times when network response time is long, fixed-value time-out timers that are used to prevent a computer from waiting too long for a response to a communication request might prematurely abort data communications. Varying the baseline timer value according to network conditions allows at least some communications to occur.
The baseline timer value is set to a value which is used to determine how long a computer should wait for a response to a command or data message (or data packet) sent to a destination. The value to which the baseline timer value is set will usually reflect experience and/or historical performance of the data network.
Four different categories of round-trip time delay factors are employed the baseline timer value. The first category of round-trip time delay factors reflects variations in actual round-trip delay time and will vary with network loading. First, the actual round-trip delay time of a message or data packet transmission is measured. This actual round-trip delay time is compared to the baseline timer value. An adjustment factor is derived from the difference between the baseline timer value and the actual round-trip delay time. The adjustment factor need not be exactly equal to the difference between the actual round-trip delay time and the baseline timer values but might be a fractional part thereof so as to more slowly adjust the baseline value according to actual network conditions.
In the preferred embodiment of the invention, the amount of time that the baseline timer value can be adjusted is limited. The maximum and minimum baseline timer values should reflect the allowable round-trip delay time. Adjusting the baseline value to be too short, for example during periods when network use is low, might adversely affect data communications when network loading increases. If the maximum and minimum baseline timer values are not exceeded, the baseline timer value is re-calculated based on the actual round-trip delay time to reflect actual delay time experience. In addition, actual network conditions are taken into account when determining baseline timer values.
The second category of round-trip time delay factors is based upon the number of time zones traversed by a message packet. The number of time zones traversed is compared to determine, in part, an estimate of the geographic distance a message might travel before being answered. The number of traversed time zones is used to add or subtract a baseline time factor. The baseline time factor is used to adjusts the baseline timer value. The baseline time factor can be based upon the actual round-trip delay time or upon a relative round-trip delay time to completion time.
The third category of round-trip delay factors used to adjust delay time is the time of day. The maximum allowable round trip delay time for a message may vary based upon the time of day. For example, a short round-trip message delay time might be more important during business hours. If computers are identified by geographically significant addresses, consulting a database of such addresses that can be correlated to time zones, it might be possible to adjust message time out timers based upon the time of day. The baseline timer value can be adjusted based upon the time of day when a message is sent.
The fourth category of round-trip time delay factors is based on network use. Some nodes of a data network might be more congested with data to transfer than others thereby increasing message propagation delay time. A database of internet nodes and the nominal message routing delay expected from such nodes might be used to calculate an expected response time delay and to recalculate or replace the nominal message delay time.
By adjusting the allowable response delay time for a message in a data network, a computer can be prevented from unnecessarily waiting too long for responses to messages. On the other hand, data and communications are less likely to be prematurely aborted and lost when network conditions, time of day, geographic distances and other reasons require more time for data to traverse a network.
Other embodiments of the invention would include delay timer adjustment based upon the identity of particular internet nodes. For example, some nodes or web sites might be particularly popular with internet users for a variety of reasons and all other factors being equal, perhaps therefor inherently less responsive. Delay timers of a computer accessing such a site might preferably be adjusted on the basis of the internet node domain name or address. Certain high-traffic and/or slow response time internet nodes identities might be cataloged in a database or table of such nodes. Alternatively, a data base or table might be used to record message delay timer values for previously accessed nodes. Reading data from a data base file or a data table is well known prior art.
Closely related to the accessibility of popular web sites or internet nodes is the time of day that nodes are accessed. Certain nodes might be more frequently accessed during certain times of the day. Accordingly, an alternate embodiment contemplates adjusting time-out timer values heuristically, based at least in part upon the local time of day.
Time-out timers that are adjusted based upon the time of day might also be adjusted based upon the time zone that the particular computer is in with respect to the time zone of the internet node being accessed. For example, if a first computer that provides internet node service is on one side of the globe, and if a second computer accessing the first computer is on the opposite side of the globe, using the method disclosed above, the two computers might calculate different delay times because of the anticipated node loading simply because of the time zones differences in which the two computers reside. Accordingly, another alternate embodiment of the invention contemplates adjusting delay timers based upon the particular time zones of computers accessing internet nodes and of computers providing internet access and of the number of time zones between computers communicating with each other.
Of course, a computer in one time zone accessing a computer in another time zone would need to determine the time zone difference. Such a determination might be made by way of a message from one computer to the other, however, such an inquiry would itself be subject to the propagation delay between the two machines. At least one alternative method for determining time zone differences would be to use the internet address as an index to a table listing of time zones for particular internet addresses.
Those skilled in the art will recognize that the invention disclosed herein is readily applicable to asynchronous transfer mode (ATM) networks. The invention might also be useful with other networks including but not limited to frame relay networks or other data packet transmission schemes. Those skilled in the art will also recognize that the invention disclosed herein might also be useful with synchronous networks as well. | Computers that exchange data over communication networks frequently wait for responses to messages and therefor use timers to control the amount of time that the computer will wait for a response to a command issued over a network. Communication network responsiveness varies as traffic loading on the network changes. Fixed-value timers that don't take network loading into account can inadvertently terminate communications if a response is not timely received. Varying or adjusting data communication timers according to data network responsiveness can prevent erroneous data communication session termination. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to heat pipes and, more particularly, to a method of sealing a heat pipe.
2. Description of Related Art
With the ever-increasing density and high power of electronic components, e.g., memories and logic arrays in high speed computers, the problem of heat generation by electronic components in close proximity to one another on electronic circuit cards has become of increasing concern to industry. In response, over the past several years heat pipes have been developed to cool electronic circuit cards. Typically, a number of heat pipes are formed and placed into a metal substrate which is bonded to a circuit card. In its conventional form, a heat pipe is a closed tube or chamber of various shapes whose inner surfaces are lined with a porous capillary wick. The wick is saturated with a working fluid. The heat pipe has an evaporator section where the heat pipe absorbs heat, and also has a condensor section where heat is released to a heat sink in contact with that section of the pipe. In operation, heat absorbed by the evaporator section causes liquid to evaporate from the wick. The resultant vapor is transferred within the tube to the condensor section of the heat pipe where it condenses releasing the heat of vaporization to a heat sink. The capilliary action of the wick pumps the condensed liquid back to the evaporator section for reevaporation. The process will continue as long as working fluid is contained within the heat pipe.
However, too often the liquid in the heat pipe chamber is lost due to a break in the heat pipe seal. The ability to reliably and effectively seal heat pipes has been sought by the industry for many years, because if the fluid within the heat pipe is lost due to a leak in the heat pipe the equipment cooled by the heat pipe could be subject to great heat damage. Several means of sealing heat pipes have evolved over the last couple of years.
In one conventional arrangement, for example, a heat pipe includes a hollow tube with end caps inserted into each end of the tube. One end cap has a hole therethrough with a copper pinchoff tube brazed to the hole. The heat pipe is purged and filled with the proper working fluid using the copper tube. To seal the heat pipe the copper tube is pinched shut using a roller pinch off tool. See, for example, Dunn & Reay, Heat Pipes 154 (3rd Ed. 1982). However, the rollers of the pinch off tool get close to the braze and may crack the braze during pinch off. Additionally, after being sealed the fragile copper tube protrudes outwardly a short distance from the end cap, and therefore is very susceptible to breakage and consequently loss of fluid. In order to adequately protect this protruding copper tube, a cover must be placed over the end cap and copper tube. The end cap cover and copper tube disadvantageously consumes a large portion of the condenser section at the end of the heat pipe. Both reliability and efficiency of the heat pipe fabricated by this technique are limited.
In an attempt to improve upon this design, the copper tube has been attached directly to the side of the heat pipe tube instead of to the end cap. A copper tube is welded to a hole within the side of the heat pipe tube, and the heat pipe tube chamber is purged and filled with working fluid using this copper tube. After filling the heat pipe with fluid the copper tube is pinched shut to seal the tube. As with the above described process, the braze can be cracked during pinch off. Furthermore, this sealing technique is disadvantageous in that a portion of the copper tube extends outwardly from the side of the heat pipe. In this arrangement the fragile copper tube has no cover and is very susceptible to breakage. Additionally, the placement of the copper pinchoff tube on the side of the heat pipe tube hampers expulsion of noncondensable gases during purging. Furthermore, because the copper tube protrudes outwardly from the side of the heat pipe, heat pipes formed by this technique cannot be placed adjacent to each other.
Consequently, there is a need in the industry for a means of sealing a heat pipe which is economically accomplished and provides a strong and reliable seal.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a more reliable technique of sealing a heat pipe tube.
It is a further object of the present invention to provide a heat pipe with improved heat transfer characteristics.
It is still a further object of the present invention to provide a heat pipe which is more easily sealed.
It is an advantage of the present invention that it provides a heat pipe with more available area for the condenser.
It is a further advantage of the present invention that it provides improved purging of noncondensable gases.
It is a feature of the present invention in that a one piece end cap can be used to both fill and provide a seal for a heat pipe.
A method for sealing a heat pipe according to the present invention includes providing an elongated hollow pipe with an opening at one end and also providing an end cap with a hole therethrough. A wick is inserted into the tube, and the end cap is brazed into the open end of the elongated hollow pipe. Thereafter, the pipe is filled with a working fluid. To seal the heat pipe, the end cap is plastically squeezed, thereby closing the hole and sealing the heat pipe.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1a-c are perspective views of a heat pipe being assembled and sealed at various stages of fabrication according to a preferred embodiment of the invention.
FIG. 2a-c are perspective views of another heat pipe being assembled and sealed at various stages of fabrication of the invention.
DETAILED DESCRIPTION
Referring to FIG. 1a with greater particularity, a heat pipe 10 is shown including a flat elongated hollow pipe 12 made of good thermally conductive material such as monel or copper. The elongated pipe 12 may be a rectangular pipe or a flattened round tube having a hole therethrough, the walls of the elongated pipe being about 10-12 mils thick, for example. An elongated rectangular pipe 12 is illustrated in FIG. 1a which has top and bottom surfaces 32 and 34, respectively, and side walls 36 and 38, all of which are essentially parallel to one another. Rectangular pipe 12 further has ends 35 and 37 which are essentially perpendicular to the top, bottom and side walls. Ends 35 and 37 have rectangularly shaped openings 18 and 16.
End cap 14 is slid into opening 16 and welded or brazed to end 37 of elongated pipe 12, thereby sealing that end. End cap 14 is typically a rectangularly shaped copper block of such dimensions that it can be slidably inserted into opening 16. Wick 19, which may be notched, is inserted into elongated pipe 12, and sits in very close contact with the inner walls of the pipe. Wick 19 may be made of a porous material such as copper felt, for example; however, other wick materials can be used which are chemically compatible with the working fluid, provide good capillary pumping capability between the condensor and evaporator and have a sufficiently high thermal conductive path between the heat pipe wall and the liquid-vapor interface.
Sealable end cap 20 may be a rectangularly shaped block of copper material having opposing end walls 21 and 22 which are essentially parallel to one another and further having top and bottom walls 25 and 26 and side walls 23 and 24 which are essentially parallel to each other but substantially perpendicular to end walls 21 and 22. Sealable end cap 20 has a hole 28 therethrough from end wall 21 to end wall 22, which hole is typically essentially parallel to the side walls 23 and 24. The top, bottom and side walls 23, 24, 25 and 26 are machined or otherwise shaped such that sealable end cap 20 can be slidably inserted into open end 18 of elongated pipe 12.
Sealable end cap 20 is slid into opening 18 of hollow pipe a short distance, typically about 0.02 to 0.03 inches, as shown in FIG. 1b. Sealable end cap 20 is brazed or electron beam welded into open end 18. A portion 30 of sealable end cap 20 extends out from elongated pipe 12, with hole 28 forming a passageway from the exterior of elongated pipe 12 to its interior. Accordingly, hole 28 provides access to the interior of the heat pipe so that it can be purged and filled with a suitable working fluid. Extended portion 30 of sealable end cap 20 may protrude from the end of pipe 12 about 1/4 to 1/2 of an inch which provides sufficient length to perform the pinch off described hereinbelow.
Using hole 28, the interior of elongated pipe 12 is evacuated and filled with a working fluid (not shown). In the temperature range of from about 20° C. to 200° C. water is a good working fluid, for example. Methanol works well at low temperature ranges between about -50° C. to +50° C.
After the elongated pipe 12 has been filled with the proper working fluid, it is sealed by pinching sealable end cap 20 between a pair of rollers (not shown). The rollers are applied on top and bottom surfaces 25 and 26 to plastically squeeze the metal together therebetween, which closes hole 28 by cold welding, thereby sealing the heat pipe, and also shears off a portion 40 of sealable end cap 20; see FIG. 1c. A roller pinch off tool may be used to perform the sealing process, for example. A small portion 42 of sealable end cap 20 remains and extends outwardly a short distance from the end 35 of elongated pipe 12. For additional details on the manufacture of heat pipes, reference may be made to Dunn & Reay, Heat Pipes (3rd Ed. 1982) which is incorporated herein by reference, and serves to provide further background information and understanding as well as to suggest various details and alternatives that may be included.
Consequently, heat pipe 10 is formed having a reliable seal which is easily and cost effectively implemented. The effective condensor length of heat pipe 10 is maximized since the end cap 20 takes up only a small portion of the condensor section at the end of heat pipe 10. Typically, sealable end cap 20 can be pinched off so that the remaining small portion 42 of end cap 20 extends only about 1/16 to 1/10 of an inch outwardly from end 35 of the elongated pipe 12.
An alternative embodiment of a preferred heat pipe is illustrated in FIG. 2. Components in the embodiment of FIG. 2, which are the same as or equivalent to respective components in the embodiment of FIG. 1, are designated by the same second and third reference numeral digits as their corresponding components in FIG. 1, along with the addition of a prefix numeral "1". In FIG. 2a, rectangularly shaped hollow tube has top and bottom walls 132 and 134 and side walls 136 and 138 which are essentially parallel to each other. End 137 is substantially perpendicular to the top, bottom and side walls, and has a rectangular cross-section opening 116. End cap 114 is typically a rectangularly shaped block of copper material dimensioned to fit into rectangular opening 116 at end 137. Elongated tube 112, wick 119 and end cap 114 are assembled as described above with reference to FIG. 1a.
Opening 118 forms the other opening to elongated tube 112 at the other end 135. End 135 is essentially perpendicular to top, bottom and side walls 132, 134, 136, and 138. End 135 further has one corner cut out forming recessed end portion 117.
After elongated pipe 112, end cap 114, and wick 119 have been assembled as described above, sealable end cap 120 is slid into open end 118 of elongated pipe 112. Sealable end cap 120 is a flat rectangularly shaped piece 150 of copper material having four sides 123, 124, 124 and 126. A smaller portion of rectangularly shaped piece is bent to form a small angled portion 152 which conforms with recessed end portion 117. The four sides 123, 124, 125 and 126 of sealable end cap 120 are machined or otherwise shaped so that end cap 120 will fit snugly into opening 118. Tab 154 protrudes outwardly from angled portion 152 about 1/4 to 1/2 inch and is typically in the shape of a rectangular block. End cap 120 has a hole 128 therethrough extending through tab 154 and angled portion 152.
Sealable end cap 120 is brazed or election beam welded to elongated pipe 112. Using hole 128, the interior of elongated pipe is evacuated and filled with a suitable working fluid. Tab 154 is thereafter pinched between two rollers to seal the heat pipe. The rollers (not shown) are applied to surfaces 157 and 158 to squeeze the copper metal together therebetween, which welds hole 128 shut and simultaneously cuts off a portion 140 of tab 154.
A heat pipe is thus described with improved means of sealing. It should be understood that although the invention has been shown and described for one particular embodiment, nevertheless various changes and modifications obvious to a person skilled in the art to which the invention pertains are deemed to lie within the spirit and scope of the invention as set forth in the following claims. | A method of purging and sealing a heat pipe includes brazing an end cap to the end of a heat pipe. The end cap has a hole therethrough, through which the heat pipe is charged. After charging, the heat pipe can be sealed simply by pinching the end cap to cold weld the hole shut, and at the same time any excess portion of the end cap can be severed off. Using this process the end cap takes up less of the condensor zone, providing for more efficient heat exchange. Additionally, the seal is more reliable. | 8 |
FIELD OF THE INVENTION
This invention relates to a medical construct useful as a stent, among other things, and more specifically, biocompatible, absorbable polymer medical constructs; for opening occlusions and maintaining patency in body lumens or for providing flow out of or between parts of a living body.
BACKGROUND OF THE INVENTION
Metallic stenting, especially in cardiovascular angioplasty, has become important in simplifying surgical procedures and reducing patient hospital stays. Most significantly, stenting has dramatically reduced restonosis.
Several issues, however, still remain for metallic based stents. These include thrombogenicity and persistence of restonosis in some patients, poor capabilities to deliver drugs, and damage to the lumen during expansion. Furthermore, in some instances, such as stenting of the urethra after surgical intervention for benign prostate hypertrophy (BPH) to prevent post-operative urinary retention, it would be highly desirable to have a stent formed from a polymer which keeps the lumen open until swelling has subsided, then is passed in the urine stream.
One potential method to overcome these challenges is to provide an absorbable stent which is engineered with the proper strength and stiffness to resist the hydrostatic, axial and compressive loads in a tubular vessel (e.g., urethra), but not over-engineered to cause tissue damage, as in the case of metals, can be expanded to conform to the organ's vessel walls, and can deliver drugs to specific sites, both in the lumen and in the body fluids (e.g., urine, bile). In addition, the device should maintain the advantages of metallic stents such as flexibility for ease in delivery, thinness in its walls so as to not disrupt fluid flow, radio-opaqueness for post-operative management, and support for the organ's vessel wall until healing has occurred.
Several patents describe absorbable stents to overcome the disadvantages of metallic stenting. However, these either require the use of a balloon catheter to expand them, and/or are not sufficiently flexible in any direction transverse to their longitudinal axis. Examples of such stents, along with their use of pores to allow tissue ingrowth, are shown in, e.g., U.S. Pat. Nos. 5,059,211; 5,171,262; 5,551,954; and European Patent Application 183,372.
Yet another approach is to use a resorbable or non-resorbable coil spring stent that is collapsed within or on an insertion device for insertion into, e.g., a urethra, but which when ejected from the insertion device automatically expands. Such a stent does not need the use of a balloon catheter. However, insertion and placement within the urethra occurs while the stent is confined within or on an insertion device. Such a requirement can reduce flexibility transverse to the longitudinal axis, because of that insertion device. As a result, the placement of the stent might not easily accommodate sharp turns in the body lumen in which the stent is being placed. Examples of such stents include those shown in U.S. Pat. Nos. 5,160,341 and 5,246,445.
Therefore, what has been needed prior to this invention is a device which is flexible during delivery and deployment so as to ensure easy pass through long tortuous paths and will expand to match the diameter of the tissue lumen, and additionally, dramatically increases in radial stiffness after deployment to resist hydrostatic and compressive pressures.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, there is provided a tubular construct for insertion into a body lumen to open occlusions or to provide flow out of or between parts of a living body, the construct comprising:
an elongated flexible tube with opposite ends, the tube having a central axis extending along its length;
a portion of the tube between the ends comprising collapsible bellows, the bellows being constructed of a material and dimensions sufficient to provide negligible resistance to flexure transverse to the axis and negligible recoil under compression or expansion along the axis;
so that the construct is easily flexed at the bellows to negotiate turns in the body lumen, and is expandable under axial compression at the bellows from a relatively narrow diameter configuration transverse to the axis, to a relatively wide diameter configuration which is retained when the axial compression force is released.
In accordance with another aspect of the invention, there is provided an apparatus for opening occlusions in a body lumen or to provide flow out of or between parts of a living body, comprising:
a tubular construct comprising an elongated flexible tube with opposite ends, the tube having a central axis extending along its length, a portion of the tube between the ends comprising collapsible bellows, the bellows being constructed of a material and dimensions sufficient to provide negligible resistance to flexure transverse to the axis and negligible recoil under compression along the axis, so that the construct is easily flexed at the bellows to negotiate turns in the body, and is expandable under axial compression at the bellows from a relatively narrow diameter configuration transverse to the axis, to a relatively wide diameter configuration which is retained when the axial compression force is released; and
an applicator for inserting, guiding, and deploying the construct within the body.
In accordance with another aspect of the invention, there is provided a method of delivering and deploying a tubular construct into a body lumen to open occlusions or to provide flow therein, comprising the steps of:
a) inserting a tubular construct comprising a flexible and axially collapsible bellows of a diameter sufficiently less than that of the lumen when axially uncompressed, and greater when axially compressed, into the lumen;
b) advancing the construct through the lumen and around any bends therein to a desired site of deployment; and
c) axially compressing at least the bellows of the construct until the bellows achieves a diameter approximately equal to that of the lumen site, so as to be retained at the lumen site.
Accordingly, it is an advantageous feature of the invention that an axially compressive corrugated stent is provided that overcomes the radial deficiency of absorbable stents of the prior art and the insufficiency described above for metallic stents, while maintaining the advantages of both.
It is another advantageous feature of the invention that such a stent and a method of use are provided that give enough flexibility to allow the surgeon to pass it through a lumen having a tortuous path (e.g., urethra).
Yet another advantageous feature of the invention is that a balloon catheter or other mechanical assistance is not required to expand the stent to the desired shape and diameter. By simply axially compressing the stent to form the expanded diameter, it presses against the tissue lumen to open the vessel and maintain patency. In addition, when the stent of the present invention is in the compressed state, its radial stiffness is dramatically increased proportional to its increased mass moment of inertia.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary isometric view of an embodiment of the invention on an applicator, ready for insertion into a lumen;
FIG. 2 is a fragmentary axial sectional view taken generally along the plane II--II of FIG. 1, in which the body lumen is shown added at the intended site of deployment;
FIG. 3A is a view similar to that of FIG. 1, except showing the stent in place at the site of FIG. 2 and compressed for deployment;
FIG. 3B is a view similar to that of FIG. 3A, showing the next step in the deployment;
FIG. 3C is a view similar to that of FIG. 3B but showing the applicator being withdrawn;
FIG. 4 is a fragmentary, partially schematic elevational view depicting a test configuration;
FIG. 5 is a sectional view similar to that of FIG. 2 but showing the stent fully deployed; and
FIG. 6 is a fragmentary, simplified cross-sectional view of a male pelvis with the stent of the invention in place.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is described herein with respect to certain preferred embodiments, in which a stent is applied post-surgically to a body lumen such as a urethra, using a cystoscope or a catheter (but not a balloon catheter). In addition, the invention is applicable to a bellows construct applied in place of or before surgery, into lumens other than urethras, by insertion devices other than catheters or cystoscopes, and indeed for uses in a living body other than as a stent.
As used herein, "bellows" refers to the alterable shape achieved by repeated corrugations extending around the complete circumference of the tube with a pitch "P", FIG. 2, before compression, measured between peaks of the corrugations, and the fact that such corrugations are capable of compression and expansion towards and away from each other. It does not refer to a function of drawing in or expelling a fluid by expansion or compression of the corrugations, since that in fact is not its use. Nor for that matter does it refer to multiple cycles of compression and expansion as that also is not a feature of its use.
As used herein, "flexure transverse to said axis" means at a significant angle to the axis, including but not limited to, 90° to the axis. It is such a flexure that the stent must undergo while being advanced through a body lumen and around variously angled turns. Hence, its resistance is substantially negligible.
Also, as used herein, "negligible resistance to flexure" means, when measured using a method shown in FIG. 4, described below, a resistance no greater than about 2 Newtons of force (0.4 pounds) in an exactly perpendicular direction to the axis, per cm of travel per 2.5 cm of length. "Negligible recoil under compression" means, when closed by any force, the bellows remains closed with essentially zero spring-back. Force is required to return it to the original configuration.
In accord with one aspect of the invention, the construct 10, FIGS. 1-2, comprises an elongated flexible tube 12 of a biocompatible, biodegradable polymer, the tube having a total length L between opposite ends 14 and 16 and a longitudinal axis 18, FIG. 2, extending between the ends. A portion of the tube, indeed preferably at least 50% of its length, comprises a bellows 20 formed by repeated corrugations having a pitch "P", the length of the pitch varying with the intended use of the construct. When tube 12 is uncompressed, it has a relatively narrow outside diameter "D 1 " that the bellows that is easily accommodated within a body lumen "B".
Bellows 20 in turn comprises a series of conical sections joined back to back so that a ridge 22 is formed spaced from the next ridge by a groove 24. The axial distance between a ridge and its groove defines a distance "l" which, of course, is one-half the pitch "P" in FIG. 2.
For use as a stent in a urethra, useful dimensions for construct 10 are as follows:
L=150 mm
D 1 =from 1 mm to 50 mm
P=0.1 mm to about 5 mm
l=0.05 mm to about 2.5 mm
The thickness of the wall of tube 12, in such cases, would be from about 0.04 mm to about 2 mm.
For insertion of the construct into lumen B, it is preferably mounted on an applicator 30. A variety of applicators are useful, for example, a cystoscope or a catheter. As shown in FIGS. 1 and 2, applicator 30 comprises a cystoscope, and in particular one in which a hollow tube 32 with a longitudinal bore 34, that extends outwardly from a stiff sleeve 36, tube 32 having a distal end 38 which has a groove 40 extending transversely to bore 34. A control wire 42 freely extends through bore 34 to end 38, where it is pinned to a pivotal finger 44 pivoted at 46 to rotate, arrow 48, from a position transverse to bore 34 and in contact with end 16 of construct 10, to a position aligned with axis 18 and not in contact with construct 10, FIG. 3B.
Useful polymers for the manufacture of construct 10 comprise bio-absorbable aliphatic polyesters, especially those formed from lactone monomers in a conventional manner. Suitable lactone monomers may be selected from the group consisting of glycolide, lactide (l, d, dl, meso), p-dioxanone, delta-valerolactone, beta-butyrolactone, epsilon-decalactone, 2,5-diketomorpholine, pivalolactone, alpha, alpha-diethylpropiolactone, ethylene carbonate, ethylene oxalate, 3-methyl-1,4-dioxane-2,5-dione, 3,3-diethyl-1,4-dioxan-2,5-dione, gamma-butyrolactone, 1,4-dioxepan-2one, 1,5-dioxepan-2-one, 1,4-dioxan-2-one, 6,8-dioxabicycloctane-7-one and combinations of two or more thereof. Preferred lactone monomers are selected from the group consisting of glycolide, lactide, trimethylene carbonate, ε-caprolactone and p-dioxanone.
Thus the preferred polymers are polyesters selected from the group consisting of poly(lactide), poly(glycolide), poly(ε-caprolactone), poly(p-dioxanone), poly(trimethylene carbonate), copolymers and blends thereof.
Alternatively, the polymer can be a nonabsorbable biocompatible polymer selected from the group consisting of poly(propylene), poly(ethylene), poly(alkyleneoxide), thermoplastic elastomers, nylon, polyurethane, polyester, hydrogels, a flouropolymer, and copolymers and blends thereof. Such polymers are useful when the construct is intended to be permanent. Therapeutic agents can still be delivered by such polymers, by coating them on the outside of the construct, or by having them be leached out by water, especially if the polymer is water-swellable.
The construct of the present invention is formed from such polymers by use of various injection and extrusion molding equipment equipped with dry nitrogen atmospheric chamber(s) at temperatures and residence times to sufficiently form the structure of the bellows of the present invention.
The corrugated structure of the bellows is formed by a process in which the extruded thin-walled polymer tube is cut into the desired lengths. These tubes are then placed on a mandrel which has grooves. The tube is then cold stretched and formed into the grooved shape by using a rotating head which forces the tube wall into the depressions on the mandrel. The formed tube is then held in the compressed state for a certain time so that the polymer relaxes and stays in shape. The depth and the angle of these depressions are the critical design factors in the ability of the corrugated tube to function as desired.
The corrugated structure can also be formed by a one-step process in which the hot extrudate from an extruder is fed directly into a vacuum forming process, wherein the die head of the extruder extends into the closed area of revolving mold-block halves. A combination of air pressure inside the tube and the use of an external vacuum forces the hot plastic to form into the shape of the mold block. The corrugated tube is then cooled and wrapped or cut into given lengths.
Furthermore, bellows 20 can be perforated with various apertures for tissue ingrowth. Selective annealing of cross-sections of the device of the present invention can be used to stiffen the structure.
Additionally, the polymers of construct 10 can be used as a drug delivery matrix. To form this matrix, the polymer is mixed with a therapeutic agent. The variety of different therapeutic agents which can be used in conjunction with the polymers of the present invention is vast. In general, therapeutic agents which may be administered via the pharmaceutical compositions of the invention include, without limitation: antiinfectives such as antibiotics and antiviral agents; analgesics and analgesic combinations; anorexics; antihelmintics; antiarthritics; antiasthmatic agents; anticonvulsants; antidepressants; antidiuretic agents, antidiarrheals; antihistamines; antiinflammatory agents; antimigraine preparations; antinauseants; antineoplastics; antiparkinsonism drugs; antipruritics; antipsychotics; antipyretics, antispasmodics; anticholinergics; sympathomimetics; xanthine derivatives; cardiovascular preparations including calcium channel blockers and beta-blockers such as pindolol and antiarrhythmics; antihypertensives; diuretics; vasodilators including general coronary, peripheral and cerebral; central nervous system stimulants; cough and cold preparations, including decongestants; hormones such as estradoil and other steroids, including corticosteroids; hypnotics; immunosuppressives; muscle relaxants; parasympatholytics; psychostimulants; sedatives; and tranquilizers; and naturally derived or genetically engineered proteins, polysaccharides, glucoproteins, lipoproteins, or thrombogenetic and restenoic reducing agents.
Matrix formulations may be formulated by mixing one or more therapeutic agents with the polymer. The therapeutic agent, may be present as a liquid, a finely divided solid, or any other appropriate physical form. Typically, but optionally, the matrix will include one or more additives, such as diluents, carriers, excipients, stabilizers or the like.
The amount of therapeutic agent will depend on the particular drug being employed and medical condition being treated. Typically, the amount of drug represents about 0.0010% to about 70%, more typically about 0.001% to about 50%, most typically about 0.001% to about 20% by weight of the matrix.
The quantity and type of polymer incorporated into the drug delivery matrix will vary depending on the release profile desired and the amount of drug employed.
Importantly, such a construct 10, because of the bellows 20, has a negligible resistance to flexure transverse to axis 18, FIG. 1. That is, if the construct 10 alone, without the applicator, is subjected to a force F (as per the arrow), it takes only 0.9 Newtons of force to push end 16 1 cm away from axis 18, because of the corrugations. This is the familiar "bendable straw" phenomenon that is conventionally used with drinking straws.
This test is done in the manner shown in FIG. 4. That is, a test device 2.5 cm in length, such as the tubular construct of the invention or any other, is epoxied to a fixed support at one end, and if the device is an open tube, a thumb tack is epoxied at the other end. The force F is applied as shown to determine how much is needed to bend it perpendicularly, one cm.
In contrast, a control comprising a straight tube otherwise of the same dimensions and material, required at least 18 Newtons of force to push it one cm.
In use, FIGS. 2, 3A, 3B, and 3C, the construct 10 and its applicator 30 are inserted into body lumen B, FIG. 2, and advanced to a desired site of deployment, for example, a site of occlusion or potential occlusion Then, bellows 20 is axially compressed by the operator pushing sleeve 36 along tube 32, arrow 50, to force relative movement between distal end 16 of construct 10 and proximal end 14. This in turn, FIG. 3A, causes the bellows 20 to expand radially, preferably to take on an outside diameter D 2 , FIG. 5, that is approximately equal to the inside diameter of lumen B. For the urethral example noted above, a useful value for D 2 is about 10 mm, for a D1 value of 6 mm in FIG. 2. Pitch "P" is then reduced from an initial value of about 5 mm to about 2 mm.
Optionally, in the event the operator wishes to deploy construct 10 so that ridges 22, FIG. 2, do not scrape the interior of lumen B, the stent can be deployed while inside a smooth protective sleeve of the applicator (not shown).
Once at the site, FIG. 2, finger 44 is pivoted downward to align with axis 18, FIG. 3B, so that applicator tube 32 can be pulled out the interior of stent 10, arrow 60, FIG. 2, and applicator 30 withdrawn entirely.
When construct 10 is in its diameter-expanded form, FIGS. 3C and 5, the bellows provides a high degree of compressive stiffness as well as negligible recoil of expansion or compression. That is, when axially compressed, there is substantially no resilience such as would cause the bellows to return to its axially uncompressed form. This, of course, is important in retaining the construct in the configurations shown in FIG. 5.
The compressive strength of the construct 10 having the dimensions noted above, is approximately 40 Newtons per cm length, when tested with a compressive force F, FIG. 5.
FIG. 6 illustrates construct 10 deployed in its axially compressed state in the portion of the urethra "U" that extends through the prostate P to the bladder B, alleviating occlusion due to the prostate. It is positioned there by access through the urethra, as is conventional.
In addition, pores, slits or other openings can be incorporated into the inner or outer surface or through the entire tube for increased tissue growth or cell seeding. This would be especially important for nerve guides and vascular grafts. Such pores are formed by extraction of salts from the formed device, by laser cutting, lyophilization or super critical fluid (SCF) techniques. A tubular wall thickness of 0.025 mm to 1 mm and a outer diameter (O.D.) of 0.25 mm to 50 mm are most preferred. BaSO4 or other contrast agents can be added to improve the surgeon's vision of the device during delivery, deployment and post-operatively.
Additionally, the construct is useful as a shunt, e.g., in draining fluids from a body cavity such as the brain, or in providing flow between the kidney and the bladder.
EXAMPLES
These are illustrative only, and the invention is not limited thereto.
A homopolymer of p-dioxanone prepared as described, for example, in U.S. Pat. No. 4,838,267, was extruded into a tube using a 3/4" extruder (L/D=24) at 110°-160° C. with discharge through 0.38 mm annular die into a water bath at 60° C., followed by a second water bath at 30° C.
The tube was taken up on a spool. The formed tube was 8 mm in outside diameter (O.D.) with a wall thickness of 0.25 mm. Stent 10 of the present invention was then formed by a process wherein the polymer tube was cut into 100 mm lengths. Each 100 mm long tube was then placed on a grooved mandrel where the grooves were 0.3 mm deep with an angle of 15 and spaced apart by 0.3 mm. The tube was then heated at 100° C. and formed into the grooved shape by using a rotating head which forces the tube wall into the depressions on the mandrel. The formed tube was then held in the compressed state for 10 seconds to form the final corrugated shape with a 7.4 mm inner diameter (I.D.) and 8 mm O.D.
For deployment, a typical deployment technique is contemplated to be that a bellows stent 10 prepared as described above, with an initial outside diameter D 1 , FIG. 2, of 6 mm, is delivered to the site of occlusion in a male urethra via a cystoscope. The tube is then axially compressed when the site is reached, as detected via the cystoscope, to approximate the diameter of the vessel (FIG. 5).
The compression/expansion ability of the construct of the present invention is highly desirable since a balloon catheter or other mechanical assistance is not required to expand the device to the desired shape and diameter, thereby eliminating several steps in the surgical procedure, reducing costs and minimizing damage to the tissue that balloons can often cause during their deployment.
Consequently, the present invention allows for a variety of needs to be met for a wide range of medical applications that would not otherwise be abated by the devices of the prior art. For example, there is a great need for such a device in the urethra to maintain patency following surgical procedures for, e.g., benign prostate hypertrophy. A construct, such as that of the present invention, meets the needs for applications as broad in scope as urethral stents, grafts, and anastomotic couplers.
Therefore, the invention is useful for applications such as stents, grafts, nerve guides and anastomotic couplers.
The invention disclosed herein may be practiced in the absence of any element which is not specifically disclosed herein.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | A medical construct particularly useful as a stent, comprising an axially compressible bellows of a material and dimensions sufficient to provide negligible resistance to flexure transverse to the axis and negligible recoil under compression or expansion along the axis, and apparatus and a method for deploying the same. | 0 |
TECHNICAL FIELD
The present invention relates to a catalyst for synthesizing a polypropylene with a wide molecular weight distribution, and use of the same.
BACKGROUND ART
It is well known that, for isotactic polypropylene, the higher its isotacticity, the higher the crystallinity of the corresponding products. As a result, the mechanical properties such as hardness, rigidity, modulus, break strength and yield strength or the like are relatively good, and accordingly, the melting point, the thermal stability, aging resistance of the polymer are also relatively outstanding, however, the properties such as toughness, impact resistance, extension at break or the like will somewhat drop. The higher the isotacticity of the polypropylene, the narrower the molecular weight distribution and less benefitting the processing application and more difficult for injection molding and orientative film forming.
The methods for improving the processing properties of polypropylene include adjusting the isotacticity of polypropylene (e.g. Chinese Patent CN85101997) and widening the molecular weight distribution of polypropylene. As to product with wide molecular weight distribution, its fractions with high molecular weight provide good impact strength, modulus, melt strength and thermal property; and its fractions with low molecular weight provide processing flowability. Therefore, for polypropylene resins with the same grade number, polypropylene with wide molecular weight distribution has better rigidity, toughness and processing behavior, and has outstanding advantage in producing extrusion or injection molding article. Chinese Patent Application CN1156999A and Chinese Patent CN1137156C employed the method of mixing electron donor to adjust the molecular weight distribution of the polymers, while widened the molecular weight distribution, it increased the processing complexity, and accordingly, also increased production costs.
SUMMARY OF THE INVENTION
This invention employs a catalyst for synthesizing a polypropylene with a wide molecular weight distribution. By using organic phosphate type compounds as internal electron donors, the object of preparing polypropylene with wide molecular weight distribution by single electron donor catalyst was realized, and the catalyst synthetic process and production costs were simplified and reduced. The disadvantage brought about by mixing electron donors was overcome.
The object of the present invention is to provide a catalyst for synthesizing a polypropylene with a wide molecular weight distribution comprising magnesium halide, a titanium-containing compound and an organic phosphate type electron donor compound. Polypropylene polymer with relatively wide molecular weight distribution, easily controllable polymer isotacticity and good processing properties can be synthesized.
This invention provides a catalyst for synthesizing a polypropylene with a wide molecular weight distribution comprising magnesium halide, a titanium-containing compound and an organic phosphate type electron donor compound. The molar ratios of the components are as follows: per mole magnesium halide, the addition amount of the titanium-containing compound in terms of metal Ti is 0.5-150 mol, preferably 1-20 mol; the addition amount of the organic phosphate type electron donor compound is 0.02-0.40 mol, preferably 0.05-0.20 mol.
Suitable magnesium halide includes but not limited to: magnesium dihalides, complexes of magnesium dihalide with water or alcohols, derivatives wherein a halogen atom in the molecular formula of magnesium dihalide was replaced by a hydrocarbyl group or a haloalkoxy group; said magnesium dihalide is selected from a group consisting of magnesium dichloride, magnesium dibromide, and magnesium diiodide. Among them, magnesium dichloride is preferred.
Said titanium-containing compound is a liquid titanic (4 valent) compound with the general formula of TiX n (OR) 4-n , wherein, n is an integer from 1 to 4; X represents a halogen; R represents a C 1 -C 4 alkyl group. Said titanium-containing compound is preferably selected from a group consisting of titanium tetrachloride, titanium tetrabromide, titanium tetraiodide, titanium tetrabutoxide, titanium tetraethoxide, titanium monochlorotriethoxide, titanium dichlorodiethoxide, and titanium trichloromonoethoxide. Among them, titanium tetrachloride is more preferred.
The general formula of the organic phosphate type electron donor compound is as follows:
Wherein, the groups R 1 , R 2 or R 3 are identical or different and each of them independently represents a C 1 -C 20 linear or branched alkyl group, aryl group, alkoxyaryl group, or alkylaryl group.
Examples of said organic phosphate type electron donor compounds include but not limited to: trimethyl phosphate, triethyl phosphate, tributyl phosphate, triphenyl phosphate, tritolyl phosphate, triisopropylphenyl phosphate, tritertbutylphenyl phosphate, trimethoxylphenyl phosphate, phenyldimethyl phosphate, phenyldiethyl phosphate, phenyldibutyl phosphate, tolyldimethyl phosphate, tolyldiethyl phosphate, tolyldibutyl phosphate, isopropylphenyldimethyl phosphate, isopropylphenyldiethyl phosphate, isopropylphenyldibutyl phosphate, tertbutylphenyldimethyl phosphate, tertbutylphenyldiethyl phosphate, tertbutylphenyldibutyl phosphate, phenylditolyl phosphate, phenyldiisopropylphenyl phosphate, phenylditertbutylphenyl phosphate, tolyldiphenyl phosphate, tolyldiisopopylphenyl phosphate, tolylditertbutylphenyl phosphate, isopropylphenylditolyl phosphate, isopropylphenyldiphenyl phosphate or isopropylphenylditertbutylphenyl phosphate.
Among them, triphenyl phosphate and tritolyl phosphate are more preferred.
The steps and conditions for the preparation method of a catalyst for synthesizing a polypropylene with wide molecular weight distribution are as follows:
CN85100997 can be taken as reference. Briefly, the catalyst can be obtained by a process comprising the following steps:
(1) The Preparation of Magnesium Halide Solution
A uniform solution was formed by dissolving magnesium halides into the solvent system composed of organic epoxy compounds and organic phosphorous compounds at a dissolution temperature of 0-100° C., preferably 30-70° C. During the dissolution, one or more inert diluting agent selected from a group consisting of hexane, heptane, octane, toluene, xylene, chlorobenzene, and other hydrocarbon type or halohydrocarbon type compounds can be added. The ratios between each component, in terms of per mole magnesium halide, are as follows: the organic epoxy compound is 0.2-10 mol, preferably 0.5-4 mol; and the organic phosphorous compound is 0.1-3 mol, preferably 0.3-1.0 mol, thus magnesium halide solution was obtained.
Said organic epoxy compounds include the oxides, glycidyl ethers, inner ethers or the like of aliphatic olefins or dialkenes or of haloaliphatic olefins or dialkenes which have 2-8 carbon atoms. The examples of specific compounds include but not limited to: ethylene oxide, propylene oxide, butylene oxide, butadiene oxide, butadiene dioxide, epoxy chloropropane, methylglycidyl ether, diglycidyl ether or tetrahydrofuran. Among them, epoxy chloropropane is more preferable.
Said organic phosphorous compounds include alkyl esters or haloalkyl esters of orthophosphoric acid and of phosphorous acid, and the specific compounds include but not limited to: trimethyl orthophosphate, triethyl orthophosphate, tributyl orthophosphate, triphenyl orthophosphate, trimethyl phosphite, triethyl phosphite, tributyl phosphite or benzyl phosphite. Among them, tributyl orthophosphate is preferred.
(2) Precipitation of the Solid
At the low temperature in a range from 0 to −40° C., in the presence of coprecipitator in the reaction system, liquid titanic compound was mixed with magnesium halide solution, and a solid was precipitated as the temperature of the reaction system was gradually increased. Organic phosphate type electron donor compound can be added before or after the precipitation of the solid. The ratios between each component are, in terms of per mole magnesium halide, as follows: liquid titanic compound is 0.5-150 mol, preferably 1-20 mol; and coprecipitator is 0.03-1.0 mol, preferably 0.05-0.4 mol.
Said coprecipitator was selected from a group consisting of organic acids, organic acid anhydrides, organic ethers, organic ketones, or the mixtures thereof. The examples of specific compounds can be listed as follows: acetic anhydride, phthalic anhydride, succinic anhydride, maleic anhydride, 1,2,4,5-benzene tetracarboxylic acid dianhydride, acetic acid, propanoic acid, butyric acid, acrylic acid, methacrylic acid, acetone, methyl ethyl ketone, diphenyl ketone, methyl ether, ethyl ether, propyl ether, butyl ether or amyl ether. Among them, phthalic anhydride is preferred.
(3) Treatment and Washing of the Solid Precipitate
The solid precipitate described above was treated by titanium tetrahalide or the mixture of titanium tetrahalide and inert diluting agent, and subsequently washed with inert diluting agent. Thus, a catalyst for synthesizing a polypropylene with wide molecular weight distribution was obtained.
This invention provides a catalyst for synthesizing a polypropylene with a wide molecular weight distribution. In addition to the present catalyst, it is needed to add a cocatalyst and an external electron donor during the polymerization.
Said cocatalyst may be an alkylaluminium compound with the general formula of AlR n X 3-n , wherein R represents hydrogen or alkyl groups with the carbon number of 1-20; X represents halogen, especially chlorine or bromine; and n represents an integer of 0<n≦3.
The specific alkylaluminium compounds include but not limited to: aluminium trimethyl, aluminium triethyl, aluminium triisobutyl, aluminium monohydrobiethyl, aluminium monohydrobiisobutyl, aluminium monochlorobiethyl, aluminium monochlorobiisobutyl, aluminium sesquiethyl chloride or aluminium bichloroethyl. Among them, aluminium triethyl or aluminium triisobutyl is preferred.
Said external electron donors are organic silicon compounds with the general formula of R n Si(OR) 4-n , wherein 0≦n≦3, n is an integer; R and R′ are identical or different alkyl groups, cycloalkyl groups, aryl groups or haloalkyl groups.
The examples of specific organic silicon compounds include but not limited to: trimethylmethoxy silicane, trimethylethoxy silicane, bimethylbimethoxy silicane, bimethylbiethoxy silicane, methylcyclohexylbimethoxy silicane, bibutylbimethoxy silicane or biphenylbimethoxy silicane. Among them, methylcyclohexylbimethoxy silicane, bibutylbimethoxy silicane and biphenylbimethoxy silicane are preferred.
The proportion of said aluminium alkyl to the catalyst is (5-1000): 1 in terms of the molar ratio of aluminium and titanium, preferably (100-800): 1; and the proportion of the aluminium alkyl to external electron donors is (1-400): 1 in terms of the molar ratio of aluminium and silicon, preferably (25-250): 1.
Use of the catalyst for synthesizing a polypropylene with wide molecular weight distribution can be described as follows.
The catalyst for synthesizing a polypropylene with wide molecular weight distribution according to this invention can particularly be used for the homopolymerization of propylene and the copolymerization of propylene and other α-olefin(s). The polymerization can be a liquid-phase polymerization or a vapour-phase polymerzation.
The catalyst for synthesizing a polypropylene with wide molecular weight distribution according to this invention can also be used for the polymerization or the copolymerization of α-olefins having 2-20 carbon atoms, especially for the homopolymerization or copolymerization of ethylene, 1-butylene, 4-methyl-1-amylene, 1-hexene, 3-methyl-1-butylene, 1-decene, 1-tetradecene or 1-eicosylene.
Advantageous Effect
By adjusting internal electron donors, the catalyst according to this invention can be used to synthesize propylene polymer with a relatively high and easily adjustable isotacticity and a molecular weight distribution with a medium width. Especially for the catalyst system described by CN85100997, by using phosphates as internal electron donor compounds, the resulted propylene polymer has an easily adjustable isotacticity and a widened molecular weight distribution, which benefits the development of many kinds of polypropylenes.
When the catalysts according to this invention were used for the polymerization of propylene, for example, if adjusting Al/Si (mol/mol) from 25 to 100, the isotacticity of polypropylene will be reduced from 98% to 90%, and the molecular weight distribution thereof will also be widened.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Due to the multi-complex groups and complex structure, the organic phosphate type electron donor compounds according to this invention make the environment of the active center change. The active centers in different environments have different sensitivities to hydrogen. Therefore, when hydrogen is used as molecular weight control agent, different molecular weights are produced, thus polypropylene with a wide molecular weight distribution is obtained.
EXAMPLE 1
The Preparation of a Catalyst for Synthesizing a Polypropylene with Wide Molecular Weight Distribution
The preparation of catalyst components:
To a reactor which have been sufficiently purged by high-purity nitrogen, 0.05 mol anhydrous MgCl 2 , 95 ml toluene, 0.05 mol epoxy chloropropane (ECP) and 0.046 mol tributyl phosphate (TBP) were added in this order. Raised the temperature to 50° C. under stirring, and kept it for 2.5 h. The solids were dissolved completely, then 0.0095 mol phthalic anhydride was added. The temperature was kept for 1 h, then the solution was cooled to −25° C., and 56 ml TiCl 4 was added dropwise over 1 h. The temperature was gradually raised to 80° C. while a solid was precipitated. 0.0027 mol triphenyl phosphate was added and the reactor was kept at 80° C. for 1 h. After filtration, a washing was made twice with 100 ml toluene, and a brown yellow solid precipitate was obtained. Then 60 ml toluene, and 40 ml TiCl 4 were added. The washed precipitate was treated at 90° C. for 2 h. After removing the filtrate, the treatment was repeated once more. After washing with 100 ml toluene for 3 times and with 100 ml hexane for 2 times, a catalyst for synthesizing a polypropylene with a wide molecular weight distribution was obtained. In this catalyst, the weight of titanium is 2.5 wt %, the weight of magnesium is 17.10 wt %, and the weight of chlorine is 54.03 wt %.
Polymerization of Propylene
In a 5 L stainless steel autoclave which has been sufficiently purged by propylene, 0.4 ml AlEt 3 , and 0.004 ml methylcyclohexylbimethoxy silicane were added to make Al/Si (mol/mol)=25. 10 mg catalyst of this invention produced as above, and 800 g propylene were also added. The reaction was carried out at 70° C. for 2 h. Then the temperature was dropped, the pressure was reduced, and a polypropylene (PP) resin was obtained. The results were shown in Table 1.
COMPARATIVE EXAMPLE
The Preparation of a Catalyst Comprising Bibutyl Phthalic Ester as Internal Electron Donor
To a reactor which have been sufficiently purged by high-purity nitrogen, 0.05 mol anhydrous MgCl 2 , 95 ml toluene, 0.05 mol epoxy chloropropane (ECP) and 0.046 mol tributyl phosphate (TBP) were added in this order. The temperature was raised to 50° C. under stirring and kept for 2.5 h, the solids were dissolved completely, then 0.0095 mol bimethyl phthalic ester was added, the temperature was kept for additional 1 h, then the solution was cooled to −25° C., 56 ml TiCl 4 was added dropwise over 1 h. The temperature was raised to 80° C. gradually while a solid was precipitated gradually. 0.0056 mol bibutyl phthalic ester was added and the reactor was kept at 80° C. for 1 h. After filtration, a washing was made twice with 100 ml toluene, and a brown yellow solid precipitate was obtained. Then 60 ml toluene and 40 ml TiCl 4 were added to treat the precipitate at 90° C. for 2 h, after removing the filtrate, the treatment was repeated once more. The treated precipitate was washed with 100 ml toluene for 3 times and 100 ml hexane for 2 times, and finally a catalyst comprising bibutyl phthalic ester as internal electron donor was obtained. The results were shown in Table 1.
Polymerization of Propylene
In a 5 L stainless steel autoclave which has been sufficiently purged by propylene, 0.4 ml AlEt 3 and 0.004 ml methylcyclohexylbimethoxy silicane (CHMMS) were added to make Al/Si ratio (mol/mol)=25, and 10 mg catalyst of comparative example, 800 g propylene were also added. The reaction was carried out at 70° C. for 2 h, the temperature was dropped, the pressure was reduced, and a PP resin was obtained. The results were shown in Table 1.
EXAMPLE 2
Except that triphenyl phosphate in Example 1 was changed to tributyl phosphate, Example 2 was carried out at the same way as Example 1. The results were shown in Table 1.
EXAMPLE 3
Except that triphenyl phosphate in Example 1 was changed to tritolyl phosphate, Example 3 was carried out at the same way as Example 1. The results were shown in Table 1.
EXAMPLE 4
Except that triphenyl phosphate in Example 1 was changed to phenyldibutyl phosphate, Example 4 was carried out at the same way as Example 1. The results were shown in Table 1.
EXAMPLE 5
Except that triphenyl phosphate in Example 1 was changed to trimethoxylphenyl phosphate, Example 5 was carried out at the same way as Example 1. The results were shown in Table 1.
EXAMPLE 6-51
Except that the internal electron donors were changed, Examples 6-51 were carried out at the same way as Example 1 by using the catalyst of Example 1. The results were shown in Table 1.
EXAMPLE 52, 53
Except that the addition amount of methylcyclohexylbimethoxy silicane was changed to adjust the molar ratio of aluminium and silicon to be 70 (Example 52) and 100 (Example 53), Examples 52-53 were carried out at the same way as Example 1 by using the catalyst of Example 1. The results were shown in Table 2.
EXAMPLE 54, 55
Except that the catalyst of Example 3 was used, and the addition amounts of methylcyclohexylbimethoxy silicane was changed to adjust the molar ratio of aluminium and silicon to be 70 (Example 54) and 100 (Example 55), Examples 54-55 were carried out in the same way as Example 1. The results were shown in Table 2.
TABLE 1
Activities, isotacticities and molecular weight distributions of
catalysts containing different internal electron donor compounds
molecular
weight
Apparent
Electron donor
distribution
Activity
Isotacticity
Density
compounds
Mw/Mn
kgPP/g · cat
I.I %
g/cm 3
Example 1
triphenyl
9.0
31.2
97.9
0.46
phosphate
Example 2
tributyl
8.5
30.0
96.1
0.43
phosphate
Example 3
tritolyl
9.3
33.42
98.2
0.45
phosphate
Example 4
phenyldibutyl
8.2
29.8
98.3
0.43
phosphate
Example 5
trimethoxylphenyl
7.9
22.4
94.1
0.39
phosphate
Comparative
biisobutyl
4.8
42.0
98.3
0.45
Example
phthalic ester
Example 6
trimethyl
7.2
31.2
95.6
0.42
phosphate
Example 7
triethyl
30.5
95.9
0.42
phosphate
Example 8
tri-p-isopropyl
8.6
29.8
98.0
0.42
phenyl
phosphate
Example 9
tri-p-t-butylphenyl
7.4
28.6
98.2
0.43
phosphate
Example 10
tri-p-methoxyl
7.9
22.4
94.1
0.39
phenyl
phosphate
Example 11
phenylbimethyl
30.5
98.2
0.43
phosphate
Example 12
phenylbiethyl
30.0
98.3
0.44
phosphate
Example 13
biphenylmethyl
32.5
97.2
0.43
phosphate
Example 14
biphenylethyl
31.9
98.0
0.45
phosphate
Example 15
biphenylbutyl
8.9
30.7
98.2
0.46
phosphate
Example 16
p-tolylbimethyl
31.2
98.5
0.44
phosphate
Example 17
p-tolylbiethyl
8.3
31.0
98.6
0.43
phosphate
Example 18
p-tolylbibutyl
8.5
30.8
98.8
0.43
phosphate
Example 19
o-tolylbimethyl
26.8
97.9
0.43
phosphate
Example 20
o-tolylbiethyl
7.1
26.5
98.2
0.44
phosphate
Example 21
o-tolylbibutyl
26.0
97.5
0.43
phosphate
Example 22
m-tolylbimethyl
28.5
98.5
0.42
phosphate
Example 23
m-tolylbiethyl
7.4
28.3
98.6
0.42
phosphate
Example 24
m-tolylbibutyl
7.8
28.0
98.8
0.44
phosphate
Example 25
p-bitolylmethyl
33.0
97.2
0.44
phosphate
Example 26
p-bitolylethyl
32.5
98.0
0.43
phosphate
Example 27
p-bitolylbutyl
7.5
32.2
98.4
0.44
phosphate
Example 28
o-bitolylmethyl
31.2
96.5
0.42
phosphate
Example 29
o-bitolylethyl
30.1
97.0
0.45
phosphate
Example 30
o-bitolylbutyl
29.4
97.5
0.44
phosphate
Example 31
m-bitolylmethyl
6.9
30.1
95.2
0.42
phosphate
Example 32
m-bitolylethyl
29.4
96.5
0.43
phosphate
Example 33
m-bitolylbutyl
28.1
97.0
0.43
phosphate
Example 34
p-isopropylphenyldimethyl
32.5
99.0
0.43
phosphate
Example 35
p-isopropylphenyldiethyl
7.3
32.2
98.9
0.42
phosphate
Example 36
p-isopropylphenyldibutyl
6.9
31.9
98.7
0.43
phosphate
Example 37
p-biisopropylphenylmethyl
32.8
97.5
0.45
phosphate
Example 38
p-biisopropylphenylethyl
8.2
31.2
98.1
0.44
phosphate
Example 39
p-biisopropylphenylbutyl
30.9
98.3
0.45
phosphate
Example 40
p-t-butylphenylbimethyl
7.0
33.6
99.1
0.42
phosphate
Example 41
p-t-butylphenylbiethyl
33.3
99.0
0.42
phosphate
Example 42
p-t-butylphenylbibutyl
7.3
33.0
99.0
0.43
phosphate
Example 43
phenyl-p-bitolyl
30.4
97.5
0.41
phosphate
Example 44
phenyl-p-biisopropylphenyl
7.4
28.4
97.6
0.42
phosphate
Example 45
phenyl-p-bi-t-
7.6
27.6
97.8
0.42
butylphenyl
phosphate
Example 46
p-tolylbiphenyl
7.3
29.8
96.8
0.44
phosphate
Example 47
m-tolyl-p-bi-t-
7.3
28.6
98.9
0.44
butylphenyl
phosphate
Example 48
p-isopropylphenyl-
7.6
27.2
98.0
0.42
p-bitolyl
phosphate
Example 49
p-isopropylphenyl-
26.0
97.4
0.43
o-bitolyl
phosphate
Example 50
p-isopropylphenyl-
27.0
97.3
0.45
m-bitolyl
phosphate
Example 51
p-isopropylphenyl-
7.0
27.2
98.1
0.42
p-biphenyl
phosphate
TABLE 2
The activities of the catalysts with different silicon/aluminium
ratios and isotacticities of the polymers
Apparent
Electron
Al/Si
Activity
Isotacticity
Density
Examples
donor
(mol)
kgPP/g · cat
I.I %
g/cm 3
Example 1
triphenyl
25
31.2
97.9
0.46
phosphate
Example
triphenyl
70
32.1
96.5
0.45
52
phosphate
Example
triphenyl
100
34.1
94.2
0.44
53
phosphate
Example 3
tritolyl
25
33.42
98.2
0.45
phosphate
Example
tritolyl
70
35.2
97.0
0.45
54
phosphate
Example
tritolyl
100
37.4
95.4
0.43
55
phosphate | The present invention relates to a catalyst for synthesizing a polypropylene with a wide molecular weight distribution and use of the same. The catalyst comprises magnesium halide, titanium-containing compound, and an organic phosphate type electron donor compound. By the catalyst according to the present invention, a propylene polymer with a wide molecular weight distribution, easily controllable isotacticity and good processing properties can be synthesized. | 2 |
BACKGROUND
[0001] The disclosed subject matter is directed to a vehicle storage container, and methods of use and manufacture thereof. More particularly, the disclosed subject matter is directed to methods and apparatus for enhancing storage capacities in vehicles, and facilitating insertion and/or assembly of storage containers within vehicles.
[0002] Spaces can be provided in an interior compartment of a vehicle for the purpose of storing or otherwise housing various articles, such as money (including change), writing instruments, documents, cleaning supplies, glasses, gum, etc. Some related art storage spaces include compartments that provide the ability to shield or otherwise enclose stored articles, while also allowing vehicular passengers access or limited access to the stored articles. Shielding or otherwise enclosing articles may be beneficial for various reasons, such as to control the location of the stored articles, which would otherwise be subject to movement within the interior of the vehicle based on the vehicle's motion.
SUMMARY
[0003] Some types of vehicles, such as all-terrain vehicles (ATVs), provide limited accessories within the vehicle compartment, and thus it may be beneficial to integrate storage areas with various structures in the vehicular passenger compartment that are usable for other purposes. For example, these storage areas can be integrated with one or more of the vehicle seats.
[0004] In some of these cases, an open area can be defined by the vehicle body or vehicle frame beneath the vehicle seat, and a bottom of the vehicle seat that supports a vehicle passenger can be moved or removed to expose the open area. A storage container can be disposed within the open area, and this storage container can define an open upper end so that articles stored therein can be accessed by moving or removing the seat bottom. In some of these embodiments, the seat bottom is completely removable from the vehicle body or frame such as by lifting it in an upwardly direction, while in other embodiments a portion of the seat bottom remains attached to the vehicle body or frame and is movable such as via rotation.
[0005] In some such structures, the seat bottom is attached to the vehicle body or frame by a seat frame, and this seat frame defines a hole. Thus, once the seat bottom is moved or removed, access to the open end of the storage container is provided via the hole of the seat frame. However, this structure may be subject to the disadvantage that only storage containers that are sufficiently small in size to fit through the hole in the seat frame can be inserted into the open area defined by the vehicle body or frame. In other words, the only storage containers that can be used must be small enough to fit through the hole in the seat frame, which limits the volume of storage space available.
[0006] It may therefore be beneficial to provide methods and apparatus that increase the volume of storage space available under the passenger seats, and/or facilitate the insertion or removal of storage containers disposed under the passenger seats. For example, it may be beneficial to provide a storage container that includes an upper ring that is small enough to be insertable through the hole defined in the seat frame and is attachable to the seat frame. A lower receptacle that is larger than the upper ring can be connected to the upper ring. Prior to this connection, the lower receptacle can be inserted laterally into the open space of the vehicle body or frame upon removal of a vehicle body panel. This structure enables the use of a lower receptacle that is relatively large in size and that thereby increases the volume of storage space available beneath the vehicle seat.
[0007] Some embodiments are therefore directed to a storage assembly for use with a vehicle seat assembly that includes a seat frame and a seat bottom configured to support a vehicle passenger. The seat frame can define an opening that is contiguous with an open space defined in part by a removable vehicle body panel. The seat bottom can be movable to expose the opening of the seat frame. The storage assembly can include an upper ring that is configured for attachment to the seat frame. The upper ring can be structured to facilitate travel through the opening of the seat frame, and can define a hollow interior with open upper and lower ends. A lower receptacle can have an upper opening and configured for attachment to the upper ring such that the upper opening is contiguous with the hollow interior of the upper ring. The lower receptacle can define an interior storage space that is defined by sides and a bottom, the lower receptacle being larger in size than the upper ring such that the lower receptacle is impeded from travel through the opening of the seat frame. The lower receptacle can be configured to be insertable into the open space of the vehicle upon removal of the vehicle body panel.
[0008] Some other embodiments are directed to a seat and storage assembly for use with a vehicle having an open space that is defined in part by a removable vehicle body panel. The vehicle can be configured to transport a vehicle passenger. The seat and storage assembly can include a vehicle seat assembly that includes a seat frame and a seat bottom configured to support the vehicle passenger. The seat frame can define an opening that is contiguous with the open space of the vehicle, and the seat bottom can be movable to expose the opening of the seat frame. The seat and storage assembly can also include a storage assembly that can include an upper ring that is configured for attachment to the seat frame. The upper ring can be structured to facilitate travel through the opening of the seat frame, and can define a hollow interior with open upper and lower ends. A lower receptacle can have an upper opening and configured for attachment to the upper ring such that the upper opening is contiguous with the hollow interior of the upper ring. The lower receptacle can define an interior storage space that is defined by sides and a bottom, the lower receptacle being larger in size than the upper ring such that the lower receptacle is impeded from travel through the opening of the seat frame. The lower receptacle can be configured to be insertable into the open space of the vehicle upon removal of the vehicle body panel. .
[0009] Still other embodiments are directed to a method of installing a storage assembly within a vehicle, the vehicle including a vehicle seat assembly having a seat frame and a seat bottom configured to support a vehicle passenger, the seat frame defining an opening that is contiguous with an open space defined in part by a removable vehicle body panel, the seat bottom being movable to expose the opening of the seat frame. The method can include: passing an upper ring through the opening of the seat frame; attaching the upper ring to the seat frame, the upper ring defining a hollow interior with open upper and lower ends; inserting a lower receptacle into the open space of the vehicle upon removal of the vehicle body panel by moving the lower receptacle in a direction that is substantially perpendicular to an axis of the upper ring; and attaching the lower receptacle to the upper ring such that an upper opening of the lower receptacle is contiguous with the hollow interior of the upper ring, the lower receptacle defining an interior storage space that is defined by sides and a bottom, the lower receptacle being larger in size than the upper ring such that the lower receptacle is impeded from travel through the opening of the seat frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The disclosed subject matter of the present application will now be described in more detail with reference to exemplary embodiments of the apparatus and method, given by way of example, and with reference to the accompanying drawings, in which:
[0011] FIG. 1 is a perspective view of an exemplary vehicle including a body having seat assemblies for accommodating a storage assembly in accordance with principles of the disclosed subject matter.
[0012] FIG. 2 is a partial perspective view of the body and the seat assembly of FIG. 1 .
[0013] FIG. 3 is a perspective view of an exemplary storage assembly in accordance with principles of the disclosed subject matter.
[0014] FIG. 4 is a top view of an upper ring of the storage assembly of FIG. 3 .
[0015] FIG. 5 is a side view of the upper ring of FIG. 3 .
[0016] FIG. 6 is a top view of a lower box of the storage assembly of FIG. 3 .
[0017] FIG. 7 is a side view of the lower box of FIG. 3 .
[0018] FIG. 8 is a partial perspective view of the seat assembly of FIG. 2 shown with a side cover removed.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] A few inventive aspects of the disclosed embodiments are explained in detail below with reference to the various figures. Exemplary embodiments are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
[0020] Various headings are provided below for convenience and clarity. However, these headings are not intended to limit the scope or content of the disclosure, and/or the scope of protection afforded the various inventive concepts disclosed herein.
[0021] I. Overall Vehicle
[0022] FIG. 1 is a perspective view of an exemplary vehicle 10 including a body 12 having seat assemblies 20 L,R for accommodating a storage assembly in accordance with principles of the disclosed subject matter. The vehicle 10 shown in FIG. 1 is specialized for use on an unimproved path or on an unmarked path, and can be referred to as a multipurpose utility vehicle (MUV) or as a side-by-side all-terrain vehicle (SxS, or SxS ATV).
[0023] However, the disclosed storage assembly can be used with any vehicle that is configured for travel along any one or combination of improved, unimproved, and unmarked paths. For example, embodiments are intended to include or otherwise cover any type of automobile, including a passenger car, minivan, truck, other types of all-terrain vehicle (ATV), semi-tractor, off-highway vehicle, etc.
[0024] The vehicle 10 can include the body 12 , a pair of front wheels, 14 L, 14 R, a pair of rear wheels 16 L, 16 R (the right-side rear wheel 16 R is obstructed from view), and a powertrain. The powertrain is omitted from FIG. 1 for simplicity and clarity of the drawing.
[0025] The vehicle 10 can include a pair of seat assemblies 20 L, 20 R and backrest 23 mounted in a passenger area of the vehicle 10 . The seat assemblies 20 L, 20 R can be disposed on respective seat frames 22 L, 22 R, the left-side (driver's-side) seat frame 22 L shown adjacent a removable side cover 24 which is described below. The side cover 24 can be removed to provide unobstructed access to an under-seat cavity 26 underneath the left-side seat frame 22 L to install or remove a storage assembly.
[0026] The body 12 can include a roll cage 28 configured to extend around and above the passenger area. The roll cage 28 can cooperate with the body 12 to define openings through which a passenger may pass in order to enter or exit the passenger area.
[0027] In some embodiments, the openings through which a passenger may pass may be configured as door assemblies, which occupy the openings. Each door assembly can include a door and window panel assembly, and can be configured to selectively open and close access through the openings by moving between a closed position and a fully opened position. In the closed position, the door assemblies may span the respective openings to obstruct access to the passenger area via the openings. In the closed position, front portions of each door assembly may be latched to the roll cage 28 . The fully opened position can be any position where the door assemblies are pivoted away from the respective openings to provide substantially unobstructed access to the passenger area via the openings.
[0028] II. Seat Assembly
[0029] FIG. 2 is a partial perspective view of the body 12 and the left-side seat assembly 20 L of FIG. 1 . The seat assembly 20 L can be disposed within the passenger area of the body 12 . The seat assembly 20 L can be configured to support a passenger seated thereon so as to enable the passenger to operate the vehicle 10 . As will be discussed in greater detail below, the seat assembly 20 L can be configured to open and close to provide and restrict access to a storage assembly located within the under-seat cavity 26 .
[0030] The seat assembly 20 L can include a cushion 21 L, a seat frame 22 L, an under-seat cavity 26 and a side cover 24 . As will be discussed in greater detail below, the seat assembly 20 L can accommodate a storage assembly within the under-seat cavity 26 , as well as provide access to the storage assembly through the seat frame 22 L. A passenger can therefore utilize the storage assembly for storing items proximate the passenger area for advantageous storage space packaging and access to stored items.
[0031] The cushion 21 L can be disposed on a top side of the seat frame 22 L within the passenger area. The cushion 21 L can be configured with mounting points for affixing the cushion 21 L to the seat frame 22 L, the mounting points capable of receiving any appropriate fasteners for securing the cushion 21 L to the seat frame 22 L. The mounting points and fasteners may include fixtures such as but not limited to bolts, snap, hooks, etc., or may alternatively have adhesive applications. In some embodiments, the cushion 21 L may be hingedly attached along an edge of the seat frame 22 L so as to form a lid capable of being rotated between opened and closed positions. Specifically, the cushion 21 L in some embodiments is hingedly attached to a rearmost edge of the seat frame 22 L. The cushion 21 L may be formed of plastic, rubber, foam, or any other appropriate material for providing seating support for a passenger.
[0032] The seat frame 22 L can be connected to the passenger area of the body 12 . The seat frame 22 L can be configured as a frame surrounding the under-seat cavity 26 and supporting the cushion 21 L, as described above. The seat frame 22 L can have an upper portion that approximately aligns with edge portions of the cushion 21 L, or may be alternatively configured. In some embodiments, the seat frame 22 L may be separate and spaced from a seat frame of the right-side (passenger's-side) seat assembly 20 R. However, other embodiments may incorporate a single seat frame extending an approximate width of the passenger area so as to support both the seat assemblies 20 L, 20 R.
[0033] The seat frame 22 L can be made from any appropriate structural element(s), such as but not limited to tubes, beams, stampings, etc., that can provide sufficient strength and rigidity for supporting a passenger. The seat frame 22 L can be formed from a single type of structural element, or alternatively the seat frame 22 L can be formed from any combination of these structural elements. The structural elements can have any appropriate cross-sectional shape, such as but not limited to circular, rectangular, regular polygonal, irregular polygonal, hollow, solid, variable along the length of the structural element, etc.
[0034] The seat frame 22 L can be formed by any appropriate process, such as but not limited to rolling, hydroforming, bending, welding, extruding, stamping, any combination of these processes, etc. Additionally, the seat frame 22 L can be formed from any appropriate material, such as but not limited to steel, aluminum, titanium, magnesium, fiber-reinforced plastic, carbon fiber, a composite formed from any combination of these exemplary materials, etc. Portions of the seat frame 22 L can be connected to other adjoining portions in any appropriate manner, such as but not limited to mechanical fasteners, welding, adhesive, any combination thereof, etc.
[0035] The under-seat cavity 26 can be a space defined by surrounding portions of the seat frame 22 L and disposed substantially underneath the cushion 21 L. The under-seat cavity 26 can be configured to receive a storage assembly. The under-seat cavity 26 can be further defined by the side cover 24 connected to at least one of the body 12 and the seat frame 22 L proximate the opening to the left-side seat assembly 20 L of the passenger area, as described below.
[0036] The side cover 24 can be configured to extend from the seat frame 22 L to a floor of the under-seat cavity 26 , the side cover 24 oriented to extend along a side of the seat assembly 20 L adjacent the opening to the passenger area. The side cover 25 can overlap with other panels of the body 12 , and can include cover fasteners 25 configured to secure the side cover 24 to at least one of the seat frame 22 L or the body 12 . The side cover 24 can extend along a left-side edge of the seat frame 22 L, and may additionally extend along a portion of a front edge of the seat frame 22 L.
[0037] The side cover 24 can be made from any appropriate structural element(s), such as but not limited to sheets, stampings, etc., that can provide sufficient coverage and rigidity for covering the under-seat cavity 26 . The side cover 24 can be formed by any appropriate process, such as but not limited to rolling, hydroforming, bending, welding, plating, stamping, any combination of these processes, etc. Furthermore, the side cover 24 can be formed from any appropriate material, such as but not limited to steel, aluminum, titanium, magnesium, fiber-reinforced plastic, carbon fiber, a composite formed from any combination of these exemplary materials, etc. The seat cover 24 can be connected to the adjoining structural elements such as the seat frame 22 L and/or the body 12 in any appropriate manner, such as but not limited to mechanical fasteners, such as the cover fasteners 25 , welding, adhesive, any combination thereof, etc. In the present embodiment, the cover fasteners 25 may be configured as bolts.
[0038] III. Storage Assembly
[0039] FIG. 3 is a perspective view of an exemplary storage assembly 30 in accordance with principles of the disclosed subject matter. The storage assembly 30 can be configured for storage of items and can include an upper ring 40 connected to a lower box 50 .
[0040] The upper ring 40 of the storage assembly 30 can be approximately rectangular in shape, with at least a portion being indented. A top portion of the upper ring 40 can include a ring flange 42 extending around a perimeter of the upper ring 40 , such that the ring flange 42 is configured for connecting the upper ring 40 to the seat frame 22 L. The ring flange 42 can extend around each edge of the top portion of the upper ring 40 , or alternatively may extend from a fewer number of edges. The ring flange 42 may be contoured so as to mate with corresponding portions of the seat frame 22 L and/or body 12 which contact the ring flange 42 during installment of the storage assembly 30 within the vehicle 10 . The ring flange 42 can additionally include flange fasteners 44 configured to secure the ring flange 42 to at least one of the seat frame 22 L or the body 12 . However, the ring flange 42 can be connected to adjoining structural elements such as the seat frame 22 L and/or the body 12 in any appropriate manner, such as but not limited to mechanical fasteners, such as the flange fasteners 44 , welding, adhesive, any combination thereof, etc. In the present embodiment, the flange fasteners 44 may be configured as bolts. The ring flange 42 extends around an opening through the upper ring 40 which is smaller relative to a space defined by an interior of the lower box 50 , as will be described below. Therefore, the opening in the upper ring 40 may not unnecessarily constrain storage space in the lower box 50 below.
[0041] The lower box 50 of the storage assembly 30 can be approximately rectangular or box-like in shape. In some embodiments, the lower box 50 can be trapezoidal, with a top side of the lower box 50 having a greater surface area than a bottom side. The lower box 50 can have a larger volume than that of the upper ring 40 , and a portion of the top side can be connected to a bottom side of the upper ring 40 . Furthermore, the top side of the lower box 50 can include an opening configured to mate against a similar opening in the bottom side of the upper ring 40 . The respective openings are configured so as to permit passage therethrough of items to be stored and removed from the storage assembly 30 .
[0042] Both of the upper ring 40 and the lower box 50 of the storage assembly 30 can be formed by any appropriate process, such as but not limited to rolling, hydroforming, bending, welding, extruding, stamping, injection molding, extrusion molding, extrusion blow molding, vacuum forming, etc. Each element of the storage assembly can be formed from any appropriate material, such as but not limited to steel, aluminum, titanium, magnesium, fiber-reinforced plastic, carbon fiber, thermoplastic, rubber, polyvinyl chloride (PVC), a composite formed from any combination of these exemplary materials, etc. The upper ring 40 and the lower box 50 can be connected to each other in any appropriate manner to form the assembled storage assembly 30 , such as but not limited to mechanical fasteners, welding, adhesive, any combination thereof, etc. In the present embodiment, the upper ring 40 and the lower box 50 can be secured together by assembly fasteners 52 , which may be configured as bolts.
[0043] IV. Upper Ring
[0044] FIG. 4 is a top view of the upper ring 40 of the storage assembly 30 of FIG. 3 . As described above, the ring flange 42 can extend around the perimeter of a top portion of the upper ring 40 . The ring flange 42 can be a continuous flange extending around the edges of the upper ring 40 , or alternatively may be comprised of multiple tabs extending off of the edges. The tabs may follow contours of the perimeter, or may be formed to mate with corresponding structural elements to which the ring flange 42 is connected, such as the seat frame 22 L and the body 12 . The ring flange 42 can have flange apertures 48 through which the flange fasteners 44 are inserted to connect the upper ring 40 to the adjoining structural element(s) such as the seat frame 22 L and/or the body 12 . In embodiments featuring the ring flange 42 as separate tabs, the ring flange 42 can be configured to include flange apertures 48 on each tab, or otherwise on some but not all of the tabs.
[0045] The upper ring 40 can be configured to have a ring opening 46 extending through a bottom portion of the upper ring 40 . The ring opening 46 can be defined by sides of the upper ring 40 such that the ring opening 46 approximately follows a perimeter of a bottom portion of the upper ring 40 . The ring opening 46 can be polygonal, curved, or a combination and is formed to mate with a corresponding box opening 56 when the storage assembly 30 is
[0046] FIG. 5 is a side view of the upper ring 40 of the storage assembly 30 of FIG. 3 . The sides of the upper ring 40 can have base apertures 49 extending through lower portions thereof such that the base apertures 49 are spaced from the ring flange 42 . The base apertures 49 are configured for use with fasteners so as to connect the upper ring 40 to the lower box 50 during installation of the storage assembly 30 in the vehicle 10 . Each side of the upper ring 40 can have at least one base aperture 49 to overlap complementary apertures in an upper portion of the lower box 50 . In some configurations, some sides of the upper ring 40 may not include any apertures. Furthermore, some embodiments may not include apertures at all, instead having other attachment mechanisms such as clips or snaps.
[0047] V. Lower Box
[0048] FIG. 6 is a top view of the lower box 50 of the storage assembly 30 of FIG. 3 . As described above, the lower box 50 is approximately box-shaped having an interior space defined by exterior walls. The lower box 50 can have a top wall 52 having a box opening 54 therein, such that a bottom wall 56 is visible through the box opening 54 when viewed from above. The box opening 54 can be complementary to the ring opening 46 in the upper ring 40 . Therefore, upon connecting the upper ring 40 to the lower box 50 , the ring opening 46 and the box opening 54 are aligned to permit items to be passed therethrough for storing within the storage assembly 30 . The box opening 54 can have a lip 55 formed thereon, as well as box apertures 58 configured to extend through the lip 55 , as will be described below.
[0049] FIG. 7 is a side view of the lower box 50 of FIG. 3 . The present embodiment of the lower box 50 can include the lip 55 having box apertures 58 formed therein. The box apertures 58 can be configured to overlap with the corresponding base apertures 49 in the upper ring 40 , assembly fasteners being inserted thereafter to connect the upper ring 40 and the lower box 50 .
[0050] VI. Storage Assembly Installation
[0051] FIG. 8 is a partial perspective view of the seat assembly 10 of FIG. 2 shown with the side cover 24 removed, with the storage assembly 30 shown installed in the vehicle 10 .
[0052] In the present embodiment, the lower box 50 can be inserted into the under-seat cavity 26 once the side cover 24 has been removed. Specifically, the lower box 50 can be inserted laterally from a side of the body 12 adjacent the opening to the right side of the passenger area. The lower box 50 can be configured so as to have a complementary shape for insertion within the under-seat cavity 26 . Once inserted, the lower box 50 can be disposed so as to extend beyond the seat frame 22 L through which the upper ring 40 is inserted, as will be described below.
[0053] Before the upper ring 40 can be connected to the lower box 50 , the cushion 21 L must be lifted away from the seat frame 22 L. The cushion 21 L can be hinged open away from the seat frame 22 L, for example hinged along the back of the seat frame 22 L. However, the cushion 21 L can also be removed entirely from the seat frame 22 L by either unfastening the cushion 21 L or simply lifting the cushion off of the seat frame 22 L. Alternatively, the cushion 21 L can be slid away from the seat frame 22 L to reveal the under-seat cavity 26 .
[0054] With the cushion 21 L lifted away from the seat frame 22 L, the upper ring 40 can be dropped into the under-seat cavity 26 from above the seat frame 22 L. The upper ring 40 can be configured so that the ring flange 42 catches on the seat frame 22 L at attachment portions when the upper ring 40 is fully inserted into the under-seat cavity 26 . The flange apertures 48 of the ring flange 42 overlap corresponding apertures on an upper surface of the seat frame 22 L that contacts the ring flange 42 . Flange fasteners 44 can thereby in inserted through aligned apertures in the ring flange 42 and the seat frame 22 L to connect the upper ring 40 to the seat frame 22 L. Specifically, push pins can be used to connect the above-described structures. However, the ring flange 42 can be connected to the seat frame 22 L in any appropriate manner to secure the upper ring 40 to the seat assembly 20 L, such as but not limited to mechanical fasteners, welding, adhesive, any combination thereof, etc. When fully inserted, a lower portion of the upper ring 40 contacts and overlaps with an upper portion of the lower box 50 so as to form a connection, as will be described below.
[0055] While inserting the upper ring 40 through the seat frame 22 L and into the under-seat cavity 26 , the bottom portion of the upper ring 40 is overlapped with the upper portion of the lower box 50 that is disposed within the under-seat cavity 26 . Specifically, the lower portion of the upper ring 40 overlaps the lip 55 of the lower box 50 such that the upper ring 40 extends into or outside of the lip 55 . Base apertures 49 of the upper ring 40 are thereby aligned with the box apertures 56 in the lip 55 of the lower box 50 . Once aligned, assembly fasteners 58 can be inserted therethrough to connect the upper ring 40 to the lower box 50 . Presently, push pins can be used to connect the above-described structures. However, the upper ring 40 and the lower box 50 can be connected to each other in any appropriate manner, such as but not limited to mechanical fasteners, welding, adhesive, any combination thereof, etc. With fasteners connecting the lower box 50 and the upper ring 40 , as well as connecting the upper ring 40 to the seat assembly 20 L, the storage assembly 30 is effectively secured to the body 12 within the under-seat cavity 26 . The fastening of the above-described structures to one another can occur in any order and is not limited to the order in which it is described above. For instance, the upper ring 40 and the lower box 50 can be connected via fasteners prior to the upper ring 40 being fastened to the seat frame 22 L, etc.
[0056] Once the storage assembly 30 has been assembled within the under-seat cavity 26 and is attached to the seat frame 22 L, the cushion 21 L can be placed or hinged back onto the seat frame 22 L so as to form the seat assembly 20 L with the backrest 23 . The cushion 21 L may be disposed on the ring flange 42 of the upper ring 40 , or may alternatively rest on the flange fasteners 44 . Further, the cushion 21 L may contact the seat frame 22 L in embodiments featuring tabs included in the ring flange 42 , with spaces exposing the seat frame 22 L being present between tabs. The cushion 21 L can be attached to the seat assembly 20 L or be disposed within the seat assembly 20 L without being attached. Moving the cushion 21 L onto and away from the top opening of the under-seat cavity 26 through the seat frame 22 L permits access to the interior of the storage assembly 30 . Items can thereby be placed into and removed from the storage assembly 30 by moving the cushion 21 L.
[0057] The side cover 24 can also be attached to the body 12 and/or the seat frame 22 L of the vehicle by inserting fasteners through corresponding apertures such that the side cover 24 covers the under-seat cavity 26 and adjacent portions of the storage assembly 30 . With the side cover 24 secured to cover the under-seat cavity 26 , the storage assembly 30 is fully installed.
[0058] VII. Alternative Embodiments
[0059] While certain embodiments of the invention are described above, and FIGS. 1-8 disclose the best mode for practicing the various inventive aspects, it should be understood that the invention can be embodied and configured in many different ways without departing from the spirit and scope of the invention.
[0060] For example, embodiments are disclosed above in the context of the storage assembly 30 configured for installation underneath the driver-side seat assembly 20 L as shown in FIGS. 1-8 . However, embodiments are intended to include or otherwise cover storage assemblies installed within any seat assemblies and seat frames of the vehicle disclosed above, such as underneath a passenger-side seat assembly or underneath rear seat assemblies.
[0061] For example, exemplary embodiments are intended to include the upper ring 40 inserted through the top of the seat frame 22 L and connected to the lower box 50 . This configuration can have the upper ring 40 fastened to the seat frame 22 L, and the lower box 50 then fastened to the upper ring 40 . In another alternative embodiment, the lower box 50 can be fastened to the seat frame 22 L and/or the body 12 , while the upper ring 40 is then secured in place by virtue of its connection to the lower box 50 .
[0062] In fact, in some embodiments, the upper ring 40 and the lower box 50 may both be fastened to structural elements of the vehicle 10 such that they are not necessarily connected to one another, yet they still may be for added support.
[0063] All or some of the alternative structures disclosed above with regard to the upper ring 40 may also apply to the lower box 50 . The above alternative structures of the upper ring 40 and the lower box 50 are merely provided for exemplary purposes, and as indicated above, embodiments are intended to cover any type of storage assembly that is integrated within an exemplary vehicle, particularly a seat assembly, or otherwise configured as disclosed above.
[0064] As disclosed above, embodiments are intended to be used with any type of vehicle. The power source of the vehicle can be an internal combustion engine, an electric motor, or a hybrid of an internal combustion engine and an electric motor. The power source configured as an internal combustion engine or a hybrid power source can have the engine output axis oriented in the longitudinal direction or in the traverse direction of the vehicle. The engine can be mounted forward of the front axles, rearward of the rear axles, or intermediate the front and rear axles.
[0065] The vehicle can include any type of transmission, including an automatic transmission, a manual transmission, or a semi-automatic transmission. The transmission can include an input shaft, an output shaft, and a speed ratio assembly.
[0066] Embodiments are also intended to include or otherwise cover methods of using and methods of manufacturing any or all of the elements disclosed above. The methods of manufacturing include or otherwise cover processors and computer programs implemented by processors used to design various elements of the adjustable arm rest mechanism disclosed above.
[0067] While the subject matter has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention. All related art references discussed in the above Background section are hereby incorporated by reference in their entirety. | A storage assembly is usable with a vehicle seat assembly having a seat frame and a seat bottom. The storage assembly includes an upper ring configured for attachment to the seat frame. The upper ring facilitates travel through the opening of the seat frame, and defines a hollow interior with open upper and lower ends. A lower receptacle having an upper opening is configured for attachment to the upper ring, such that the upper opening is contiguous with the hollow interior of the upper ring. The lower receptacle includes an interior storage space that is defined by sides and a bottom, the lower receptacle being larger in size than the upper ring such that the lower receptacle is impeded from travel through the opening of the seat frame. The lower receptacle is configured to be insertable into the open space of the vehicle upon removal of the vehicle body panel. | 1 |
This is a continuation of application Ser. No. 06/535,041, filed Sept. 23, 1983, which is itself a continuation of application Ser. No. 337,592, filed Jan. 7, 1982.
This invention relates to moveable bulkheads for use in swimming pools and more particularly to a novel wheeled supporting system provided with means for removing the load of the bulkhead from the wheels when the bulkhead is in a stationary position.
BACKGROUND OF THE INVENTION
It is the present practice in the art to fabricate moveable bulkheads for swimming pools with supporting wheels mounted on the ends of the bulkhead with the wheels being positioned on tracks that extend along the length of the pool.
Prior art supporting wheels have rim portions formed of hard plastic and rubber materials due to the smooth, quiet operational characteristics of such wheels when operated on tracks formed by stainless steel portions of the gutter. With the advent of larger pools and longer and heavier bulkheads a problem has been present in that wheels having rim portions formed of hard plastic and rubber materials become deformed under the increased loadings and take an out-of-round "set" or configuration when they remain stationary under load for extended periods of time. As a result, the deformed wheels resist movement and are no longer smooth in operation. Another problem has been present in that the supporting wheels for such bulkheads inherently tend to bind, causing canting and jamming that arrest movement when the bulkhead is being repositioned.
SUMMARY OF THE INVENTION
In general, the present invention uses novel supporting carriages for mounting the bulkhead on its tracks, which carriages include jacking means for selectively raising and lowering the above mentioned supporting wheels between upper unloaded positions wherein the wheels are clear of their track, and a lower loaded position wherein the wheels engage their track and thereby moveably support the bulkhead.
It is another object of the present invention to provide a swimming pool bulkhead that comprises novel supporting carriages that include bearing plates which can be selectively moved into load supporting positions on the tracks wherein the load of the bulkhead is distributed over relatively large load supporting areas of the tracks.
It is another object of the present invention to provide a swimming pool bulkhead that includes load distributing bearing plates for selective engagement with the tracks and adjustable jacking means for distributing the load along the linear length of the bearing plates.
It is another object of the present invention to provide a swimming pool bulkhead that comprises novel supporting carriages provided with selectively positionable load supporting bearing plates, and adjustable mounting means for accurately aligning the supporting carriages and bearing plates with respect to their tracks.
It is still another object of the present invention to provide a swimming pool bulkhead that includes supporting wheels for movement of the bulkhead along its tracks, and supporting carriages for selectively relieving said wheels from their load, said bulkhead being uniquely adapted to shift laterally with respect to its supporting wheels and tracks when the bulkhead is being moved, thereby preventing binding at said wheels. Hence, canting of the bulkhead is prevented or relieved, with the result that the bulkhead can be readily moved and repositioned without jamming.
Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein a preferred form of embodiments of the invention is clearly shown.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view showing a typical swimming pool with a bulkhead of the present invention installed therein;
FIG. 2 is a top elevational view showing the frame structure of a bulkhead constructed in accordance with the present invention;
FIG. 3 is a side elevational view corresponding to FIG. 2;
FIG. 4 is a side elevational view of a supporting carriage comprising a portion of the bulkhead of the present invention;
FIG. 5 is a partial end sectional view showing the carriage of FIG. 4 mounted on an end plate of the bulkhead of the present invention;
FIG. 6 is a partial side elevational view showing a modified carriage that comprises a modified embodiment of the present invention; and
FIG. 7 is an end sectional view showing the modified carriage of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in detail to the drawings, FIG. 1 illustrates a typical swimming pool, indicated generally at 20, which includes a stainless steel gutter construction, indicated generally at 22.
A bulkhead constructed in accordance with the present invention is indicated generally at 24 and is moveably mounted on tracks formed by gutter construction 22 and functions to divide the pool into various selected activity areas.
With reference to FIGS. 1-3, bulkhead 24 includes a frame constructed as a truss including longitudinal frame members 28 and 30, transverse frame members 34, 36, 40 and 42. As seen in FIG. 1, the truss frame is covered with side walls 44 and a top walkway 46, and includes one or more air compartments 32 to provide flotation support for the structure.
As seen in FIGS. 2 and 3, each end of bulkhead 24 is moveably supported by a supporting carriage, with the locations of these carriages being indicated generally at 50 in FIGS. 2 and 3. Each carriage includes a removable protective cover 51.
Reference is next made to FIGS. 4 and 5, which illustrate in detail the structural components of the supporting carriages 50.
Each supporting carriage 50 functions as a jacking means for relieving two supporting wheels 70 and 72 from the weight of bulkhead 24, when the bulkhead is in a stationary position. The carriage 50 also includes a bearing plate 58 that functions to distribute the load of the bulkhead over a relatively large area of a track 80, thereby greatly decreasing the unit loading on the track. In addition, carriage 50 serves to anchor the bulkhead in various selected positions and includes mounting means for effecting alignment of the carriage with its respective track.
As seen in FIGS. 4 and 5, each carriage 50 includes a carriage frame 52 that includes a side plate 54, bottom plate 56, and spaced reinforcing gussets 68. The frame 52 is mounted on an end plate 26 of the bulkhead by four bolts 122 which extend through vertical slots 120 in side plate 54 and into threaded engagement with a respective threaded hole 124. It will now be understood that each end of carriage frame 52 can be vertically adjusted independently, thereby permitting alignment of carriage frame 52 with its respective track.
It should be mentioned that two axles 74 and 76 are mounted on each end of the bulkhead by extending each axle through holes in end plate 26 and axle mounting plate 75, which plates comprise part of the bulkhead frame structure. Since axles 74 and 76 extend through side plate 50 of carriage 50, the vertical slots 116 are provided in side plate 54 to permit the above mentioned vertical adjustment thereof.
With reference to FIGS. 4 and 5, bearing plate 58 is mounted under bottom plate 56 by two threaded guide pins 102 and 103 which have their bases welded to the top of bearing plate 58 and which extend freely through holes 108 in bottom plate 56. Each guide pin 102 and 103 includes a compression spring 106 and retainer nut 104 which serve to bias bearing plate 58 upwardly and clear of track 80.
With continued reference to FIGS. 4 and 5, each carriage 50 includes jacking means for lifting the carriage frame 54 and wheels 70 and 72 to upper positions wherein the wheels are clear of track 80 and wherein the bearing plates 58 engage track 80 and support the weight of the bulkhead. Such jacking means comprises two bolts 91 and 93 which are located at respective ends of carriage frame 54, with each bolt being in threaded engagement with a nut 94 welded to bottom plate 56. The tip 98 of each bolt extends freely through a hole in bottom plate 56 and into rotatable engagement with the bottom of a bearing recess 100.
It should be mentioned that wheel clearance openings 60 and 62 are provided in bottom plate 56 and bearing plate 58, respectively, so as to permit engagement of wheels 70 and 72 with tracks 80.
As is best seen in FIGS. 4 and 5, the carriage means 50 is locked in selected positions along track 80 by means of a tie-down bolt 112 that extends freely through slots 114 and 115 in base plate 56 and bearing plate 58, respectively.
It should be mentioned that the spacing of tracks 80 will, as a practical matter, vary due to errors in fabrication and erection.
Another problem is present when the bulkhead is being repositioned in that, if one side of the bulkhead is moved more than the other, then the guide plates 92, at diagonally opposite corners of the bulkhead, will be biased against the sides of their respective tracks 80. This causes binding of such diagonally opposite wheels, which will arrest movement of the bulkhead.
It should also be mentioned that wheels 70 and 72 include central hub or bearing portions 128 formed of suitable bearing material and resilient rim portions or tires 130 formed of rubber, plastic or the like. Each wheel may also be provided with a fixed circular guide plate 92 mounted on the side of the rim portion and extended to engage the side of track 80. Also, each wheel is mounted freely on necked axle portion 86, so as to be laterally shiftable with respect to a shoulder 87 that is spaced from the side of bearing portion 128 to provide clearance 90 for self aligning movement of the wheel when the bulkhead is being moved and when the guide plate 92 encounters a misaligned portion of track 80.
Since each wheel is free to move laterally along necked axle portion 86, due to clearance 90 between shoulder 87 and the side of the wheel, it will be understood that each wheel can adjust laterally for variations in alignment of their tracks 80 and thereby avoid binding engagement when the bulkhead is being moved.
Clearance 90 between wheels 70-72 and their respective shoulders 87 serves an additional function in that such clearance 90 permits lateral shifting of the entire bulkhead 24 with respect to wheels 70-72 when the wheels are frictionally engaging the tracks 80. This feature eliminates the above mentioned canting problem which occurs when the bulkhead is being repositioned and one side of the bulkhead is moved more than the other side, as discussed above.
It should also be mentioned that clearance 90 for lateral shifting of the wheels and bulkhead can be varied by repositioning nut 73 with respect to shoulder 87.
Hence it will be understood that clearance 90 can be established by adjusting nut 73 to provide sufficient lateral movement of wheels 70 and 72 to accommodate the maximum and minimum track spacing that will encounter the particular track installation.
Reference is next made to FIGS. 6 and 7 which illustrate a modified carriage means 50-A that differs from the carriage means 50 of FIGS. 4 and 5 in that front and rear guide rollers 160 and 162 are respectively mounted on opposite ends of modified carriage means 50-A. One of these guide rollers 160 is shown in the partial side view of FIG. 6 with the other guide roller 162 being of identical construction and mounted on the opposite end of the carriage.
It should be pointed out that guide rollers 160 and 162 function as guide means for maintaining wheels 70-A and 72-A on their respective tracks 80, whereby the fixed circular guide plates 92 mounted on wheels 70 and 72 of the embodiment of FIGS. 4 and 5 are not required in the modified embodiment of FIGS. 6 and 7.
Referring in detail to FIGS. 6 and 7, each of the guide rollers 160 and 162 is mounted on a respective end of a modified carriage bottom plate 56-A which includes roller mounting slots 163 formed through end extensions 150 on bottom plate 56-A. Each guide roller 160-162 is rotatably mounted on a threaded shaft 152 that is secured in hole 163 by mounting nuts 154 and 156.
The modified embodiment of FIGS. 6 and 7 includes various identical structural components previously described above in the description of the embodiment of FIGS. 4 and 5, with such identical components being marked with identical numerals.
In operation of the embodiment of FIGS. 6 and 7, it should be mentioned that the guide means provided by guide rollers 160 and 162 functions to prevent canting of the bulkhead during movement thereof. Such guide means also cooperate with the clearance spaces 90 provided at wheels 70-A and 72-A. Such clearance space 90 permits lateral shifting movement of bulkhead 24 with respect to wheels 70-A and 72-A, thereby precluding binding of wheel rotation. As a result, canting of bulkhead 24 is usually prevented from starting, and in instances where the canting tendency has started, it is relieved as movement of bulkhead 24 progresses. As a result, binding against rotation of the wheels is eliminated. | A bulkhead for use in a swimming pool that is moveable to selected positions along the length of the pool to divide the pool into various activity areas. The bulkhead includes supporting wheels mounted on tracks and is further characterized by jacking means for unloading the supporting wheels when the bulkhead is stationary. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to heat-curable resinous compositions preferably containing microparticles, such as small glass microspheres and other light-enhancing particles, for forming soft, abrasion-resistant, light-refractive and/or light-reflective coatings on substrates such as garment fabrics, automobile headliner fabrics and other fabric substrates on which light-reflective or light-refractive abrasive-resistant surface coatings are desirable to enhance the appearance and to impart high-visibility for safety, aesthetic and other purposes.
[0002] 1. Field of the Invention
[0003] The inclusion of microspheres, both clear and metallized, in heat-curable resinous coating compositions is well known in the art, including automotive paint compositions and screen printing ink compositions for fabrics.
[0004] 2. State of the Art
[0005] Reference is made to commonly-owned U.S. Pat. No. 6,242,056 (Spencer et al.) which discloses aesthetic, light-refracting resinous microsphere coating compositions. Water-based compositions based upon water-soluble, curable resinous binder materials such as acrylic ester resins or polyurethane polyester resins are disclosed. Reference is also made to U.S. Pat. No. 5,650,213 (Rizika et al.) for its disclosure of aesthetic, retroreflective screen printing inks containing microspheres for the decorative printing of fabrics such as garments, without interfering with flexibility, crock or launderability. The use of water is disclosed as a volatile vehicle or dispersant for the resinous non-volatile matrix material which may include an acrylic copolymer.
[0006] Reference is also made to U.S. Pat. No. 4,263,345 (Bingham) which discloses coating compositions for making fabrics brightly retroreflective at nighttime, comprising aqueous compositions including acrylic-based polymers, or polyurethanes, and up to about 34% by volume of the solids content of transparent glass microspheres having an average diameter less than 100 microns, i.e., between 21 and 63 microns. The coating compositions are applied to tightly-woven nylon oxford fabric as thin layers providing low densities of microspheres, and heat cured to form a continuous layer of binder material with microspheres distributed over the surface of the fabric. The coated fabric is said to handle and feel about the same as it did before coating, i.e., supple and flexible.
[0007] However, an unattractive fabric “hand” results because the glass content is large relative to the amount of binder present. For example, the ratio of glass to binder can be as high as 4 to 1. The glass spheres present can be either clear or can be hemispherically coated with aluminum. Two problems that result with low bead content are poor aesthetics and poor reflective characteristics. A problem that results with high bead content is that there may be a lack of softness as well as abrasion resistant due to the low binder present. The invention solves these problems.
SUMMARY OF THE INVENTION
[0008] The present invention is based upon the discovery of novel curable polymeric binder materials for providing exceptionally soft, flexible coatings for fabrics, which preferably contain large volumes of glass microspheres and which bind such microspheres in and on the fabric against removal under the effects of strong abrasion. The present curable polymeric binder materials comprise a) mixtures of water-soluble acrylic acid ester polymers, including copolymers, and up to about 20% by weight of urethane polymers, or b) acrylic polyurethane polymers formed by reacting polyacrylic alcohols such as diols with aliphatic polyisocyanates.
[0009] The present invention relates to improved curable fabric-coating compositions containing glass microspheres, preferably glass spheres having an average diameter up to about 20 microns, and cross-linkable resinous binder materials. This invention also relates to methods for producing curable coating compositions which contain high loads of glass microsphere particles that are more tightly bonded within the composition, resulting in compositions having improved bonding properties for substrates.
[0010] The present invention is concerned with both improving the adhesion and the abrasion resistant properties of the coating and films formed that are applied over textiles. It is understood that such improvements also improve the coated or printed underlying text by giving a protective abrasion resistant coating or film on the surface of the textile. The incorporation of glass microspheres is for two purposes. Hemispherically aluminum-coated or silver-coated glass spheres will give retroreflection of light. The use of clear glass spheres promotes light transmission through the coating, thus enhancing the resulting aesthetic effects. The composition of said film includes micro particles such as the mentioned glass spheres, glass flakes, mica and similar pigment as well as color enhancing materials within the fabric coating composition. The invention improves the abrasion resistant properties of the fabric. High loads of glass spheres, up to 400% of the weight of the polymeric binder are possible, and yet the softness and flexibility are not sacrificed. The beneficial properties of aluminized as well as the clear glass spheres can thus be optimized without sacrificing tactile properties. Automotive as well as safety apparel fabrics are two of the many applications.
DETAILED DESCRIPTION
[0011] Example 1 illustrates the preparation of a suitable water-soluble acrylic acid ester/acrylic acid co-polymer for use according to the present invention in association with a water-soluble polyester polyurethane or a water-soluble polyether polyurethane to provide a polymeric binder material capable of binding a large load of small glass microspheres, greater than 50% by weight and up to 400% by weight of the binder material in a polymeric coating in which the microspheres are so tightly bound that they resist being removed under the effects of strong abrasion.
EXAMPLE 1
[0012] [0012] Monomer moles Methylmethacrylate 10 Butyl methacrylate 10 Acrylic acid 2 Catalyst polymer initiator 1 (Isopropylpercarbonate or benzyl peroxide) Phosphate emulsifier surfactant 2% Water 60%
[0013] The above composition is subjected to conventional emulsion polymerization conditions to produce a water-soluble MMA/BMA/AA copolymer which, even with a suitable crosslinking agent such as aziridine or a polycarbodiimide, by itself, is not capable of sustaining a large load of micro size glass, over 50% and up to 300% by weight of the binder material, and provide abrasion resistance.
[0014] The use of a soft acrylic polymer coating with a suitable crosslinking agent (polycarbodiimide) provides softness as well as optical clarity. An acrylic polymer based on methyl methacrylate monomer with a small amount of acrylic acid gives the clarity as well as the softness required. Increased softness is provided by replacing the methyl ester group with larger alkyl groups such as propyl and butyl groups. A blend then of the following acrylic monomers, methyl methacrylate, butyl methacrylate and propyl methacrylate, with 5 to 10% acrylic acid, provides a water soluble acrylic ester polymer having suitable properties of softness and optical clarity. The monomers are polymerized in situ (in water) using a peroxide initiator such as benzoic peroxide. Isopropyl percarbonate is another peroxide used where optical clarity is desired.
[0015] The acrylic polymer alone, even with a suitable crosslinking agent such as aziridine, a polycarbodiimide, polyisocyanate or melamine is not capable of sustaining a large load of micro size glass, over 50% by weight, and maintaining integrity after abrasion and repeated washing of the resulting fabric such that the beads will not fall out and that the coating or print will have abrasion resistance.
[0016] The abrasion resistance is achieved by the addition, to the acrylic polymer, of a water-soluble polyurethane polymer in small amounts not to exceed 20% by weight. The polyurethane polymer has to be chosen to give compatibility to the acrylic polymer as well as be optically transmissive. Polyurethanes are based on preexisting polymers such as polyesters and polyethers. They also are based on either aromatic or aliphatic isocyanates. For the application of optically transmitting polymers however aliphatic isocyanates are preferred as they do not yellow as the aromatic variety do.
[0017] For polyester-based polyurethane components, the reaction products of aliphatic diols and saturated dibasic acids give enhanced optical clarity such as the choice of tetra phthalic and iso phthalic acid as well as hexahydro phthalic and iso phthalic acids. The diols of butane and hexane are preferred.
[0018] The preferred polyether polurethanes are the water soluble reaction products of aliphatic polyethers such as polypropylene ether and polytetramethylene ether with polyisocyanates such as aromatic diisocyanates or, preferably, aliphatic diisocyanates such as isophorone diisocyanate, which are clearer in color than the yellowish aromatic type.
[0019] The present polyurethane polymer compositions also preferably contain dimethyl propionic acid (DMPA) which serves two important functions. First, it provides water solubility in association with a tertiary amine such as triethyl amine (TFE). Secondly, the pendant carboxyl group reacts with the curing agents to facilitate the curing mechanism, binding the polymer(s) and encapsulating the glass beads in a tight matrix.
[0020] The following Example 2 illustrates the preparation of a preferred polyether polyurethane for use in an amount up to 20% by weight, based upon the total weight of the binder material of the present compositions, i.e., in combination with at least 80% by weight of the water-soluble acrylic polymer.
EXAMPLE 2
2 Polyether-Based Polyurethane
[0021] [0021] Material Parts by Wt. Mol. Wt. Moles Equivalents ratio Polytetra 100 2000 .05 1 1.0 methylene ether Isophorone 25.25 202 .125 .25 2.5 Diisocyanate Dimethyol 3.7 148 .025 .05 .5 Propionic Acid (DMPA) Isophorone 6.57 146 .045 .09 .9 Diiamine Triethylamine 2.52 101 .025 .025 .25 (TEA)
[0022] The polyurethane in Example 2 is technically a polyurea since diamines are used to chain-extend the urethane prepolymer (react with the diisocyanates). The DMPA allows the urethane to go into water solution. Amines are preferred to react with aliphatic diisocyanates in commercial applications as they give good film tensile properties whereas the use of diols, typical in aromatic urethane usage, would not.
[0023] Isophorone diamine is used as the chain extension agent since an aliphatic diisocyanate(s) must be used when diamines are used as the chain extending agents.
[0024] Polyethers such as polytetramethylene oxide are used because they will not hydrolyze or break down in the presence of water or moisture. This increases the washability compared to polyester-based polyurethanes. Also they are resistant to fungus and mildew.
[0025] As discussed above, the formed aqueous polyurethane comprises a polyurea formed by the reaction of the diamine, which functions as a chain extending agent, with the isophorone diisocyanate(s). The dimethylol propionic acid assists in the curing or crosslinking of the polyurethane by reaction with pendant carboxyl groups.
[0026] Examples 3, 4 and 5 illustrate a composition comprising a mixture of the acrylic copolymer binder material of Example 1 and the polyether and polyester polyurethanes of Example 2 and a large content of glass microspheres having an average diameter between about 10-18μ, together with a polycarbodiimide curing agent.
EXAMPLE 3
[0027] [0027] Material dry Weight Acrylic formula 1 100 Polyurethane Formula 2 10 to 20 Glass Microspheres 100 to 200 (10μ average size) Polycarbodiimide 20 to 40
[0028] [0028] Example 4 Ratio dry Materials Wet weight Dry weight wt. Trade name Acrylic resin 6.08 .4864 1.0 LF412 Ailphatic .3476 .121 .248 Ru40-512 urethane Aluminized 1.46 3.00 P2453BTA glass beads Clear glass .36 .740 P2415BT beads (10μ size) Ionic .30 .075 .154 LF411 thickening agent Carbodiimide .06 .30 .616 XR 5570 curing agent* *replaces .3 .30 .616 XR 2500 aziridine
[0029] The above formula provides a very soft hand. The addition of up to 20 percent urethane provides the abrasion resistance. The limits of the urethane that are effective for abrasion resistance can be as low as 12.5% of the weight of the acrylic where exceptional softness, “hand” is desired. This is the case for headliner fabrics.
[0030] In the case of purely aesthetic coatings, where retroreflectivity is not an objective, the aluminized glass is replaced with the clear Barium titanate glass and soda glass. A formula is given below:
EXAMPLE 5 Wet Dry Trade Materials weight weight Ratio name 1. acrylic resin 6.08 .4864 1.0 LF412 2. aliphatic .1738 .0605 .124 RU40-512 urethane 3. Barium 1.0 2.05 P2415BT titanite glass spheres (10 to 18 micron average) 4. soda glass 1.0 2.05 P2015SL spheres micron 5. ionic .3 .075 .154 LF411 thickener 6. carbodiimide .6 .30 .616 XR 5290 curing agent
[0031] The amount and ratios of P2415BT to P2015SL glass used depends on gloss levels and color matching desired. The P2015SL glass shifts the color to a darker hue in the light spectrum.
[0032] The ratios of glass are important factors in achieving certain colors and three dimensional effects. The present invention is more concerned with the resin binder materials than the glass. However, the use of glass makes the entire composition work for the transmission of light, the effect of color matching, and softness with abrasion resistance. The use of clear glass with two different refractive indexes gives a three dimensional depth to the coating.
[0033] It is very unusual to have such a high glass load and not stiffen the coated substrate. The use of the acrylic resin gives the exceptional softness.
[0034] The usual acrylic resin is made from methyl acrolein (acrylic aldehyde) and some acrylic acid, polymerized in an emulsion using peroxide free radicals. The small amount of acrylic acid provides water solubility.
[0035] An alternative binder material to the mixture of the water-soluble acrylic acid ester polymer and the water soluble polyether polyurethane or polyester polyurethane polymeric binder material is a water soluble acrylic diol polyurethane polymer, which also has been found to be capable of strongly bonding large amounts of glass microbeads in fabric coatings, and providing abrasion-resistance while leaving the fabric as soft and pliable as it was before coating and yet imparting beautiful light-refracting and color-enhancing properties to fabrics useful in the garment, upholstery, window-dressing and automotive fields. The acrylic diol aliphatic diisocyanate based polymers provide enhanced optical and physical properties. The ratios of acrylic diol can be adjusted to give high optical transmission. The use of diisocyanate in different ratios (stoichiometry) controls the softness and hardness of the polymer used to carry the glass microspheres. Such coatings provide enhanced optical properties, as an alternative to a mixture of an acrylic polymer and a polyurethane polymer. Dimethylol propionic acid (DMPA) is included in small amounts to improve water solubility, and as a curing and crosslinking agent which reacts with pendant carboxyl groups of the acrylic polyurethane polymer. Additional crosslinking agents such as aziridines, polycarbodiimides and water-soluble aliphatic diisocyanates can also be used.
[0036] The following Examples 6 and 7 illustrate the preparation of water-soluble polyacrylic diol polyurethane polymer binder materials for use according to the present invention.
Material Parts by Wt. Mol. Wt. Moles Equivalents ratio Polyacrylic 100 2000 .05 .01 1.0 diol Isophorone 25.25 202 .125 .25 2.5 Diisocyanate Dimethylol 3.7 148 .025 .05 .5 Propionic Acid (DMPA) Isophorone 6.57 146 .045 .09 .9 Diiamine TEA 2.52 101 .025 .025 .25
[0037] The composition of Example 6 above produces a soft coating. Increasing the weight of the polyol will require less of the diisocyanate. This decreases the stiffness or the modulus of the polymer as opposed to lower molecular weight materials. Another technique is to vary the ratio of the isocyanate to the hydroxyl groups. This however means the amount of chain extender to be used, whether diol or amine, will vary. It is easier to vary the molecular weight of the polyacrylic diol, whereby a harder coating is produced to provide an increase of abrasion resistance.
EXAMPLE 7
[0038] [0038] Material Parts by Wt. Mol. Wt. Moles Equivalents ratio Polyacrylic 100 1000 .1 .2 1.0 diol Isophorane 40.4 202 .2 .4 2.0 Diisocyanate (IPDI) Dimethyol 2.96 148 .02 04 .2 Propionic Acid (DMPA) Isophorone 10.95 146 .075 .15 .75 Diamine TEA 7.57 101 .075 .075 .375
[0039] By adjusting the molar ratio of isocyanate to the molar ratio of the hydroxyl present on the acrylic polymer it is seen that the hardness can be either increased or decreased. This is accomplished by going from a 2000 molecular weight polyether to a 1000 molecular weight polyether as seen in the difference in formula between Examples 7 and 8. The ratio of isocyanate to polyol increases as the molecular weight of the polyol decreases. In Example 7, the ratio was changed from 2.5 to 2.0 since the use of 2.5 with a 1000 MW/polyol would result in too hard a polymer.
[0040] Thus, adjustment of the molecular weight of polyol and changing the ratios of polyol to isocyanate result in a useful technique to control hardness.
[0041] This is a better method than using mixtures of the polyurethane and the acrylic in Examples 4 and 5 above.
[0042] Isophorone diisocyanate is used as an aliphatic diisocyanate since it is easy to work with and not overly toxic.
[0043] Other commercial diisocyanates that are aliphatic are (4,4, bis cyclohexyl methylene diisocyanate) by Dow Chemical Co., and TDX by Allied Chemical.
[0044] The following Example 8 illustrates the polyacrylic polyurethane composition of Example 7 used as a polymeric binder material for a large content of glass microbeads to provide an aesthetic coating composition for soft pliable fabrics such as nylon, while retaining the softness and pliability of the fabric.
EXAMPLE 8
[0045] [0045] Wet Ratio dry Material Weight Dry weight weights PAU resin* 100 35 1.0 Barium — 35 1.0 titanate Glass spheres Clear 18μ) Soda glass — 35 1.0 spheres Polycarbodiimide 21.00 10.5 0.3
[0046] The aqueous coating is coated or printed onto the surface of a soft, pliable fabric such as a thin nylon or cotton/polyester blend fabric and heated to cure the polymer binder material and evaporate the water vehicle to form a thin abrasion-resistant aesthetic surface layer which is light-refractive.
[0047] The coating includes two types of glass beads. One is clear and the other is aluminized for retroreflectance.
[0048] The addition of mixtures of clear glass microspheres of the same or different refractive indexes, within the range of about 1.7 and 2.5, more preferably between about 1.9 and 2.1, in various ratios refracts the light throughout the coating. The sum of the many refractions is in effect a transmission of light throughout the coating. The intensity of the color is increased. This results in a darker shade or hue. The word magnifying has been used for this effect. When other colored additives such as mica, pigments and dyes are used, the colors are refracted and mixed. The refracted light leaves the coating at the surface, exiting at all angles between 0 and 180 degrees when viewed. This omnidirectional view allows the same color intensity when viewed from any direction.
[0049] In summary, the use of glass microspheres in fabric coatings or prints dramatically improves the aesthetic look and the attractiveness of fabrics, while preserving the softness and feel. The application of a coating containing glass microspheres to automobile headliner fabric dramatically improves the visual aspects by reflecting and transmitting light.
[0050] In prior known coating systems, the high load or content of glass microbeads that is required to achieve these effects make the underlying fabric stiff and rigid. Stiffness is an unsatisfactory characteristics in automotive, as well as apparel, fabrics.
[0051] The present invention employs a water based acrylic ester or acrylic urethane polymer as the main resin component or binder of the glass beads. The acrylic is used because its light transmission of 99% does not interfere with the light transmission of the glass beads. The aesthetic properties are thus preserved by using the acrylic polymer.
[0052] The acrylic ester polymer by itself, however, is not strong enough to hold the up to 400% weight load of glass. The 400% represents a 4 to 1 ratio of the glass to acrylic polymer. The addition of up to 20 percent of a water based polyurethane that has carboxyl groups attached to it allows a very tough polymer to be formed but one, with the acrylic, that does not increase the stiffness of the fabric such coating is applied to. The use of the aliphatic urethane gives the highest transmission of light, about 90 percent compared to the much lower value, 75% provided by other, aromatic based polyurethanes. The reflectivity does not work well with aromatic based polyurethanes. Aromatic urethane use requires much higher loads of clear or aluminized glass to approach effects provided by aliphatic polyurethanes.
[0053] The inclusion of curatives that react with the carboxyl groups on both the acrylic and polyurethane allows a tough but soft film to be formed. There are four main crosslinking agents. Aziridine and carbodiimide react primarily with the pendant carboxyl groups. Melamine resins react with any active hydrogen whether carboxyl, urea, or urethane hydrogen. The diisocyanates will also react with the same active hydrogen as the melamines. In the case of melamine resins an acidic catalyst is used such as para toluene sulphonic acid. This acid is typically buffered with a tertiary amine that is volatile at processing temperatures present in the drying ovens. Once the amine volatizes, the catalyst becomes active and causes the melamine to react. A disadvantage of the melamine aldehyde resins is the release of formaldehyde which has a threshold of 1 part per million in the work place. Recent regulations and concerns about formaldehyde curtail the use of these melamine resins.
[0054] Polycarbodiimide has replaced the aziridines where the conditions are not available to incinerate the fumes or to handle such a reactive crosslinker as the aziridines.
[0055] A fourth novel crosslinker is an aliphatic polyisocyanate such as the adduct of dimethylol propionic acid (DMPA) and isophorone diisocyanate (IPDI). When emulsified and added to water, the material has a long shelf life since the aliphatic isocyanate is resistant to reacting with the water. Ordinary aromatic diisocyanates will react immediately with water. This material, the DMPA adduct, is also relatively non toxic, being dispersed in water. Use of this crosslinker with the water based polyurethane and poly acrylic resins gives the advantage of an environmentally safe as well as a non toxic coating.
[0056] The adduct of dimethylol propionic acid and isophorone diisocyanate is used because the carboxyl group present can be ionized by addition of an amine and thus the adduct is water soluble. The slowness of reacting with water of the aliphatic isocyanate present allows suitable pot life once the said curative is added to the glass and particular resin chosen. The curative is environmentally friendly.
[0057] An additional technique is to add a tertiary amine such as polycat 41 from Air Products. This technique is used in rigid urethane foams to produce cyanurate or trimerization of the free isocyanate. However the trimerization of isocyanate produces a matrix with a high crosslink density that further entraps or holds large weights of glass beads present in the composition.
[0058] The use of the coating systems thus described provides abrasion resistance to the coated fabric. This phenomenon of a high load of glass and soft coating providing abrasion resistance is unexpected. This feature, providing softness and abrasion resistance at the same time is unique.
[0059] The following example 9 shows a formulation using the trimerization catalyst as well as the DMPA/IPDI adduct.
EXAMPLE 9
[0060] [0060] Material Wet Weight Dry weight Ratio dry weight PAU resin* 100 35 1.0 Barium 35 1.0 Titanate Glass spheres Soda glass 35 1.0 Spheres DMPA/IPDI 42 21 .6 Polycat 41 .1 to .2 .1 to .2 .003 to .006
[0061] Also one can use Desmodur W (Dow Chemical) and TDX (Allied Chemical) as aliphatic diisocyanates in place of IDPI to react with DMPA. The following formula illustrates preparing the IPDI/DMPA adduct.
EXAMPLE 10
Formula for DMPA/IPDI Adduct
[0062] [0062] Material Wt. M. Wt. Moles Equivalents Ratio equivalents DMPA 35.59 148 .24 .481 1.0 IPDI 100 208 .481 .962 2.0 TEA 48.58 101 .481 .481 1.0
[0063] The two to one isocyanate to hydroxyl ratio allows the free isocyanate to be available to react with the coating system as well as be available to be trimerized by a tertiary amine catalyst. The Triethyl Amine (TEA) ionizes the carboxyl group thus allowing the adduct to be water soluble.
[0064] It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. | An aqueous polymeric composition for applying prints or coatings to soft, pliable fabrics and curing them to produce aesthetic prints or coatings which are resistant to removal by abrasion and which also maintain the softness and pliability of the fabric. The present composition comprises a curable water-soluble polymer binder material(s) comprising acrylic ester groups and urethane groups, preferably a plurality of glass microspheres in a weight equal to at least 50% by weight of the polymeric binder materials(s), and a water soluble curing agent. The composition forms an insoluble, abrasion-resistant light-reflective and/or light-refractive print, or coating on the fabric upon evaporation of water and curing of the polymeric binder materials. | 3 |
BACKGROUND OF THE INVENTION
Powdered laundry detergents have typically been provided in cartons fabricated from paperboard. While cartons have many acceptable properties, difficulties have sometimes been encountered in pouring product therefrom. Cartons have often been provided with die cut perforations in the paperboard along which the consumer makes an opening in the carton. Frequently, however, consumers find it difficult to rupture the perforations so as to open the carton. Moreover, once an opening in the carton has been made it is often difficult to control the product during pouring due to the irregular shape of the pouring aperture created by the consumer. Furthermore, openings formed in the paperboard are usually not reclosable. As a result, a tendency exists for the product to spill undesirably from the carton if tipped, and especially during transport. Moreover, products which are sensitive to moisture pick-up tend to cake because of the exposed opening.
Recently, attempts have been made to solve the aforementioned problems through the use of plastic fitments. Plastic fitments have been proposed which can be adhesively attached to the carton. It is generally desirable for detergent manufacturers that the fitment be affixed during or prior to the period when the paperboard carton is in a flat, tubular form prior to erection of the carton. However, according to Gunn U.S. Pat. No. 4,732,315, when a thin, plastic fitment is affixed to the carton in its flat, tubular form problems may arise during stacking of the tubes due to an imbalance in the otherwise flat cartons caused by the extra thickness of the fitment. Gunn discloses a plastic closure device having an aperture configured in a pentagonal, "home plate" shape said to have rounded corners, which is balanced by means integral with the carton. For instance, the means may comprise score lines which are thickened to offset the extra thickness of the fitment.
Previous attempts at developing carton closures have included use of thin folded strips of material. For example, Vincent U.S. Pat. No. 2,007,553 is directed to a device which may be used with collapsible container blanks to permit their shipment in collapsed form when empty and which is adapted to form in the erected carton a closure in the closed position and a pouring spout in the open position. The carton has a wall severed to form an angular opening, such as a triangular opening, and is fitted with a spout-forming closure blank hinged to the wall of the carton, preferably by a flap formed during the severance. The closure blank is formed of relatively stiff material such as that from which the carton is formed and comprises a cover position and a wing position separated by a fold line preferably made by scoring. Preferably, the cover and wing positions are generally in the shape of a sector of a circle. A slot in the carton wall receives the upper edge of the wing portion. When the closure is in the closed position, a sticker may be posted over the closure to ensure a tight seal. When discharge of the contents of the carton is desired, the sticker or seal is broken and the closure is swung outward to form a trough-shaped spout.
Dietz et al. U.S. Pat. No. 3,565,300 discloses a carton which includes a V-shaped retractable pouring spout. The spout comprises a spout blank which has two positions separated by a fold line. The carton includes an aperture and a flap which is connected to the carton along one of its borders and which is formed in the course of making the aperture. One of the portions of the spout blank includes prongs which attach to the flap so that in the open position one portion of the spout blank rests on the flap. The other portion of the spout slides along one of the sides of the aperture as the spout is brought from the open to the closed position and is provided with a stop to limit the spout's outward movement and lugs at each end for retaining the spout in the open and closed positions. The Dietz et al. spout blank can be formed of materials such as rigid or semi-rigid aluminum as well as plastic or paperboard.
Harrington U.S. Pat. No. 1,464,073 discloses a salt-pouring spout. The spout blank comprises two spout-forming sections separated by a score line, x, and a securing tab or tongue which is to be glued to the inner face of the cap. A stop lug is provided to prevent the spout from swinging out too far.
Read U.S. Pat. No. 2,735,605 discloses a carton having a pouring spout. A triangular-shaped opening having a flap attached by one side is provided. A blank, which may be secured to the inner wall of the carton, is integral with a sector-shaped section which is glued to the inner surface of the cut out flap. A fold line separates the section from another substantially sector-shaped section. The spout is opened by pulling outwardly a tab on the flap. The flap and the sector-shaped panels of the blank move outwardly. The upper edge of the second sector-shaped section is received within a notch and the gradual frictional resistance between the upper edge of the section and the bottom of the notch as the pouring spout moves to its fully extended position tends to hold the spout in its outward position.
Arneson U.S. Pat. No. 3,989,171 discloses in FIGS. 9 through 12 a V-shaped spout which emerges from a triangular opening in a carton. As seen in FIG. 11, the spout blank includes a first panel, which is attached to a carton cut out flap, and a second panel, which together with the first panel forms the spout when extended through the triangular aperture. The first panel includes a pull tab. The second panel includes a curved or bowed portion adjacent a stop-forming edge portion. FIG. 4 discloses a spout blank which comprises two side panels including stop means and a middle panel which includes a pull tab. Among the described objects of the Arneson invention are a spout which can be readily incorporated in the carton in collapsed condition. The pouring spout is said to be of the same or similar material as the carton.
Whitney U.S. Pat. No. 830,694 discloses a cover for can heads made of paper or paperboard. The cover is formed of pasteboard or similar material and includes two panels disposed at a 90° angle to each other and which form a spout. One of the panels includes a tongue for opening the can and an extension which is to be fixed to the can opening and which is creased to permit movement of the cover along the creased line. The other spout-forming segment includes a stop to prevent it from being opened too far. A label or other protective part can be pasted over so as to seal the cover.
Zalkind U.S. Pat. No. 1,426,439 discloses a container including a chute for pouring its contents. The chute includes two spout-forming walls, stop means and a pull tab.
Groner U.S. Pat. No. 1,714,363 discloses a dispensing carton for items such as soap. The carton includes an integral v-shaped pouring spout. The spout includes a notch 9 and a tab 13.
Perkins U.S. Pat. No. 2,123,546 discloses a package having a spout with stop lugs, and an adhesive patch for sealing the spout.
SUMMARY OF THE INVENTION
The present invention is a folding v-shaped pour spout having three panels, which is attached to the inside of a carton by one of its panels. The invention is also directed to erected cartons, flattened tubular cartons and carton blanks including the pour spout. The thin, preferably plastic, material from which the spout is formed permits the spout to be affixed to the flattened, two dimensional carton blank without making the carton blank unbalanced, which would otherwise cause the blank or the folded tube into which it is formed to stack unevenly.
The pour spout of the invention includes an attachment panel, a first spout-forming panel contiguous therewith and a second spout-forming panel contiguous to the first spout-forming panel. The first spout-forming panel includes means to assist the consumer in grasping the spout. The second spout-forming panel includes notches to keep it in the open and closed positions, stop means and a curved arc-like portion separating the notches. In a preferred embodiment the notches are supplemented with ridges. In a more preferred embodiment a wall is provided to confine the movement of the second spout-forming panel within the carton to prevent interference with product.
The invention also relates to the process of making a carton having a flat, folding pour spout. The process includes attaching to a panel of a carton blank the attachment panel of a spout blank according to the invention, folding the carton blank into a flat tube, and erecting the carton by positioning the panels so that the main and side panels are exactly opposite each other to form a tube of rectangular cross section and folding inwardly the minor and major flaps thereof.
For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of a preferred embodiment and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear elevational view of a folding pour spout in accordance with the present invention.
FIG. 2 is an elevational view of the inside of a carton blank having the folding spout of the invention attached.
FIG. 3 is a top perspective view of folded tubular carton blank having a folding pour spout which is the mirror image of that of FIG. 2 attached thereto with portions shown in phantom.
FIG. 4 is a cross section along the lines 4--4 of FIG. 3.
FIG. 5 is a cross section along the lines 5--5 of FIG. 3.
FIG. 6 is a perspective view of an erected carton having the folding pour spout of the invention affixed thereto.
FIG. 7 is a cross section along the line 7--7 of FIG. 6.
FIG. 8 is a cross section along the line 8--8 of FIG. 6.
FIG. 9 is a perspective view of an erected carton with the folding pour spout of the invention opened to pouring position.
FIG. 10 is a cross section along the lines 10--10 of FIG. 9.
FIG. 11 is a cross section along the lines 11--11 of FIG. 9.
FIG. 12 is a perspective view of an interior corner of a carton having an alternative embodiment of the spout of the invention.
FIG. 13 is a cross section along the line 13--13 of FIG. 12.
FIG. 14 is a front elevational view of an alternate folding pour spout according to the invention.
FIG. 15 is a perspective view of an outside corner of a carton having the alternate folding pour spout affixed thereto.
FIG. 16 is a perspective view showing the alternate folding pour spout in pouring position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the folding pour spout 21 of the invention initially takes the form of a spout blank which comprises a generally triangular attachment panel 20 contiguous with a first spout-forming panel 24 and separated therefrom by a first fold line 22. First spout-forming panel generally resembles a sector of a circle. The top of first spout-forming panel 24 includes a pull tab 25 projecting therefrom and an arc-like section 38 adjacent to the pull tab. Also contiguous with first spout-forming panel 24 is second spout-forming panel 28, which is separated from first spout-forming panel 24 by second fold line 26. Like first spout-forming panel 24, second spout-forming panel 28 is generally sector-shaped. The first and second spout-forming panels are similarly oriented with their narrow aspects at the bottom and their wider aspects at the top. Second spout-forming panel 28 includes at its upper end stop means 36 projecting therefrom, a notch 30, and an arc-like section 40. Notch 34 is formed between second spout-forming panel 28 and first spout-forming panel 24.
The two fold lines of the spout blank preferably form an angle of less than 90°, more preferably less than about 60°, and still preferably 45° or smaller.
The spout blank is a flat, single sheet of thin plastic such as PETG (glycol-modified polyethylene terephthalate) or PET (polyethylene terephthalate). It can be used in the configuration shown in FIG. 1, or in other variations, such as the mirror image of the spout of FIG. 1.
In general, folding pour spout 21 will be attached to the carton when it is in the form of a flat, essentially two-dimensional carton blank 42, as illustrated in FIG. 2. Attachment of the folding pour spout to the carton blank instead of to an erected or partially erected carton simplifies manufacture. Folding pour spout 21 is attached to the inside of carton blank 42. The carton blank is comprised of paperboard or other suitable material such as a plastic. The paperboard may be inside or outside film laminated, if desired. Carton blank 42 comprises a side panel 44 and two main panels 46 and 48, one of which will constitute a front panel and the other of which will comprise the rear panel, as desired. A second side panel is not shown in FIG. 2. The front and side panels are separated by score lines such as score lines 50 and 52. Adjacent to the tops of the main panels are upper major flaps 54 and 56, whereas lower major flaps 64 and 66 (FIG. 3) are adjacent the bottom of the main panels. The flap attached to the front panel will comprise the outside major flap and the flap attached to the rear panel will constitute the inside major flap. Attached to the top and bottom, respectively of side panel 21 are upper minor flap 58 and lower minor flap 68.
Attachment panel 20 is fastened to the inside of side panel 44 by fastening means such as a glue 70 or hot melt. A generally triangular aperture 60 (FIG. 9) is present in side panel 44. When the mirror image of the spout configuration of FIG. 1 is used, the carton aperture is a mirror image of that used for the carton of FIG. 3. Depending from side panel 44 at the top of the aperture is locking flange 62. First spout-forming panel 24 protrudes through aperture 60 so that pull tab 25 rests against the outer wall of panel 44 and is at least partly prevented from going though the aperture by locking flange 62. Second spout-forming panel 28 rests loosely against main panel 48.
As indicated above, the folding pour spout of the invention can be used in the form shown in FIG. 1, or in its mirror image. FIG. 3 illustrates a carton blank folded into tubular form and including a folding pour spout 21' which is the mirror image of folding pour spout 21. Hereinafter, the mirror image form is illustrated and primed numbers shall designate features corresponding to the mirror image form. Partially erecting the carton blank into tubular form as shown in FIG. 3 is the next step in the fabrication of the carton after gluing attachment panel 20 to the inside of the side panel. Partial erection is accomplished by gluing the glue flap (not shown), which is a narrow strip adjacent one of the main panels, to one of the side panels to form a flattened tube.
During manufacture, it may be necessary to stack the folded tubular form of the carton. Because it is a thin sheet of plastic, the folding pour spout of the invention is used to particular advantage as compared to other recently proposed fitments since it does not add unduly to the thickness of the folded tubular cartons. Thus, balancing means to permit the tubes to stack evenly, such as those proposed by the Gunn patent mentioned above, are not required when the folding spouts of the invention are employed.
The carton is fully erected by folding inwardly the upper and lower minor flaps, the upper and lower inner major flaps and finally the upper and lower outer major flaps. Fully erected carton 72 is shown in FIG. 6. In order to ensure that the carton remains completely sealed during transport, it may be desirable to place a patch 74 over folding pouring spout 21'. Patch 74 may be made of plastic or paper and preferably includes a pre-applied pressure sensitive adhesive layer 76 (FIG. 7) to permit it to cover the folding pour spout temporarily. Patch 74 may extend over to one or more of the major panels, as well, as shown in FIG. 6. It may be desirable to cut away a portion 78 of the corner 80 of the carton to enlarge the aperture and facilitate opening and closing of the spout. A portion of the main panel adjacent the aperture may be cut away for this purpose, as well. Whether or not a patch is used, when the spout is in the sealed position, notch 34 helps keep the spout closed.
Referring particularly to FIGS. 2, 6, 7, 9 and 10, when a consumer wishes to open the carton, he/she will tear away patch 74 to reveal folding pour spout 24'. Grasping pull tab 25', he/she will pull the spout forward. Upon pulling the spout forward, second spout-forming panel 28 slides along the wall of main panel 48. Initially, a certain amount of force must be exerted to pull the spout forward since notch 34 serves to lock the spout in the closed position by abutting wall 82 of corner 80. (See FIGS. 2 and 6) Once notch 34 has been pulled forward, arc-like portion 40 of second spout-forming panel 28 contacts wall 82 of corner 80. The dimensions of arc-like portion 40 are set such that when the spout is pulled forward, arc-like portion 40 abuts tightly corner wall 82. As the spout is pulled further, corner portion 82 reaches notch 30 and stop means 36 which prevents it from proceeding further. Corner wall 82 fits snugly within notch 30 between stop means 36 and notch wall 84 to keep the spout in the open position seen in FIGS. 9, 10 and 11. First and second spout-forming panels 24' and 28' constitute the spout. Unlike many spouts of the prior art, the spout of the invention does not require a flap integral with the carton for attachment.
If desired, a longitudinal notch in corner 80 at 82 may be provided to receive second spout-forming panel and to limit the movement thereof.
When the consumer desires to re-close the container, he/she simply pushes the spout at tab 25 and it returns to the closed position, with corner wall 82 being snugly accommodated within notch 34.
In a preferred embodiment, a confining wall is provided to limit the movement of the second spout-forming panel. Referring particularly to FIGS. 12 through 14, panel 48 is provided with second spout-forming panel confining wall 86 disposed parallel and adhering thereto. Adhesive means 88 adhere confining wall 86 to wall 48 on three sides, the fourth being open to accommodate second spout-forming panel 28'. Confining wall 86 limits the movement of second spout-forming panel 28' to a direction essentially parallel to panel 48 and prevents interference by the product held within the carton with the movement of panel 28'.
A further alternate embodiment is illustrated in FIGS. 15 and 16. The alternate folding pour spout 121 of the invention comprises an attachment panel 120 contiguous with a first spout-forming panel 124 and separated therefrom by a first fold line 122. Attachment panel 120 is adhered to side panel 144. First spout-forming panel 124 generally resembles a sector of a circle. The top of first spout-forming panel 124 projects beyond the top of adjacent panels 120 to form a grasping surface. Also contiguous with first spout-forming panel is second spout-forming panel 128, which is separated from first spout-forming panel 124 by second fold line 126. Second spout-forming panel 128 includes at its upper aspects stop means 136 projecting therefrom, a notch 130, a first ridge 131, an arc-like section 140 and a second ridge 133. Notch 134 is formed between second spout-forming panel 128 and first spout-forming panel 124.
The operation of spout 121 is the same as for spout 21, except that second ridge 133 assists in keeping the spout in the closed position by making it more difficult for corner wall 182 to leave the notch and ridge 131 assists in keeping the spout in the open position by making it more difficult for corner wall 182 to leave notch 130. As can be seen in FIG. 14, ridge 131 is smaller than ridge 133. Main panel 148 may be provided with a confining wall, as previously described in connection with spout 21.
The term "fold lines," as used herein encompasses both perforated lines upon which a fold may be made as well as unperforated fold lines such as score lines.
It should be understood, of course, that the specific form of the invention herein illustrated and described is intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention. | A folding pour spout, particularly, for detergent cartons. The spout is formed from a spout blank preferably comprising a single thin sheet of plastic. The spout blank includes a first spout-forming panel having a pull tab, a second spout-forming panel including notches and a panel for attachment to a carton. The reduced thickness of the spout blank facilitates manufacturing of the carton. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a national stage application under 35 USC 371 of and claims priority to International Application PCT/EP2006001668, filed Feb. 23, 2006 and claims priority to DE 10 2005 008 889.9, filed Feb. 26, 2005.
TECHNICAL FIELD
The invention concerns an optical monitoring system for coating processes, particularly for the measurement of layer thicknesses of layers applied to moving substrates during the coating process whereby signals are generated in measurement, reference, and dark phases that follow each other in a timed sequence, and are evaluated for measuring the transmission or reflection from substrates.
BRIEF DISCUSSION OF RELATED ART
For substrates that are coated with thin layers in the scale of light-wave lengths to achieve prescribed optical properties, layers must be applied with high evenness and exact layer thickness to achieve the prescribed transmission or reflection properties. Layer thickness is transmitted by transmission and reflection measurements and takes place in situ in order to precisely control layer thickness. For measuring such thin layer thicknesses, photometers are frequently used that include a monochromatic transmission or reflection signal of the coated substrate in a measuring phase and a reference signal of the light source of the photometer. However, such photometer configurations have the disadvantage that signals are recorded by two different detectors, the drifts of which affect the measurement result, and in doing so, changes in the color temperature of the light source are only insufficiently considered.
To eliminate these disadvantages, EP 0 257 229 B1 proposes generating a measurement phase, a reference phase, and a dark phase, one after the other in time, by means of a chopper that consists of two chopper disks revolving about an axis, with openings, not overlapping each other, at an angle of 120°, respectively, between which the light source is arranged. The registration of light signals in the measuring and reference phases takes place with a light detector in the same wavelength, adjusted with a monochromator, so that aging and temperature drift can be compensated for by the light source and the detector. The dark phase serves as compensation for errors from outside influences and drifts from electronic amplifiers. A processor unit evaluates the signals.
In the coating of small-format substrates it is common to arrange several substrates on revolving substrate carriers. If a layer thickness measurement should take place during the coating process with a photometer arrangement described above on the revolving substrate carrier, there must be an exact synchronization between the chopper drive and the substrate rotary operating mechanism, as unsynchronized drives will produce a time jitter in the amount of the period of the chopper, which will result in an undesired variation in the measuring point on the substrate.
By synchronizing the rotary operating mechanism this time jitter can be reduced, though not eliminated entirely.
BRIEF SUMMARY
The invention improves further the precision of the layer thickness measurement of thin layers applied on substrates during the coating process.
The optical monitoring system according to the invention comprises a light source, a light detector unit, a reference light guide by which the light of the light source is supplied or is able to be supplied to the light detector unit, a first measuring light guide, with which the light of the light source is directed or is able to be directed onto a substrate, and a second measuring light guide, with which the light from the light source reflected or transmitted from the substrate is supplied or can be supplied to the light detector unit. A first piezoelectric or electrostrictive or magnetostrictive light chopper is arranged in the reference light guide, and a second piezoelectric or electrostrictive or magnetostrictive light chopper is arranged in the first or second measuring light guide. Thus, the first and second light choppers are connected to a processor unit for generating a measuring phase, a reference phase, and at least one dark phase.
A further optical monitoring system according to the invention comprises a light source, a light detector unit, a first measuring light guide, by which the light of the light source is directed or is able to be directed onto a substrate, and a second measuring light guide, by which the light from the light source transmitted from the substrate is supplied or able to be supplied to the light detector unit. A piezoelectric or electrostrictive or magnetostrictive light chopper is arranged in the first or second measuring light guide. In this case the reference light path is formed by at least one corresponding opening in a revolving substrate carrier that clears the light path during the movement of the substrate carrier. On a revolving substrate carrier the opening can be designed as a free drill hole, for example, on the same radius on which one or several substrates are arranged. Reference measuring is then executed when the free drill hole crosses the light beam. The chopper clears the light path during the measuring and reference phases. In the dark phase the chopper closes the light path.
In the process according to the invention, the light intensity of a light source in a reference phase, the light intensity of the light reflected or transmitted from the substrate in a measuring phase, and the remaining light intensity in at least one dark phase is registered by a light detector unit for the layer thickness measurement of steamed or dusted layers on moving substrates, in particular revolving about an axis during the coating process, wherein the reference phase, measuring phase, and dark phase are staggered in time by at least one piezoelectric, electrostrictive, or magnetostrictive light chopper and are digitally adjusted in dependence on the position of the substrate.
In a preferable embodiment, the light intensity of the light from a light source injected into a reference light guide and cleared by a first piezoelectric or electrostrictive or magnetostrictive light chopper is registered in a reference phase, in a measuring phase the light from the light source is injected into a first measuring light guide and the light cleared by a second piezoelectric or electrostrictive or magnetostrictive light chopper is directed onto the substrate and the light intensity of the light reflected or transmitted from the substrate is registered by the light detector unit over a second measuring light guide. Then, the second light chopper closes the first measuring light guide in the reference phase and the first light chopper closes the reference light guide in the measuring phase. In addition, in at least one dark phase the remaining light intensity is registered by the light detector unit, wherein the first light chopper closes the reference light guide and the second light chopper closes the first measuring light guide. The reference phase, the measuring phase, and the dark phase are staggered in time by the corresponding settings of the light choppers, and are digitally focused based upon the position of the substrate.
If the reference light guide is not applied and the reference measuring occurs over the measuring light guide, it is preferable that the reference phase, measuring phase, and dark phase are implemented by a light chopper arranged in the first or second measuring light guide.
The focusing of reference, measuring, and dark phases with piezoelectric or electrostrictive or magnetostrictive light choppers enables a direct and very exact positioning of the individual phases by means of the flexible digital control of the light choppers that is available at all times. The measuring phases can thereby be synchronized exactly with the desired measuring point of the substrate.
The piezoelectric light choppers are piezoelectric actuators that execute a positioning movement upon electrical activation. In this, an electric field is applied to a piezocrystal and a length variation is produced in the direction of the field intensity. If the deformation is hindered from the outside a force arises that acts in the direction of the deformation. Thus, electrical energy is converted into mechanical energy. Piezoeletric actuators can also be described simply by their capability of converting electrical tensions into mechanical motion. Piezoeletric effects are observed in various crystalline substances like quartz, sodium potassium tartrate, and ethylene diamine tartrate, as examples.
Alternatively to piezoeletric actuators, electrostrictive or magnetostrictive actuators can be installed as light choppers. With electrostrictive actuators, symmetrical crystals are changed depending on the electrical field. Magnetostrictive actuators change their geometric properties by applying an outside magnetic field.
In a preferable embodiment of the invention, the light detector unit comprises a dispersive element, in particular a monochromator, and a light detector by which the light wave length of the light directed at the light detector can be focused by the dispersive element and spectrophotometrical measurements are possible.
For the further treatment of light intensities detected by the light detector, the signals adjacent to the exit of the light detector are preferably amplified and digitalized by means of an A/D converter. Then the registered values can be set up in a processor unit by the creation of differential values from the measuring and dark phases and from the reference and dark phases. The relationship between the differential values thus determined (| meas -| dark -/| ref -| dark ) forms a measure for the reflection or transmission of the coated substrate. Preferably, an adjustment of the amplifier will also take place through the processor unit depending on the respective phase since the difference between the light intensity in the measuring phase and the reference phase can be very great. The degree of amplification should preferably be adjusted such that the largest possible signal is available at the A/D converter in order to achieve a high signal resolution.
Further, it is preferable if the processor unit is connected or can be connected to a rotary operating mechanism of a substrate carrier for the registration of the position of the substrate arranged on the substrate carrier. This is possible preferably by means of an incremental encoder coupled to the rotating operation mechanism, which sets a counter at a defined value with each revolution on a defined rotation angle, and sends pulses to the counter depending on the rotation angle. A rotation angle and thereby the position of the substrate can thus always be assigned to the counter reading. The counter reading is evaluated by the processor unit, and from that signals are generated to control the light choppers for adjustment of the reference, measuring, and dark phases.
In a further advantageous embodiment of the invention, the measuring of the transmission or reflection can take place continuously on stationary substrates during the steaming process. The adjustment of the reference, measuring, and dark phase then takes place periodically by means of an integrated time control into the processor unit. The sequence as well as the duration of the individual phases can be freely controlled. The frequency with which the light choppers are adjusted for set-up of the individual phases can be thus chosen such that any interfering frequencies from outside light of the steaming source or the noise of the light detector can be maximally suppressed. Typical frequencies lie in the range from 5 to 100 Hz.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described further in more detail with reference to exemplary embodiments. Shown are:
FIG. 1 a schematic representation of an optical monitoring system with two light choppers
FIG. 2 a schematic representation of an optical monitoring system with one light chopper.
DETAILED DESCRIPTION
The optical monitoring system shown in FIG. 1 for measuring the layer thickness of a substrate revolving about an axis during a coating process operates with two light choppers to generate the measuring, reference, and dark phases.
The substrate 2 is arranged in the coating chamber 1 on a disk-shaped substrate carrier 3 ca. 300 mm removed from the rotational axis. The substrate carrier 3 is moved by the rotating mechanism 4 at ca. 200 R/min and is coated by one or several coating sources 5 in a vacuum. The substrate 2 is transparent, for example glass, so that a layer thickness determination can take place with a transmission measurement.
For measurement, a light source 6 injects light into a first light guide injector 14 . The first light guide injector 14 leads the reference light guide 7 and the first measuring light guide 8 together in front of the light source 6 . In the reference light guide 7 there is a first piezoelectric light chopper 10 arranged between two light guide heads 12 of the reference light guide 7 , and in the first measuring light guide 8 there is a second piezoelectric light chopper 11 arranged between two further light guide heads 12 . The light guide heads 12 can also be configured as optical collimators. The chopper rims of the first and second piezoelectric light choppers 10 , 11 can be so moved with respective actuators independently of one another, so that the light is blocked, or guided on unhindered. The light guide heads 12 are to be brought to the light chopper rims as tightly as possible. The control of the “open” or “closed” position of the piezoelectric light choppers 10 , 11 takes place with the processor unit 21 .
At the end of the first measuring light guide 8 , a light guide head is fastened with collimator 13 . This is arranged in a vacuum of the coating chamber 1 such that the light from the first measuring light guide 8 reaches the substrate 2 .
The light guide head fastened on the second measuring light guide 9 with the collimator 13 is arranged on a view window of the coating chamber 1 such that the light transmitted from the substrate can be received and guided to the light detector unit 15 .
The light of the reference light guide 7 is likewise directed to the light detector unit 15 . In front of the monochromator 17 of the light detector unit 15 the second measuring light guide 9 and the reference light guide 7 are brought together in a second light guide injector 16 .
A light detector 18 is fixed at the exit of the monochromator 17 . The light detector 18 can be realized as a signal detector that measures monochromatic light or as a line detector that measures light of several wavelengths simultaneously. The exit signals of the light detector 18 are amplified in the amplifier 19 and digitalized by an A/D converter 20 . The point of time of the digitalization is set by the processor unit 21 . The processor unit 21 reads the digitalized values and processes them further.
An incremental encoder 22 is rigidly coupled with the drive shaft of the rotation mechanism 4 of the substrate carrier 3 . The signal of the incremental encoder 22 is switched to a counter 23 . The counter 23 gets a null impulse from the incremental encoder 22 with each rotation at a defined rotation angle. The null impulse sets the counter 23 to null or to a defined value. A transmission of the incremental encoder 22 sends pulses to the counter 23 depending on the rotation angle. A typical value is 2048 pulses per revolution. The counter 23 is incremented or decremented by the pulses. In this way a defined rotation angle can be assigned to the actual counter reading. A comparator 24 programmed by the processor unit 21 evaluates the counter and sends a signal to the processor unit 21 upon the preprogrammed counter reading.
Measuring Provides at Least Three Phases:
Measuring Phase:
The chopper rim of the first piezoelectric light chopper 10 is closed and blocks light passage with the reference light guide 7 . The chopper rim of the second piezoelectric light chopper 11 is open so that the light from the light source 6 is directed through the first measuring light guide 8 to the substrate 2 . The substrate 2 is illuminated once per each revolution. The light transmitted by the substrate 2 is further guided over the second measuring light guide 9 to the light detector unit 15 .
In the most simple case, the monochromator 17 is a line filter with only one conducting wavelength. However, it is advantageous to use a grid monochromator with adjustable wavelengths. In this manner an advantageous wavelength can be chosen based upon the layer thickness. The wavelength of the monochromator 17 is adjusted to the desired value before the start of coating.
Instead of a monochromator 17 a so-called polychromator with a row detector can also be used. With that, a diode or CCD row is illuminated by an optical grid. Each single element is illuminated with another wavelength. Thus an entire wavelength spectrum is simultaneously measurable.
The beginning and end of the measuring period are adjusted by the comparator 24 for the A/D converter 20 such that measuring takes place while the substrate 2 is located in the optical path. At the end of the measuring period the digitalized value of the measurment is read out by the processor unit 21 .
Reference Phase:
The chopper rim of the second piezoelectric light chopper 12 is closed and blocks light passage with the first measuring light guide 8 . The chopper rim of the first piezoelectric light chopper 11 is open so that the light from the light source 6 is further directed through the reference light guide 7 to the light detector unit 15 . The monochromator adjustment is unchanged vis-à-vis the measuring phase. The beginning and end of the measuring period are thus independent of the angle position of the substrate 2 , but are defined likewise by the counter 23 and the comparator 24 . Reference measuring takes place sensibly immediately before or after a measuring phase. At the end of the measuring period the digitalized value of the measurement is read out by the processor unit 21 .
Dark Phase:
The chopper rim of the first and second piezoelectric light choppers 10 , 11 is closed. The beginning and end of the measuring period are likewise independent of the angle position of the substrate 2 and are defined by the counter 23 and comparator 24 . Dark measuring takes place sensibly immediately before or after a measuring phase and/or a reference phase. At the end of the measuring period the digitalized value of the measurement is read out by the processor unit 21 .
After the conclusion of the phases the measurement values are calculated thus: The differential values of the light intensities from the measuring and dark phases as well as from the reference and dark phases are put into the ratio (| meas -| dark /| ref -| dark ). So a measurement value is available that is proportional to the light transmission of the substrate 2 . Fluctuations in the light source 6 and in the sensitivity of the detector are compensated.
The optical monitoring system shown in FIG. 2 for measuring the layer thickness of a substrate revolving about an axis during a coating process operates with just one light chopper to generate measuring, reference, and dark phases.
The substrate carrier 3 herein exhibits an opening 25 on the same radius as the substrate 2 for forming a reference light path.
For measurement, a light source 6 injects light via a light guide head with collimator 13 in the first measuring light guide 8 . In the first measuring light guide 8 there is a piezoelectric light chopper 11 arranged between two further light guide heads 12 . The light guide heads 12 can also be realized as optical collimators. The chopper rims of the piezoelectric light chopper 11 can be moved with a piezoelectric actuator such that light is blocked or guided on unhindered. The control of the “open” or “closed” condition of the piezoelectric light chopper 11 takes place through the processor unit 21 .
A light guide head with collimator 13 is fastened at the end of the first measuring light guide 8 . This is arranged in a vacuum realization of the coating chamber 1 such that the light coming from the first measuring light guide 8 reaches the substrate 2 or goes through the opening 25 .
The light guide head with collimator 13 fastened to the second measuring light guide 9 is arranged on a view window of the coating chamber 1 such that the light transmitted from the substrate 2 is received as measuring light, or the light let through the opening 25 is received as reference light and can be guided to the light detector unit 15 .
A light detector 18 is fastened at the exit of the monochromator 17 . The exit signals of the light detector 18 are amplified in the amplifier 19 and digitalized by an A/D converter 20 . The time period of the digitalization is prescribed by the processor unit 21 . The processor unit 21 reads out the digitalized values and processes them further.
An incremental encoder 22 is rigidly coupled with the drive wave of the rotation mechanism 4 of the substrate carrier 3 . The signal of the incremental encoder 22 , analogous to the practical example above, is switched to a counter 23 and evaluated by the processor unit 21 .
Measuring Provides at Least Three Phases:
Measuring Phase:
The chopper rim of the piezoelectric light chopper 11 is open, so that light from the light source 6 is conducted through the first measuring light guide 8 to the substrate 2 . The substrate 2 is illuminated once per each revolution. The light transmitted by the substrate is further guided through the second measuring light guide 9 to the light detector unit 15 .
The beginning and end of the measuring period are adjusted for the A/D converter 20 by the comparator 24 such that measuring takes place when the substrate 2 is situated in the optical path. At the end of the measuring period the digitalized value of the measurement is read out by the processor unit 21 .
Reference Phase:
The chopper rim of the piezoelectric light chopper 12 is open so that the light of the light source 6 is further lead through the opening 25 to the light detector unit 15 . The monochromator adjustment is unchanged vis-à-vis the measuring phase.
The beginning and end of the measuring period are adjusted for the A/D converter 20 by the comparator 24 such that measuring takes place when the opening 25 is situated in the optical path. At the end of the measuring period the digitalized value of the measurement is read out by the processor unit 21 .
Dark Phase:
The chopper rim of the piezoelectric light chopper 11 is closed. The beginning and end of the measuring period are independent of the rotation angle of the substrate 2 and are defined by the counter 23 and comparator 24 . Dark measuring takes place sensibly immediately before or after a measuring phase and/or a reference phase. At the end of the measuring period the digitalized value of the measurement is read out by the processor unit 21 .
To eliminate influences from outside light sources it is wise to carry out dark measuring when the substrate 2 is still situated in the optical path. Outside light is measured in the measuring phase as well as the dark phase and can be calculated out in the ensuing evaluation by differential formulation.
After the conclusion of the phases the measurement values are calculated thus: The differential values of the light intensities from the measuring and dark phase as well as from the reference and dark phase are put into the ratio (| meas -| dark /| ref -| dark ). So a measurement value is available that is proportional to the light transmission of the substrate 2 . Fluctuations in the light source 6 and in the sensitivity of the detector are compensated. | The invention concerns an optical monitoring system for the measurement of layer thicknesses of thin coatings applied in a vacuum, particularly on moving substrates, during the coating process, in which the light intensity of the light of a light source injected into a reference light guide and released by a first piezoelectric or electrostrictive or magnetostrictive light chopper is registered by a light detector unit in a reference phase, the light of the light source in a measuring phase is injected into a first measuring light guide and the light released by a second piezoelectric or electrostrictive or magnetostrictive light chopper is directed to the substrate, and the light intensity of the light reflected or transmitted from the substrate is registered by the light detector unit through a second measuring light guide, and a remaining light intensity is registered by the light detector unit in at least one dark phase, wherein the reference phase, the measuring phase, and the dark phase are shifted in time by the light chopper and are digitally adjusted depending on the position of the substrate. | 7 |
FIELD OF THE INVENTION
The present invention provides quick and commercially economical methods and apparatus for producing multi-pane insulating glass assemblies having interpane spaces filled with a gas having a coefficient of thermal conductivity lower than that of air.
BACKGROUND OF THE INVENTION
Various methods and devices have been proposed for filling the space between panes of insulating glass assemblies with dry or generally inert gases for the purpose of avoiding internal corrosion, condensation and the like, often associated with moist air. U.S. Pat. No. 4,369,084, for example, describes filling of the interpane space of an insulating glass assembly with sulfur hexafluoride, whereas U.S. Pat. No. 3,683,974 employs a fluorocarbon gas for the same purpose. Nitrogen is the gas of choice for this purpose in U.S. Pat. No. 2,756,467, and U.S. Pat. No. 4,393,105 discloses the use of a low heat-transfer gas such as argon.
Prior art methods for replacing air with another gas in an insulating glass assembly are cumbersome and time consuming. In the above-mentioned U.S. Pat. No. 2,756,467, rubbery peripheral spacers are employed between pairs of glass panes, and hypodermic needles are forced through the spacers to withdraw air from the interpane spaces and to deliver nitrogen to the spaces. In U.S. Pat. No. 4,369,084, SF 6 , a heavy gas, is caused to enter the space between panes at the bottom of a glass assembly and to gradually fill the assembly from its bottom, thus displacing air. In U.S. Pat. No. 3,683,974, sealed, multi-pane glass assemblies are provided with holes through the glass panes through which a fluorocarbon gas is injected, air again being displaced from the interiors of the assemblies. In U.S. Pat. No. 4,393,105, a vacuum can either be drawn on individual multi-pane glass assemblies or the units can be assembled in an environment of vacuum or low heat-loss gas. In U.S. Pat. No. 4,780,164 a vacuum is drawn on a stack of multi-pane glass assemblies having holes in the spacers to permit air to escape and subsequently the desired gas to re-enter; the holes are then plugged.
Modern insulating glass assemblies may employ extruded metal spacers that may be generally rectangular in cross section and that have hollow interiors. The spacers are bonded to confronting glass pane surfaces by means of adherent strips of a polymeric material such as polyisobutylene, and the spacers often have a plurality of small slots or holes in their walls that face the interpane spaces. Desiccants, such as calcium sulfate, may be placed within the hollow spacers for the purpose of absorbing moisture from the gas within the interpane space, the slots in the spacer wall permitting some diffusion of gas across the wall.
When hollow spacers of the type described above are employed, the use of the various methods of the prior art to replace air in the interpane space with argon or the other gas generally does not provide good results since air that is present within the hollow spacer interiors commonly is not fully exchanged.
Moreover, the use of vacuum systems to draw air from an interpane space and the introduction of a different gas into the interpane space causes pressural forces to be exerted on the panes and spacer which can result in pane damage or spacer failures. Even small pressure differentials across a pane, acting on the large pane surface, can give rise to substantial pneumatic forces resulting in substantial bowing of the panes. Such methods therefore must proceed at a controlled pace, limited by the speed at which gases enter and exit the interpane space.
SUMMARY OF THE INVENTION
The present invention provides a method for quickly and economically fabricating a plurality of gas-containing insulating glass units without damage to panes or spacers. In its broader aspect, the invention relates to a method in which a plurality of glass units are formed into a self-supporting assembly, each unit comprisingat least a pair of aligned, parallel, spaced glass panes having a peripheral spacer and confronting surfaces defining with the spacer an interpane space. The units are assembled with separator means for spacing at least a portion of one of thepanes of each unit from the other pane and from the peripheral spacer to provide an opening therebetween, each glass unit being generally in surface-to-surface supporting relationship with an adjacent glass unit. The generally vertical assemblies are either assembled in or moved as a unit into a chamber which is then evacuated to draw substantially all of the air from the interpane spaces. A gas having a coefficient of thermal conductivity ("K c ") lower than that of air is then introduced into the chamber, the gas refilling and occupying the interpane spaces. The separator means is then disabled, allowing the panes to relax against the spacers, closing the opening and thereby completely sealing the interpane spaces of the glass units from the vacuum chamber environment. If desired, the assembly of units may be gently compressed to assure a tight seal of the panes against the spacers. Such compression may be accomplished mechanically, as by a pneumatic cylinder, or by raising the pressure in the chamber after the separator means has been disabled. The units are then removed from the chamber for further processing.
In a preferred embodiment, a conveyor is provided for conveying a stack of glass units into and out of the vacuum chamber, the conveyor having a generally horizontal portion for supporting edges of the glass units and a generally vertical portion normal to the generally horizontal portion for supporting a generally vertical portion of the stack. The conveyor extends along a path through aligned front and rear door of the chamber, and includes a first section outside the front chamber door and upon which may be provided a stack of glass units, a second section within the chamber, and a third section beyond the rear door of the chamber to provide a work station for sealing the openings of the units.
Preferably, when the evacuation step has been completed, the stack of glass units is maintained at a pressure of about 10 torr or less for a period of about fifteen seconds or less to insure that substantially all of the air within the glass units has been removed.
DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of an apparatus according to the invention;
FIG. 2 is a view taken along Line 2--2 of FIG. 1;
FIG. 3 is a view taken along Line 3--3 of FIG. 1;
FIG. 4 is a partially broken away, cross-sectional view of FIG. 3 taken along line 4--4 thereof;
FIG. 5 is a partially broken away, top view of FIG. 3;
FIG. 6 is a partially broken away, cross-sectional view of FIG. 4 taken along line 6--6 thereof;
FIG. 7 is an alternative embodiment of the apparatus of FIG. 6;
FIG. 8 is another alternative embodiment of the apparatus of FIG. 6;
FIG. 9 is a schematic representation of one means of operation of the invention;
FIG. 10 is a broken away, cross-sectional view of the edge of a completed glass unit in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, a vacuum chamber is designated generally as 10, the vacuum chamber being generally box-shaped and having top and bottom walls 12, 14 and side walls of which one is shown at 16. The chamber 10 is provided with front and rear sliding doors 18, 20, the doors being shown in their open position in FIGS. 1 and 2 and movable in the direction of arrow "A" (FIG. 2). The vacuum chamber is mounted above the floor (shown at 21) by means of a supporting framework designated generally as 22, the framework including a tilted upper portion 24 supporting the chamber in a tilted position as shown best in FIG. 2. The doors 18, 20 are supported by means of mounting blocks 26 slidable along parallel rails 28 at either end of the vacuum chamber 10, the rails serving to guide the doors 18, 20 between open positions shown in FIGS. 1 and 2 and closed positions in which the door seal the open ends of the vacuum chamber. The rails 28 each are supported at one end by the side wall 16 of the vacuum chamber and at the other end by a floor-mounted side frame designated 30 in FIGS. 1 and 2. The doors and enclosing walls of the vacuum chamber are provided with stiffening ribs depicted generally at 32. Lines 34 and 36 connect the chamber to a source of vacuum (shown schematically at 38 in FIG. 9) and to a source 40 of a low K c gas such as argon. The source of vacuum 38 may be a simple reciprocating vacuum pump, and the source of low K c as may be a tank of the gas as is commercially available.
Means is provided within the vacuum chamber to disengage the cams 113 from the panes, as described in greater detail below. In a preferred embodiment, such means may comprise a pneumatic cylinder 120, which may be mounted in part exteriorly of the chamber (FIG. 2). The pneumatic cylinder in turn is connected to an engagement bar 121 oriented within the chamber to engage the rear portion 115 of cams 113 for removing the separating arms 114 of the cams 113 from their separating positions between the glass panes. Other mechanical or electro-mechanical apparatus may alternatively utilized to accomplish the function of so manipulating the cams. A second pneumatic cylinder 125, or equivalent means, may similarly be positioned on the vacuum chamber for use in compressing the stack of glass units after the separating arms 114 of the cams 113 have been removed from their separating positions, as described in greater detail below.
Referring to FIGS. 1-3, a conveyor is shown generally at 50. The conveyor typified in the drawing comprises a series of generally horizontally extending rollers 52 having ends journaled into angle iron supports 54, 56, the angle iron supports having a first section extending up to the doorway of the vacuum chamber, a second section within the vacuum chamber, and a third section, shown in FIGS. 1 and 3, extending outwardly of the vacuum chamber on the other side of door 20. The three sections are aligned in a straight path. The gaps 58 (FIG. 1) in the angle iron supports between adjacent sections provide room for the doors 18, 20 to slide into their closed positions between adjacent rollers 52.
The conveyor also includes a generally vertical series of rollers, designated as 60, which are journaled between the previously identified angle iron frame 56 and upper frame 62, the rollers 60 extending generally at right angles to the rollers 52. As shown best in FIGS. 2 and 3, the rollers 52, 60 are not truly horizontal or vertical, but rather are tilted through an angle, preferably of about 15°, to provide the conveyor with a generally upwardly-open "V" configuration, each set of rollers 52, 60 forming each arm of the "V." The rollers 60 extending along the third portion of the conveyor (beyond the door 20 of the vacuum chamber) are supported as shown in FIG. 3 by a ground-mounted frame 64; a similar frame (not shown) is provided for the first section of conveyor extending outwardly from the door 18 of the vacuum chamber. The angle iron frames supporting the rollers within the chamber 10 are supported by the floor and walls of the chamber. As shown in FIG. 2, the inner side walls 16 of the chamber desirably are tilted to run parallel to the rollers 60.
Individual multi-pane glass units are shown generally at 70 in FIG. 3, each comprising a pair of generally parallel glass panes 72 and a peripheral spacer 74 at least partially joined to the panes by sealing strips of a polymer such as polyisobutylene, the latter being shown at 76 in FIG. 6. Adjacent units 70 may have their confronting panes in surface-to-surface contact, or, preferably, individual units may be separated by flexible protective sheets 78 of paper or the like. As shown in FIGS. 2 and 3, the individual multi-pane glass units 70 are stacked one against another so that their individual panes 72 are generally parallel and extend generally in vertical planes; that is, the panes 72 extend in planes parallel to the rollers 60. The lower ends of the panes 72 may rest directly upon the rollers 52, or, preferably, may be supported instead upon a rigid sheet such as board 80, the latter rolling upon the rollers 52 and moving with the panes as they travel from Section I to Section III of the conveyor.
The spacer 74, as depicted particularly in FIGS. 6 and 10, is desirably made from aluminum or other convenient metal or plastic by extrusion or by bending or other fabrication techniques. The spacer may be of any convenient cross-sectional configuration, one such configuration being generally C-shaped with the arms of the C extending outwardly parallel to the panes and toward outer edges of the glass panes. The spacer shown in FIGS. 6 and 10, however, is particularly preferred and is generally "D" shaped in cross section, with the flat wall 90 with its central seam 91 facing the interpane space. The spacer may be provided with a series of small slots 94 extending along the length of the spacer and communicating its hollow interior with the interpane space. Granules of calcium sulfate may be placed within the hollow interior of the spacer. The spacer for each glass assembly desirably is formed from a single length of extrusions, being bent at right angles at each of thre corners and having its ends abutting at the fourth corner, where they may be attached, as by mechanical linkages or soldering.
A separator assembly 110 (FIG. 5) associated with the stack of glass units includes a support shaft 111 on which are carried a plurality of cams 113 or equivalent separating means. Each cam 113 includes a separating arm 114 configured and arranged to separate a portion of one pane of a glass unit from the spacer 74 and the other pane of the unit, as described below. FIGS. 6-8 depict three alternative embodiments of the separating arm, respectively designated as 114, 114', and 114". When inserted between two panes of a glass unit, desirably the separating arm spaces one of the panes about 1/16 to 1/8 inches from the adjacent spacer 74, providing a sufficiently large opening 117 for air and the low K c gas to relatively freely exit and enter the interpane space. The opening 117 may be fairly narrow, as its length, which is dependent on both the width of the opening 117 and the size and flexibility of the glass, provides the necessary total area for preventing any substantial pressure differential from developing between the interpane space and the vacuum chamber during evacuation of air and refilling of low K c gas, at least under all but the severest of operating conditions.
The cams 113 desirably are mounted upon a support shaft 111, which in turn may be mounted to the board 81 against which the stack of glass units rests. In one embodiment, the shaft 111 is detachably mounted to the board 81 by means of a shaft support collar 112. Other suitable means may also be employed. The cams may be rotatably mounted to the shaft 111, or, alternatively, the shaft 111 itself may be rotatably mounted to the board 81. In either case, the cams are mounted so as to permit them to rotate about an axis parallel to the shaft when it is desired to disengage the cams from the panes to allow the panes to completely seal against the spacer 74.
Selective rotation of the cams to disengage them from the panes may be accomplished by any suitable means. In a preferred embodiment the cams include a rear bar engaging portion 115 (FIGS. 4-5); when this portion of the cam 113 is depressed, the cam rotates about the shaft 111 axis, disengaging the separating arm 114 of the cam 113 from the panes. Alternately, if the cams are rigidly attached to the shaft 111, the shaft may be rotated by suitable means to disengage the separating arms 114 of the cams 113.
In the method of the invention, glass units as described are stacked as shown in FIGS. 2 and 3 upon the conveyor for subsequent evacuation and refilling with gas. The stack of units initially may be assembled on a horizontal surface and then repositioned upon the conveyor as shown in FIGS. 2 and 3, or may be assembled directly upon Section I of the conveyor. In assembling the stack, glass panes first are suitably prepared, as by washing. A first pane is properly positioned, and then a spacer 74, provided with beads of an adhesive rubber on opposed surfaces, is then laid against the one pane. The separating portion 114 of a cam 113 is suitably positioned adjacent an edge of the glass pane in operative position. A second glass pane then is placed over the spacer, the adhesive rubber beads forming the polymer strips 76 and sealing each glass pane about its periphery to the spacer, except for the portion spaced apart by the cam 113.
Glass units as thus prepared are positioned against one another as shown in FIGS. 2 and 3, interliners such as paper 78 being preferably positioned between adjacent glass units, and lower edges of the glass units resting upon a rigid sheet 80 or other support which rests upon rollers 52. A second flat support, shown at 81 in FIGS. 2 and 3, is positioned against the rollers 60 and has a flat, smooth plane surface against which rests the first paper interliner 78, the support 81 supporting, in surface-to-surface contact through the interlayer, the confronting surface of the first glass assembly. Although only five glass units are shown in FIGS. 2 and 3, the vacuum chamber and conveyor desirably are dimensioned so as to accommodate assemblies of up to 10 to 20 or more glass units at one time.
Once the stack of glass units 70 has been appropriately positioned on the conveyor, including the associated separator assembly 110, it is moved along the conveyor into the vacuum chambers. The doors 18, 20 are closed and sealed, and air is evacuated from the vacuum chamber. As the chamber is evacuated, air escapes from the interpane spaces in each glass unit through the spacers 117 created by the cams 113. In comparison to a single hole in the spacer, such as is shown in U.S. Pat. No. 4,780,164, the spaces 117 created by the cams 113 are sufficiently large that little, if any, pressure differential develops between the chamber environment and the interpane space during evacuation. Thus, the rate at which the chamber is evacuated and refilled need not be as carefully controlled, at least within the broad range of typically attainable rates.
Once a suitably low pressure within the vacuum chamber has been attained (pressures of not greater than about 10 torr are desired, and pressures down to approximately 1 torr and below are preferred), the chamber desirably is maintained at such low pressure for a brief period (e.g., up to about fifteen seconds) to assure that the hollow interiors of the spacers have been fully evacuated as well. Thereafter, argon or another low K c gas is introduced to the vacuum chamber. Again, the rate of pressure increase during refilling with the low K c gas need nott be strictly controlled, as the spaces 117 are sufficiently large to accommodate typically desired rates. It is also desired to permit the low K c gas to remain in contact with the glass units within the closed vacuum chamber for a period of up to about fifteen seconds to assure that the gas pressure within the hollow spacers has come into equilibrium with the interpane pressures.
If desired, a pressure monitor and controller may be included. Such a system would, in simple form, compare the measured pressure in the vacuum chamber with a preprogrammed desired pressure and a danger limit pressure, providing an error signal to the vacuum pump or gas valve to regulate pressure as desired. Pressure regulating controllers are well-known, and a suitable controller is shown schematically at 102 in FIG. 9. A chamber pressure signal may be supplied to the controller through Line 104 which, in turn, provides appropriate signals through leads 106, 108 to the vacuum pump and to the supply of gas 40.
When the chamber is at the desired pressure with the low K c gas the pneumatic cylinder 120 is actuated to pivot the cams 113 out of engagement with the glass panes. As the panes are tilted slightly from vertical on the conveyor, removal of the cams permits them to relax into sealing engagement with the bead of adhesive, completing the sealing and compression of the adhesive into the polymer strips 76. Desirably a gentle compression force is applied to the assembly of units to assure complete compression of the adhesive bead and formation of the seal. In one embodiment, such compression is supplied by pneumatic cylinder 125, which presses with a suitable pad 126 against the outer-most glass unit. Alternatively, additional low K c gas may be supplied to the vacuum chamber to a final pressure slightly higher than the pessure in the now sealed interpane space, thereby exerting a suitable compression force against the outer-most glass unit.
Because sealing of the glass units is accomplished in the vacuum chamber, the exact final pressure of low K c gas in the units will be uniform and may be accurately controlled, particularly in comparison to prior methods involving sealing a hole in the spacer of each unit after remioval of the units from the vacuum chamber. Once the glass units have been sealed in the vacuum chamber, the door 28 is opened and the glass units 70 are removed along the conveyor onto Section III thereof. A sealant such as vulcanizable silicone rubber 118 (FIG. 10) may be inserted within the small spaces between the edges of the glass planes and the outer portion of the spacer 74. The sealant may be applied while the panes are maintained in the generally vertical position shown in FIG. 3, or the panes may be swung through a suitable mechanism (not shown) into a generally horizontal configuration to facilitate application of the sealant.
While a preferred embodiment of the invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | A method of producing multi-pane glass units having a non-air gas in the interpane space. The method includes the steps of assembling several glass units, each of which has a pair of spaced glass panes and a peripheral spacer. A separator device is interposed between one of the panes and the peripheral spacer of each of the units. When the units have been so assembled, a vacuum is drawn on the units in an evacuable chamber to remove substantially all of the air from the interpane spaces. The chamber is then refilled with a suitable gas, such as argon, to refill the interpane space of each of the units. The separator is then removed from the glass units, to close the opening between the pane and the peripheral spacer of each unit, thereby completely sealing the interpane space of each unit from the vacuum chamber environment. The units can then be removed from the vacuum chamber and further processed. | 4 |
PRIORITY CLAIM
This patent application is a continuation in part non-provisional patent application and claims priority under 35 U.S.C. §119(e) to: U.S. Provisional Patent Application Ser. No. 61/562,905 titled A Method Of Transmitting Coded Messages And Providing For Calendaring Events, filed Nov. 22, 2011 which is hereby incorporated by reference as if fully stated herein.
FIELD OF THE INVENTION
The present invention relates generally to a system and method of transmitting coded messages electronically using a wireless mobile communication device to transmit coded messages identifiable by pre-programmed or programmable keys associated with icons corresponding to the coded messages being transmitted and providing for scheduling calendar events, e.g. calendared responses, which may include returning a phone call.
DESCRIPTION OF THE PRIOR ART
Although we are all aware of the dangers of driving and texting, a small minority still persists in engaging in this dangerous practice either out of perceived necessity or fear of missing an important call or message. Many states have cracked down on this practice enforcing traffic laws by issuing traffic tickets, but still the problem persists. Several mobile communicating devices, e.g. cellular phones, include voice activation options for dialing or answering calls, but not all phones include this option or not all users are fully conversant with this functionality. Notwithstanding, voice activation does not necessarily solve the underlying problem of trying to communicate a short message to callers in a quick, efficient and safe manner.
Individuals also face similar challenges in varied social settings where protocol dictates that phone conversations are kept to an absolute necessity, e.g. in a meeting or in attendance at a concert. Yet in an effort not to be discourteous, many call recipients choose to answer the phone and quickly acknowledge the caller even though they may not be able to engage in a full blown conversation. Thus, it would be useful to have a system and method of transmitting short coded messages in a quick and efficient manner.
In instances where the call recipients choose not to answer the incoming call, generally there is an intent to return the call in a timely manner. However, certain unanswered calls are soon forgotten and never returned. Thus, it would be useful to have a quick and efficient system and method of reminding the call recipient to return calls in an expedient manner.
This invention satisfies these long felt needs in a new and novel manner and solves the foregoing problems that the prior art has been unable to resolve.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system and method for transmitting coded messages using a wireless mobile communication device that overcomes the limitations of the prior art.
Another object of the present invention is to provide a system and method for sending short coded messages via mobile communication devices using pre-programmed and/or programmable keys.
Yet another object of the invention is to provide the means for users to customize a coded message for a particular icon.
Another object of the invention is to provide the means for users to customize and edit the coded messages associated with particular icons.
Yet another object of the invention is to provide a system and method for correlating short coded messages with display icons which can be used to transmit at least one coded message to at least one or a plurality of electronic address.
Still yet another object of the invention is to allow users to customize the short coded messages being transmitted to communicate in a language of their choice.
Another object of the present invention is to provide a method wherein a user may selectively transmit at least one or more messages to one or a plurality of electronic address using any one or more of the pre-programmed or programmable keys.
Yet another object of the invention is to provide a calendaring system and method for incoming calls to remind call recipients of calendared responses, which may include returning a phone call.
A system is provided comprising of at least one processor and computer executable instructions readable by the at least one processor and operative to host a coded message application (herein referred to as “app”) for transmitting coded messages. The app 110 may be any type of software application, such as a mobile application designed to run on a mobile platform, such as a mobile communication device running an operating system, such as IOS™, ANDROID™, WINDOWS MOBILE™, BLACKBERRY™, and the like. In another embodiment, the application program may be designed to run on a social network platform, such as FACEBOOK™ or JUSTSYNC™.
A system and method for transmitting at least one coded message comprises of: at least one mobile communication device that includes at least one processor positioned within, in electronic communication with the at least one mobile communication device's communication means; an application program comprising of computer executable instructions readable by the at least one processor, and configured to perform any one or more of the following: display at least one icon on a virtual keyboard on the mobile communication device's at least one displaying means, wherein the at least one icon corresponds to at least one coded message available for transmission to at least one electronic address via the at least one mobile communication device's communication means; receive selection of the at least one icon for transmission to the at least one electronic address; convert the selected at least one icon to a coded message; display the converted icon's coded message on the at least one displaying means; receive selection of the at least one electronic address; transmit the coded message to the at least one electronic address; or display confirmation of transmission of the coded message. The computer executable instructions readable by the computer processor are further operative to launch the coded message application for transmitting coded messages to the at least one electronic address. Electronic address may include any one or more of the following: name, telephone number, email address and social network electronic identifier. Communications means is configured for accessing a data network and transmitting electronically voice or data communications.
In some embodiments, system and method comprises of computer executable instructions readable by the computer processor configured to perform any one or more of the following: receive and publish notification of an incoming communication from a sender's electronic address on the mobile communication device's displaying means; receive selection of an icon for calendaring a response to the incoming communication; capture the sender's electronic address and generate and store a reminder message for the response that was calendared; or publish the reminder message on the mobile communication device's displaying means at predetermined intervals unless alternate instructions are received. Alternate instructions may comprise of any one or more of the following: okay, cancel, delete; and completed.
In some embodiments, system and method further comprise of computer executable instructions readable by the computer processor configured to perform any one or more of the following: receive a request to edit the coded message that corresponds to the selected at least one icon; replace a display of a virtual keyboard on the mobile communication device's displaying means that comprises of at least one icon with a virtual display of a keyboard with alphanumeric characters; receive at least one edit to the converted coded message; store the at least one edit for the converted coded message; or display an electronic address for at least one electronic address of the at least one coded message.
In some embodiments, system and method further comprises of launching an application program; activating a display of a virtual keyboard comprising of at least one or more icons on the at least one displaying means, wherein the at least one icon corresponds to at least one coded message available for transmission to at least one electronic address; receive selection of the at least one icon for transmission to at least one electronic address; convert the selected at least one icon to a coded message; display the converted icon's coded message on the mobile communication device's displaying means; receive selection of the at least one electronic address of the intended message recipients; transmit the coded message to the at least one electronic address for the message recipients; and display confirmation of transmission of the coded message. In some embodiments, user may receive an incoming transmission from one electronic address but may choose to respond to the original sender's at least one electronic address 122 or a plurality of electronic addresses 122 , 122 ′.
For a further and more fully detailed understanding of the present invention, various objects and advantages thereof, reference is made to the following detailed description and the accompanying drawings.
Additional objectives of the present invention will appear as the description proceeds.
The foregoing and other objects and advantages will appear from the description to follow. In the description, references are made to the accompanying drawings, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objectives and advantages of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures.
FIGS. 1A-1C are exemplary embodiments of the system according to one embodiment.
FIG. 2A shows exemplary icons for calendaring a response as displayed on a mobile communication device.
FIG. 2B shows a reminder message pursuant to a calendared response according to one embodiment.
FIG. 3 is a sample flowchart of block diagram of an exemplary method according to one embodiment of the invention.
FIG. 4 describes a sample flowchart of a block diagram of an exemplary method of calendaring a response.
FIG. 5 describes a sample flowchart of a block diagram of an exemplary method of editing at least one coded message according to one embodiment.
FIG. 6 describes a sample flowchart of a block diagram of an exemplary method of transmitting at least one coded message according to another embodiment.
FIG. 7 is a block diagram representing an apparatus according to various embodiments.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following discussion describes in detail an embodiment of the various methods for transmitting coded messages as described below. However, this discussion should not be construed, as limiting the invention to those particular embodiments, as practitioners skilled in the art will appreciate that an apparatus and system may vary as to configuration and as to details of the parts, and that a method may vary as to the specific steps and sequence, without departing from the basic concepts as disclosed herein. Similarly, the elements described herein may be implemented separately, or in various combinations without departing from the teachings of the present invention. Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views.
Systems
FIGS. 1A & 1B are exemplary embodiments of the system 100 according to one embodiment. System 100 comprises of at least one mobile communication device 102 , 102 ′ configured for communicating over a network 104 such as the Internet or a wireless communication network, which includes at least one computer processor 106 positioned within, in electronic communication with the at least one mobile communication device's communication means 108 ; a coded message application (“coded message app”) program 110 comprising of computer executable instructions 112 readable by the at least one computer processor 106 and configured to perform any one or more of the following: display at least one icon 114 on a virtual touch-screen keyboard 116 (as are well known and used in the arts) on the mobile communication device's at least one displaying means 118 , wherein the at least one icon 114 corresponds to at least one coded message 120 available for transmission to at least one or more electronic addresses 122 , 122 ′ via the at least one mobile communication device's communication means 108 ; receive selection of the at least one icon 114 for transmission to the electronic addresses 122 , 122 ′; convert the selected at least one icon 114 to a coded message 120 ; display the converted icon's coded message 120 on the at least one displaying means 118 ; receive selection of the at least one or more electronic addresses 122 , 122 ′; transmit the coded message 120 to the at least one or more electronic addresses 122 , 122 ′; display confirmation of transmission of the coded message 120 ; launch the coded message app 110 for transmitting coded messages 120 , 120 ′ to at least one or more electronic addresses 122 , 122 ′; receive and publish notification of an incoming communication 124 from a sender's electronic address 122 on the mobile communication device's displaying means 118 ; receive selection of an icon 114 for calendaring a response to the incoming communication 124 ; capture the sender's electronic address 122 , generate and store a reminder message 128 for the response that was calendared; publish the reminder message 128 on the mobile communication device's displaying means 118 at predetermined intervals unless one or more alternate instructions 130 , 130 are received; receive a request to edit the coded message that corresponds to the selected at least one icon; replace a display 132 of a virtual keyboard 116 on the mobile communication device's displaying means 118 that comprises of at least one or more icons 114 , 114 , with a display of a virtual keyboard 116 with alphanumeric characters 134 , e.g. QWERTY alphanumeric keyboard; receive at least one edit to the converted coded message 120 ; store the at least one edit for the converted coded message 120 for the corresponding icon 114 for current and/or future use; or display an electronic address 122 for at least one or more electronic addresses 122 , 122 ′ of the at least one coded message 120 . Electronic addresses 122 , 122 ′ as used herein may include any one or more of the following: name, telephone number, email address and social network electronic identifier, e.g. a TWITTER™ handler, and the like.
Mobile communication device 102 may be any type of computerized electronic device configured with means for communicating wirelessly and/or wired with other mobile communication devices 102 , 102 ′, such as but not limited to, cellular phones (e.g., an iPhone, Android, Palm, Blackberry, or any “smart phone” as are generally known and used in the arts), location-aware portable phones (such as GPS), a personal computer, server computer, or laptop or netbook computer, a personal digital assistant (“PDA”) such as a Palm-based device or Windows CE device, a laptop computer, a tablet personal computer, a portable screen, a portable processing device and/or any other portable device capable of communicating wirelessly over a computer network 104 , local area network, wide area network such as the Internet, or any other type of network device that may communicate over a network 104 .
Computer processor 106 may be any type of processor, such as, but not limited to, a central processing unit (CPU), a microprocessor, a video processor, a front end processor, a coprocessor, a single-core computer processor, a multi-core processor, and the like. Computer processor 106 may be programmed to activate a coded message application (“coded message app”) 110 for displaying at least one icon 114 on a virtual keyboard 116 on the mobile communication device's at least one displaying means 118 , wherein the at least one icon 114 corresponds to at least one coded message 120 available for transmission to at least one or more electronic addresses 122 , 122 ′. Processor 106 may also be programmed to solicit instructions from the user, e.g. request an electronic address 124 for one or more message recipients 136 , 136 and/or other like instructions which may be displayed on the mobile communication's displaying means 118 . In some embodiments, mobile communication device 102 also includes a speaker 138 (as is well known and used in the arts) for broadcasting in audio the coded message 120 being transmitted, edited or saved, or for broadcasting reminder messages 128 , 128 ′ at predetermined intervals unless one or more alternate instructions 130 , 130 are received. Alternate instructions 130 , 130 ′ may comprise of any one or more of the following: okay, cancel, delete; and completed or the like.
In some embodiments, user may customize the predetermined intervals to select for example in Setup of the coded message app 110 , time preferences (e.g. 5 minutes, 10 minutes, 15 minutes, etc.) for a reminder message 128 to be published (on the displaying means 118 via a text or broadcasted over the speaker 138 ) if the user elects to change his/her standard or current settings for the same.
In other embodiments, the reminder message 128 may continue publishing for the predetermined intervals until the system 100 detects that an electronic communication (e.g. a return call or text message) is transmitted to the electronic address 122 that is the subject of the calendared response 126 to the incoming communication 124 . Practitioners of the art can appreciate that if multiple electronic addresses 122 , 122 ′ were identified in the incoming communication 124 , the reminder message 128 may continue publication until the system 100 detects electronic communications transmitted to one, a plurality, or all electronic addresses 122 , 122 ′ as originally identified in the incoming communication 124 .
Computer processor 106 positioned within the mobile communication device 102 includes computer executable instructions 112 readable and executable by the at least one computer processor 106 , where the computer executable instructions 112 are configured to perform all the necessary functions for the system 100 and methods disclosed herein, including but not limited to launching the coded message app 110 . Computer executable instructions 112 may be loaded directly on the mobile communication device's processor 106 , or may be stored in its memory means 140 such as, but not limited to, computer readable media, such as, but not limited to, a hard drive, a solid state drive, a flash memory, random access memory, CD-ROM, CD-R, CD-RW, DVD-ROM, DVD-R, DVD-RW, and the like. The computer executable instructions 112 may be any type of computer executable instructions 112 , which may be in the form of a computer program, the program being composed in any suitable programming language or source code, such as C++, C, JAVA, JavaScript, HTML, XML, and other programming languages.
Computer executable instructions 112 are configured to perform any all the necessary functions for the system 100 and methods disclosed herein which may include any one or more of the following: display at least one icon 114 on a virtual touch-screen keyboard 116 on the mobile communication device's at least one displaying means 118 , wherein the at least one icon 114 corresponds to at least one coded message 120 available for transmission to at least one or more electronic addresses 122 , 122 ′ via the at least one mobile communication device's communication means 108 ; receive selection of the at least one icon 114 for transmission to the electronic addresses 122 , 122 ′; convert the selected at least one icon 114 to a coded message 120 ; display the converted icon's coded message 120 on the at least one displaying means 118 ; receive selection of the at least one or more electronic addresses 122 , 122 ′; transmit the coded message 120 to the at least one or more electronic addresses 122 , 122 ′; display confirmation of transmission of the coded message 120 ; launch the coded message app 110 for transmitting coded messages 120 , 120 ′ to at least one or more electronic addresses 122 , 122 ′; receive and publish notification of an incoming communication 124 from a sender's electronic address 122 on the mobile communication device's displaying means 118 ; display at least one icon 114 on a virtual keyboard 116 comprising of icons 114 , 114 ′ on the mobile communication device's at least one displaying means 118 , wherein at least one icon 114 corresponds to an option for calendaring a response 126 ; receive selection of an icon 114 for calendaring a response to the incoming communication 124 ; convert the selected at least one icon 114 into instructions for calendaring a response 126 to be displayed as a reminder message 128 on the mobile communication device's displaying means 118 ; capture the sender's electronic address 122 , generate and store a reminder message 128 for the response that was calendared; publish the reminder message 128 on the mobile communication device's displaying means 118 at predetermined intervals unless one or more alternate instructions 130 , 130 are received; receive a request to edit the coded message that corresponds to the selected at least one icon; replace a display 132 of a virtual keyboard 116 on the mobile communication device's displaying means 118 that comprises of at least one or more icons 114 , 114 , with a display of a virtual keyboard 116 with alphanumeric characters 134 ; receive at least one edit to the converted coded message 120 ; store the at least one edit for the converted coded message 120 for the corresponding icon 114 for current and/or future use; or display an electronic address 122 for at least one or more electronic addresses 122 , 122 ′ of the at least one coded message 120 .
Memory means 140 may be either electrically or mechanically connected to the at least one computer processor 106 . In the case of electronic connections, the electronic connections may be wired and/or wireless connections. Memory means 140 may comprise of a storage device and may include memory, such as, but is not limited to, read-only memory, such as CD-ROMs, DVDs, floppy disks, and the like, read and write memory, such as a hard drive, floppy disc, CD-RW, DVD-RW, solid state memory, such as solid state hard drives, flash memory, and the like, and random access memory. Memory means 140 may be used to store information, such as coded message app 110 , coded messages 120 , 120 ′, edits to the coded messages 120 , 120 ′, reminder messages 128 , 128 ′, electronic addresses 124 , 124 ′, alternate instructions 130 , 130 ′ and the like. Electronic addresses 124 , 124 ′ include, but are not limited to, name, address, telephone number, email address, internet protocol address and the like. Stored information may be retrieved from the at least one memory means 140 using the computer processor 106 .
Mobile communication device 102 may include any kind of displaying means 118 , such as, but not limited to: a liquid crystal display (“LCD”) screen, a light emitting diode (“LED”) display, touchpad or touch screen display, and/or any other means known in the arts for emitting a visually perceptible output. Displaying means 118 may include a control means, such as, but not limited to, a touch screen, a stylus, and the like. Mobile communication device's processor 106 is in electronic communication with its displaying means 118 . In other embodiments, displaying means 118 is wirelessly connected to processor 106 . In some embodiments, displaying means 118 may be electronically connected to a mobile communication device 102 or client device 102 ′ according to the hardware and software protocols that are well known and used in the arts.
Mobile communication device's computer processor 106 controls its displaying means 118 , which is configured for displaying at least one icon 114 on a virtual keyboard 116 , wherein the at least one icon 114 corresponds to at least one coded message 120 available for transmission to at least one or more electronic addresses 122 , 122 ′; displaying the converted icon's coded message 120 ; displaying one or more reminder messages 128 , 128 ′; displaying confirmation of transmission of the coded message 120 ; displaying a virtual keyboard 116 comprising of a plurality of icons 114 , 114 ′ or alphanumeric characters 134 , 134 ′, e.g. QWERTY alphanumeric keyboard; and/or displaying one or more electronic addresses 124 , 124 ′ for receipt of the coded messages 120 , 120 ′ or response 126 , i.e. return calls, texts or emails, TWEETS™, and the like.
Mobile communication device 102 may include other hardware components, e.g. one or more communication means 108 , either electrically or mechanically connected to its computer processor 106 . In the case of electronic connections, the electronic connections may be wired and/or wireless. In some embodiments, communication means 108 may be a wireless communication means 108 , which employ short range wireless protocol, such as, but not limited to, a radio frequency transceiver, a radio frequency receiver, and/or a radio frequency transmitter. In embodiments where the wireless communication means 108 is a radio frequency receiver, the radio frequency receiver may be any type of radio frequency receiver, including, but not limited to, a positioning system receiver, such as a global positioning system receiver and a local positioning system receiver, such as a Wi-Fi positioning system receiver. In other embodiments, the communication means 108 may employ wireless protocols like Blue Tooth, ZigBee, 702.11 series, or a wireless modem, such as, but not limited to, a global system for mobile communications (GSM) modem, or any other short range wireless protocol that is well known and used in the arts and other future short range wireless protocol suitable for transmitting and receiving data. Communication means 108 are operative to transmit or receive electronic communications, i.e. coded messages 120 , 120 ′, audio, data, text, pictures, and the like via a short range wireless protocol, such as, but not limited to, a radio frequency receiver, a radio frequency transmitter, or a radio frequency transceiver.
In some embodiments, mobile communication device 102 may have one or more icons 114 , 114 ′ or other visual indicators displayed thereon that allows user to launch and access the coded message app 110 . When a user selects the launch icon 114 (e.g. by touching a touchscreen, or selecting it using a pointing device, roller ball, arrow keys, or other controller), the user may access the coded message app 110 .
System 100 also includes software component, i.e. a coded message app 110 , which may comprise in part of a browser, such as for use on the mobile communication device 102 , or a similar browsing device to transmit coded messages 120 , 120 ′ to one or more electronic addresses 122 , 122 ′ for one or a plurality of message recipients 136 , 136 ′. The app 110 may be any type of software application, such as a standalone application designed to run on a mobile platform, such as a mobile communication device running an operating system, such as iOS™, Android™, Windows Mobile™, Blackberry™, and the like. Coded message app 110 may be operative for an iPhone, any other “smart phone,” mobile communication device, cellular phone, PDA, GPS or any other mobile communication device 102 capable of handling transactions dealing with dynamic content, object, application, or software. In another embodiment, the app 110 may be designed to run on a social network platform, such as FACEBOOK™ or JUSTSYNC™.
In some embodiments, a coded message app 110 may reside on a server and/or on a mobile communication device 102 or client device 102 ′, where the server computer 106 may have a software program residing in memory. A client device 102 ′ may have the coded message app 110 residing in local memory or the coded message app 110 maybe downloadable to the client device 102 ′ from the server. For example, in one embodiment, the coded message app 110 may be on a mobile communication device (such as an iPhone, Blackberry, or other ‘smart phone’) and the full-sized software program may be on a computer, where communications may occur over a network or directly, either wired or wirelessly.
FIGS. 1B-1C are exemplary embodiments of the system 100 according to one embodiment. In some embodiments, once an incoming communication 124 is detected by the mobile communications device's processor 106 , the coded message app 110 is automatically launched and triggers the display of a virtual keyboard 116 of varied icons 114 , 114 ′, 114 ″ representative of coded messages 120 , 120 ′ available for transmission to varied electronic addresses 122 , 122 ′, including but not limited to the original sender of the electronic incoming communication 124 as seen in FIG. 1B . As shown, the incoming communication 124 is published via a display 132 on the mobile communications displaying means 118 including the icons 114 , 114 ′, 114 ″ for the associated coded messages 120 , 120 ′ for transmission to message recipients 136 , 136 ′. The coded messages 120 , 120 ′ may be the standard coded messages 120 , 120 ′ as included with the app 110 or user customized where the original coded message 120 associated with an icon 114 can be edited for a customized coded message 120 and stored for future use in the mobile communications device's memory means 140 . For example, as seen in FIG. 1C , listed are several icons 114 , 114 ′, 114 ″ and their corresponding coded messages 120 , 120 ′, 120 ″ where a student user may for instance customize the icon 114 representative of coded message for “AT WORK” to mean “AT SCHOOL.” By saving the edits and storing the changes, user may use the stored customized icon 114 in the future to notify his/her message recipients 136 , 136 ′ that he or she is AT SCHOOL. By simply clicking the icon 114 as modified for “AT SCHOOL,” processor 106 converts the selected at least one icon 114 to a coded message 120 that may be displayed on the displaying means 118 for transmission to one or a plurality of message recipients 136 , 136 .′
Similarly, the coded message 120 may be customized to reflect a language or dialect of the user's choice. In this manner, by user can maintain privacy over the coded messages 120 being transmitted as the language or dialect being used only requires the message recipient's 136 understanding of the same.
FIGS. 2A & 2B show exemplary icons 114 , 114 ′ on a mobile communication device 102 for calendaring a response 126 with a level of urgency (icon 114 ) based on an incoming communication 124 from a sender's electronic address 122 and a calendared response 126 . For example, if a sender initiates an incoming communication 124 , e.g. a text message or telephone call to user, processor 106 receives the incoming communication 124 and publishes by text or audio, notification of the incoming communication 124 on a mobile communication device 102 . In the exemplary embodiment, the incoming communication 124 is published via a display on the mobile communication device's displaying means 118 , e.g. by text message or phone number 202 (for incoming voice communications). User has the option to select the icon 114 (e.g., by touching a touchscreen, or selecting it using a pointing device, roller ball, arrow keys, or other controller) for calendaring a reminder message 128 to be published at predetermined intervals.
Methods
FIG. 3 is a sample flowchart of a block diagram of an exemplary method 300 according to one embodiment of the invention. Method 300 comprises of: providing at least one mobile communication device 102 that includes at least one processor 106 positioned within in electronic communication with at least one mobile communication device's communication means 108 (step 302 ). Mobile communication device 102 may include at least one displaying means 118 , which includes but is not limited to: a LCD screen, a LED screen, or a monitor and the like. As previously discussed, computer processor 106 may be any type of processor, such as, but not limited to, a central processing unit (CPU), a microprocessor, a video processor, a front end processor, a coprocessor, a single-core computer processor, a multi-core processor, and the like.
Method 300 further comprises of providing a coded message application program 110 comprising of computer executable instructions 112 readable by the at least one processor 106 , and configured to perform any one or more of the following: display at least one icon 114 on a virtual keyboard 116 on the mobile communication device's at least one displaying means 118 , wherein the at least one icon 114 corresponds to at least one coded message 120 available for transmission to at least one electronic address 122 , 122 ′ via the at least one mobile communication device's communication means 108 ; receive selection of the at least one icon 114 for transmission to the at least one or more electronic address 122 , 122 ′; convert the selected at least one icon 114 to a coded message 120 ; display the converted icon's coded message 120 on the at least one displaying means 118 ; receive selection of the at least one or more electronic address 122 , 122 ′; transmit the coded message 120 to the at least one or more electronic address 122 , 122 ′; or display confirmation of transmission of the coded message 120 (step 304 ). The mobile device's at least one communications means 108 is configured for accessing a data network 104 and transmitting electronically voice or data communications.
Processor 106 is further configured to launch the coded message application 110 for transmitting coded messages 120 to the at least one electronic address 122 , 122 ′ either automatically upon receipt of a detected incoming communication 124 or via an affirmative selection of an icon 114 on the mobile device's displaying means 118 .
FIG. 4 describes a sample flowchart of a block diagram of an exemplary method 400 of calendaring a response 126 . Method 400 comprises of receiving and publishing notification of an incoming communication 124 from a sender's electronic address 122 on the mobile communication device's displaying means 118 (step 402 ). User may choose to respond to the incoming communication 124 (text, email, incoming call social network communications, and the like) in any manner deemed appropriate including but not limited to sending a coded message 120 to the sender and or other message recipients 136 , 136 ′. The incoming communication 124 may automatically trigger the launch of the coded message app 110 or upon publication of the incoming communication 124 in audio or text on the displaying means 118 , the user may elect to launch the coded message app 110 for transmission of a coded message 120 .
As such, the app's computer executable instructions 112 readable by the at least one processor 106 , is configured to display a virtual keyboard 116 comprising of icons 114 , 114 ′ on the mobile communication device's at least one displaying means 118 , wherein at least one icon 114 corresponds to an option for calendaring a response 126 (step 404 ) for the user's selection.
The coded message app's computer executable instructions 112 receive the selection of the icon 114 for calendaring a response 126 to the incoming communication 124 (step 406 ); capture the sender's electronic address 122 (step 408 ); generate and store a reminder message 128 for the response 126 that was calendared (step 410 ). For example, user receives an incoming call from a known caller, e.g. an employer, user may select the appropriate icon 114 for calendaring a return call. In that manner, app 110 displays a reminder message 128 at predetermined intervals reminding user of the return call needed until the predetermined intervals have expired or some other event, for instance user returns the phone call.
Method further comprises of publishing the reminder message 128 on the mobile communication device's displaying means 118 at predetermined intervals until alternate instructions 130 , 130 ′ are received (step 412 ). Alternate instructions 130 , 130 ′ as used herein may include but is not limited to any one or more of the following: okay, cancel, delete, completed or the like. The predetermined intervals are customizable for the user's preferences (e.g. 5 minutes, 10 minutes, 15 minutes, 30 minutes, an hour, etc.) for a reminder message 128 to be published (on the displaying means 118 via a text or broadcasted over the speaker 138 ) if the user elects to change his/her standard or current settings for the same.
FIG. 5 describes a sample flowchart of a block diagram of an exemplary method 500 of editing at least one coded message 120 according to one embodiment. In some embodiments, user may modify one or a plurality of coded messages 120 , 120 ′ associated with an icon 114 when using the app 110 . The exemplary method 500 comprises of receiving a request to edit a coded message 120 that corresponds to a selected at least one icon 114 (step 502 ); replacing a display 132 of a virtual keyboard 116 on the mobile communication device's displaying means 118 that comprises of at least one icon 114 with a display of a virtual keyboard 116 with alphanumeric characters 134 , 134 ′ (step 504 ). Once the alphanumeric characters 134 , 134 ′ are displayed, user may edit the at least one coded message 120 to a more relevant description. Accordingly, the app's computer executable instructions 112 readable by the at least one processor 106 receives at least one edit to the coded message 120 (step 506 ); and stores the at least one edit for the coded message for future use (step 508 ). Once the edits are completed, user has the option of continuing to edit or to transmit the edited or another coded message 120 to one or more electronic addresses 122 , 122 ′ for one or a plurality of message recipients.
FIG. 6 describes a sample flowchart of a block diagram of an exemplary method 600 of transmitting at least one coded message 120 according to another embodiment. Method 600 comprises of launching the coded message app 110 (step 602 ) either automatically because of an incoming communication 124 or by an selection by user. In either embodiment, once launched, the app's computer executable instructions 112 readable by the at least one processor 106 , is configured to activate a display 132 on the at mobile communication device's at least one displaying means of a virtual keyboard 116 , e.g. a touchscreen, comprising of at least one or more icons 114 , 114 ′ (step 604 ) each corresponding to at least one coded message 120 available for transmission to at least one or a plurality of electronic address 122 , 122 ′.
Method 600 further comprises of receiving selection of the at least one icon 114 for transmission to the electronic addresses 122 , 122 ′ (step 606 ); convert the selected at least one icon 114 to a coded message 120 (step 608 ) e.g. if the user selected the at least one icon 114 representative for coded message 120 “I'm Driving,” the icon 114 would be converted and processor 106 causes the display of the converted icon's coded message 120 on the mobile communication device's displaying means 118 (step 610 ); receive selection of the at least one or more electronic addresses 122 , 122 ′ (step 612 ) of the intended message recipients 136 , 136 ′; transmit the coded message 120 to the at least one or more electronic addresses 122 , 122 ′ (step 612 ) for the message recipients 136 , 136 ′; and display confirmation of transmission of the coded message 120 (step 614 ).
Hardware and Operating Environment
This section provides an overview of example hardware and the operating environments in conjunction with which embodiments of the inventive subject matter can be implemented.
A software program may be launched from a computer readable medium in a computer-based system 100 to execute the functions defined in the software program. Various programming languages may be employed to create software programs designed to implement and perform the methods 300 - 700 disclosed herein. The programs may be structured in an object-orientated format using an object-oriented language such as Java or C++. Alternatively the programs may be structured in a procedure-oriented format using a procedural language, such as assembly or C. The software components may communicate using a number of mechanisms, such as application program interfaces, or inter-process communication techniques, including remote procedure calls. The teachings of various embodiments are not limited to any particular programming language or environment. Thus, other embodiments may be realized, as discussed regarding FIG. 7 below.
FIG. 7 is a block diagram representing an apparatus 700 according to various embodiments. Such embodiments may comprise a computer, a memory system, a magnetic or optical disk, some other storage device, or any type of electronic device or system. The apparatus 700 may include one or more processor(s) 704 coupled to a machine-accessible medium such as a memory 702 (e.g., a memory including electrical, optical, or electromagnetic elements). The medium may contain associated information 704 (e.g., computer program instructions, data, or both) which, when accessed, results in a machine (e.g., the processor(s) 704 ) performing the activities previously described herein.
The principles of the present disclosure may be applied to all types of computers, systems, and the like, include desktop computers, servers, notebook computers, personal digital assistants, microcomputers, and the like. However, the present disclosure may not be limited to the personal computer.
While the principles of the disclosure have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the disclosure. Other embodiments are contemplated within the scope of the present disclosure in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present disclosure. | The present invention relates generally to a system and method of transmitting coded messages electronically using a wireless mobile communication device to transmit coded messages identifiable by pre-programmed or programmable keys associated with icons corresponding to the coded messages being transmitted and providing for scheduling calendar events, e.g. calendared responses, which may include returning a phone call. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/954,432, filed Sep. 30, 2004, which claims the benefit of priority under 35 U.S.C. Sections 119 and/or 120 to the extent applicable to United States Provisional patent application Ser. No. 60/508,102 filed Oct. 2, 2003 for Multi-Layer Impact Resistant Bumper.
FIELD OF THE INVENTION
[0002] The present invention relates to multilayered products comprised of polymeric material and methods for producing such products. More particularly the invention relates to extruded or molded polymeric material products comprising layers that are bonded to each other, each layer comprising a polymeric material having a different selected durometer, hardness, bendability, impact resistance and/or melting point and/or concentration of dye and/or plasticizer materials.
BACKGROUND OF THE INVENTION
[0003] Extruded or injection molded products comprising two or more layers of polymer material are typically produced using complex molding or extrusion equipment and/or requiring complex processing steps that are difficult to reproduce from one extrusion or molding cycle to the next cycle. Processing methods for producing products comprised of polymer materials are typically developed by trial and error experimentation with a variety of different polymer materials having specific properties and molecular weights which, once determined are specific to production of the desired product and cannot be varied without substantially changing the end product.
SUMMARY OF THE INVENTION
[0004] The present invention relates to structural products that comprise a body of two or more polymer materials adhered or bonded to each other each polymer material having a different durometer, hardness, bendability, molecular weight or melting point or concentration of dye materials and/or plasticizers. The structural products of the invention are preferably formed as a multi-layered strip of polymer materials which is/are resistant to impact by solid objects and/or shock absorbent and resistant to shrinkage along the longitudinal or axial direction/length of the strip-form product.
[0005] In accordance with the invention there is provided an elongated strip of polymer material having a cross-section comprising:
[0006] a first inner core layer of a first polymer material having a selected configuration along the cross-section of the strip;
[0007] a second outer layer of a second polymer material bonded to an outer surface of the first inner core layer having a second selected configuration along the cross-section;
[0008] wherein the first polymer material has a softness, hardness or durometer selected to be manually bendable and compressible; and, wherein the second polymer material has a durometer or hardness greater than the durometer or hardness of the first polymer material.
[0009] The first and second layers are preferably co-extruded simultaneously through a die and bonded during their simultaneous co-extrusion. The second polymer material comprises a meltable polymer material that is melted for the first time after its initial manufacture during the co-extrusion. The first polymer material comprises a meltable polymer material that has been melted at least one once prior to the co-extrusion. The second polymer material typically contains at least one selected dye. The first polymer material typically contains at least two selected dyes.
[0010] The elongated strip may further comprise a third layer of a polymeric material bonded to an inner surface of the first layer. In such an embodiment, the first, second and third layers are co-extruded simultaneously through a die and bonded during their simultaneous co-extrusion. The third layer typically comprises a polymeric material that is first melted during the co-extrusion.
[0011] Further in accordance with the invention there is provided, an elongated strip of polymer material extruded in an extrusion cycle having a cross-section comprising:
[0012] a first inner core layer of a first polymer material having a selected configuration along the cross-section of the strip;
[0013] a second outer layer of a second polymer material bonded to an outer surface of the first inner core layer having a second selected configuration along the cross-section;
[0014] wherein the second polymer material is first melted during the extrusion cycle; and
[0015] wherein the first polymer material has been melted at least once prior to the extrusion cycle.
[0016] In another aspect of the invention there is provided, a method of producing a structural body of two or more layers of polymeric material, the method comprising:
[0017] selecting a first polymer material that has been melted and cooled to solid form;
[0018] selecting a second polymer material that has not been melted;
[0019] extruding the first and second polymer materials simultaneously in molten form through a selected mold or die in first and second strips;
[0020] layering the simultaneously extruded first and second strips into contact with each other in their molten form upon exiting the selected mold or die in a configuration wherein the first strip as formed has an outer surface and the second strip is deposited on the outer surface of the first strip.
[0021] The step of selecting the first polymer material includes selecting a polymer material that contains a dye material and has been melted prior to the step of extruding and most preferably comprises selecting a mixture of two or more polymer materials that have been melted and cooled to solid form.
[0022] The step of extruding typically comprises forming the first polymeric material upon exiting the mold or die into a strip form having an outer visible surface and an undersurface wherein, the step of layering comprises layering the second extruded polymer onto the outer visible surface of the second polymer material.
[0023] The step of selecting the second polymer material typically comprises selecting a predetermined first polymer material having a first durometer, hardness, bendability or molecular weight wherein the predetermined polymer material converts upon melting and cooling to a converted state having a second durometer, hardness, bendablity or molecular weight that is less than the first durometer, hardness, bendability or molecular weight; and wherein the step of selecting the first polymer material comprises selecting the predetermined polymer material in the converted state.
[0024] The step of selecting the second polymer material may comprise selecting a predetermined second polymer material and the step of selecting the first polymer material may comprise selecting a mixture of two or more polymer materials each being comprised of the predetermined second polymer material and each containing a dye. In another aspect of the invention there is provided, a method of producing a structural body of two or more layers of polymeric material, the method comprising: selecting a first polymer material that has been melted and cooled to solid form; selecting a second polymer material that has not been melted; extruding the first and second polymer materials simultaneously in molten form through a selected mold or die into first, second and third strips; layering the simultaneously extruded first, second and third strips into contact with each other in their molten form upon exiting the selected mold or die;
[0025] wherein the first strip is comprised of the first polymer material and the second and third strips are comprised of the second polymer material; and;
[0026] wherein the first strip is sandwiched between the second strip and the third strip.
[0027] In such an embodiment, the step of selecting the second polymer material may comprise selecting a predetermined polymer material having a first durometer, hardness, bendability or molecular weight wherein the predetermined polymer material converts upon melting and cooling to a converted state having a second durometer, hardness, bendablity or molecular weight that is less than the first durometer, hardness, bendability or molecular weight; and wherein the step of selecting the first polymer material may comprise selecting the predetermined polymer material in the converted state.
[0028] The step of selecting the second polymer material may comprise selecting a predetermined second polymer material wherein the step of selecting the first polymer material may comprise selecting a mixture of two or more polymer materials each being comprised of the predetermined second polymer material and each containing a dye.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is an underside/perspective cross sectional view of a composite material extruded bumper product according to the invention showing a solid strip form extruded body of material comprising a top outer layer of relatively hard polymer material, an inner or intermediate layer of relatively soft or less hard and more bendable polymer material and an undersurface strip of relatively hard, shrink resistant polymer material;
[0030] FIG. 2 is a topside/perspective cross sectional view of the FIG. product showing the product mounted or snap fit onto a railing;
[0031] FIG. 3 is a schematic cross sectional view of the FIG. 1 product;
[0032] FIG. 4 is a rear elevational view of the first plate as seen along line 4 - 4 of FIG. 3 ;
[0033] FIG. 5 is a rear elevational view of the second plate as seen along line 5 - 5 of FIG. 3 ;
[0034] FIG. 6 is a rear elevational view of the third plate as seen along line 6 - 6 of FIG. 3 ;
[0035] FIG. 7 is a rear elevational view of the fourth plate as seen along line 7 - 7 of FIG. 3 ;
[0036] FIG. 8 is a front elevational view of the fourth plate as seen along line 8 - 8 of FIG. 3 ;
[0037] FIG. 9 is a front cross-sectional view of the FIG. 1 product; and,
[0038] FIG. 10 is an exploded perspective view of the third and fourth plates shown in FIG. 3 .
DETAILED DESCRIPTION
[0039] FIGS. 1 , 2 and 9 show an extruded length of a multi-strip formed bumper product 8 comprising an outer facing strip 10 of relatively hard polymer material, and intermediate strip 20 of relatively soft, rubbery or bendable polymer material and an undersurface strip 40 of relatively hard, rigid, shrink resistant polymer material. The outer coat or strip component/layer 10 is bonded during the extrusion process, preferably immediately upon exit from the final extrusion die, to the outer surface of the inner soft or manually bendable layer or strip 20 such that the end product assumes the outward visual appearance of a relatively hard, shiny surface as opposed to the inner layer 20 which cannot be visually seen when mounted on a rail 30 as shown in FIG. 2 .
[0040] FIG. 2 shows the elongated strip-like product 8 mounted on a rigid, inflexible metal rail 30 by snap fitting of preformed tongues or detents 55 formed on the underside 57 , FIG. 1 , of the core 20 strip/layer onto a complementary receiving set of grooves or detents 59 formed on the outside surface the rail 30 shown in FIG. 2 .
[0041] As shown in FIG. 3 , the composite material feed for the core 20 is fed directly from the exit barrel 6 of the extruder through a central composite material bore 50 that extends through each of plates 1 - 4 . The polymer feed for the cap coat 10 is fed through an aperture 60 extending from the exit side to the entrance side of plate 4 through plate 4 , the feed then being routed through a bore 70 , FIGS. 7 , 8 , 10 on the entrance side of plate 4 such that the cap coat material feed is ultimately routed through plate 4 and out the exit side of bore 70 on the exit side of plate 4 , FIGS. 7 , 8 , 10 simultaneously with the extrusion of the feed material for the core 20 being routed through central bore 50 . The polymer feed for the rigid non-shrink strip 40 is initially fed through an aperture 80 extending from the exit side to the entrance side of plate 4 through plate 4 , the feed then being routed through a groove 90 , FIGS. 7 , 8 , on the entrance side of plate 4 such that the rigid strip 40 material is ultimately routed through plate 4 and out the exit side of bore 100 on the exit side of plate 4 simultaneously with the extrusion of the feed material for the core 20 being routed through central bore 50 and the feed material for the cap coat 10 being routed through bore 70 . Thus all three separate streams of polymer materials comprising the cap coat 10 , core 20 and rigid undersurface strip 40 are simultaneously co-extruded and come into contact with each other in a molten state immediately upon exit from the exit side of plate 4 . Once the three co-extruded streams of materials come into contact with each other in the molten state, the materials firmly bond to each other during and upon cooling to form the product shown in FIGS. 1 , 2 , 9 .
[0042] FIG. 3 shows an additional end plate 5 that may be used together with the plates 1 - 4 assembly, the exact configuration and use of plates and equipment to effect the fluid material feed connections to the bores of plates 1 - 4 being a matter of design choice for the skilled artisan. The disclosed embodiment showing the use of four separate plates 1 - 4 is shown for purposes of example only. Any number or configuration of extrusion plates that achieve the function of routing of the thermoplastic polymer materials as shown may be used in the process. Positioning the exit ends of feed bores 50 , 70 , 80 in close adjacency to each other such that the separate streams of exiting polymer materials contact the surfaces of each other upon exit from the extrusion plates is most preferred so that the separate streams of exiting polymer materials come into contact with each other in a molten state immediately upon exit and thereby adhere to each other upon cooling from the molten state to a stable cooled state. When the separate streams of polymer materials come into contact with each other in the molten state the mating surfaces mix together somewhat at the point of contact and upon cooling to a crystalline state become essentially adhered to each other to form a the unitary product 8 shown in FIGS. 1 , 2 , 9 . The separate streams of extruded polymer materials may alternatively be bonded to each other with a bonding material.
[0043] FIGS. 3 , 10 show a solid rod or wire 200 that may be positioned through the end portion of bore 50 in the middle of the detent 55 configuration of the core 20 strip to enable an elongated aperture 25 to be formed within the body of the detent during the extrusion process to impart additional bendability or flexibility to the detent 55 . Such additional flexibility imparted to the detent 55 better enables the detent to be manually snap fit around or over the outer surface of the complementary protrusion or detent 59 of the rail 30 onto which the bumper strip 8 is mounted. The snap fitted mounting of detents 55 onto the protrusions 59 firmly holds the bumper 8 on the rail 30 .
[0044] The core material 20 typically comprises a mixture of polymer materials that have been previously processed and melted in a prior extrusion or injection molding cycle, e.g. a mixture of scrap materials from previous extrusion cycle runs of one or more selected thermoplastic polymer materials such as polyvinyl chloride (PVC) where each scrap material contains a different concentration/amount of dye material and/or a different durometer or hardness. The subsequent extrusion processing cycle carried out on previously extruded or molded materials causes the composite material now being melted a second time in the course of an extrusion or molding process to assume a lower durometer than the originally extruded product comprising virgin material and/or a greater rubberiness, flexibility or bendability than the original virgin material. The lower durometer of scrap material may also be a result of the scrap materials containing several different dye and other additives such as plasticizers and the like.
[0045] As used herein the phrase “melted for the first time” or “first melted” or the like means that the polymer material has not been previously melted during an extrusion or molding process, it being understood that the starting polymer material may have been previously in a molten form as a result of its having been produced/manufactured in the first instance.
[0046] The cap coat 10 thermoplastic material selected is preferably virgin polymer material that has not been previously extruded or otherwise melted and typically does not initially contain a dye. The cap coat 10 material upon extrusion has a higher durometer, rigidity and less rubberiness, flexibility and bendability than the core material 20 . One or more dye materials that comprise between about 3% and about 10%, e.g. 4-7%, by weight of the cap coat polymer material may be mixed with/added to the thermoplastic starting feed material for the cap coat 10 .
[0047] The non-shrink strip material 40 is also preferably comprised of a virgin polymer material that has not been previously extruded or otherwise melted. Most preferably, the non-shrink strip material is the most rigid of the three polymer materials and is the most resistant to shrinkage particularly in/along the longitudinal direction of the elongated strip-form product 8 . The non-shrink material may comprise the same or substantially the same virgin polymer material as the core 20 material. The rigid strip 40 provides a particular resistance to shrinkage of the core material 20 along the longitudinal or axial length of the elongated extruded strip-like product 8 by virtue of being bonded to the underside of the core 20 strip. Such resistance to shrinkage by virtue of the bonding of the non-shrink strip 40 to the core strip component 20 thus obviates the necessity for replacing edge, end or corner pieces that are typically attached to or mounted at the ends of a finished strip product 8 once installed on a rail 30 in an actual shelf, counter or other retail store environment.
[0048] The polymer material selected for use in comprising the cap coat 10 and the core 20 typically comprises the similar basic polymers, mixture of polymers or thermoplastic materials, e.g. thermoplastic polyvinyl chlorides, nylons, polyesters, polyethers, polyamides, rubbers and latex rubber materials and copolymers of one or more of all of the foregoing. That is the polymer materials of which the cap coat 10 and the core 20 are comprised typically have essentially the same units making up the polymer backbone. The polymer material of the cap coat 10 and core 20 materials typically differ somewhat in polymer chain length, degree of cross polymerization (if any) or in concentration and composition of dye materials contained within the matrix of the materials. For example, the virgin cap coat 10 material typically comprises a polymer material having a durometer of between about 75 and 90, e.g. 80-85, and the core layer 20 material comprises a mixture of two or more scrap materials that were originally extruded from the same basic material as the cap coat 10 material containing the same or different dye materials at the same or different concentrations as the cap coat 10 material contains.
[0049] Polymer materials suitable for use in the invention are thermoplastic polymers that are relatively pliable or manually bendable such as polyvinyl chloride, polyamide, polyether, polyester and copolymers of all of the foregoing with one or more of each other or with urethane or other polymer units that impart a suitable manual bendability to the end polymer. Stiffeners, plasticizers, catalysts and the like may be contained within the polymer materials to impart any desired degree of flexural modulus, hardness, impact resistance and like mechanical/physical properties to the polymer material. | An impact resistant bumper device that is elongated along a longitudinal axis and mountable on a mounting member, the device having a cross-section having an open undersurface configuration comprising:
a first layer of a first polymer material having a first hardness or durometer;
a second layer of a second polymer material having a second hardness or durometer;
wherein the first layer is formed into an inner core body having an outer surface and an open undersurface;
wherein the second layer is formed into a layer bonded to the outer surface of the first layer;
a third layer of a third polymer material formed into an elongated strip bonded to the undersurface of the first layer; and
wherein the hardness or durometer of the first polymer is selected to be readily manually bendable and compressible. | 1 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/396,926, filed Jul. 17, 2002.
FIELD OF THE INVENTION
[0002] The present invention is directed to compositions and methods for the treatment of patients with cephalotaxines, for example, homoharringtonine. The invention is also directed to improvements in the purity, manufacturing process, formulation and administration of homoharringtonine for the treatment of cancer and other aberrant cellular diseases. The invention also provides methods and compositions for antiparasitic, antifungal, antiviral and antibacterial treatments.
BACKGROUND OF THE INVENTION
[0003] Cephalotaxanes are alkaloids extracted from skins, stems, leaves and seeds of Cephalotaxus fortunei Hook and other related species, such as Cepholotaxus sinensis Li, C. hainanensis and C. wilsoniana , including C. oliveri mast and C. harringtonia . Cephalotaxanes exhibit a unique structure, as shown in FIG. 1. Although cephalotaxine (wherein X in FIG. 1 is —OH) is abundant in C. harringtonia , it is devoid of biological activity. The presence of an ester side chain at C-3 appears to be critical to the antitumor potency.
[0004] Homoharringtonine (4-methyl-2-hydroxy-2-(4-hydroxy-4-methylpentyl), “HHT”) is the butanediocate ester of cephalotaxine. HHT is a naturally occurring cephalotaxine compound and has the structure shown in FIG. 2.
[0005] Reports suggest that HHT can be chemically synthesized with purity greater than 99.8% and total related impurity less than 0.5% (see L. Keller, et. al., Tetrahed. Lett., 42, 1911-1913 (2001)); international publication WO 02/32904 A1). Although at least 50% of Cephalotaxus alkaloids are cephalotaxine, the use of cephalotaxine as a source for semi-synthesis of HHT has not yet been economically justified.
[0006] HHT can also be prepared from cultured cells of C. harringtonia (U.S. Pat. No. 4,152,214). However, unlike preparations from cultured cells, whole plant-derived HHT has been clinically tested in various cancers including a number of forms of leukemia and preleukemic conditions, such as myelodysplastic syndrome (MDS). Furthermore, HHT derived from whole plants has been widely used in China as the front-line chemotherapy for acute myeloid leukemias, particularly acute promyelocytic leukemia (APL). There is little data on efficacy and toxicity of the chemically synthesized or tissue culture derived HHT.
[0007] Also, like most anticancer agents, HHT has dose-limiting toxicities, including myelosuppression, cardiotoxicity, and hypotension. Therefore, it is highly desirable to improve the dosage form of the drug, dosage amounts, and schedule of administration. Thus, improvements are sought to improve efficacy, reduce side effects, improve quality of life and increase survival of patients.
[0008] For naturally occurring products like HHT, it is desirable to increase the purity of HHT preparations away from related analogs, as well as reduce or eliminate additives, preservatives or excipients used to make the agent more pharmaceutically acceptable. More purified preparations will reduced physiologic stresses arising from the metabolic processing of or physiological responses to unwanted impurities and undesirable excipients. For example, additives such as sodium bisulfite, used as an antioxidant in pharmaceutical preparations, are known to cause allergic or hypersensitivity reactions in some patients. This also occurs for pharmaceutical diluents such as cremophor EL. Moreover, mannitol, a pharmaceutical excipient, can cause hypotension for some patients.
[0009] The National Cancer Institute conducted clinical trials in cancer chemotherapy using a lyophilized HHT product, provided as a sterile 10-mg vial. Mannitol (50 mg) and hydrochloric acid were included in the vial. The intact vials required frozen storage (at −10° C. to −20° C.). The lyophilized HHT in vials was to be reconstituted with 4.9 mL of 0.9% Sodium Chloride Injection, USP, to obtain a solution containing HHT at 2 mg/mL and having a pH of 3 to 5. The act of reconstitution could be problematic if improperly performed.
[0010] An object of the present invention was to provide a stable, therapeutically acceptable, intravenously injectable dosage form of HHT that does not require lyophilization and reconstitution, and that can be packaged and shipped as a single vial instead of a dual-vial package.
[0011] It is another object of the present invention to provide new methods and compositions for administering HHT for periods different from current dosage forms, and to provide new administration schedules to improve efficacy and reduce side-effects associated with drug treatment.
SUMMARY OF THE INVENTION
[0012] The invention described herein encompasses a method for the manufacture of homoharringtonine in scale suitable for pharmaceutical product development.
[0013] According to another aspect of the invention, a pharmaceutical composition which comprises a therapeutically amount of HHT purified from the natural plant according to methods described herein, is provided.
[0014] According to another aspect, the invention allows for the use of HHT as a soluble liquid dosage form, stable at room temperature for over two years in a convenient form for further dilution prior to administration to patients.
[0015] In a preferred embodiment, the liquid dosage form is further diluted for intravenous administration in dosages ranging from 1 to 5 mg/m 2 as an infusion. Administration is intermittent or continuous for 1 to 21 days per month.
[0016] These compositions and methods are designed for improved therapeutic benefit for patients suffering with drug sensitive disease conditions, for example, cancer, for example, leukemias, preleukemia conditions or other hyperproliferative or aberrant cellular conditions.
[0017] One aspect of the invention is a process for producing homoharringtonine. The process comprises
[0018] a) contacting a Cephalotaxus plant with citric acid to obtain an extraction mixture;
[0019] b) adjusting the pH of the extraction mixture of a) to between about 8 and 9 with ammonia;
[0020] c) extracting said extraction mixture of b) with chloroform;
[0021] d) applying reduced pressure to the extraction mixture of c) to remove said chloroform;
[0022] e) contacting the extraction mixture of d) with a silica gel column and eluting a purified extraction product;
[0023] f) concentrating the purified extraction product of e);
[0024] g) drying the concentrated purified extraction product of f);
[0025] h) contacting the dried extraction product of g) with methanol to obtain a precipitate; and
[0026] i) collecting said precipitate, wherein said precipitate comprises homoharringtonine.
[0027] According to one aspect of the invention, the contacting of step a) is for at least 48 hours. According to another aspect, the adjusting of step b) is to pH 8.5.
[0028] The process of the invention may further comprise concentrating the extraction mixture of step b) under reduced pressure, contacting the concentrated extraction mixture with citric acid, extracting the concentrated extraction mixture with chloroform, and adjusting the pH of the concentrated extraction mixture to between about 5 and 8.
[0029] According to a further aspect, the contacting of step h) is at a temperature between 4° C. and 10° C. According to another aspect, the contacting of step h) is for at least 16 hours.
[0030] The homoharringtonine produced by the claimed method is at least 98% pure. According to a preferred embodiment, the homoharringtonine produced by the claimed method is at least 99% pure.
[0031] According to one aspect, homoharringtonine produced by the claimed method is dissolved in water or buffered saline without pharmaceutical excipients.
[0032] Also claimed are compositions obtained by the process of the invention. According to one aspect, the compositions do not include mannitol. According to another aspect, the compositions do not require lyophilization to create a pharmaceutically acceptable dosage form.
[0033] Also claimed herein are methods of treatment using the claimed compositions. According to one aspect, the method of treatment includes administering a composition of the invention by intravenous administration for 5 to 25 days per month. According to another aspect, the method of treatment includes administering the compositions of the invention by a non-intravenous route. According to a further aspect, the non-intravenous route is intramuscular, subcutaneous, oral or intraocular administration. The composition of the invention can alternatively be administered as a depot.
[0034] Also included in the invention are aqueous solutions of HHT. According to one aspect, an aqueous solution of HHT, which is stable, is in a unit dosage form, and is suitable for administration by injection, is covered by the present invention. The aqueous solution, in some aspects, has a concentration between 0.1 and 50 mg/mL HHT. According to other aspects, the HHT concentration is between 1 and 5 mg/mL. The aqueous solution preferably has a pH at between about 3.0 and 5.0. According to other aspects, the aqueous solution has a pH of about 4.0. The aqueous solution is, in some aspects, provided in a sealed container.
[0035] Also covered by the present invention are methods of treatment of a host with an aberrant cellular condition. The method comprises contacting a host with a cephalotaxine in an amount sufficient to modulate the aberrant cellular condition. Preferably, the contacting occurs for at least 5 consecutive days. According to one aspect, the cephalotaxine is homoharringtonine. The aberrant cellular condition, in some aspects, is cancer, leukemia, a preleukimic condition, or myelodysplastic syndrome. According to one aspect, the homoharringtonine is administered by infusion in a dose between 1 and 5 mg/m 2 .
DETAILED DESCRIPTION OF THE FIGURES
[0036] [0036]FIG. 1 depicts the general structure of a cephalotaxane. The X at position 3 is a substituent group, examples of which are shown in Table I.
[0037] [0037]FIG. 2 depicts the structure of homoharringtonine (4-methyl-2-hydroxy-2-(4-hydroxy-4-methylpentyl), “HHT”).
DETAILED DESCRIPTION OF THE INVENTION
[0038] The structures of cephalotaxine analogs with various R1 and R2 substitution groups are shown in Table I, below.
TABLE I X (Figure 1) Name OH Cephalotaxine CH 3 COO Acetylcephalotaxine See Table II
[0039] [0039] TABLE II R1 R2 n Name H OH 2 Harringtonine (HT) OH H 2 Isoharringtonine (isoHT) H H 2 Deoxyharringtonine H OH 3 Homoharringtonine (HHT) OH H 3 Isohomoharringtonine (isoHHT)
[0040] Preparation of HHT
[0041] Homoharringtonine (HHT) is extracted from Cephalotaxus fortunei Hook, f and other related species. The process comprises extraction with citric acid or 90% ethanol, pH is then adjusted to alkaline range (pH 8.5-9.5) with ammonia or sodium carbonate. The solution is extracted with chloroform, and the chloroform is then removed under reduced pressure. The dried material is dissolved in citric acid and extracted with chloroform at gradient pH range, e.g. pH 5-7. The purified material is passed through liquid chromatography column packed with silica gel and monitored by TLC. The resulting mixture is separated by countercurrent distribution with chloroform and pH 5 buffer or tartaric acid. After removal of chloroform, the material is recrystallized from methanol. The employed process results HHT with yield about 0.002%, at least 98% pure with individual impurities less than 0.8% in concentration.
[0042] Mode of Administration
[0043] The compositions include compositions suitable for oral, rectal, topical, parenteral (including subcutaneous, intramuscular, and intravenous), ocular (ophthalmic), pulmonary (nasal or buccal inhalation), or nasal administration, although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. They may be conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
[0044] In addition, HHT can be delivered via drug delivery devices such as cellulose acetate membranes, osmotic pump, and the like, also through target delivery system such as liposomes. The active compounds can also be administered intranasally as, for example, liquid drops or spray.
[0045] A. Oral Dosage Form
[0046] Because of their ease of administration, tablets and capsules represent a particularly advantageous oral dosage unit form in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be coated by standard aqueous or nonaqueous techniques. Such compositions and preparations should contain at least 0.1 percent of active compound. The percentage of active compound in these compositions may, of course, be varied and may conveniently be between about 2 percent to about 60 percent of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that an effective dosage will be obtained. In preparing the oral dosage form, inactive ingredients such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binders, disintegrating agents and the like can be used.
[0047] B. Parenteral Dosage Form
[0048] Previous HHT dosage forms have required a lyophilized preparation containing mannitol as an excipient to improve the lyophilization process, stability, reconstitution characteristics, dosage form homogeneity and solubility.
[0049] There is provided by the present invention a stable, sterile, aqueous solution of HHT in a sealed container, for example, an ampoule or vial. The solution is provided in unit dosage form suitable intravenous administration. The solution, according to one embodiment, has a concentration of HHT between about 0.1 and about 10 mg/mL. Preferably, the solution has a concentration of HHT of about 1 mg/mL. In a preferred embodiment, the solution has a pH at between 3.0 and 5.0. More preferably, the solution has a pH of about 4.0.
[0050] In a preferred embodiment, the HHT solution is free of any other added chemicals. “Free of other added chemicals” means that the solution consists of HHT as purified according to the methods of the invention, dissolved in water. In other embodiments, the HHT solution also contains a customary, physiologically acceptable excipient or carrier, for example, a preservative or buffer.
[0051] The HHT solution is preferably a stable solution. A “stable” solution is one that exhibits less than 5% loss of potency as measured by high performance liquid chromatography (HPLC) upon storage for 7 weeks at 60° C. A “stable” solution is stable at room temperature for periods of at least one year such that the active compound does not degrade by more than 5% within that time period.
[0052] In the case where an intravenous injection or infusion composition is employed, the HHT solution is provided in a suitable dosage with one or more pharmaceutically acceptable carriers, excipients or diluents. In some embodiments, the HHT solution for intravenous injection or infusion is provided in combination with one or more chemotherapeutic drugs.
[0053] The liquid dosage form may range from less than 1 mg/mL of diluent to greater than 1 mg/mL including from less than 0.1 mg/ml to soluble concentrations greater than 1 mg/ml with appropriate adjustment of pH with buffers such as tartrate, phosphate, citrate, carbonate, etc. in ranges common or standard in pharmaceutical practice.
[0054] In another embodiment, the drug dose can be introduced subcutaneously, for example, as a depot administration, where an intravenous administration is less advantageous. In one embodiment, a depot administration is utilized in concentrations where drug particles are employed to dissolve slowly for sustained drug release.
[0055] A liquid dosage form, a buffered water soluble form without pharmaceutical excipients such as mannitol are infused over a duration of days preferably between 5 and 25 days per month 5 more preferably between 7 and 21 days utilizing dosages between 1 and 5 mg/m 2 , preferably between about 2 and 4 mg/m 2 . In a preferred embodiment, anti-proliferative effects are achieved in patients suffering from cancer, including leukemia including acute promyelocytic leukemia (APL), acute mycloid leukemia (AML) and chronic myeloid leukemia (CML) and preleukemia conditions including myelodysplastic syndrome or patients with other hyperproliferative aberrant cellular conditions through administration of HHT produced as a liquid dosage form, stable at room temperature of at least 98% purity dissolved in buffered water or saline without excipients such as mannitol administered by infusion to patient for a duration of 5 days or greater. In addition the dosage form can be administered with other chemotherapeutics such as antineoplastics including Gleevec, interferon, retinoic acids and the like.
[0056] The agents are provided in amounts sufficient to modulate aberrant cellular conditions such as solid cancers, leukemias, pre-leukemia conditions such as myelodysplastic syndrome, lymphomas and other aberrant hyperproliferative conditions. In one embodiment, modulation of an aberrant cellular condition comprises a reduction in tumor cell number or growth. In another embodiment, modulation of an aberrant cellular condition comprises inhibition of cell division and tumor cell growth. In other embodiments, modulation of an aberrant cellular condition comprises cytostasis. In still other embodiments, specific dosages, blood concentrations are delivered to the patient to affect cellular targets or enzymes unique to the actions of the compounds such as enzymes like telomerase, histone deacetylase or cellular targets such as histones, G protein coupled receptors and the like.
[0057] In some embodiments of the invention, modulation of an aberrant cellular condition comprises cytostasis or cytotoxicity. “Cytostasis” is the inhibition of cells from growing, while “cytotoxicity” is defined as the killing of cells.
[0058] In a preferred embodiment, a therapeutically effective dose of the compositions of the invention are administered to a patient in need of treatment. By “therapeutically effective dose” herein is meant a dose that produces the effects for which it is administered. The exact dose will depend on the purpose of the treatment, and will be ascertainable by one skilled in the art using known techniques. As is known in the art, adjustments for systemic versus localized delivery, as well as the age, body weight, general health, sex, diet, time of administration, drug interaction and the severity of the condition may be necessary, and will be ascertainable with routine experimentation by those skilled in the art.
[0059] A “patient” for the purposes of the present invention includes both humans and other animals, particularly mammals. Thus, the methods are applicable to both human therapy and veterinary applications. In the preferred embodiment the patient is a mammal, and in the most preferred embodiment the patient is human.
[0060] The term “treatment” in the instant invention is meant to include therapeutic treatment, as well as prophylactic, or suppressive measures for the disease or disorder. Thus, for example, successful administration of composition of the invention prior to onset of the disease results in “treatment” of the disease. As another example, successful administration of HHT after clinical manifestation of the disease to combat the symptoms of the disease comprises “treatment” of the disease. “Treatment” also encompasses administration of HHT after the appearance of the disease in order to eradicate the disease. Successful administration of an agent after onset and after clinical symptoms has been developed, with possible abatement of clinical symptoms and perhaps amelioration of the disease, comprises “treatment” of the disease.
[0061] Those “in need of treatment” include mammals already having the disease or disorder, as well as those prone to having the disease or disorder, including those in which the disease or disorder is to be prevented.
EXAMPLES
[0062] The following examples, given without implied limitation, show how the invention can be put into practice.
Example 1
Commercial Scale Manufacturing of HHT
[0063] 90 kg of the pieces of Cephalotaxus fortunei Hook, f. and 70 L of tap water are added in a cloth bag and soaked twice with 500 L citric acid for 48 hours followed by 500 L tap water. pH of the soak solution is adjusted to 8.5 with ammonia and then extracted with columns containing chloroform at 300 mL/min. The chloroform solution is concentrated under reduced pressure. Three of the concentrated solutions are combined and dried. Dried material is dissolved in 800 L chloroform and extracted with 2.5 L citric acid. The acid extraction solutions are combined and extracted with chloroform at pH 5, 6, 7 and 8, adjusted with ammonia. Chloroform is removed under vacuum and dried material is dissolved in chloroform and extracted with silica gel column monitored by thin-layer chromatography. The portions containing HHT is dried, then dissolved in 5 times volume of chloroform and extracted 4 times with tartaric acid. After removal of chloroform, the dried material is dissolved in methanol and precipitated at 4-10° C. for about 16 hours. The methanol/water mixture (1:2) is filtered, rinsed and dried. The crystallization step is repeated until the color is changed from dark reddish brown to canary. Then, the crystal is crystallized in methanol and discolored with activated carbon. The recrystallization step is repeated several times until the color changed to off-white. The purified material is dried under vacuum at 40-60° C. for 7 days.
[0064] The process if the invention can produce the homoharringtonine with a typical yield of about 0.05 g homoharringtonine per kg of Cephalotaxus fortunei Hook, f, and with a purity of greater than 99%.
Example 2
Manufacture of Aqueous, Stable, Sterile HHT with Tartaric Acid
[0065] 1. Dissolve tartaric acid in 80% batch quantity of Water for Injection.
[0066] 2. Dissolve homoharringtonine and dilute to final volume to yield a final concentration of tartaric acid at 0.4 mg/mL and homoharringtonine at 1 mg/mL.
[0067] 3. Adjust pH to 4.0 with NaOH and/or HCl, if necessary.
[0068] 4. Filter the solution through a 0.22-μm filter.
[0069] 5. Fill the filtered solution into the pre-sterilized containers (vials or ampoules) under aseptic conditions and seal.
[0070] 6. Terminally sterilize the filled ampoules at 121° C. for at least 15 minutes.
Example 3
Manufacture of Aqueous, Stable, Sterile HHT without Tartaric Acid
[0071] 1. Dissolve homoharringtonine in about 80% batch quantity of Water for Injection.
[0072] 2. Adjust pH to 4.0 with NaOH and/or HCl.
[0073] 3. Filter the solution through a 0.22-μm filter.
[0074] 4. Fill the filtered solution into the pre-sterilized containers (vials or ampoules) under aseptic conditions and seal.
[0075] 5. Terminally sterilize the filled ampoules at 121° C. for at least 15 minutes.
[0076] Advantages of liquid product over lyophilized product:
[0077] 1. Liquid form is less expensive. Lyophilization is an expensive manufacturing process (equipment, time, energy, etc.).
[0078] 2. Liquid form requires less packaging. Lyophilized product requires dual vial packaging, containing lyophilized vial and diluent vial, extra manufacturing, packaging and labeling costs, and extra room for storage, shipping.
[0079] 3. Liquid form preparation involves less time, expense, waste and risk. More preparation steps are required for a lyophilized product, more hazardous waste is generated, and risks associated with contamination and safety are increased.
[0080] 4. Liquid form is safer. Improper reconstitution can lead to an inaccurate dose.
Example 4
Method of High-Performance Liquid Chromatography
[0081] HHT is chromatographed on a reverse-phase isocratic HPLC system employing a mobile phase consisting of 24% of acetonitrile and 76% acetic acid (pH adjusted to 6.5 with 0.5% triethyleneamine) with a Keystone BDS Hypersil 5-μm C18 column. Detection is achieved by monitoring the UV absorbance at 288 nm and quantification is accomplished by peak area measurement with external calibration. Specificity; linearity, precision and accuracy have been demonstrated.
[0082] This method is applicable to bulk powder and liquid dosage formulations.
Example 5
Administration of Aqueous, Stable, Sterile HHT
[0083] The liquid or lyophilized dosage forms can be administered by intravenous infusion by adding the drug product in diluent including, but not limited to, Sterile Water for Injection, Bacteriostatic Water for Injection, Dextrose (2.5%, 5%, 10%), Dextrose-saline combination, Fructose (10%), Fructose in saline, Ringer's Injection, Lactated Ringer's Injection, Sodium Chloride (0.45%, 0.9%) or combination with one or more additional drugs.
[0084] Possible Process Steps to Improve Yield and Purity
[0085] Employing the following steps may improve the yield.
[0086] 1. Extract at optimal pH range (e.g. 5-7) in step 6.
[0087] 2. Use other acid solution (e.g. hydrochloric acid, acetic acid) in step 8 to replace tartaric acid.
[0088] 3. Use methanol instead of methanol/water mixture in step 11 for purification.
[0089] 4. Use specific part of tree (e.g. leaves, root, etc.) containing enriched content of homoharringtonine from Cephalotaxus fortunei Hook, f
[0090] The purity of the final product can be improved by the following steps.
[0091] 1. Extract with different solvent (e.g. acetone, ether, etc.) to remove impurity found in the HPLC chromatography with relative retention time of 1.1 mnutes.
[0092] 2. Use gradient column chromatography in step 7.
[0093] 3. Combine more pure portions in steps 5 and 7 monitored by thin-layer chromatography. | The present invention is directed to compositions and methods for the treatment of patients with cephalotaxines, for example, homoharringtonine. The invention is also directed to improvements in the purity, manufacturing process, formulation and administration of homoharringtonine for the treatment of cancer and other aberrant cellular diseases. The invention also provides methods and compositions for antiparasitic, antifungal, antiviral and antibacterial treatments. | 2 |
FIELD OF THE INVENTION
This invention relates to a device and method for aquatic greening or gardening in a restricted space of a dwelling or building or structure, and particularly an improved greening or gardening device and method used on a part or parts of the exterior of the dwelling or building or structure, such as a roof or passage.
BACKGROUND OF THE INVENTION
Recently house gardening, such as in a vinyl house, is now at the zenith of its popularity and various farm products are shipped to market regardless of the season. Alternately, a greening plan of a space of a dwelling or building or structure, especially a roof space, is on its way to practicality and various devices and methods, which use a fibrous foamed mat or a light artificial soil or stone, have been proposed for the greening. Further, greening concrete, which is porous and can retain moisture therein, has also been proposed to cultivate the plants on a wall surface or an inclined surface or a structure, by seeding or transplantation of the plants on these surfaces.
However, the artificial soil or the fibrous foamed mat for the greening of the structure seems to be easily blown away or carried away by a storm or a strong rain, and may contaminate a dwelling's environment. The greening concrete also seems to be higher in price than the original one, and has fault in its strength due to its porous character.
SUMMARY OF THE INVENTION
A device for hydroponics or aquatic greening in a restricted space of a dwelling or building comprises at least an aquatic rearing and cultivating device, such as an aquatic planter or a ditch which is filled suitably with culture fluid or water, and at least an aquatic float provided with plural planting beds.
A known aquatic planter may be used for soil planting, however, it is preferable to use a special one which is suitably designed to be in conformity with a restricted space in a dwelling or building, such as a passage of an apartment house, a porch or roof of a private house, etc., or a long ditch or conduit along with a passage or a fence of a roof of a dwelling or building, which is specially designed for an aquatic planting and permanently settled thereon.
A greening nursery bed of the present invention may be an aquatic float disclosed in U.S. Pat. No. 4,926,584, provided with or without a supplemental large float in which the former are set into the holes on the later and floated in or supported on the aquatic planter.
However, preferably a cover plate is supported on inside projections of the planter, the ditch or conduit and is provided with many holes or slits to insert the seed cages or beds, just as described above.
The aquatic planter may also be provided with a set of vertical, planar or inclined trellis or lattice means or supports to lead growth of the plants, such as a morning-glory, a cucumber, a watermelon, etc., which is disposed on or with a part of a dwelling or building, such a fence on the roof or the passage described hereinbefore, by ropes or binders.
The culture fluid or water in the aquatic planter is supplied from a storage tank, and circulated or transferred periodically to or from the other planter, with or without blowing into the air.
Rain water or town water may be used for the culture fluid, which may be prepared with a fertilizer for aquatic planting in the storage tank, prior to periodical circulation.
The blowing into the air for the aquatic planter may be performed by an air pump equipped on the planter and mainly driven with a solar electric means even if commercial electric power is practical.
The aquatic planter or the aquatic greening system may be controlled by a computer to cultivate the flowers, vegetables, etc., in a restricted space or a dwelling or building here and there, for labor saving, and may use partially or mainly the solar energy and rain water for material saving.
Accordingly, it is an object of the present invention to provide an aquatic greening device and method for cultivation of plants in a restricted space of a dwelling or building.
It is another object of the present invention to provide an aquatic greening device and method for cultivation of plants in a restricted space of a dwelling or building which uses natural energy and material.
It is a further object of the present invention to provide an aquatic greening device and method for cultivation of plants in a restricted spaced of a dwelling or building, here and there, which is controlled automatically with a computer.
It is a further object of the present invention to provide an aquatic greening device and method for cultivation of plants in a restricted spaced of a dwelling or building, which can control heat in the dwelling or building, and absorbs carbonic acid gas in the air, due to the plants cultivated thereon.
It is an object of the present invention to provide a dwelling or building having at least an aquatic plant garden, etc., thereon, for private use.
It is still a further object of the present invention to provide a dwelling or building having at least an aquatic green curtain or screen with the plants cultivated thereon for a fence or net.
It is still another object of the present invention to provide a dwelling or building having at least an aquatic farm block on its roof provided with a set of vertical planar trellis or lattice means for the plants.
It is still another object of the present invention to provide a dwelling or building having at least an aquatic farm block on its roof provided with an inclined trellis or lattice means which is disposed against a fence or a net on the roof
It is a further object of the present invention to provide a dwelling or building having arranged permanently at least an aquatic farm block and/or aquatic flower garden on its roof
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional front view for an aquatic greening device of the present invention;
FIG. 2 is a sectional side view of FIG. 1, along line A—A;
FIG. 3 is a sectional front view for another aquatic greening device of the present invention;
FIG. 4 is a sectional front view for another aquatic greening device of the present invention showing it arranged with a fence of a roof or passage for a dwelling or building through a vertical trellis or lattice means for the plants;
FIG. 5 is a plan view of FIG. 4;
FIG. 6 is a sectional front view, as in FIG. 4, except for supporters of the vertical trellis or lattice means for the plants;
FIG. 7 is a schematic flowsheet of an aquatic greening controlled by a computer;
FIG. 8 is a partial sectional front view of a further aquatic greening device in a type of a ditch, provided with a vertical trellis or lattice net for the plants;
FIG. 9 is a plan view of FIG. 8 omitting the vertical trellis or lattice net for the plants;
FIG. 10 is a sectional front view through a line X—X in FIG. 9, and shows a meshed rectangular seed bed or plant nursery used in the present aquatic greening;
FIG. 11 is the same view as in FIG. 10 and shows a foamed polyurethane seed bed;
FIG. 12 is a sectional side view of FIG. 11;
FIG. 13 is a partial plan view of still another aquatic greening device of the present invention and shows a foamed polyurethane seed bed provided with two series of holes or crevices for seeding;
FIG. 14 is a partial sectional front view of FIG. 13 cut through a line XIV—XIV;
FIG. 15 is a partial plan view of an aquatic greening device of the present invention combined with a planar trellis or lattice means for the plants thereon;
FIG. 16 is a front view of FIG. 15;
FIG. 17 is a side view of FIG. 15;
FIG. 18 is a front view of an aquatic greening device shown in FIG. 15 combined with a vertical rope trellis or lattice means for the plants; and
FIG. 19 is a perspective view of a building having arranged permanently thereon aquatic greening devices on its roof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and particularly FIGS. 1 and 2, an aquatic greening or gardening device G of the present invention is in a restricted space of a dwelling or building. The device G comprises fundamentally an aquatic planter 1 for a plant P′ filled with culture fluid W′ or water W to a suitable level, a supplemental float or cover 3 provided with holes 5 on which seed beds 4 is inserted, respectively, a circulation means for the culture fluid W′ or water W, including pipes 2 and a suction or circulation pump P, a storage tank T for the culture fluid W′ or the water W, a solar electric system SB and an air pump 6 which blows the air into the culture fluid W′ or the water W through an air discharge means 7 .
In such an aquatic greening device, the culture fluid may be prepared by mixing in the storage tank T water, especially rain water W from a storage tank (not shown) and fertilizer H for hydroponics farming or gardening, and circulated into the greening device through the pump P. The device may also be set along a fence t in a passage, a veranda, or a roof of a dwelling or building to be used for leading a vertical growth of the plants on the greening device, as shown in FIG. 4 and described hereunder.
The culture fluid W′ or water W in the planter 1 may be blown in the air by the air pump 6 driven periodically with power from a solar battery B to activate all of the plants on the culture beds 4 by oxygen in the bubbles through holes 8 of a buffer plate 9 .
The embodiment in FIG. 3 shows connected aquatic greening devices G 1 , G 2 , but lacks the blowing means of FIG. 1 . However, the greening devices G 1 , G 2 have a reversible water pump 35 on a connecting base plate BP between a flange of the devices G 1 , G 2 to replace periodically the culture fluid W′ from the devices G 2 to G 1 or from G 1 to G 2 , and supply oxygen to the plants P on the seed beds 34 during a fixed time, from their roots 36 exposed in the air in either of the greening devices G 1 , G 2 , in a known manner. In this embodiment, the reversible water pump 35 is controlled automatically with a timer 40 and a current exchange-over switch 41 and the direction of its rotation is periodically changed over with the above control means during a fixed time to replace the culture fluid W′ into the other greening device G 1 or G 2 through output and input holes 42 , 43 of the pump 35 . Accordingly, the roots 36 under a supplemental float or cover 33 in either greening device G 1 or G 2 is exposed to the air, due to a space 38 underneath the float 33 supported on the inclined inside walls of the devices G 1 or G 2 , when the water level is significantly decreased.
The aquatic greening devices G 1 , G 2 may also be arranged adjacent the fence or net of the passage, the porch or the roof of the dwelling or building, as mentioned before.
FIGS. 4 to 6 show aquatic greening devices G 3 , G 4 , respectively, installed adjacent fence t of the dwelling or building and combined with legs 14 of the later by ropes or binders 13 through supports 11 , 12 of a vertical trellis or lattice M for plants P. The supports 11 , 12 in FIG. 4 are on a flange 10 and the vertical trellis or lattice net M is stretched between supports 11 , 12 by horizontal ropes 15 . In FIG. 6 the supports 11 , 12 of the net M are joined directly with the legs 14 of the fence t, because the device G 4 does not have a flange and stretched between the supports 11 , 12 , as is in the same manner of FIG. 4 .
The stretched vertical trellis or lattice M lead, respectively, the plants especially vine plants such as a morning glory, in all directions to grow on it, and forms a green curtain beside the fence t to shut out sunlight or public notice from the dwelling or building, and to prevent a fall of things.
FIG. 7 shows schematically an aquatic greening device G 5 which uses natural energy and rain water, in or on the restricted space of the dwelling or building, such as a roof, passage, veranda, etc. The device G 5 comprises an aquatic planter 71 or an aquatic long ditch 71 B connected with a water tank T 2 through a culture fluid tank T and a filter F provided with a circulation pipe 78 connected with the planter 71 or the ditch 71 B through a pipe 77 .
The aquatic greening device G 5 is also provided with a solar electric generating set E comprising a solar panel SP and a battery B to supply partially an electric power for the system, and may be controlled automatically by a computer C, together with the other systems on the same or other dwelling or building, according to well known prior art.
The aquatic planter 71 or the aquatic long ditch 71 B may be plural planters 1 connected with the others mutually through pipes 2 , shown in FIGS. 1, 3 , 4 , or 6 , and be set detachably with a part of the dwelling or building such as a fence t in the roof or veranda. However, it is preferable that the long aquatic ditch or conduit is settled permanently on the restricted space of the dwelling or building, such as the roof, without hindrance of the function for the other equipment on it, when the dwelling or building is constructed.
The long ditch or conduit 71 B for the aquatic planter 71 may be provided with plural seed beds, such as the aquatic floats, disclosed in U.S. Pat. No. 4,926,584, and the supplemental floats or cover 3 shown in FIGS. 1, 4 or 6 , but it may be preferable to provide a cover plate 83 supported on its upper-most inside and the later provided with holes and/or slits 84 , 85 , in which circular or square seed beds 86 , 87 are set thereon, as shown in FIGS. 8 and 9 described hereinafter.
The ditch 71 B also juxtaposes a trellis or lattice M set with poles or the fence equipped in a restricted space of the dwelling or building etc., described hereinbefore, for leading vertical growth of the plants P′ in the seed beds 86 , 87 .
The storage tank T for the culture fluid is connected with the ditch 71 B through a pipe 73 and a supply pump P 1 , and with the water storage tank T 2 through a pipe 74 and a pump P 2 . The tank T may supply also the culture fluid into another parallel aquatic greening means (not shown) through a pipe 82 with a pump P 6 , while it prepares mainly a culture solution by adding the water supplied from the storage tank T 2 and a water soluble fertilizer for hydroponics, such as “Hylizer” described hereunder, if it is necessary to use the culture fertilizer solution but not the water.
The culture fluid generally is circulated repeatedly from the tank T′ to the ditch 71 B through a pipe 73 by the supply pump P 1 and pipes 76 , 77 , 78 by a pump P 4 , without blowing into the air as shown in FIG. 1 . The fluid may also be circulated into the ditch 71 B, after filtering in a filter F through the pipes 72 , 77 , 78 by a pump P 5 , when it is soiled with dust, such as cut roots, sediments, etc., and to which may be added the fresh culture fluid from the storage tank T by means of the pump P 1 through the pipe 73 , if the fluid has been decreased. The culture fluid is finally drained from a pipe 79 after it is neutralized or diluted in a neutralizing tank 81 , when the farm products have been harvested or its agricultural effects have been lost.
In operation of the present aquatic greening, firstly the rain water from an underground storage tank (not shown) is charged into the water tank T 2 through the pipe 75 by the pump P 3 and thereafter to the culture fluid tank T through the pipe 74 by the pump P 2 . If the plants to be cultivated on the ditch 71 B require the use of the aquatic fertilizer solution, the aquatic fertilizer H is added therefore to the water and discharged into the ditch 71 B by the pump P 1 through the pipe 73 , after the solution is arranged in a suitable concentration. However, if the water can be used as the culture fluid, it may be charged directly into the ditch 71 B.
The seeds or young plants thereafter are sowed or transplanted on the rectangular or round seed beds or cage 86 , 87 supported on the cover 83 of the ditch 71 B described hereafter. The plants P′ grown on the seed cage 86 , 87 are supplied continuously with the fertilizer solution to their roots and grow along the vertical trellis or lattice mesh or net M 7 stretched and joined between the poles forming the fence t on the roof or the passage of the dwelling or building.
The fertilizer solution may be continuously or periodically circulated from one side of the ditch 71 B through pipes 72 , 76 , 77 , 78 by the pump P 4 . If the solution has been seriously contaminated with cut roots of the plants, etc., it may also be purified with the filter F and circulated to the other end of the ditch 71 B by the pump P 5 , through the pipes 73 , 77 , 78 , after releasing valves V 2 , V 2 ′.
The solution is also supplied additionally from the tank T 1 , if it has decreased to a selected fluid level in the ditch 71 B, through the pipe 73 and the pump P 1 after releasing a valve V 1 , and finally discharged from the ditch 71 B to a neutralizing tank 81 , after releasing a valve V 3 and drained from a pipe 79 , after the neutralization or dilution until a legal permissible limit for the discharge.
The plants P′, after cropping or blooming in the ditch 71 B, are taken off together with the vertical trellis or lattice net M 2 and a new aquatic greening is repeated with the same or different culture fluid from the storage tank T.
In the aquatic greening system, young leaf vegetables, such as a seed leaf of radish, a bean malt such as a sprout or a bulbous plant such as tulip or crocus, etc., may be cultivated with water, however, almost all of the plants have to use a culture solution for their growth.
An aquatic fertilizer used in the present greening system is “Hylizer” (trade name) and its concentration with respect to each cultivated plant is a follows:
Cultivated Plants and Concentrations of “Hylizer” Solution
First Group:
Cucumber, Melon, Watermelon
10 liter of water
Pumpkin, Cabbage, Chinese
per 26 gram of
Cabbage, Rose, Carnation
Hylizer
Second Group:
Honewort, Celery, Parsley
15 liters of water
Eggplant, Pimento, Tomato
per 20 gram of
Hylizer
Third Group:
Lettuce, Turnip, Spinach
20 liters of water
Welsh, Chrysanthemum
per 20 gram of
Hylizer
Fourth Group:
Cleson, Strawberry
30 liters of water
per 20 grams of
Hylizer
Fifth Group:
Pot Marigold, Horseradish,
40 liters of water
Sweet Pea, Sun Plant, Orchid
per 20 grams of
Hylizer
FIGS. 8 and 9 shown another embodiment of a vertical trellis or lattice net or mesh M 8 set in a long ditch 71 B as shown in FIG. 7 . The trellis or lattice M 8 is stretched between two or more supports tl which are inserted in projections b on a bottom 82 of the ditch 71 B through a cover 83 . The cover 83 may also be supported on multiple pairs of supports 89 a along both the longitudinal inside walls of the ditch 71 B and disposed thereon the circular or square seed beds 86 , 87 , so that their undersurface are in contact with the culture fluid W 1 which is charged through the pipe 73 .
The little plants, such as the seed leaf of radish, lean malt, etc., which have a short term growth, may be planted on a mesh m of the seed bed 88 , as shown in FIGS. 9 and 10. However, it the plant is a large one, such as liana, or a seedling for transplanting it is necessary to plant on or in a sponge material such as a foamed polyurethane 89 , as shown in FIGS. 11 and 12, to hold their stems S firmly so that the plant may grow without falling down, by absorbing the culture fluid W 1 from the root R.
In the case of an aquatic planting of a vegetable such as lettuce, it is preferable to plant it in two ridges 90 or more of the foamed polyurethane bed 89 due to a large crop from the ditch 71 B. The polyurethane bed 89 is supported on crosspieces 93 furnished detachably on both inside walls of the ditch 71 B and sectioned on the crosspieces into blocks 92 for easy treatment of the crop. The ridges 90 are made by two rows of slits on a cover 83 , when the cover is set forcibly on lateral inside projections 94 of the ditch 71 B, and seeds or seedlings of lettuce are sown or transplanted in crevices 95 on the ridges 90 .
FIGS. 15 to 17 show a planar trellis or lattice means PL for the present invention, and comprises frames FR which are detachable from a ditch 71 B, as shown in FIG. 9, and each is fabricated from separated frame pieces 98 , 99 , 100 , 101 and a net or mesh MP, which is provided on the planar frame piece by pins 104 . The frame pieces 98 , 99 , 100 , 101 are connected with hinges 97 and the connected frame pieces are bent at right angles from the first end frame piece 98 , under a bottom 95 a of the ditch 71 B to the second frame piece 99 along with vertically outer-surface 96 of the ditch 71 B, and thereafter a third piece 100 is bent further at the same angle. The last frame piece 101 is bent more downwardly at a right angle so that its end 102 is received into a recess on a frame holder 103 to form a fixed wisteria trellis beside the ditch 71 B, with three frame pieces 99 , 100 , 101 . The net MP is stretched on the multiple frames FR that is respectively arranged in parallel, as shown in FIGS. 15 and 16, and is fixed on the frames by pins 104 . The plant P′, such as melon, green pea, etc., is cultivated in a seeding cage or bed 87 on the ditch 71 B and grown on the trellis or lattice net MP to form a crop of fruit or melon FL in the restricted space of the dwelling or building, such as its roof or veranda.
In FIG. 18, a plant, for example, morning glory, is cultivated in a series of ditches or planters 71 B with vertical leading ropes R′ hanging down from lateral wire 107 between poles 106 on a roof or the dwelling or building, and makes a green curtain or blind for the dwellers. The culture fluid is, of course, circulated into the planters 71 or ditches 71 B along the direction of arrows f from the storage tank (not shown) described hereinbefore.
A building BL, as shown in FIG. 19, is covered with flowers P 1 , P 2 and vegetables or fruits P 3 grown in connected ditches 71 B arranged about an inside of the fence t on a wall 110 on its roof The ditch 71 B may be replaced by a series of connected planters, as shown in FIG. 18, and supplied with the culture fluid, such as water or a culture solution, from a pipe and drained to a storage tank or drainage (not shown) through a pipe 108 , after being treated suitably as mentioned before. The fence t and a latch means 112 , with ropes or wires 113 on a surface of the roof RS, are used for as set of an inclined trellis or lattice net 111 for the purpose of cultivating the flowers or vegetables and the crops may be sold or used for market or private use.
A pool 71 ′, controlled by valves V 9 , V 10 , may be installed on the roof surface RS and supply the water or culture solution from pipes 114 through the ditch 71 B to cultivate the flowers P 1 , P 2 on the aquatic floats, as mentioned before, and may include raising fish 109 , if the fruit is water.
The roof of the dwelling or building may be covered with a vinyl sheet or glass to protect the plants, and may be provided with a solar generator and a storage tank for rain water to be used partially as electric power or a natural resource for the present system. The aquatic greening or gardening on single or multiple dwellings or buildings may be controlled in the same building or another building by the computer as described hereinbefore.
Thus, the aquatic greening provides not only many fresh flowers and vegetables but also many fruits such as melon, strawberry, watermelon, etc., for the dwellers, commuters, managers and their families. The plants cultivated in the restricted spaces in the dwellings or the buildings also absorb carbonic acid gas from the atmosphere and release oxygen into the air to purify the town's environment, and control the temperature of the dwelling or building in which they are cultivated.
The plants, such as morning glory, cultivated with the vertical trellis or lattice net or ropes, along with the fence of the dwelling or building, may be a green curtain or fence to intercept the field of vision from outside, and to prevent a fall or a person or an object from the dwelling or building.
In the present invention there has been described and pointed out the fundamental novel features as applied to a preferred embodiment. It will be understood that various omissions and substitutions and changes in the form and details of the aquatic greening system and device and method illustrated may be made by those skilled in the art without departing from the spirit of the invention. The invention therefore is to be limited only by the scope of the following claims. | A method and device for aquatic greening in a space of a structure including a storage tank for a cultivating fluid, pump and pipes for circulating the cultivating fluid in a prescribed concentration and flow to a cultivating device, a tank for collecting the cultivating fluid drained from the cultivating device wherein the drained cultivating fluid may be filtered and neutralized or diluted. The cultivating fluid may be a fertilizer fluid or water or a mixture thereof. Electric power for operation may be provided by a solar energy source. The operation of the method and device may be controlled by a computer located in the structure or an adjacent structure. Air may be blown partially or thoroughly into the cultivating fluid. A mesh or net or wires, which may form a trellis and which may be attached to the structure, is adjacent the cultivating device and assist in the growth of the aquatic greening. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for generating hydraulic pressure, and more particularly to a hydraulic pump using shape memory alloys.
2. Description of the Prior Art
FIG. 1 illustrates a conventional hydraulic generating system 10 installed in vehicles for driving an actuator of various hydraulic systems. As illustrated, the conventional hydraulic generating system includes a pump 16 for generating hydraulic pressure and a motor 12 for driving pump 16 via a coupling 14 by means of an electric power.
Motor 12 is fixed to a base plate 18 by using bolts and the like, and pump 16 is fixed to base plate 18 while being attached to a bracket 15. Motor 12 is coupled with pump 16 by means of coupling 14.
Once electric power is supplied to motor 12, motor 12 is rotated and pump 16 which is joined to coupling 14 receives the rotational force of motor 12 via coupling 14 to generate the hydraulic pressure which, in turn, is transmitted to various hydraulic systems to drive them.
In the above conventional hydraulic generating system, however, motor 12 is required as a driving power for generating the hydraulic pressure, and coupling 15 for transmitting the power of motor 12 is a requisite element.
Furthermore, bracket 15 for attaching pump 16 thereto and base plate 18 for fixing motor 12 and bracket 15 are added, which complicates the structure, makes the weight heavy, requires high cost and is difficult to repair.
On the other hand, shape memory alloys refer alloys that preserve a shape deformed by an external force below a critical temperature, whereas a shape memory effect of the alloy is activated for recovering a memorized original shape by a shape recovering force after being heated to the critical temperature. The shape memory alloys such as a titan-nickel alloy and an aluminum alloy are fabricated at a high temperature to have a predetermined shape.
There are two methods of applying heat the shape emory alloys. In the first method, fluid is forced to flow around the shape memory alloys to change the temperature of the fluid. In the second method an electric current is forced to flow along the shape memory alloys to generate heat by an electric resistance of the shape memory alloys, thereby heating the shape memory alloys.
The shape memory alloys shaped as a spring mainly respond to the temperature of the fluid flowing around the shape memory alloys or of an object contacting the alloys. In more detail, when the temperature of the fluid flowing around the spring formed of the shape memory alloy reaches the critical temperature, the shape memory alloy spring restores its original shape; otherwise, when the temperature of the fluid goes below the critical temperature, the shape thereof is deformed by the external force.
However, a structure using the above-described shape memory alloy spring has a slow response rate with respect to the temperature of the fluid, and it is difficult to accurately control the operative range of the shape memory alloy spring. Furthermore, the shape of the shape memory alloy spring is complicated, thereby making manufacturing difficult.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a hydraulic generating system using shape memory alloys of which the structure is simple, light and easily repaired.
To accomplish the above object of the present invention, there is provided a pump which comprises:
a body having a cylinder formed on one side thereof with an intake port for introducing a fluid, an exhaust port for externally discharging the fluid introduced into the cylinder, a drain port formed on a lower portion of the cylinder for discharging the fluid introduced to the lower portion of the cylinder, and a drain flow passage for connecting the drain port to intake port, said body having a lower portion opened;
a piston mounted to be able to slide within the cylinder, permitting the fluid to flow into the cylinder while moving from a first position to a second position, and discharging the fluid introduced in the cylinder via the exhaust port while moving from the second position to the first position;
an end cap mounted with a pair of electric terminals and coupled to the lower portion of said body to tightly close the cylinder of said body;
a biasing means installed between a lower end of said piston and an upper end of said end cap for exerting a biasing force to maintain said piston at the first position and for moving said piston from the second position to the first position; and
a shape memory alloy member suspended to an outer circumference of a connecting pin penetrating through a lower portion of said piston and connected to the electric terminals of said end cap for moving said piston from the first position to the second position while overcoming the biasing force of said bias means when an electric power is supplied via the electric terminals.
Here, a unilaterally opened/closed first check valve is installed to an intake port, and a unilaterally opened/closed second check valve is installed to an exhaust port. A drain port is formed to the lower portion of a cylinder, and a unilaterally opened/closed third check valve is installed to the drain port which is connected to the intake port via a drain flow passage to drain fluid admitted in the lower portion of the cylinder.
By supplying electric power to a shape memory alloy member via a pair of electric terminals (ON), the shape memory alloy member moves a piston from a first position to a second position while overcoming the biasing force of a bias spring as the biasing means. At this time, the fluid is introduced into the cylinder via the intake port.
When the piston reaches the second position, the electric power supplied via the pair of electric terminals is cutoff to exert the biasing force of the bias spring upon the piston, so that the piston is moved to the first position while relaxing the shape memory alloy member. At this time, the fluid introduced in the cylinder is externally discharged via the exhaust port. Thus, the pump using the shape memory alloys according to the present invention is light, simple in its structure and easily repaired and maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail the preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a schematic view for showing a conventional hydraulic generating system using a motor;
FIG. 2 is a sectional view for showing a pump using shape memory alloys according to a first embodiment of the present invention;
FIG. 3 is a sectional view for showing a state that an electric power is supplied to the shape memory alloys of the pump shown in FIG. 2;
FIG. 4 is a sectional view for showing a state of generating pressure when electric power is not being supplied to the pump of FIG. 2;
FIG. 5 is a sectional view for showing a pump of a multi-cylinder system using shape memory alloys according to a second embodiment of the present invention; and
FIG. 6 is a plan view for showing the pump of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A pump using shape memory alloys according to the present invention will be described in detail.
EMBODIMENT 1
FIG. 2 shows a sectional view of a hydraulic pump 100 using shape memory alloys according to a first embodiment of the present invention.
Hydraulic pump 100 according to the first embodiment of the present invention includes a body 30, a piston 40 slidably mounted into body 30 for introducing and discharging fluid, and a shape memory alloy member 50 for moving piston 40 from a first position to a second position of piston 40. In addition, a bias spring 44 moves piston 40 from the second position to the first position thereof.
Body 30 is provided with an intake port 20 formed to one side thereof for introducing the fluid when piston 40 is moved from the first position to the second position, and a cylinder (or hydraulic chamber) 28 filled with fluid which is introduced via intake port 20. Also, an exhaust port 24 discharges the fluid while piston 40 is moved from the second position to the first position, and a drain flow passage 34 connects intake port 20 to the lower portion of cylinder 28 for draining resultant fluid.
Intake port 20 as above is installed with a unilaterally opened/closed first check valve 22, and exchaust port 24 is with a unilaterally opened/closed second check valve 26. A drain port 32 for draining is formed to the cylinder side of drain flow passage 34, and a unilaterally open/close third check valve 36 is installed to drain port 32. The upper portion of cylinder 28 has a jaw to block excess movement of piston 40 when moving from the second position to the first position.
At the lower portion of body 30, i.e., at the lower portion of cylinder 28, an end cap 38 mounted with electric terminals 52 is coupled to tightly close cylinder 28.
In order to maintain piston 40 at the first position, bias spring 44 for exerting a biasing force to piston 40 is mounted between piston 40 and end cap 38.
Shape memory alloy member 50 which moves piston 40 from the first position to the second position while overcoming the biasing force of bias spring 44 is suspended to the outer circumference of a connecting pin 42 penetrating piston 40 and is connected to electric terminals 52 installed to end cap 38. Shape memory alloy member 50 is contracted while overcoming the biasing force of bias spring 44 when the electric power is supplied via electric terminals 52, thereby moving piston 40 from the first position to the second position.
In order to be utilize the shape memory alloys to the pump, the total contraction and relaxation time of the shape memory alloy member should be below 100 ms, preferably ranging from 20 ms to 100 ms, and the maximum tensile force thereof should be 10 Kgf/mm 2 . Such a shape memory alloy memory is described in a patent, e.g., U.S. Pat. No. 5,211,371 (issued to Coffee) which discloses a valve utilizing shape memory alloys. The shape memory alloys utilized in the valve of Coffee is in the shape of a wire which is electrically controlled by an electric circuit. The electric circuit is a closed circuit having a plurality of transistors and a plurality of capacitors, so that the shape memory alloys are actuated in accordance with a cycle using operations of charging/discharging the capacitors and switching of the transistors. Also, U.S. Pat. No. 5,092,901 (issued to Hunter et al.) describes shape memory alloy fibers with a very short total contraction and relaxation time suitable for being employed as an electromagnetic operator.
In the present embodiment, the shape memory alloy, e.g., disclosed in U.S. Pat. No. 5,092,901, may be utilized. In order to satisfy the conditions of the shape memory alloy member, i.e., 20 to 100 ms and 10 Kgf/mm 2 , a single or bundle of commercially available shape memory alloy fiber may be used for forming the shape memory alloy member.
Bias spring 44 applies the biasing force upon piston 40 when the electric power supplied to shape memory alloy member 50 is turned off to move piston 40 from the second position to the first position, so that the fluid introduced into cylinder 28 is discharged via exhaust port 24 and contracted shape memory alloy member 50 is relaxed. Also, if the electric power is not applied to shape memory alloy member 50 via electric terminals 52, bias spring 44 imposes the biasing force upon piston 40 to maintain piston 40 on the first position thereof.
An operation of pump 100 having the above described structure will be described.
FIG. 2 shows an initial state of pump 100 using shape memory alloys according to the first embodiment of the present invention.
Piston 40 is placed on the upper end of cylinder 28, i.e., at the first position ,by the biasing force of bias spring 44, and bias spring 44 and shape memory alloy member 50 maintain the relaxing state. At this time, the electric power to electric terminals 52 connected with shape memory alloy member 50 is turned off, and first, second and third check valves 22, 26 and 36 maintain the closed state (initial state).
Here, upon turning on the electric power to shape memory alloy member 50 via electric terminals 52, current flows through shape memory alloy member 50 heating. Then, when reaching a preset critical temperature, shape memory alloy member 50 begins to contract while overcoming the biasing force of bias spring 44. Accordingly, by the contraction of shape memory alloy member 50 suspended to connection pin 42, bias spring 44 compresses while piston 40 starts to move from the first position to the second position (refer to FIG. 3).
When piston 40 is moved from the first position to the second position by the contraction of shape memory alloy member 50, first check valve 22 is opened and the fluid is introduced into cylinder 28 via inlet port 20 (suction process).
Once piston 40 is placed at the second position, the electric power supplied via electric terminals 52 is turned off.
If the electric power to shape memory alloy member 50 is turned off, piston 40 starts to move from the second position to the first position by the biasing force of bias spring 44, and contracted shape memory alloy member 50 begins to be relaxed. At this time, first check valve 22 is closed and second check valve 26 is open to discharge the fluid from cylinder 28 via exhaust port 24 (exhausting process).
Piston 40 moving toward the first position by the biasing force of bias spring 44 is impeded by the upper portion of cylinder 28 to be placed at the first position, thereby finishing the exhaust process (initial state).
The fluid introduced into the lower portion of cylinder 28 is discharged via drain port 32 at the moment third check valve 36 is opened during the suction process, i.e., during the movement of piston 40 to the second position.
In pump 100 using shape memory alloy member 50 according to the first embodiment of the present invention as described above, the fluid (chiefly an oil) is supplied to an actuator of various oil hydraulic systems while repeating the initial state, suction process and exhausting process.
EMBODIMENT 2
FIG. 5 illustrates a pump using shape memory alloys according to a second embodiment of the present invention.
A pump 200 using shape memory alloys according to the second embodiment of the present invention includes an upper cover 60, a body 30 and an end cap 38.
Upper cover 60 has an inlet 62 for introducing fluid from a fluid source. Also, an outlet 64 which is connected to the actuator of various hydraulic systems is formed on the opposite side of inlet 62.
Body 30 includes five cylinders 28, 128, 228, 328 and 428. A first piston 40 is installed within first cylinder 28 to be able to slide between a first position and a second position of first piston 40. A second piston 140 is installed within second cylinder 128, a third piston 240 is within third cylinder 228, a fourth piston 340 is within fourth cylinder 328 and fifth piston 440 is within fifty cylinder 428, respectively slidable between their first and second positions.
On the upper portion of first cylinder 28, there are provided a first intake port 20 for introducing the fluid to first cylinder 28 and a first exhaust port 24 for discharging the fluid introduced into first cylinder 28 when first piston 40 slides from the second position to the first position of first piston 40. Similarly, a second intake port 120 and a second exhaust port 124 are provided to the upper portion of second cylinder 128; a third intake port 220 and a third exhaust port 224 are to the upper portion of third cylinder 228; a fourth intake port 320 and a fourth exhaust port 324 are to the upper portion of fourth cylinder 328; and a fifth intake port 420 and a fifth exhaust port 424 are to the upper portion of fifty cylinder 428, respectively. First, second, third, fourth and fifth intake ports 20, 120, 220, 320 and 420 are connected to one another to be further connected to inlet 62 of upper cover 60. Then, first, second, third, fourth and fifth exhaust ports 24, 124, 224, 324 and 424 are connected to outlet 64 formed in upper cover 60 via first, second, third, fourth and fifth exhaust check valves 26, 126, 226, 326 and 426.
A first drain port 32 is formed on the lower portion of first cylinder 28, a second drain port 132 is on the lower portion of second cylinder 128, a third drain port 232 is on the lower portion of third cylinder 228, a fourth drain port 332 is on the lower portion of fourth cylinder 328 and a fifth drain port 432 is on the lower portion of fifth cylinder 428, respectively. First, second, third, fourth and fifth drain ports 32, 132, 232,, 332 and 432 are connected to one another, and further connected to first, second, third, fourth and fifth intake ports 20, 120, 220, 320 and 420 via a drain flow passage 34 installed with third check valve 36.
End cap 38 is coupled to the lower portion of body 30 to tightly close cylinders 28, 128, 228, 328 and 428.
A first bias spring 44 installed between the lower end of first piston 40 within first cylinder 28 and end cap 38 exerts a biasing force to move first piston 40 from the second pg,12 position to the first position of first piston 40. A second bias spring 144 is installed between second piston 140 and end cap 38, a third bias spring 244 is between third piston 240 and end cap 38, a fourth bias spring 344 is between fourth piston 340 and end cap 38, and a fifth bias spring 444 is between fifth piston 440 and end cap 38.
A first shape memory alloy member 50 for moving first piston 40 from the first position to the second position of first piston 40 while overcoming the biasing force of first bias spring 44 is suspended to the outer circumference of a first connecting pin 42 penetrating through first piston 40. Both ends of first shape memory alloy member 50 are connected to first electric terminals 52 installed to end cap 38 to be supplied with the electric power. In the same way as first shape memory alloy member 50, a second shape memory alloy member 150 is installed between a second connecting pin 142 of second piston 140 and second electric terminals 152, a third shape memory alloy member 250 is between a third connecting pin 242 of third piston 240 and third electric terminals 252, a fourth shape memory alloy member 250 is between a fourth connecting pin 342 of fourth piston 340 and fourth electric terminals 352, and a fifth shape memory alloy member 450 is between a fifth connecting pin 442 of fifth piston 440 and fifth electric terminals 452.
Upper cover 60 and end cap 38 are respectively joined to the upper end and lower end of body 30 by means of bolts, etc.
Hereinbelow, the operation of pump 200 using the shape memory alloys according to the second embodiment of the present invention will be described.
One of first electric terminals 52 is electrically connected to ones of second, third, fourth and fifth electric terminals 152, 252, 352 and 452 to be grounded. Then, the nongrounded terminals of respective first, second, third, fourth and fifth electric terminals 52, 152, 252, 352 and 452 are electrically connected to a rotary switch or an electronic control unit (ECU; not shown) supplied with the electric power. Inlet 62 of upper cover 60 is connected with the fluid source, and outlet 64 thereof is connected with the actuator of the hydraulic system.
Upon supplying the electric power to first shape memory alloy member 50 via first electric terminals 52, first shape memory alloy member 50 moves first piston 40 from the first position to the second position of first piston 40 while overcoming the biasing force of first bias spring 44. At this time, inlet check valve 22 is open to allow the fluid to flow into first cylinder 28 from inlet 62 (suction process).
After first piston 40 finishes the movement toward the second position, the electric power supplied from first electric terminals 52 is cut off. Once the electric power is cut off, first bias spring 44 exerts the biasing force upon first piston 40 to move first piston 40 from the second position to the first position of first position 40 while relaxing the contracted first shape memory alloy member 50. At this time, first exhaust check valve 26 is opened, and inlet check valve 22 is closed, so that the fluid introduced into first cylinder 28 is discharged to outlet 64 via first exhaust port 24 (exhausting process).
Like this, the suction and exhausting processes of the fluid within second, third, fourth and fifth cylinders 128, 228, 328 and 428 are similarly executed, only that first, second, third, fourth and fifth cylinders 28, 128, 228, 328 and 428 are operated having a time difference in the sequence of a fixed order. Therefore, the fluid discharged from pump 200 using the shape memory alloy members according to the second embodiment of the present invention has a constant pressure.
As described above, the hydraulic pump using shape memory alloys according to the present invention is light and has a simple structure as compared with a conventional hydraulic generating system to facilitate its maintenance. Furthermore, the pump using shape memory alloys according to the present invention is applied to vehicles for reducing the weight of the vehicles.
While the present invention has been particularly shown and described with reference to particular embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be effected therein without departing from the spirit and scope of the invention as defined by the appended claims. | A pump utilizing a shape memory alloy member which is connected to electric terminals to be contracted by the supply of electric power for lowering a piston, the piston mounted to slidably move within a cylinder to thereby introduce a fluid into the cylinder is raised by a biasing force of a bias spring to externally discharge the fluid introduced in the cylinder. The pump has a simple structure which is light and easily repaired and maintained. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for effecting in succession the transportation on a road vehicle a container which has received a granular, pulverulent or liquid product at a filling station, the placing in a fixed installation of a full container for use, after the departure of the vehicle, as storage means, for example as a silo or cistern, and, after the placing of the full container, the taking of an empty container located at another site by means of the vehicle for bringing it to the filling station.
Many arrangements have been proposed for solving this problem but all have drawbacks. In French Pat. No. 2,240,883 (Poirier), the container is held, in the course of pivoting, in a cradle mounted on the fixed equipment to pivot about an axis which is on principle coincident with the pivot, the pivot pin connecting the container to the vehicle. Bearing in mind that this pin is longitudinally offset with respect to the point of the rear part of the vehicle which is exactly positioned vertically and laterally, it is in practice impossible -- owing in particular to the variations in height that may be undergone by the coupling bolster normally provided in the front of the vehicle (which is most often constituted by a semi-trailer) for its coupling to a tractor -- to achieve coincidence between the axis of the articulation of the moving cradle and pivot axis of the articulation of the container on the vehicle. Moreover, the final position of the container on the fixed installation is vertical, which requires the use of auxiliary jacks during the final stage for placing the container on the fixed installation, for braking the descending movement.
Moreover, there is known from British Pat. No. 704,550 (Devis) a handling device for unloading a silo from a vehicle and putting it in an inclined position of use, but this device only lends itself to the treatment of cylindrical silos of small dimensions and in any case cannot be employed for handling heavy rectangular-sided containers such as those widely employed at the present time.
SUMMARY OF THE INVENTION
An object of the invention is to overcome the drawbacks of known apparatus.
According to the invention, there is provided a system for handling a container usable as storage means, for example as a silo, and provided at one of its ends with at least two corners which are disposed symmetrically with respect to the medium longitudinal plane of the container, each of which corners defines three, preferably trirectangular faces, said systems comprising a vehicle on which the container may bear in the transporting position and which comprises at least one jack for raising or lowering the container by pivoting it about an axis of pivotal connection between the container and the vehicle, and a fixed installation for receiving the container in the position of use, which comprises means for locking the vehicle, after the vehicle has moved rearwardly, said system comprising the following features:
the position of use of the container is an inclined position in which the lower end part of the container is set in position in a frame of the fixed installation;
the axis of the pivotal connection between the container and the vehicle is embodied by two articulations, each of which articulations comprises a male element having a surface of revolution about a horizontal axis and a female element comprising a conjugate surface of revolution to which surface of revolution there are connected divergent surfaces, said elements being symmetrically laterally mounted, one element being mounted on the container and the other element on the vehicle, and being, under the effect of the force of gravity, in mutual supporting relation by their surfaces of revolution for the transporting position and in the course of the pivoting corresponding to the start of the raising operation, while being disengageable from each other in the course of said raising operation;
the frame of the fixed installation comprises two fixed cradles disposed symmetrically with respect to a median longitudinal plane, each of the cradles comprising two longitudinally spaced bearing surfaces which are conjugate to the corresponding corner of the container to ensure, after the locking of the central region of the rear of the vehicle and during the raising, the angular movement of the container, the self-centering of the container, that is to say the putting of the median longitudinal planes of the container and the fixed frame into coincidence, and the setting of the container in the inclined position of use.
In the course of the raising, after at least one of the rear lower corners has come into contact with the associated cradle, each edge of the container is constantly carried at three points, one of which points is formed by support means connected to the jack or to the jacks, whereas the other two points are formed either on the articulation between the container and the vehicle and on one of the bearing surfaces of the cradle, or by the two bearing surfaces of the cradle. The container can therefore be moved in a continuous jerk-free manner.
The vehicle -- in the middle of its rear lower part -- and the fixed equipment -- in its centre and substantially at the same height -- are provided with conjugate means serving as a longitudinal abutment for the vehicle at the end of the rearward movement, the arrangement being such that if the driver reverses the vehicle toward the fixed installation at an excessively large angle with respect to the plane of symmetry of the installation, or if the vehicle has an excessive lateral offset, the locking is impossible and, moreover, the container cannot come into contact with the cradles. At the end of rearward movement of the vehicle, and when the locking has been effected, the cradles are located in the vicinity of the corners of the container, the distance between the cradles and the corners always being very small with respect to the distance between the corners and the articulations of the container and the vehicle.
When, for putting the container on the site, the driver has the luck to exactly centre the container with respect to the frame of the fixed installation, the two rear lower corners of the container remain on the same level during the raising operation and effect exactly synchronized movements. There is first a pivoting about the horizontal axis common to the surfaces of revolution of the articulations, then contact of the two corners with the rear support surface of the cradles, sliding of the corners on said surface and simultaneously relative sliding between the male articulation element and the front divergent surface of the female articulation element and the front divergent surface of the female articulation element until the corners reach the front bearing surface of the cradles, one of two elements of each articulation then rising relative to the other until the final position of inclination is reached.
When the plane of symmetry of the container makes a small but non-zero angle with the plane of symmetry of the fixed installation, which almost always occurs, five distinct stages can be observed in the course of the operation for putting the container in the position of use under the action of the jack or jacks of the vehicle.
The first stage, in the course of which the container pivots about the two articulations which pivotally connect it to the vehicle, terminates at the moment when, owing to the fact that the planes of symmetry of the container and the fixed equipment do not coincide, only one of the corners of the container, corresponding to a first side, comes in contact with the rear bearing surface of the associated cradle of the fixed installation.
In the course of the second stage, the second side of the container remains in bearing relation solely to the vehicle at the corresponding articulation and the first side of the container is simultaneously in bearing relation to the vehicle and the fixed frame. The first corner slides downwardly on the rear bearing surface of the corresponding cradle, which constitutes an abutment for the rearward direction of movement of the container, and simultaneously the male element of the first articulation slides on the front divergent surface of the corresponding female element, which constitutes an abutment for the forward direction of movement of the container. The second stage, which produces a slight swaying movement or "yaw" which causes the plane of symmetry of the container to approach the plane of symmetry of the fixed installation, stops when the second corner of the container comes into contact with the front bearing surface of the second cradle.
In the course of the third stage, on both sides, the container bears simultaneously on the vehicle in the region of the articulation and on the cradles. The slidings between the first corner and first cradle and the male element and female element in the first articulation occur as in the second stage, whereas the second corner slides downwardly on the front bearing surface of the associated cradle which constitutes a front abutment and the male element of the second articulation slides on the rear divergent surface of the associated female element which constitutes a rear abutment. The third stage, which produces another swaying movement or "yaw" which brings the plane of symmetry of the container very close to the plane of symmetry of the fixed installation, terminates at the moment when the male element and female element of the first articulation separate from each other.
In the course of the fourth stage, the container bears, on the first side, only on the fixed installation and, on the second side, simultaneously on the vehicle and on the fixed installation. On the first side, the corner slides on the two bearing surfaces of the cradle forming front and rear abutments; on the other or second side, the sliding occurs as before. The fourth stage, which produces a slight final swaying movement which puts the plane of symmetry of the container in coincidence with the plane of the fixed equipment, terminates at the moment when the male element and female element of the second articulation separate from each other.
In the course of the fifth stage, the container bears on both sides on the cradle of the fixed equipment, each corner sliding on the two bearing surfaces of its cradle. The fifth stage terminates when the container has reached its final inclination. Support means provided in the fixed installation in addition to the cradles are then united with the container.
Of course, abutment surfaces are provided to ensure that the container is laterally perfectly positioned on the vehicle in the road position and on the fixed installation in the position of use. The surfaces are inclined to the vertical so as to produce a progressive centering of the container on the fixed installation during its placing on the site. The lateral elasticity of the suspension of the vehicle permits avoiding any possible jamming before the aforementioned fourth stage has finished.
After the fifth stage, the supporting means act in such manner as to ensure the equilibrium of the container in the position of use and enables the driver to return to the road positions the mechanisms of the vehicle which had been used for putting the container on the site, and to unlock the vehicle from the fixed installation and leave with the vehicle, for example for taking an empty container from another fixed installation and effecting the same operations in the opposite direction.
Note that the container could advantageously be a standardized container whose lower standardized corners located at the rear cooperate with the cradles of the fixed installation.
Likewise, the supporting means brought into action at the end of the aforementioned fifth stage, may be constituted in accordance with the teaching of French Pat. No. 2,296,544, by a gantry supporting the front of the container or by an auxiliary support disposed behind the cradles for positively retaining the upper corners of the lower end wall of the container. It is also possible to employ masts which are capable of being dismantled and are disposed between bearing surfaces located, on one hand, under the front part of the container and, on the other hand, on the ground. Such an arrangement is similar to that described in French Pat. No. 2,271,069.
It will be observed that the handling system according to the invention permits the elimination of all the drawbacks of presently-known systems for placing in position, by means of the transporting vehicle, a container for pulverulent, granular or liquid materials, for its use as a storage apparatus, its position being then the most convenient for its unloading. Thus, within the scope of the invention, the container is transported full, the fixed installation requires no source of energy, the container can be of a standardized type, for example in conformity with ISO standards, the placing on the site or the taking up of the container can be carried out within a few minutes by the driver of the vehicle without outside aid, the positioning of the vehicle with respect to the fixed installation requiring no means other than longitudinal abutments and a locking device. The container is in table equilibrium throughout the operations for placing it on the site and taking up the container.
A better understanding of the invention will be had from the ensuing description, it being understood that arrangements other than those descriptions can be employed while remaining within the scope of the invention.
DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a side elevational view of a special transporting and handling semi-trailer loaded with a standardized container in the road position;
FIG. 2 is a side elevational view of the same semi-trailer locked to fixed equipment at the end of the operation for placing the container on a site;
FIG. 3 is a front elevational view of the container in position of use;
FIG. 4 is a plan view of the semi-trailer locked to the fixed installation;
FIG. 5 is a sectional view taken on line 5--5 of FIG. 4, to an enlarged scale;
FIG. 6 is a longitudinal sectional view, to an enlarged scale, of the rear part of the left edge, as viewed in FIG. 4, of the container and of the vehicle locked longitudinally to the fixed installation, at the start of the raising operation;
FIG. 7 is a sectional view taken on line 7--7 of FIG. 6;
FIG. 8 is a view, corresponding to FIG. 6, of the right edge;
FIGS. 9 and 10 are sectional views corresponding to FIGS. 6 and 8, in the course of a subsequent stage of the raising operation;
FIG. 11 is a sectional view of a corner of the container set or blocked in position in its cradle at the end of the raising;
FIG. 12 is a sectional view taken on line 12--12 of FIG. 1;
FIG. 13 is a transverse elevational view of a cradle and the corresponding corner;
FIG. 14 is a sectional view, to an enlarged scale of a modification of FIG. 8, and
FIG. 15 is a view of means for locking the container in the position of use.
DETAILED DESCRIPTION OF THE INVENTION
The fixed installation, symmetrical with respect to a vertical plane X--X, comprises (FIGS. 2 and 3), at the rear, a frame A comprising two cradles 27--27 and, under the latter, a locking device 18 and, in the front, a supporting device B comprising two bearing members 47 for removable masts 43 the bearing members 47 being in accordance with for example the teaching of French Pat. No. 2,271,069.
The vehicle is constituted by a tractor 1 and a semi-trailer 2 adapted for transporting a rectangular-sided container 3 having standardized corners. The semi-trailer 2 is equipped on each side with an arm 4 mounted on the semi-trailer 2 to pivot about a pivot pin 5 and provided at its other end with a roller 6 . Each arm 4 is shifted by a jack 7 which is pivoted to the semi-trailer 2 by a pin 8 and to the arm 4 by a pin 9. V-shaped bearings 10 are disposed on each side at the rear of the semi-trailer 2. In the road position, the container 3 bears adjacent the rear end, on the bearings 10 through its journals 11. The container is laterally perfectly centered owing to cooperation between the oblique surface 39 of two guide elements 40, disposed symmetrically on the semi-trailer with respect to the plane Y--Y, with complementary oblique surface 38 of a corresponding block 37 of the container, in which the rear journal 11 is fixed. Two plates 12 (FIG. 3) provided under the container 3 form runways for respective rollers 6 during the raising of the container by means of the jacks 7 and the placing thereof on the frame A with respect to which latter the semi-trailer initially took up the correct position.
The semi-trailer 2 is equipped at the rear with bumpers or fenders 13 disposed at the end of longitudinal members 14 in the region of a connecting cross-member 15. The vertical central planar part 16 of the cross-member 15, formed in a recess, is set back with respect to the bumpers 13 and is connected to the latter by two vertical planar faces 17 which are inclined with respect to the plane of symmetry Y--Y of the semi-trailer 2. The frame A comprises, substantially at the height of the bumpers 13, a central buffer 19 the width of which is less than the distance between the faces 17 by an amount corresponding to the precision that the driver can achieve in the centering of the semi-trailer. The frame A comprises two lateral buffers 21 also mounted at the height of the bumpers 13. The distance between the vertical plane through the end of the buffers 21 and the end face 20 of the central buffer 19 exceeds the distance between the rear face of the bumpers 13 and the vertical plane 16 of the cross-member 15. This arrangement enables the semi-trailer 2 to abut the central buffer 19 only if the angle that the plane of symmetry Y--Y of the semi-trailer 2 makes with the plane of symmetry X--X of the frame A is less than an angle which is small but compatible with a precision that it is possible to achieve with normal driving. If the driver has presented the semi-trailer 2 at an excessively large angle, one of the two bumpers 13 comes into contact with a lateral buffer 21 whereas the central part 20 of the central buffer 19 is not yet in contact with the planar face 16 of the cross-member 15 in which case the driver must repeat his manoeuvring until contact between the parts 20 and 19 is established.
The locking device 18 comprises a pin 23 carried by the frame A on which there is pivotally mounted a central lock member 22 whose nose 24 comprises a ramp 24a which, in coming into contact with the upper edge 16a of the part 16 in the course of the rearward movement of the semi-trailer, causes the nose to rise in pivoting about the pin 23. When the central part 16 of the cross-member 15 comes into abutment with the central buffer 19, the raised nose 24, after having slid over the upper face of the cross-member 15, drops by the effect of gravity, into an oblong aperture 25 in the cross-member 15 and locks the semi-trailer to the frame A. In this locked position, each of the lower rear corners 26 of the container 3 carried by the semi-trailer 2 is located above a cradle 27 of the frame A, without touching the cradle.
Each cradle 27 comprises a front bearing surface constituted by a cylindrical surface 34 whose generatrices are parallel to the direction in which the axis Z--Z of the container is oriented for the final inclined position of the latter (FIG. 2), this cylindrical surface being formed on the rear part of a stud 33 which is fixed in a position perpendicular to a plate 48 which defines a rear bearing surface 29 which is rearwardly and upwardly inclined. The configuration of the stud 13 is such that its upper end can penetrate an aperture 32 which extends through the planar lower face 49 of the corresponding corner 26 of the container and the the corner 26 bears on the cylindrical face 34 by the rear region of a chamfer 31 located between the inner cylindrical surface 50 of the aperture 32 and the lower planar face 44. Under these conditions, the rearwardly directed horizontal component of the force by which the container bears on the cylindrical surface 34 has a high value which facilitates the positioning of the container.
Each cradle 27 further comprises a lateral abutment 41 constituted by an outwardly inclined side wall.
After the locking of the semi-trailer on the frame owing to the slight angle that the axis Y--Y of the semi-trailer makes with the axis X--X of the frame A, the two corners 26 have a different position longitudinally and laterally with respect to the respective cradles 27 as shown in FIGS. 6 and 8.
FIG. 6 shows the left side of the semi-trailer and container as viewed in FIG. 4 in respect of which the corner 26 is longitudinally the most remote from the rear bearing surface 29 on the associated cradle 27. FIG. 8 shows the right side in respect of which the corner 26 and the rear support surface 29 of the corresponding cradle are at a short longitudinal distance from each other. If the jack 27 is actuated in the course of a first stage of the operation for placing the container on the site, the container is tipped, by rotation of the journals 11 in contact with the cylindrical surface 36 of the bearings 10. It is on the right side (FIG. 8) that the corner 26 contacts first, by its lower edge 28, the inclined plane 29 constituting the rear bearing surface of the associated cradle 27. The second stage starts at this moment, in the course of which the edge 28 slides along the inclined plane 29 (FIG. 10), which causes the journal 11 to slide on the inclined plane 30 constituting the front divergent surface of the bearing 10, whereas the left journal 11 continues to rotate in the cylindrical surface 36. During this second stage, the rear of the container is slanted and undergoes simultaneously a swaying movement or yaw which tends to correct the angular offset between the axes X--X and Y--Y. The third stage corresponds to the contact of the left corner 26 (FIG. 9) by the chamfer 31 of the lower aperture 32 with the front bearing surface 34 of the stud 33 of the associated cradle 27. The chamfer 31 then slides on this surface 34 and causes the journal 11 to slide on the inclined plane 35 constituting the rear divergent surface of the left bearing 10. In the course of the third raising stage, in view of the fact that the two journals 11 move away in opposite directions from the cylindrical surfaces 36 of the bearings 10, while rising, the swaying movement (which has a correcting action), of the rear of the container continues but there is also produced a rolling movement which tends to cancel out the slant.
The third stage terminates when the chamfer 31 of the right corner 26 (FIG. 10) comes into contact with the cylindrical surface 34 of the corresponding stud 33. The right journal 11 then reaching the limit of its sliding travel along the divergent surface 30, whereas on the left side, the relative slidings between the journal 11 and bearing 10 and between the corner 26 and the stud 33 continue (FIG. 9).
The fourth stage starts when the right journal 11 is raised out of contact with the divergent surface 30 and terminates at the instant when the edge 28 of the left corner 26 (FIG. 9) comes into contact with the rear bearing surface 29 of the associated cradle 27. The axes X--X and Y--Y are then coincident and the container bears fully against the frame A. The fifth stage or final stage, in respect of which the two journals 11 are fuly disengaged from the bearings 10, can then commence, the container tipping exclusively by the sliding of the corners 26 in contact with the cradles 27 and then by a double sliding, namely between the edge 28 and the inclined plane 29 and between the chamfer 31 and the cylindrical surface 24. The final position is shown in FIG. 11.
In the position of the semi-trailer locked to the frame A shown in FIG. 4, and owing to the clearance between the buffer 19 of the frame A and the planar faces 17 of the cross-member 15 of the semi-trailer, the right corner 26 is nearer to the inclined planar face 41a of the side wall 41 of the cradle 27 than the other corner 26. Consequently in the course of the raising operation, the right corner 26 the nearer to the plane of the surface 41a comes into contact with the latter by its lower end edge 28. The resulting sliding brings about a transverse reaction on the container 3 which displaces it transversely either without friction on the semi-trailer if the journals 11 of the container are already disengaged from the two bearings 10, or with friction by a sliding of the journals 11 in the bearings 10 and possibly a sliding between the surfaces 38 and 39 (FIG. 12). In the latter case, the flexibility of the suspension of the semi-trailer 2 enables this operation to be carried out without jamming. The lateral centering is therefore achieved without jerks and smoothly during the raising operations. Note that the transverse sliding just described has only a small influence on the previously described swaying movements or yaws.
When the container has reached the inclination corresponding to its storage position, the rear faces of the two corners 26 are fully in contact with the rear bearing surfaces 29 of the cradles. The cylindrical surface 34 of the studs 33 is then tangent to the lower plane 49 of the corners of the container. The masts 43 are then placed in position with the upper spherical ends 44 of the masts 43 bearing against cups 45 disposed on the sides and under the container toward the highest point of the floor thereof. The lower spherical parts 46 of the masts 43 bear against the cups 47 secured to the ground. The jacks 7 can now be retracted to lower the arms 4. As the container bears, on one hand, on the two cradles 27 of the fixed equipment 18 and, on the other hand, on the two masts 43, it is now possible to raise the lock member 22 and advance the semi-trailer 2.
The container take-up operations are the same as those for placing the container on the site but are carried out in reverse. The swaying movement or yaw which the container undergoes for aligning itself on the semi-trailer 2 and for its lateral positioning are obtained by the same means as for placing the container on the site.
Note that the inclination to the horizontal of the planar bearing surface 29 and of the stud 33 of the cradles 27 and, moreover, of the divergent planar surfaces 30 and 35 of the bearings 10, must be sufficient to ensure that the sliding is easy. This is why it is of interest to employ, as described and illustrated, corners constructed in accordance with the French standard NF H - 90- 005, which have in their lower part an opening which the stud 33 can enter. However, if for any reason it was decided to employ corners 44 which do not have an opening in the lower part thereof, it is possible to operate in accordance with the invention by replacing the cylindrical bearing surface 34 of the studs 33 by a cylindrical surface or a convex crown of rollers 45 which are rotatably mounted on a horizontal pin 46 (FIG. 14). The cradle 27 still has a planar rear bearing surface 29. Each of the members supporting the rollers further comprises a planar surface 51 which is perpendicular to the planar surface 29 and is tangent to the roller so as to form an additional bearing surface.
Means for locking the container to the frame A and the container to the semi-trailer, constructed in accordance with known means, ensure safety of operation. Thus, as described in French Pat. No. 2,296,544 (FIG. 15), the frame A is completed at the rear of the cradles 27 by an auxiliary support comprising two posts 56 each of which has in its upper part an inclined bearing plate 57 and a locking member 59 parallel to this plate. In the final position of inclination of the container 3 the upper standardized corners 58 of the end wall of the container abut the plates 57 and the locking members 59 enter the corner 58 and hold the container stationary. The locking members 59 may be disengaged by pulling on chains 60.
Other modifications or additions may be envisaged. Thus the journals 11 could be replaced by spherical heads in which case spherical cups extended in the form of a funnel would be substituted for the bearings 10. The bearings or cups could be provided on the container and the journals or spherical heads on the vehicle. | The system for handling a container comprises a vehicle on which the container may bear in the transporting position and which comprises at least one jack for raising or lowering the container by pivoting it about an axis of pivotal connection between the container and the vehicle, and a fixed installation for receiving the container in the position of use, which comprises a device for locking the vehicle, after the vehicle has moved rearwardly. The position of use of the container is an inclined position in which the lower end part of the container is set in position in a frame of the fixed installation. The axis of the pivotal connection between the container and the vehicle is embodied by two articulations, each of which articulations comprises a male element having a surface of revolution about a horizontal axis and connected to the container and a female element connected to the vehicle and comprising a conjugate surface of revolution to which surface of revolution there are connected divergent surfaces. The frame of the fixed installation comprises two fixed cradles disposed symmetrically with respect to a median longitudinal plane. Each of the cradles comprises two longitudinally spaced spaced bearing surfaces which are conjugate to faces of the corresponding container corner. | 1 |
TECHNICAL FIELD
This disclosure is directed generally to electrical connections and more particularly to a power line auto-disconnect apparatus for use with an electrical power connection.
BACKGROUND
Emergency vehicles (such as fire trucks and ambulances), recreational vehicles, and power boats, often utilize power lines that are connected to stationary power sources for supplying electrical power for starting engines, charging batteries, and other purposes. However, such vehicles may need to uncouple swiftly from the power line when they are to be driven away in response to an emergency, or the like. Consequently, the mating power line plug should eject on activation of the vehicle's engine, and also should eject in a manner that reduces or eliminates drawing an arc between the plug and the vehicle connector. Arcing, if not suppressed, is a major source of wear on contacts in both the vehicle connector and the plug. It is this wear that significantly reduces the service life of these components.
SUMMARY
This disclosure provides a power line auto-disconnect apparatus for use in an electrical power connection.
In a first embodiment, a power line disconnect apparatus includes a housing; an electrical connector that projects from a surface of a connector plate coupled to the housing, the electrical connector configured to receive a plug of a power cable; an ejector pin configured to project through a first aperture in the connector plate and eject the plug from the electrical connector; a microswitch configured to activate and deactivate a power circuit associated with the power cable; and a sensor pin configured to project through a second aperture in the connector plate, the sensor pin having a sensor pin extension, the sensor pin extension configured to control the microswitch.
In a second embodiment, a vehicle includes an engine and a power line disconnect apparatus attached to a surface of the vehicle. The power line disconnect apparatus includes a housing; an electrical connector that projects from a surface of a connector plate coupled to the housing, the electrical connector configured to receive a plug of a power cable; an ejector pin configured to project through a first aperture in the connector plate and eject the plug from the electrical connector; a microswitch configured to activate and deactivate a power circuit associated with the power cable and the vehicle; and a sensor pin configured to project through a second aperture in the connector plate, the sensor pin having a sensor pin extension, the sensor pin extension configured to control the microswitch.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows an external perspective view of an auto-disconnect apparatus for use in an electrical power connection, according to this disclosure;
FIG. 2 shows a perspective view of the auto-disconnect apparatus of FIG. 1 from another angle;
FIG. 3 shows another perspective view of the auto-disconnect apparatus of FIG. 1 ;
FIG. 4 shows yet another perspective view of the auto-disconnect apparatus of FIG. 1 from a different angle;
FIG. 5 shows a side section view of the auto-disconnect apparatus of FIG. 1 with a plug connected to the auto-disconnect apparatus; and
FIG. 6 illustrates an electrical schematic diagram of the auto-disconnect apparatus of FIG. 1 .
DETAILED DESCRIPTION
The figures, discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.
As described above, some vehicles—particularly emergency vehicles—may need to quickly uncouple a connected power line when the vehicles are to be driven away in response to an emergency, or the like. Consequently, the mating power line plug should eject on activation of the vehicle's engine, but also it must eject in a manner that reduces or eliminates drawing an arc between the plug and the vehicle. Arcing, if not suppressed, is a major source of wear on contacts in both the vehicle connector and the plug. It is this wear that significantly reduces the service life of these components.
To address these and other issues, embodiments of this disclosure provide a power line auto-disconnect apparatus that includes a sealed housing on which an electrical connector is mounted. Typically, the power line auto-disconnect apparatus is mounted (or otherwise coupled) to a sidewall or other body portion of an emergency vehicle (e.g., a fire truck or ambulance), a recreational vehicle, or a power boat. During use, the electrical connector mates with an electrical plug that is part of a shore cable. Once connected, the shore cable is electrically coupled to an engine starting circuit or battery on the vehicle. Voltage that is applied to the starter when the engine is cranked is also applied to a solenoid in the automatic power line disconnect apparatus. The solenoid operates an ejector mechanism which is mounted in the housing. The ejector mechanism ejects the shore cable from the apparatus, and a switch that is mounted in the housing interrupts the current prior to the completion of the ejection action, thereby preventing arcing at the connector contacts and assuring long contact life.
FIGS. 1 through 5 illustrate various views of an auto-disconnect apparatus 100 for use in an electrical power connection, according to this disclosure. The embodiments of the auto-disconnect apparatus 100 illustrated in FIGS. 1 through 5 are for illustration only. Other embodiments could be used without departing from the scope of this disclosure.
FIG. 1 shows an external perspective view of the auto-disconnect apparatus 100 . The auto-disconnect apparatus 100 includes a housing comprising a front housing 102 and a rear housing 104 . A part of the housing (e.g., the front housing 102 ) includes multiple wire ports 106 . Typically, there are two wire ports 106 , although in some embodiments there may be more or fewer wire ports 106 . As shown in FIG. 1 , a plug 108 is engaged with the front housing 102 of the auto-disconnect apparatus 100 , concealing a male connector (which is shown in FIG. 4 as the male connector 404 ). The plug 108 is at the end of a shore cable 110 . The plug 108 and the shore cable 110 are not part of the auto-disconnect apparatus 100 .
The auto-disconnect apparatus 100 is typically coupled to a vehicle 112 (e.g., mounted to a sidewall of the vehicle 112 ) and electrically coupled to a battery charger or other device on the vehicle 112 that requires alternating current power. The auto-disconnect apparatus 100 may include one or more mounting or attachment components (e.g., brackets, fasteners, mounting holes, and the like) to secure the auto-disconnect apparatus 100 to the vehicle 112 .
FIG. 2 shows a perspective view of the auto-disconnect apparatus 100 from another angle with the rear housing 104 removed and the front housing 102 shown in transparent view. In FIG. 2 , various internal components of the auto-disconnect apparatus 100 are visible, including a microswitch 202 , an ejector arm 204 , a support bracket 206 , a pin 208 , and tension springs 212 .
The microswitch 202 activates and deactivates a power circuit that includes the shore cable 110 , the auto-disconnect apparatus 100 , and the vehicle 112 , as described in greater detail below. When the microswitch 202 activates the power circuit, power can be supplied from the cable 110 through the auto-disconnect apparatus 100 , to the vehicle 112 . When the microswitch 202 deactivates the power circuit, no current flows from the cable 110 to the vehicle 112 . In some embodiments, the microswitch 202 includes three contacts: normally open (NO), normally closed (NC), and common (C).
One end of the ejector arm 204 is pivotally mounted on the support bracket 206 by means of the pin 208 . The ejector arm 204 makes contact with the ejector pin 210 at approximately a mid-point of the ejector arm 204 . The ejector pin 210 is configured to move longitudinally back and forth, as indicated by the dashed arrows. A pair of tension springs 212 (only one of which is visible in FIG. 2 ) coupled to the second end of the ejector arm 204 provide continuous force on the ejector arm 204 and the ejector pin 210 in the direction of the plug 108 .
FIG. 3 shows a perspective view of the auto-disconnect apparatus 100 with both the front housing 102 and the rear housing 104 removed. In this view, it can be seen that the microswitch 202 includes a microswitch arm 302 , one end of which is connected to and selectively activates and deactivates the microswitch 202 in response to movement of the microswitch arm 302 . The microswitch arm 302 extends away from the microswitch 202 and, at the end of the microswitch arm 302 , makes contact with a sensor pin extension 304 . The sensor pin extension 304 is fixedly coupled to and extends laterally outward from a sensor pin 402 , which is not visible in FIG. 3 , but can be seen in FIGS. 4 and 5 . The sensor pin 402 is configured to move longitudinally within a sensor pin guide 306 , in a direction of movement that is substantially parallel to the movement of the ejector pin 210 , as indicated by the dashed arrows in FIG. 5 . The sensor pin guide 306 is generally cylindrical and fixedly secured inside the auto-disconnect apparatus 100 . The sensor pin guide 306 constrains and guides the movement of the sensor pin 402 . The sensor pin guide 306 also includes a side opening 308 that extends through and longitudinally along a wall of the sensor pin guide 306 . The sensor pin extension 304 protrudes from the sensor pin 402 through the side opening 308 and extends to make contact with the microswitch arm 302 , as shown in FIG. 3 .
FIG. 4 shows another perspective view from a different angle of the auto-disconnect apparatus 100 with both the front housing 102 and the rear housing 104 removed. In this view, the plug 108 is not coupled to the auto-disconnect apparatus 100 . Without the plug 108 , it can be seen that the auto-disconnect apparatus 100 includes the sensor pin 402 and a male connector 404 . The male connector 404 extends outside of the front housing 102 so as to be visible from the exterior. Of course, in some embodiments, the male connector 404 may be protected by a cover that is moveable to reveal the male connector 404 . A connector plate 406 is coupled to the front housing 102 and surrounds the male connector 404 . The sensor pin 402 and the ejector pin 210 pass through respective apertures of the connector plate 406 . The sensor pin 402 is spring loaded to be biased in an outward position, such as shown in FIG. 4 . The male connector 404 is configured to engage with a female connector at the end of the plug 108 . FIG. 5 shows a side section view of the auto-disconnect apparatus 100 with the plug 108 connected to the auto-disconnect apparatus 100 . When connected, the male connector 404 and the plug 108 form an electrical connection for electrical current to flow from the shore line 110 to the auto-disconnect apparatus 100 and to the vehicle 112 . Typically, the electrical current is provided at 110V or 220V, although any suitable electrical source at any suitable voltage could be used.
As shown in FIG. 4 , the contacts of the male connector 404 are significantly longer than the projection of the sensor pin 402 . However, the exposed portion of the ejector pin 210 is longer than the contacts of the male connector 404 when the ejector pin 210 is fully extended outward. In one aspect of operation, as the plug 108 is inserted for engagement with the auto-disconnect apparatus 100 , the plug 108 first makes contact with the ejector pin 210 and then with the contacts of the male connector 404 . As the plug 108 is inserted, the plug 108 pushes the ejector pin 210 inward and the female connector of the plug 108 slides over the contacts of the male connector 404 . The movement of the ejector pin 210 pushes the ejector arm 204 inward, against the force of the tension springs 212 . As the plug 108 is further inserted, the plug 108 contacts the sensor pin 402 and pushes the sensor pin 402 inward, while also continuing to depress the ejector pin 210 . The sensor pin 402 moves with the connected sensor pin extension 304 , which in turn depresses the microswitch arm 302 inward. When the plug 108 is fully engaged against the connector plate 406 , a trigger locks the ejector arm 204 into position. With the microswitch arm 302 depressed inward, the microswitch 202 and corresponding power circuit are activated to apply power from the plug 108 to the auto-disconnect apparatus 100 and to the vehicle 112 . Any electrical arcing that may result from the activation of the electrical current when the plug 108 is engaged with the auto-disconnect apparatus 100 would occur inside the microswitch 202 , which is constructed to absorb arcing occurrences.
Typically, when the shore cable 110 is plugged into the auto-disconnect apparatus 100 , the shore cable 110 will remain plugged in until the vehicle 112 is started. When the vehicle 112 is started (e.g., when the vehicle's engine is started), a solenoid (not shown) in the auto-disconnect apparatus 100 releases the trigger that frees the ejector arm 204 from its locked position. The tension springs 212 cause movement of the ejector arm 204 towards the plug 108 , which in turn causes the ejector arm 204 to advance the ejector pin 210 toward the plug 108 . This is turn pushes the plug 108 out, and decouples the plug 108 from the male connector 404 and the auto-disconnect apparatus 100 .
In some similar auto-disconnect systems, if a shore cable is manually unplugged and the vehicle is not started, the current through the shore cable would continue to flow until the moment that the plug is disconnected from the auto-disconnect system. This situation could create an arc at the male connector and/or the plug, thereby shortening the life of the connectors.
To avoid such an occurrence, the auto-disconnect apparatus 100 uses the position of the sensor pin 402 and the sensor pin extension 304 to control the current into the auto-disconnect apparatus 100 . When the sensor pin 402 is depressed by the plug 108 , the sensor pin extension 304 presses on the microswitch arm 302 , thereby activating the power circuit, which applies power from the plug 108 to the auto-disconnect apparatus 100 and to the vehicle 112 . When the shore cable 110 is unplugged, as the plug 108 is decoupled from the connector plate 406 , the spring-biased sensor pin 402 moves outward and the connected sensor pin extension 304 moves with the sensor pin 402 . The movement of the sensor pin extension 304 causes the microswitch arm 302 to move outward and causes the microswitch 202 and corresponding power circuit to be deactivated. This stops the current flow through the male connector 404 , the plug 108 , and the shore cable 110 . Because the full movement of the sensor pin 402 is less than the length of the contacts of the male connector 404 , the outward movement of the microswitch arm 302 , sensor pin extension 304 , and sensor pin 402 are completed (and thus the power circuit is interrupted) before the plug 108 is fully disengaged from the male connector 404 . This ensures that no arcing can occur at the male connector 404 and/or the plug 108 .
Because the sensor pin 402 and sensor pin extension 304 are not directly coupled to the ejector pin 210 or the ejector arm 204 , the movement of the pin 402 and extension 304 (and their control of the microswitch 202 ) is not dependent on the position of the ejector pin 210 or the ejector arm 204 . Stated another way, the control of the microswitch 202 and the power circuit are independent of the position of the ejector pin 210 . Thus, even if the plug 108 is manually removed and the ejector pin 210 is not released, the power circuit will still be interrupted before the plug 108 is completely removed. Thus, the potential for arcing at the male connector 404 and/or the plug 108 is negligible regardless of whether the plug 108 is manually removed or auto-ejected by the start of the vehicle 112 .
FIG. 6 illustrates an electrical schematic diagram of the auto-disconnect apparatus 100 . As shown in FIG. 6 , the plug 108 includes neutral, line, and ground connections that are configured to couple with corresponding contacts in the male connector 404 . The microswitch 202 includes three contacts: normally open (NO), normally closed (NC), and common (C). The NC contact is not used in normal operation. A fault indicator 602 is connected to the NC contact. In some embodiments, if the plug 108 is inserted and a fault occurs in the power circuit of the auto-disconnect apparatus 100 , the fault indicator 602 will illuminate. A power indicator 604 is connected to the NO contact. When the plug 108 is inserted and the auto-disconnect apparatus 100 is operating correctly, the power indicator 604 will illuminate. In some embodiments, the fault indicator 602 and the power indicator 604 are LED lamps. However, any other suitable indicator could be used.
Although FIGS. 1 through 6 illustrates one example of an auto-disconnect apparatus 100 for use in an electrical power connection, various changes may be made to the figures. For example, certain ones of the various components of the auto-disconnect apparatus 100 may be combined, rearranged, duplicated, separated into sub-components, or replaced with other components.
In some embodiments, various functions described above are implemented or supported by a computer program that is formed from computer readable program code and that is embodied in a computer readable medium. The phrase “computer readable program code” includes any type of computer code, including source code, object code, and executable code. The phrase “computer readable medium” includes any type of medium capable of being accessed by a computer, such as read only memory (ROM), random access memory (RAM), a hard disk drive, a compact disc (CD), a digital video disc (DVD), or any other type of memory. A “non-transitory” computer readable medium excludes wired, wireless, optical, or other communication links that transport transitory electrical or other signals. A non-transitory computer readable medium includes media where data can be permanently stored and media where data can be stored and later overwritten, such as a rewritable optical disc or an erasable memory device.
It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “application” and “program” refer to one or more computer programs, software components, sets of instructions, procedures, functions, objects, classes, instances, related data, or a portion thereof adapted for implementation in a suitable computer code (including source code, object code, or executable code). The terms “transmit” and “receive,” as well as derivatives thereof, encompass both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. | A power line disconnect apparatus includes a housing; an electrical connector that projects from a surface of a connector plate coupled to the housing, the electrical connector configured to receive a plug of a power cable; an ejector pin configured to project through a first aperture in the connector plate and eject the plug from the electrical connector; a microswitch configured to activate and deactivate a power circuit associated with the power cable; and a sensor pin configured to project through a second aperture in the connector plate, the sensor pin having a sensor pin extension, the sensor pin extension configured to control the microswitch. | 8 |
PRIORITY CLAIM
This is a U.S. national stage of application No. PCT/FI02/00866, filed on 07 Nov. 2002. Priority is claimed on that application and on the following application(s): Country: Finland, Application No.: 20012160, Filed: 08 Nov. 2001.
BACKGROUND OF THE INVENTION
The present invention relates to a blow box for controlling or supporting the web run in a paper machine, particularly in the drying section of a paper machine, or in other corresponding devices, such as in a board machine, in a finishing machine and in coating machines.
The web run needs control or support, for instance during running in the area of the pockets formed between the drying cylinders in the drying section of a paper machine, particularly in such locations where the web needs to be released in a controlled manner from a drying cylinder and to run freely together with the wire to a turning roll, suction roll or the like.
In order to support the web at the pockets of the drying section it is known to use blow boxes, which eject air away from desired regions in order to create a negative pressure in these regions. Thus the negative pressure created by the blow boxes can be used to support the release of the web from a drying cylinder and to support the web run to a turning roll or the like.
It is known to arrange in a blow box, at the beginning and/or at the end of the negative pressure region created by the box, a blocking plate or the like, which projects towards the web and which is flexibly fastened to the blow box. The object of the blocking plate is to seal the negative pressure region from the surrounding space in order to maintain an as effective negative pressure as possible in the negative pressure region. The surface of the blocking plate, which is directed towards the web, can be protrudingly arched towards the web, with respect of the running direction of the web. The arched surface forms a so called Coanda surface, which facilitates the ejection of air away from the negative pressure region and prevents leaking air from entering the negative pressure region.
In this way, with the blow boxes in use, it can be created, with reasonable blow effects, intensified negative pressure regions having negative pressures of e.g. 0.1 to 0.4 kPa. However, as the paper machine speeds still rise and as the paper quality requirements increase, the order of the negative pressure level at particularly critical points should be even higher than 5 kPa.
However, the intensifying of the negative pressure level from the present, i.e. the maintaining of an even higher negative pressure with the aid of blowers, substantially increases the required blowing effect, in other words the energy costs. The higher the aimed negative pressure level, the larger are also the air leaks and their impacts on the energy costs. It is not possible to completely seal the negative pressure region from the surrounding space in order to reduce the leaks. Blocking members, blow nozzles or other structures of a blow box arranged too close to the wire can easily damage the wire, and they can themselves be easily damaged when the wire touches them. Thus, with the present devices there must be left a certain minimum gap between the blow boxes and the web's supporting wire in order to avoid damage to these members, to the web and/or to the wire in different running situations.
For instance a “paper lump” can push the wire to touch parts of the blow box, particularly the blow nozzles or blocking members, despite the minimum gap. In known blow boxes, a spring or some other mechanical member is used to keep nozzles projected towards the wire. The object is that the spring enables the nozzle to be pushed away from the wire, when required. However, springs are generally relatively stiff, and they are not sufficiently resilient in order to be able to adapt to all situations sufficiently rapidly. In addition, the spring force cannot be adjusted to different requirements. The spring must be subjected to a relatively high minimum pressure before it allows the nozzle to be pushed away from the wire.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a blow box where the above described problems are minimized.
The object is to provide a blow box which can create a high negative pressure level in a desired region, without too high energy costs.
An object is also to provide a blow box which can create a high negative pressure level in a desired region, with as small air leaks as possible.
A further object is to provide a blow box, which enables the high negative pressure level created by the box to be maintained at a suitable level in different running situations, without danger to the wire or to the web.
A blow box according to the invention is typically used to create a negative pressure region in the pocket between two drying cylinders in the drying section of a paper machine, at the opening nip between a drying cylinder and the wire, in order to support the web run and to improve the machine's runnability. On the other hand, a blow box according to the invention can be used also in other places of a paper machine or corresponding machines as a component, which supports the web run and improves the runnability.
A typical blow box according to the invention, which is arranged for instance in the pocket between two drying cylinders in the drying section of a paper machine, comprises members to maintain the negative pressure in at least one negative pressure region between the wire and the blow box.
These members comprise
a blocking member, which is arranged, regarding the wire's running direction, at the beginning and/or at the end of said negative pressure region, which blocking member extends across the wire and projects towards the wire, and which is movable in relation to the blow box, in order to make it possible to maintain a pressure difference between said negative pressure region and the region outside this region, and blowing members, with which air is ejected with blows between said blocking member and the wire from said negative pressure region and/or with which air is prevented from entering this negative pressure region.
Said blocking member is connected to the blow box with a hinge member, such as a swing joint. The hinge member allows the blocking member to rotate around the articulation point of the hinge member due to the pressure difference between the pressure acting on the blocking member's blocking surface directed towards the wire and the pressure acting on the blocking member's back surface directed away from the wire.
Advantageously the blocking member's blocking surface projecting towards the wire is shaped so that the surface's distance from the wire supporting the web changes as the blocking member rotates about the articulation point of the hinge. Thus the blocking member is arranged to rotate around the articulation point, due to the pressure acting on its back surface directed away from the wire, so that the blocking member projects towards the wire. Correspondingly, the blocking member is arranged to rotate around the articulation point due to the pressure acting on its blocking surface directed towards the wire, so that the blocking member projects away from the wire.
The blocking member used in the solution according to the invention moves substantially more delicately than a blocking member projected by a spring towards the wire. By controlling the pressure acting on the blocking member's back surface directed away from the wire or on the blocking member's blocking surface it is easy to adjust the blocking member's distance from the wire, i.e. the gap between the blow box and the wire. The blocking member's back surface directed away from the wire can be arranged to border to a separate pressurised space, or to a pressurised space which can be controlled in part independently. By controlling the pressure of this space it is possible to push the blocking member towards the wire with a desired pressure. Already a very small change in the pressure makes the blocking member to move in the desired direction. Thus a blocking member, which can be freely rotated around the hinge's articulation point, can be easily pushed towards the blow box due to a very small “paper lump” or some other approach of the wire, without damage to the wire or to the actual blocking member.
Even a small pressure change on either side of the blocking member causes the blocking member to move towards the wire or away from the wire. The air jets, which are blown along the blocking member's surface and which eject air from die negative pressure region, will cause a negative pressure between the blocking member and the wire, whereby this negative pressure pushes the blocking member towards the wire and prevents air leaks from entering the negative pressure region. The blocking member can be prevented from extending too close to the wire with the aid of a mechanical limiter, against which the blocking member hits when it rotates to the allowed extreme position, and which thus prevents the blocking member from rotating past this extreme position. Thus a blow box according to the invention can be arranged very close to the web.
When using a blow box according to the invention it is possible to advantageously arrange both blocking members and blow nozzles both at the beginning and at the end of the negative pressure region, whereby the nozzles blow/eject air out from the negative pressure region along the blocking member's surface. Together the ejecting blows and the blocking members prevent effectively air from escaping from the outside of the negative pressure region into the negative pressure region. The nozzles, which can be fixedly joined to the blow box can be arranged at a safe distance from the web.
In addition the blocking member and the blow nozzle at the corresponding point are advantageously shaped congruently, so that the blocking member's blocking surface passes along the outer surface of the nozzle when the blocking member is rotating and leaves a gap of a desired size between the nozzle and the blocking surface. The blocking surface and the nozzle are advantageously shaped so that the gap between them grows as the blocking member is pushed away from the wire, whereby more air than in the normal state is allowed to flow out from behind the blocking member, in other words from the space between the blocking member's back surface and the blow box. Then the pressure in the space behind the blocking member will decrease, and the blocking member can be pushed more easily than before away from the wire. In this manner the blocking member can be rapidly pushed away from the wire, for instance when a “paper lump” pushes the wire towards the blow box.
When desired, it is also possible to arrange members in the blow box in order to suck air away from the negative pressure region. In this way the negative pressure can be intensified, even to a level above 5 kpa. In addition, when required it is possible to maintain a lower negative pressure than this intensified negative pressure, such as a negative pressure of 0.1 to 0.4 kPa, in the other parts of the pocket, in other words outside the intensified negative pressure region.
In a blow box according to the invention a blocking member arranged at the beginning of the negative pressure region can at its first end, as seen in the running direction of the web, be connected to the blow box e.g. with a swing joint, which allows a frictionless or almost frictionless movement of the blocking member around the articulation point of the swing joint. A counter weight can be connected to the first end of the blocking member in order to keep the blocking member in balance at the desired distance from the web during a normal run. This facilitates keeping the gap between the web and the blocking member at a desired size. Thanks to the counter weight the blocking member is at a particularly mobile state, in other words it can be turned away from the wire or towards the wire in a sensitive manner.
A blow nozzle is arranged, as seen in the wire's running direction, advantageously at the second end of the blocking member (i.e. at the output end of the wire), which blocking member is arranged at the beginning of the negative pressure region in the blow box, and which, as seen in the wire's running direction, at its first end (i.e. at the input end of the wire) is connected through a swing joint to the blow box.
A blocking member, which is arranged in the blow box at the end of the negative pressure region, can be connected at its first or second end, as seen in the wire's running direction, to the blow box via a swing joint. Advantageously a blow nozzle is arranged in connection with the first end of the blocking member, as seen in the wire's running direction.
A limiter can be arranged in the blow box, typically in the blow nozzle structure, so that the limiter prevents the blocking member from turning closer to the wire than a predetermined minimum distance from the wire.
The blocking member can be made as a uniform structure with a width substantially equal to the width of the web. When desired the blocking member can be made of two, three or more parts, for instance of pieces having a length of 0.5 to 1.5 m, typically about 0.8 m, and which are arranged one after the other in the web's cross direction, so that they form a blocking member with the width of the web. In the latter case the distance of the different blocking member parts from the wire can be controlled separately. In this manner it is for instance possible to separately allow for the movements of the edge portions of the wire and ensure that the negative pressure is kept at the desired level also in these regions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below in more detail with reference to the enclosed drawings, in which
FIG. 1 shows schematically a blow box according to the invention arranged in the pocket formed between two drying cylinders in the drying section of a paper machine provided with a single wire run;
FIG. 2 shows schematically the cross-section of a blocking member and blow nozzle construction, which is suitable for application in a blow box according to the invention;
FIG. 3 shows schematically the cross-section of the negative pressure region defined by a blow box according to the invention, its blocking members and the wire;
FIG. 4 shows the solution according to FIG. 3 when a “paper lump” presses the wire against the blow box; and
FIG. 5 shows schematically in a top view the blow box according to FIG. 1 and the wire.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cross section of the drying section of a paper machine provided with a single wire run, a pocket 16 formed between its two drying cylinders 10 , 12 and a suction roll 14 , where a blow box 18 according to the invention is arranged. The blow box 18 is arranged between the first drying cylinder 10 and the second drying cylinder 12 in the running direction of the wire 20 , which supports the web.
The blow box 18 is arranged to cover the wire run 20 at a point where the wire is released from the first drying cylinder 10 , in other words at the opening nip 22 between the wire and the drying cylinder. The blow box creates in this point a intensified negative pressure region, in the space 24 between the wire 20 and the blow box 18 , whereby this space is sealed from the rest of the space of the pocket 16 .
In the solution presented in FIG. 1 the blow box does not cover the wire run 20 on the later part 26 after the opening nip between the first drying cylinder 10 and the suction roll 14 , and no separate negative pressure is directed at this later part 26 from the side of the pocket, in the case shown in FIG. 1 . In this way a bending of the central part of the wire run is avoided, which in some cases could be the result of using a too high negative pressure. Advantageously the blow box covers less than half, typically about a fifth of the wire run 20 between the drying cylinder 10 and the suction roll 14 . Of course it is also possible to apply the invention in such blow box solutions, in which the blow box covers a larger part of the wire run than that mentioned above.
When desired, it is also possible to direct against this later wire run 26 or a portion of it, a negative pressure which is weaker than that described above. It is for instance possible to arrange one or more suction openings 19 ′, which are connected to a suction pipe or the like on the side 19 of the blow box directed towards the suction roll. On the other hand the negative pressure can be created also by ejecting air away from the space between the blow box 18 and the suction roll 14 with the aid of blows 21 .
In the case of FIG. 1 the blow box 18 covers the main part of the wire run 28 between the second drying cylinder 12 and the suction roll 14 .
In order to seal the space 24 from the rest of the pocket space the blow box 19 is provided with two blocking members 30 , 32 . Thus the blow box has a first blocking member 30 at the input side of the negative pressure region 24 , as seen in the wire's 20 running direction, and a blocking member 32 at the output side of the negative pressure region 24 , as seen in the wire's 20 running direction. In the case of FIG. 1 both blocking members are provided with Coanda surfaces 30 ′ and 32 ′, which extend from the blow box towards the wire 20 .
Blow nozzles are arranged in connection with the Coanda surfaces 30 ′, 32 ′, so that the first nozzle 34 blows air over the first Coanda surface 30 ′ against the running direction of the wire 20 and ejects air out from the negative pressure region 24 defined by the blow box 18 , the wire 20 and the blocking members 30 , 32 .
The second blow nozzle 36 blows air over the second Coanda surface 32 ′ downstream with respect of the running direction of the wire 26 , and thereby it intensifies the negative pressure in the space 24 .
In addition, in the case shown in FIG. 1 , members 38 are arranged in the blow box between the blocking members 30 and 32 in order to remove air from the negative pressure region 24 with the aid of suction. When desired the negative pressure can be created only by blows.
The blocking members 30 and 32 are connected with swing joints 40 , 42 to the other structures of the blow box, so that each blockng member freely can be turned around the articulation point of the swing joint. Thus the blocking members 30 , 32 can rotate around the articulation points of the hinges, so that the Coanda surfaces 30 ′, 32 of the blocking members move closer to the wire 20 or away from the wire.
In the case of FIG. 1 both blocking members 30 and 32 are basically identical. However, the solution according to the invention can be also applied so that the blow box has only one blocking member provided with a swing joint or the like. The second blocking member can be some other solution, which has been found adequate. The surface of the blocking members directed towards the wire may also have a form, which is different from the smoothly arched Coanda surfaces shown in FIG. 1 . The blocking surfaces of the blocking member can for instance be formed by a plate, which is bent 2 , 3 or more times into a partly arched form. Thus the blocking surfaces can be formed by linear plate sections.
FIG. 2 shows in an enlarged view a blocking member, which is of the same type as the blocking member 30 shown in FIG. 1 , whereby a blow nozzle 34 is connected to the blocking member. The blocking member 30 is connected via a swing joint 40 to the structures 44 of the blow box 18 . In addition a counter weight 48 is arranged in the blocking member 30 , so that this counter weight keeps the blocking member in a suitable position regarding the wire run 20 , in other words at a suitable distance from the wire during a normal run and/or during shutdown. The counter weight keeps the blocking surface 30 ′ of the blocking member at the desired distance from the wire run. An adjustable limiter 54 is arranged at that end of the blocking member which is away from the hinge, which limiter hits the limiting wall 34 ′ when the blocking member rotates towards the wire, and prevents the blocking member from turning closer to the wire than a predetermined distance. When desired the limiter can be arranged at other parts of the blocking member. The back surface 50 of the blocking member 30 , which is directed away from the wire, borders to the partial space 52 of the blow box 53 .
The blow nozzle 34 , which ejects air out from the negative pressure region 24 between the wire and the blow box, is arranged in the blow box structures so that only a very small gap 56 is left between the blocking surface 30 ′ of the blocking member 30 and the outer surface 34 ′ of the blow nozzle 34 . The blow nozzle 34 , particularly its outer surface, and the blocking member 30 , particularly its blocking surface, can be shaped so that the gap 56 is very small, at least in the so called rest position of the blocking member, whereby the amount of air escaping from the air space 52 through this gap 56 into the negative pressure region 24 is minimised
However, according to a preferred embodiment of the invention the outer surface 34 ′ of the blow nozzle and the blocking surface 30 ′ of the blocking member are shaped so that the size of the gap 56 depends on the position of the blocking member. The gap 56 is increased or reduced when the blocking member is rotated, as shown in the following FIGS. 3 and 4 .
The FIGS. 3 to 5 show the function of the blocking members in a blow box according to the invention in different running situations. The reference numerals used in FIGS. 1 and 2 are also used in the description of FIGS. 3 to 5 .
FIG. 3 shows the negative pressure region 24 created by the blow box 18 , whereby the negative pressure region is formed in the space defined by the wire 20 , the blow box 18 and the first blocking member 30 and the second blocking member 32 according to FIG. 2 . Both blocking members are connected at their first ends, as seen in the running direction of the wire run 20 , through swing joints 40 , 42 to the structures 44 , 44 ′ of the blow box. A first blow nozzle 34 and a second blow nozzle 36 are arranged between the negative pressure region and the blocking members 30 and 32 .
The first blow nozzle 34 is arranged to eject air from the negative pressure region 24 over the Coanda surface 30 ′ of the blocking member 30 , upstream with respect of the running direction of the wire run. The second blow nozzle 36 is arranged to eject air from the space 24 over the Coanda surface 32 ′ of the blocking member 32 , downstream with respect of the running direction of the wire run. Both blocking members 30 , 32 are kept at a suitable distance a, a′ from the wire 20 with the aid of a low positive pressure acting in the spaces 52 , 52 ′ on the back surfaces 50 , 50 ′ of the blocking members.
The first space 52 is defined by the back surface 50 of the first blocking member 30 , the structures 45 of the blow box, and the outer surface 34 ′ of the first blow nozzle 34 . A small gap 56 is left between the blocking member 30 and the outer surface 34 ′ of the nozzle, and this gap allows the blocking surface to rotate around the articulation point of the hinge 40 . This gap 56 is very small during normal run, whereby it minimises the amount of air escaping from the space 52 to the space 24 .
In a corresponding way the second space 52 ′ is defined by the back surface 50 ′ of the second blocking member 32 and the structures 45 ′ of the blow box. The structures 45 ′ bordering to the space 52 ′ comprise a partition 47 , which projects towards the wire. The partition 47 is shaped to form a relatively tight seam together with the blocking member 32 , mainly with that end of the blocking member, which points away from the negative pressure region 24 . The blocking member 32 and the partition 47 are shaped so that the very small gap 56 ′ left between them still allows the blocking member 32 to rotate around the articulation point of the swing joint 42 . During a normal run the gap 56 ′ is so small that it minimises the amount of air flowing out from the space 52 ′.
The gap between the second blocking member 32 and the second blow nozzle 36 does not border directly to the space 52 ′, and thus this gap does not have any direct effect on the pressure in the space 52 ′.
FIG. 4 shows a blow box according to FIG. 3 in a situation where a “paper lump” 27 or the like presses the wire 20 towards the blocking members 30 and 32 , however without the wire touching these members. The distances b, b′ between the wire 20 and the blocking surfaces 30 ′, 32 ′ of the blocking members 30 , 32 are shorter than the distances a, a′ in the case shown in FIG. 3 . The broken lines in FIG. 4 show the wire run in the situation shown in FIG. 3 . The ejection blows of the nozzles 34 , 36 prevent the wire from touching the blocking surface. In a solution according to the invention, which utilises very mobile blocking members 30 , 32 , a rising pressure on the blocking surface side of the blocking members will cause the blocking members to project inward into the blow box, in other words towards the spaces 52 , 52 ′.
The first blocking member 30 and the blow nozzle 34 are shaped so that the gap 56 between the blocking surface 30 ‘and the nozzle’s outer surface 34 ′ increases and air can leak out from the space 52 as the blocking member is pushed towards the blow box. As air is leaking out from the space 52 , the pressure or force contained in it, which normally pushes the blocking member towards the wire, will be reduced, and the blocking member allows the “paper lump” to be pushed towards the blow box, in other words, the blocking member is withdrawn from the path of the “paper lump” and the wire. In this way unnecessary damages to the wire or blow box components are avoided.
The pressurised space 52 ′ on the backside of the second blocking member 32 is defined by the backside 50 ′ of the blocking member and also by the blow box structures 45 ′, from which a partition 47 projects towards the second blocking member 32 . When a “paper lump” 27 presses the wire 20 and thus indirectly also the blocking member 32 , the very mobile blocking member rotates around the articulation point of the hinge 42 and is pushed towards the blow box. The motion of the blocking member results in that the gap 56 ′ between the blocking member and the partition 47 increases, whereby air can leak out from the space 52 ′. Therefore the pressure in the space 52 ′ is reduced, and the blocking member can be pushed away from the path of the “paper lump” and the wire more easily than previously, and without any damages.
The blocking member 30 shown in the FIGS. 1 to 4 can be formed of, in the cross direction of the wire, two or more separately rotating blocking member components 30 a , 30 b , . . . 30 k , which components are connected one after the other so that they form an entity extending across the web. FIG. 5 shows in a top view a blow box 18 , which is arranged in front of the wire 20 and which contains a blocking member formed by several separate blocking member components 30 a , 30 b , 30 c , 30 d , . . . 30 k . Each blocking member component takes its place according to the invention at a suitable distance from the wire. In the case shown in FIG. 5 the wire's edges bent away from the blow box, and therefore the blocking member components 30 a and 30 a ′ at the edge regions project farther out from the blow box than the other blocking member components. The next blocking member components 30 b , 30 b ′ project also slightly more outwards than the blocking member components 30 k in the central part of the blow box.
A fault in the shape of the wire and/or the blow box can be compensated for by dividing the blocking member into components, by imitating the arched form with a broken line. The distance of the blocking member to the wire can be controlled individually for each blocking member component, when required.
Now it has been realised that the blocking surface of a “floating” blocking member arranged in the blow box, similar to the blocking surface shown in the FIGS. 1 to 4 , will automatically find the correct distance to the adjacent wire. Now it is possible to eliminate springs and other mechanical obstacles, which previously were used to restrict the movements of the blocking member, and the blocking member is allowed to move freely or almost freely as close to the wire as it wants to go.
The blocking member supported to be mobile according to the invention finds the correct distance to the wire, also as the wire bends. With the aid of the blocking member it is thus possible to maintain with the blow box a negative pressure level, which is as effective as possible with as small air leaks as possible, in other words, without too high energy costs. This will also at least partly compensate for a bending wire at high negative pressures.
When desired it is possible to supply blow air on the backside of a blocking member according to the invention, i.e. into the space defined by the blocking member's surface, which is directed away from the wire. Depending on in which way the blow air is supplied, and depending on the shaping of the components, the pressure difference will press the blocking member in the desired manner towards the wire or away from the wire. On the other hand the gap or slit between the blocking member and the blow nozzle or some other limiting partition can be designed so that the gap or slit will leak air and change the pressure in a controlled way on the backside of the blocking member, when required. This gap can be shaped so that the pressure acting on the blocking member's backside is a function of the distance between the blocking member's surface and the wire. Then the pressure will change in a controlled manner in the space on the backside of the blocking member, for instance when a “paper lump” presses the blocking member inwards into the blow box, and the pressure acting on the blocking member will be reduced. Or, in this way the force towards the wire, caused by the negative pressure, can be reduced at short distances, i.e. when the distance to the wire is short.
A blocking member according to the invention, which “floats” in the air flow, and a blow nozzle connected to it provide a safe structure, which is self-controlled. The jet from the blow nozzle acts as a “bed” between the wire and the blocking member's blocking surface. The distance between the blocking member's blocking surface and the wire can be kept very short in a safe manner. | A blow box ( 18 ) for supporting the web run in a paper machine or the like, which blow box comprises members for maintaining a negative pressure at least in one negative pressure region ( 24 ) between the wire ( 20 ) and the blow box. The members comprise a blocking member ( 30, 32 ), which is arranged, regarding the wire's running direction, at the beginning and/or at the end of said negative pressure region, which extends across the wire and projects towards the wire, and which is movable in relation to the blow box, and blowing members ( 34, 36 ), with which air is ejected with blows between said blocking member and the wire from said negative pressure region and/or with which air is prevented from entering this negative pressure region. The blocking member is connected to the blow box by a hinge member ( 40, 42 ), which allows the blocking member to rotate around the articulation point of the hinge member due to the pressure difference between the pressure acting on the blocking member's blocking surface ( 30′, 32 ′) directed towards the wire and the pressure acting on the blocking member's back surface ( 50, 50 ′) directed away from the wire. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 09/707,816, filed Nov. 7, 2000 now U.S. Pat. No. 7,006,065.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a driving method and a driving circuit for a color liquid crystal display and more particularly to the driving method and the driving circuit for driving the color liquid crystal display based on a gamma compensated video signal.
The present application claims the Convention Priority of Japanese Patent Application No. Hei11-316873 filed on Nov. 8, 1999, which is hereby incorporated by reference.
2. Description of the Related Art
FIG. 19 is a block diagram showing a conventional electric configuration of a driving circuit of an analog circuit configuration of a color liquid crystal display 1 .
The color liquid crystal display 1 is a liquid crystal display of an active matrix driving type using a TFT (Thin Film Transistor) as a switching element, in which intersection points of plural scanning electrodes (gate lines) provided at predetermined intervals in a row direction and plural data electrodes (source lines) provided at predetermined intervals in a column direction are used as pixels, for each pixel, a liquid cell of a equivalent capacitive load, a TFT for driving a corresponding liquid crystal cell, a capacitor for keeping data charges during one vertical synchronous period are arranged, a data red signal, a data green signal and a data blue signal generated based on a video red signal S R , a video green signal S G , a video blue signal S B , are applied to the data electrode and a scanning signal generated based on a horizontal synchronous signal S H and a vertical synchronous signal S V is applied to a scanning electrode, and then a color character, a color image and a like are displayed. In addition, the color liquid crystal display 1 is a normal white type having a high transmittance when no voltage is applied.
Further, the driving circuit of the color liquid crystal display 1 is mainly provided with clamp circuit 2 1 to clamp circuit 2 3 , a reference voltage generating circuit 3 , gamma compensating circuit 4 1 to gamma compensating circuit 4 3 , polarity inverting circuit 5 1 to polarity inverting circuit 5 3 , video amplifier 6 1 to video amplifier 6 3 , a timing generating circuit 7 , a data electrode driving circuit 8 and a scanning electrode driving circuit 9 .
Clamp circuit 2 1 to clamp circuit 2 3 execute a clamp fixing (direct current refreshing) a level of a top or a back porch of the horizontal synchronous signal S H of the video red signal S R , the video green signal S G and the video blue signal S B supplied from outside to a black level and output a video red signal S RC , a video green signal S GC and a video blue signal S BC .
The reference voltage generating circuit 3 a generates a reference voltage V L , a reference voltage V M , a reference voltage V H used to gamma compensate the video red signal S RC , the video green signal S GC and the video blue signal S BC and supplies the video red signal S RC , the video green signal S GC and the video blue signal S BC to gamma compensating circuit 4 1 to gamma compensating circuit 4 3 . Gamma compensating circuit 4 1 to gamma compensating circuit 4 3 , based on the reference voltage V L , the reference voltage V M and the reference voltage V H supplied from the reference voltage generating circuit 3 , give a gradient to the video red signal S RC , the video green signal S GC and the video blue signal S BC by gamma compensating the video red signal S RC , the video green signal S GC and the video blue signal S BC and output them as the video red light S RG , the video green light S GG and the video blue light S BG .
Here, the gamma compensation will be explained. For example, when a logarithm value of a luminance originally provided for a subject such as a view and a person taken by a video camera is set to a horizontal axis and a logarithm value of a luminance of a reproduced image displayed on a display by a video signal from the video camera is set to a vertical axis and then an inclination angle of a reproducing characteristic curve is set to θ, tan θ is called a gamma (γ) . When the luminance of the subject is reproduced on the display with fidelity, namely, when an input (horizontal axis) increases or decreases by one and also an output (vertical axis) increases or decreases by one, the inclination angle of the reproducing characteristic curve is a straight line having an inclination angle of 45°, tan 45°=1 and then the gamma becomes 1. Therefore, in order to reproduce the luminance of the subject with fidelity, it is necessary to set a gamma of a whole system including taking the subject by the video camera though reproducing an image on the display to gamma=1.
However, an image pickup element such as CCD (Charge Coupled Device), a CRT (Cathode Ray Tube) display or a like making up a video camera has a peculiar gamma. A gamma of the CCD is 1 and a gamma of the CRT display is about 2.2.
Therefore, it is necessary to compensate a video signal in order to obtain a reproduced image of good gradation by setting gamma=1 as a whole system, and this is called gamma compensation. Generally, the gamma compensation is applied to the video signal so as to be suitable to a gamma characteristic of the CRT display.
Polarity inverting circuit 5 1 to polarity inverting circuit 5 3 , in order to alternately drive the color liquid crystal display 1 , invert respective polarities of the video red light S RG , the video green light S GG and the video blue light S BG and output them. Video amplifier 6 1 to video amplifier 6 3 amplify the video red light S RG , the video green light S GG and video blue light S BG which are polarity-inverted to a level until the color liquid crystal display 1 can be driven. The timing generating circuit 7 , based on the horizontal synchronous signal S H and the vertical synchronous signal S V supplied from outside, generates a horizontal scanning pulse P H and a verticality scanning pulse P V and supplies the horizontal scanning pulse P H and the verticality scanning pulse P V to the data electrode driving circuit 8 and the scanning electrode driving circuit 9 . The data electrode driving circuit 8 generates a data red signal, a data green signal, a data blue signal from the video red light S RG , the video green light S GG and the video blue light S BG which are amplified and polarity-inverted and applies the data red signal, the data green signal and the data blue signal to corresponding data electrodes in the color liquid crystal display 1 at a timing of the horizontal scanning pulse P H supplied from the timing generating circuit 7 .
The scanning electrode driving circuit 9 generates a scanning signal and supplies the scanning signal to a corresponding scanning electrode in the color liquid crystal display 1 at a timing of the vertical scanning pulse P V supplied from the timing generating circuit 7 .
Further, FIG. 20 is a block diagram showing a second conventional electric configuration of a driving circuit of a digital circuit configuration for the color liquid crystal display 1 .
The driving circuit for the color liquid crystal display 1 is mainly provided with a controlling circuit 11 , a gradation power supply circuit 12 , a data electrode driving circuit 13 and a scanning electrode driving circuit 14 .
The controlling circuit 11 is, for example, an ASIC (Application Specific Integrated Circuit), supplies red data D R of six bits, green data D G of six bits and blue data D B of six bits supplied from outside to the data electrode driving circuit 13 and generates a horizontal scanning pulse P H , a vertical scanning pulse P V and a polarity inverting pulse POL for alternately driving the color liquid crystal display 1 and supplies them to the data electrode driving circuit 13 and the scanning electrode driving circuit 14 . The gradation power supply circuit 12 , as shown in FIG. 21 , is provided with resistor 15 1 to resistor 15 11 connected longitudinally between a reference voltage V REF and ground and voltage follower 16 1 to voltage follower 16 9 connected with connection points of resistors adjacent to respective input terminals, and applies buffer to a gradation voltage V 0 to a gradation voltage V 9 set for the gamma compensation and appearing at connection points of adjacent resistors and supplies gradation voltage V 0 to gradation voltage V 9 to the data electrode driving circuit 13 .
The data electrode driving circuit 13 , as shown in FIG. 21 , is mainly provided with a multiplexer (MPX) 17 , a DAC 18 and voltage follower 19 1 to voltage follower 19 384 . In addition, a real data electrode driving circuit is provided with a shift register, a data register, a latch and a level shifter at a front step of the DAC 18 , however, these elements and operations are not directly related with features of the present invention, therefore, explanations are omitted in this specification and they are not shown.
The multiplexer MPX 17 switches a group of gradation voltage V 0 to gradation voltage V 4 and a group of gradation voltage V 5 to gradation voltage V 9 among gradation voltage V 0 to gradation voltage V 9 supplied from the gradation power supply circuit 12 , based on the polarity inverting pulse POL supplied from the controlling circuit 11 and supplies one of the groups to the DAC 18 . The DAC 18 applies the gamma compensation to the red data D R of six bits, the green data D G of six bits and the blue data D B of six bits supplied from the controlling circuit 11 , converts the red data D R , the green data D G and the blue data D B into an analog data red signal, an analog green signal and an analog blue signal and supplies the analog data red signal, the analog green signal and the analog blue signal to voltage follower 19 1 to voltage follower 19 384 , based on the group of gradation voltage V 0 to gradation voltage V 4 and the group of gradation voltage V 5 to gradation voltage V 9 . Voltage follower 19 1 to voltage follower 19 384 apply buffer to the analog data red signal, the analog data green signal and the analog data blue signal supplied from the DAC 18 and apply these data signals to corresponding data electrodes in the color liquid crystal display 1 .
The scanning electrode driving circuit 14 sequentially generates scanning signals and sequentially applies the scanning signals to corresponding scanning electrodes in the color liquid crystal display 1 at a timing of the vertical scanning pulse P V supplied from the timing generating circuit 7 .
Now, in the driving circuit for the color liquid crystal display 1 of the first conventional example, the gamma compensation is applied to the video red signal S RC , the video green signal S GC and the video blue signal S BC based on the common reference voltage V L , the common reference voltage V M , the common reference voltage V H , so that the gamma characteristic of the CRT display (gamma is about 2.2) is suitable for the video red signal S RC , the video green signal S GC and the video blue signal S BC .
Further, in the driving circuit for the color liquid crystal display 1 of the second conventional example, the gamma compensation is applied to the red data D R , the green data D G and the blue data D B based on the common gradation reference voltage V 0 to the common reference voltage V 4 and common gradation reference voltage V 5 to common gamma reference voltage V 9 so that the gamma characteristic of the CRT display (gamma is about 2.2) is suitable for the red data D R , the green data D G and the blue data D B .
However, a color liquid crystal display 1 has a gamma characteristic different from that of a CRT display, a characteristic curve of a transmittance T for an applied voltage V (a V-T characteristic curve) is not linear, and particularly, the transmittance hardly changes against a change of the applied voltage near a black level. Further, since the V-T characteristic curve of the color liquid crystal display, as shown in FIG. 22 , is different for each of a red (curve a), a green (curve b) and a blue (curve c), a characteristic curve of the luminance (an output) for the gradation (an input), as shown in FIG. 23 , is different for each of the red (curve a), the green (curve b) and the blue (curve c) . In FIG. 23 , the luminance is a relative luminance in which the gamma compensation is applied to the video signal so as to be suitable to a gamma characteristic of a CRT display (about 2.2 gamma) in the gamma compensating circuit.
Accordingly, in the conventional gamma compensation common with the red, the green and the blue and making suitable to the gamma characteristic of the CRT display (about 2.2 gamma), for example, in a case of the V-T characteristic curve shown in FIG. 22 , a transmittance is set to 100% when an applied voltage is 1.7 V, namely, a white level is set. However, particularly in the green (curve b), a white level is set at transmittance of 80%, therefore, it is impossible to carry out an optimal gamma compensation and then it is impossible to obtain a reproduced image of a good gradation. As a result, there a disadvantage in that it is impossible to meet a recent need of a high video quality.
Further, recently, in order to meet the need of the high video quality, a color liquid crystal display having a high transmittance is developed, and FIG. 24 shows an example of a V-T characteristic curve of a color liquid crystal display having such a high transmittance characteristic red (curve a), green (curve b), blue (curve c)) . In such the V-T characteristic curve, each of red (curve a), green (curve b) and blue (curve c) has a transmittance of 100%, namely, each best luminance is too different, therefore, there is a problem in that the color liquid crystal display 1 cannot be used since it is impossible to deal with gamma characteristics of the conventional gamma compensation which are used in common with red, green and blue.
Furthermore, as above described, in the first conventional example and the second conventional example of a driving circuit for the color liquid crystal display, gamma compensation is applied based on common reference voltage V L , common reference voltage V M and common reference voltage V H or a common group of gradation voltage V 0 to gradation voltage V 4 and a common group of gradation voltage V 5 to gradation voltage V 9 , therefore, there is a problem in that, though a gradation batter occurs in which gradation change is not displayed on a display as luminance changes, the gradation batter can not be removed.
SUMMARY OF THE INVENTION
In view of the above, it is an object of the present invention to provide a driving method and a driving circuit for a color liquid crystal display capable of carrying out a gamma compensation fully suitable to a characteristic of the color liquid crystal display and capable of removing a gradation batter though the gradation batter occurs in a specific color among red, green and blue.
According to a first aspect of the present invention, there is provided a driving method for a color liquid crystal display including:
a step of applying gamma compensations making suitable to a red transmittance characteristic, a green transmittance characteristic and a blue transmittance characteristic for an applied voltage of the color liquid crystal display to a video red signal, a video green signal and a video blue signal independently in order to obtain a compensated video red signal, a compensated video green signal and a compensated blue signal; and
a step of driving the color liquid crystal display based on the compensated video red signal, the compensated video green signal and the compensated blue signal.
According to a second aspect of the present invention, there is provided a driving method for a color liquid crystal display including:
a step of applying gamma compensations, each of the gamma compensations including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image to an input image luminance and a second gamma compensation of making suitable to a red transmittance characteristic, a green transmittance characteristic and a blue transmittance characteristic for an applied voltage of the color liquid crystal display to a video red signal, a video green signal and a video blue signal independently in order to obtain a compensated video red signal, a compensated video green signal and a compensated blue signal; and
a step of driving the color liquid crystal display based on the compensated video red signal, the compensated video green signal and the compensated blue signal.
In the foregoing, a preferable mode is one wherein the gamma compensations are applied using a common voltage or a common data to the video red signal, the video green signal and the video blue signal corresponding to an area in which the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for the applied voltage for the color liquid crystal display become an approximate similar characteristic curve.
Also, a preferable mode is one wherein voltages or data used for the gamma compensations are independently set in an area from a minimum transmittance to a maximum transmittance of each of the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for the applied voltage for the color liquid crystal display.
Furthermore, a preferable mode is one wherein the voltages or the data are independently changeable.
According to a third aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a first gamma compensating circuit for applying a gamma compensation of compensating a video red signal so as to be suitable to a red transmittance characteristic for an applied voltage in the color liquid crystal display and for outputting a compensated video red signal;
a second gamma compensating circuit for applying a gamma compensation of compensating a video green signal so as to be suitable to a green transmittance characteristic in the applied voltage of the color liquid crystal display and for outputting a compensated video green signal;
a third gamma compensating circuit for applying a gamma compensation of compensating a video blue signal so as to be suitable to a blue transmittance characteristic for the applied voltage of the color liquid crystal display and for outputting a compensated video blue signal;
a reference voltage generating circuit for supplying respectively reference voltages to the first gamma compensating circuit, the second gamma compensating circuit and the third gamma compensating circuit; and
a data electrode driving circuit for driving corresponding electrodes of the color liquid crystal display based on the compensated video red signal, the compensated green signal and the compensated video blue signal.
According to a fourth aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a first gamma compensating circuit for applying a gamma compensation to a video red signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video red signal so as to be suitable to a red transmittance characteristic for an applied voltage in the color liquid crystal display and for outputting a compensated video red signal;
a second gamma compensating circuit for applying a gamma compensation to a video green signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video green signal so as to be suitable to a green transmittance characteristic for an applied voltage of the color liquid crystal display and for outputting a compensated video green signal;
a third gamma compensating circuit for applying a gamma compensation to a video blue signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video blue signal so as to be suitable to a blue transmittance characteristic for an applied voltage of the color liquid crystal display and for outputting a compensated video blue signal;
a reference voltage generating circuit for supplying respective reference voltages to the first gamma compensating circuit, the second gamma compensating circuit and the third gamma compensating circuit; and
a data electrode driving circuit for driving corresponding electrodes in the color liquid crystal display based on the compensated video red signal, the compensated video green signal and the compensated video blue signal.
In the foregoing, a preferable mode is one wherein the reference voltage generating circuit supplies a common reference voltage to the video red signal, the video green signal and the video blue signal corresponding to an area in which the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for the applied voltage in the color liquid crystal display become an approximate similar characteristic curve.
Also, a preferable mode is one wherein the reference voltages are independently set for each area from a minimum transmittance to a maximum transmittance in each of the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for the applied voltage for the color liquid crystal display.
Furthermore, a preferable mode is one wherein the reference voltages are independently changeable.
According to a fifth aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a gradation power supply circuit for generating a plurality of red gradation voltages, a plurality of green gradation voltages and a plurality of blue gradation voltages used for independently applying a gamma compensation to a video red signal, a video green signal and a video blue signal in order to compensate the video red signal, the video green signal and the video blue signal so as to be suitable to a red transmittance characteristic, a green transmittance characteristic and a blue transmittance characteristic for an applied voltage in the color liquid crystal display; and
a data electrode driving circuit for applying a data red signal, a data green signal and a data blue signal obtained by applying the gamma compensation to a red data, a green data and a blue data and by analog-converting the red data, the green data and the blue data based on the plurality of red gradation voltages, the plurality of green gradation voltages and the plurality of blue gradation voltages to corresponding data electrodes of the color liquid crystal display.
According to a sixth aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a gradation power supply circuit for generating a plurality of red gradation voltages, a plurality of green gradation voltages and a plurality of blue gradation voltages used for independently applying a gamma compensation to a video red signal, a video green signal and a video blue signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video blue signal so as to be suitable to a blue transmittance characteristic for an applied voltage of the color liquid crystal display; and
a data electrode driving circuit for applying a data red signal, a data green signal and a data blue signal obtained by applying a gamma compensation to a red data, a green data and a blue data and by analog-converting the red data, the green data and the blue data based the plurality of red gradation voltages, the plurality of green gradation voltages and the plurality of blue gradation voltages to corresponding data electrodes of the color liquid crystal display.
In the foregoing, a preferable mode is one wherein the gradation power supply circuit generates a common gradation voltage to the video red signal, the video green signal and the video blue signal corresponding to an area in which the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for the applied voltage for the color liquid crystal display become an approximate similar characteristic curve.
Also, a preferable mode is one wherein the plurality of red gradation voltages, the plurality of green gradation voltages and the plurality of blue gradation voltages are independently set for each area from a minimum transmittance to a maximum transmittance in each of the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic in the applied voltage in the color liquid crystal display.
Furthermore, a preferable mode is one wherein the plurality of red gradation voltages, the plurality of green gradation voltages and the plurality of blue gradation voltages are independently changeable.
According to a seventh aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a first gamma compensating section for applying a gamma compensation to a digital video red signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the digital video red signal so as to be suitable to a red transmittance characteristic for an applied voltage of the color liquid crystal display and for outputting a compensated digital video red signal;
a second gamma compensating section for applying a gamma compensation to a digital video green signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the digital video green signal so as to be suitable to a green transmittance characteristic for an applied voltage in the color liquid crystal display and for outputting a compensated digital video green signal;
a third gamma compensating section for applying a gamma compensation to a digital video blue signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the digital video blue signal so as to be suitable to a blue transmittance characteristic for an applied voltage of the color liquid crystal display and for outputting a compensated digital video blue signal; and
a data electrode driving circuit for applying a data red signal, a data green signal and a data blue signal obtained by analog-converting a compensated red data, a compensated green data and a compensated blue data to corresponding electrodes of the color liquid crystal display.
According to an eighth aspect of the present invention, there is provided a driving circuit for a color liquid crystal display including:
a first gamma compensating section for applying a gamma compensation to a digital video red signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating a video red signal so as to be suitable to a red transmittance characteristic for an applied voltage of the color liquid crystal display, the second gamma compensation including a second gamma slight compensation of executing a compensation caused by a difference among a red characteristic, a green characteristic and a blue characteristic and for outputting a compensated video red signal;
a second gamma compensating section for applying a gamma compensation to a digital video green signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video green signal to be suitable to a green transmittance characteristic for an applied voltage of the color liquid crystal display, the second gamma compensation including a second gamma slight compensation of executing a compensation caused by a difference among the red characteristic, the green characteristic and the blue characteristic and for outputting a compensated video green signal;
a third gamma compensating section for applying a gamma compensation to a digital video blue signal, the gamma compensation including a first gamma compensation of voluntarily giving a luminance characteristic of a reproduced image for an input image luminance and a second gamma compensation of compensating the video blue signal to be suitable to a blue transmittance characteristic for an applied voltage of the color liquid crystal display, the second gamma compensation including a second gamma slight compensation of executing a compensation caused by a difference among the red characteristic, the green characteristic and the blue characteristic and for outputting a compensated video blue signal;
a gradation power supply circuit for generating a plurality of red gradation voltages, a plurality of green gradation voltages and a plurality of blue gradation voltages used to apply a second gamma rough compensation caused by a similarity among the red characteristic, the green characteristic and the blue characteristic to compensated red data, compensated green data and compensated blue data included in the second gamma compensation making suitable to the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for an applied voltage of the color liquid crystal display; and
a data electrode driving circuit for applying a data red signal, a data green signal and a data blue signal obtained by applying the gamma rough compensation to the compensated red data, the compensated green data and the compensated blue data and by analog-converting the compensated red data, the compensated green data and the blue data based on the plurality of red gradation voltages, the plurality of green gradation voltages and the plurality of blue gradation voltages to corresponding electrodes of the color liquid crystal display.
In the foregoing, a preferable mode is one wherein the first gamma compensating section, the second gamma compensating section and the third gamma compensating section apply the gamma compensation to the red data, the green data and the blue data by operation processes.
Also, a preferable mode is one wherein the first gamma compensating section, the second gamma compensating section and the third gamma compensating section previously hold the compensated red data, the compensated green data and the compensated blue data which are results of the gamma compensation corresponding to the red data, the green data and the blue data and the compensated red data, the compensated green data and the compensated blue data are read using the red data, the green data and the blue data as reference addresses so as to be corresponded in order to apply the gamma compensation.
Furthermore, a preferable mode is one wherein the first gamma compensating section, the second gamma compensating section and the third gamma compensating section independently apply the gamma compensation in each area from a minimum transmittance to a maximum transmittance of each of a red transmittance characteristic, a green transmittance characteristic and a blue transmittance characteristic for the applied voltage of the color liquid crystal display.
With the above configurations, it is possible to carry out an optimal gamma compensation fully suitable to a characteristic of a color liquid crystal display. Also, though a gradation batter occurs in a specific color among red, green and blue, it is possible to remove the gradation batter.
Also, since the color liquid crystal display is driven based on the compensated video red signal, the compensated video green signal and the compensated video blue signal obtained by independently applying gamma compensations to the video red signal, the video green signal and the video blue signal so as to be suitable to the red transmittance characteristic, the green transmittance characteristic and the blue transmittance characteristic for an applied voltage to the color liquid crystal display, it is possible to carry out an optimal gamma compensation fully suitable to a characteristic of the color liquid crystal display. Thus, it is possible to fully meet a recent need of a high quality image. Also, it is possible to use a color liquid crystal display having a high transmittance characteristic in which maximum luminance are very different concerning red, green and blue. Furthermore, though the gradation batter occurs in a specific color among red, green and blue, a voltage for the gamma compensation concerning the specific color can be changed, therefore, it is possible to remove the gradation batter of the specific color.
Also, using the common voltage or the common data, the gamma compensation can be applied to the video red signal, the video green signal and the video blue signal corresponding to an area in which characteristic curves become an approximately similar form in the red transmittance characteristic, the green transmittance characteristic and blue transmittance characteristic, therefore, it is possible to reduce a circuit scale.
Further, the first gamma compensating section, the second gamma compensating section and the third gamma compensating section previously memorize the compensated red data, the compensated green data and the compensated blue data corresponding red data, green data and blue data, read the corresponding compensated red data, the corresponding compensated green data and the corresponding compensated blue data using the red data, the green data. And then, the first gamma compensating section, the second gamma compensating section and the third gamma compensating section apply the blue data as reference addresses and the gamma compensation, it is possible to execute the gamma compensation at higher speed.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages, and features of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram showing an electrical configuration of a driving circuit for a color liquid crystal display according a first embodiment of the present invention;
FIG. 2 is a schematic circuit diagram showing an example of an electrical configuration of a gamma compensating circuit in the driving circuit for the color liquid crystal display of the first embodiment;
FIG. 3 is a block diagram showing an example of an electrical configuration of a reference voltage generating circuit in the driving circuit for the color liquid display of the first embodiment;
FIG. 4 is a schematic circuit diagram showing an example of an electrical configuration of an adder in the reference voltage generating circuit of the first embodiment;
FIG. 5 is a graph showing an example of a relationship between a reference voltage V LR , a reference voltage V MR and a reference voltage V HR used for applying gamma compensation to a video red signal S RC and a compensated video red signal S RG to which gamma compensation is applied in the first embodiment;
FIG. 6 is a block diagram showing an electrical configuration of a driving circuit for a color liquid crystal display according a second embodiment of the present invention;
FIG. 7 is a block diagram showing an example of an electrical configuration of a reference voltage generating circuit in the driving circuit for the color liquid crystal display of the second embodiment;
FIG. 8 is a block diagram showing an electrical configuration of a driving circuit for a color liquid crystal display according a third embodiment of the present invention;
FIG. 9 is a block diagram showing an example of an electrical configuration of a gradation power supply circuit and a data electrode driving circuit for the liquid crystal display in the driving circuit of the third embodiment;
FIG. 10 is a graph showing an example of a relationship between red data of eight bits supplied to a DAC in the data electrode driving circuit and red gradation voltage V R0 2 to red gradation voltage V R8 and red gradation voltage V R9 to red gradation voltage V R17 in the third embodiment;
FIG. 11 is a block diagram showing an electrical configuration of a driving circuit for a color liquid crystal display according a fourth embodiment of the present invention;
FIG. 12 is a block diagram showing an electrical configuration of a controlling circuit, a gradation power supply circuit and a data electrode driving circuit for the color liquid crystal display in the driving circuit of the fourth embodiment;
FIG. 13 is a graph showing an example of a relationship between compensated red data D RG of eight bits, compensated green data D GG of eight bits and compensated blue data D BG of eight bits supplied to a DAC in the data electrode driving circuit and gradation voltage V 0 to gradation voltage V 8 and gradation voltage V 9 to gradation voltage V 17 in the fourth embodiment;
FIG. 14 is a block diagram showing an electrical configuration of a driving circuit for a color liquid crystal display according a fifth embodiment of the present invention;
FIG. 15 is a block diagram showing an electrical configuration of a controlling circuit and a data electrode driving circuit in the driving circuit for the color liquid crystal display of the fifth embodiment;
FIG. 16 is a graph showing a relationship between red data D R of eight bits and compensated red data D RG of ten bits memorized in a ROM in the controlling circuit of the fifth embodiment;
FIG. 17 is a graph showing an example of a relationship between compensated red data D RG of ten bits, compensated green data D GG of ten bits and compensated blue data D BG of ten bits supplied to a DAC in the data electrode driving circuit and gradation voltage V 0 to gradation voltage V 8 and gradation voltage V 9 to gradation voltage V 17 in the fifth embodiment;
FIG. 18 is a graph showing an example of a relation between red data D R of eight bits supplied to a DAC in a data electrode driving circuit in a driving circuit for a color liquid crystal display and red gradation voltage V R0 to red gradation voltage V R8 and red gradation voltage V R9 to red gradation voltage V R17 in a modification of the third embodiment;
FIG. 19 a block diagram showing a first conventional example of an electrical configuration of a driving circuit for a color liquid crystal display;
FIG. 20 a block diagram showing a second conventional example of an electrical configuration of a driving circuit for a color liquid crystal display;
FIG. 21 is a schematic block diagram showing an electrical configuration of a gradation power supply circuit and a data electrode driving circuit in the driving circuit for the conventional color liquid crystal display;
FIG. 22 is a graph showing an example of a V-T characteristic curve in the conventional color liquid crystal display;
FIG. 23 is a graph showing an example of a gamma characteristic curve in the conventional color liquid crystal display; and
FIG. 24 is a graph showing another example of a V-T characteristic curve in the conventional color liquid crystal display.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Best modes for carrying out the present invention will be described in further detail using various embodiments with reference to the accompanying drawings.
First Embodiment
FIG. 1 is a block diagram showing an electrical configuration of a driving circuit of an analog circuit configuration for a color liquid crystal display 1 according to a first embodiment of the present invention. In FIG. 1 , the color liquid crystal display 1 is a liquid crystal display of an active matrix driving type using a TFT (Thin Film Transistor) as a switching element.
The driving circuit of the color liquid crystal display 1 is mainly provided with clamp circuit 2 1 to clamp circuit 2 3 , a reference voltage generating circuit 22 , gamma compensating circuit 21 1 to gamma compensating circuit 21 3 , polarity inverting circuit 5 1 to polarity inverting circuit 5 3 , video amplifier 6 1 to video amplifier 6 3 , a timing generating circuit 7 , a data electrode driving circuit 8 and a scanning electrode driving circuit 9 . That is, the reference voltage generating circuit 22 , and gamma compensating circuit 21 1 to gamma compensating circuit 21 3 are provided instead of the reference voltage generating circuit 3 , and gamma compensating circuit 4 1 to gamma compensating circuit 4 3 in a conventional example shown in FIG. 19 .
Gamma compensating circuit 21 1 to gamma compensating circuit 21 3 , based on a reference voltage V LR , a reference voltage V MR , a reference voltage V HR , a reference voltage V LG , a reference voltage V MG , a reference voltage V HG , a reference voltage V LB , a reference voltage V MB and a reference voltage V HB supplied from the reference voltage generating circuit 22 , apply gamma compensation to the video red signal S RC , the video green signal S GC and the video blue signal S BC independently in order to give gradients to them and then output the video red signal S RG , the video green signal S GG and the video blue signal S BG . In addition, it is assumed that the gamma compensation in the first embodiment includes a gamma compensation (hereunder, called a first gamma compensation) for giving a luminance characteristic of a reproduced image for a luminance of an input image voluntarily and a gamma compensation (hereunder, called a second gamma compensation) suitable to each of a red V-T characteristic, a green V-T characteristic and a blue V-T characteristic in the color liquid crystal display 1 .
Here, FIG. 2 shows an example of an electric configuration of the gamma compensating circuit 21 1 . The gamma compensating circuit 21 1 , is mainly provided with differential circuit 23 1 to differential circuit 23 3 , a voltage follower 24 and a resistor 25 .
The differential circuit 23 1 is mainly provided with a transistor Q 1 in which the video red signal S RC is applied to a base, a setting voltage V GC is applied to a collector through the resistor 25 and the collector is connected to each collector of a transistor Q 3 and a transistor Q 5 and an emitter is connected to a constant current source I 1 through a resistor R 1 and a transistor Q 2 in which the reference voltage V LR is applied to a base, a power supply voltage V CC is applied to a collector, an emitter is connected to the constant current source I 1 through a resistor R 2 . Similarly, a differential circuit 23 3 is mainly provided with the transistor Q 5 in which the video red signal S RC is applied to a base, the setting voltage V GC is applied to a collector through the resistor 25 and the collector is connected to each collector of the transistor Q 1 and the transistor Q 3 and an emitter is connected to a constant current source I 3 through a resistor R 3 and a transistor Q 4 in which the reference voltage V MR is applied to a base, the power supply voltage the V CC is applied to a collector, an emitter is connected to the constant current source I 2 through a resistor R 4 . Similarly, a differential circuit 23 2 is mainly provided with the transistor Q 3 in which the video red signal S RC is applied to abase, the setting voltage V GC is applied to a collector through the resistor 25 and the collector is connected to each collector of the transistor Q 1 and the transistor Q 5 and an emitter is connected to a constant current source I 3 through a resistor R 5 and the transistor Q 6 in which the reference voltage V HR is applied to a base, the power supply voltage the V CC is applied to a collector, an emitter is connected to the constant current source I 3 through a resistor R 6 . Further, each of the collectors of the transistor Q 1 , the transistor Q 3 and the transistor Q 5 is connected to an input terminal of the voltage follower 24 . The voltage follower 24 applies buffer to the video red signal S RC which is gamma compensated and outputs it.
The reference voltage generating circuit 22 ( FIG. 1 ), based on a control signal S C1 , a control signal S C2 , a control signal S C3 and a reference voltage change data D RV supplied from a CPU (Central Processing Unit) not shown, generates the reference voltage V LR , the reference voltage V MR , the reference voltage V HR , the reference voltage V LG , the reference voltage V MG , the reference voltage V HG , the reference voltage V LB , the reference voltage V MB and the reference voltage V HB used for gamma compensating the video red signal S RC , the video green signal S GC and the video blue signal Sac and supplies these reference voltages to gamma compensating circuit 21 1 to gamma compensating circuit 21 3 .
Next, FIG. 3 is an example of an electric configuration of the reference voltage generating circuit 22 . The reference voltage generating circuit 22 is mainly provided with a DAC 25 , a reference voltage supply source 26 , adder 27 1 to adder 27 9 and switch 28 1 to switch 28 9 .
The DAC 25 converts the reference voltage change data D RV supplied from the CPU (not shown) into analog change voltage V 1 to analog voltage V 9 and then respectively supplies analog change voltage V 1 to analog change voltage V 9 to each of first input terminals of adder 27 1 to adder 27 9 . The reference voltage supply source 26 is configured by connecting in parallel a pair of a resistor R 11 and a resistor R 12 lengthwise connected, a pair of a resistor R 13 and a resistor R 14 lengthwise connected, a pair of a resistor R 15 and a resistor R 16 lengthwise connected, a pair of a resistor R 17 and a resistor R 18 lengthwise connected, a pair of a resistor R 19 and a resistor R 20 lengthwise connected, a pair of a resistor R 21 and a resistor 22 lengthwise connected, a pair of a resistor R 23 and a resistor R 24 lengthwise connected, a pair of a resistor R 25 and a resistor R 26 lengthwise connected, and a pair of a resistor R 27 and a resistor R 28 lengthwise connected and by inserting these pairs between the reference voltage V REF and ground. Nine voltages generating at connection points of nine pairs of resistors in parallel are respectively supplied to second input terminals of the adder 27 1 through the 27 9 as a fixed reference voltage V LRF , a fixed reference voltage V MRF , a fixed reference voltage V HRF , a fixed reference voltage V LGF , a fixed reference voltage V MGF , a fixed reference voltage V HGF , a fixed reference voltage V LBF , a fixed reference voltage V MBF , a fixed reference voltage V HBF and are respectively applied to first selection terminals Ta of switch 28 1 to switch 28 9 .
Adder 27 1 to adder 27 9 respectively add the analog change voltage V 1 to analog change voltage V 9 supplied from the corresponding first input terminals Ta to the fixed reference voltage V LRF , the fixed reference voltage V MRF , the fixed reference voltage V HRF , the fixed reference voltage V LGF , the fixed reference voltage V MGF , the fixed reference voltage V HGF , the fixed reference voltage V LBF , to the fixed reference voltage V MBF , and the fixed reference voltage V HBF and respectively apply an addition result (V LRF +V 1 ), an addition result (V MRF +V 2 ), an addition result (V HRF +V 3 ) , an addition result (V LGF +V 4 ), an addition result (V MGF +V 5 ), an addition result (V HGF +V 6 ), an addition result (V LBF +V 7 ), an addition result (V MBF +V 8 ) and an addition result (V HBF +V 9 ) (which are not shown) to second selection terminals Tb of switch 28 1 to switch 28 9 so as to be corresponded.
Next, FIG. 4 shows an example of an electrical configuration of the adder 27 1 . The adder 27 1 is manly provided with a variable resistor VR 1 , resistor R 31 to resistor R 36 having a same resistance value and an operational amplifier OP. In addition, adder 27 2 to adder 27 9 are approximately similar to the adder 27 1 concerning the electrical configuration and operation except that supplied fixed reference voltage and change voltage are different, therefore, explanations thereof will be omitted.
Each of switch 28 1 to switch 28 9 is switched from a common terminal Tc to the first selection terminal Ta or the selection terminal Tb based on a control signal S C1 , a control signal S C2 or a control signal S C3 supplied from the CPU (not shown) and supply the fixed reference voltage V LRF , the fixed reference voltage V MRF , the fixed reference voltage V HRF , the fixed reference voltage V LGF , the fixed reference voltage V MGF , the fixed reference voltage V HGF , the fixed reference voltage V LBF , the fixed reference voltage V MBF and the fixed reference voltage V HBF or the addition result (V LRF +V 1 ), the addition result (V MRF +V 2 ), the addition result (V HRF +V 3 ) , the addition result (V LGF +V 4 ), the addition result (V MGF +V 5 ), the addition result (V HGF +V 6 ), the addition result (V LBF +V 7 ), the addition result (V MBF +V 8 ) and the addition result (V HBF +V 9 ) which are not shown, as the reference voltage V LR , the reference voltage V MR , the reference voltage V HR , the reference voltage V LG , the reference voltage V MG , the reference voltage V HG , the reference voltage V LB , the reference voltage V MB and the reference voltage V HB to gamma compensating circuit 21 1 to gamma compensating circuit 21 3 .
Next, explanations will be given of operations of gamma compensating circuit 21 1 to gamma compensating circuit 21 3 and the reference voltage generating reference circuit 22 which has features of the present invention in operations of the above-mentioned driving circuit for the color liquid crystal display 1 with reference to FIG. 5 .
FIG. 5 is a graph showing an example of a relationship between the reference voltage V LR , the reference voltage V MR and the reference voltage V HR used to apply the gamma compensation to the video red signal S RG and a gamma compensated video red signal S RC . First, the reference voltage V LR is set near a minimum voltage value (a black level) of the video red signal S RC , the reference voltage V HR is set near a maximum voltage value (a white level) of the video red signal S RC and the reference voltage V MR is set at a half-tone (gray) of the video red signal S RC . In particular, concerning the reference voltage V HR , for example, when the color liquid crystal display 1 has a V-T characteristic shown in FIG. 22 (curve a), the reference voltage V HR is set to 1.0V so as to obtain a maximum transmittance T (maximum luminance) instead of 1.7V of the conventional voltage, and, for example, when the color liquid crystal display 1 has a V-T characteristic shown in FIG. 24 (curve a), the reference voltage V HR is set to 1.0V so as to obtain a maximum transmittance T (maximum luminance).
In addition, the reference voltage V LG , the reference voltage V MG and the reference voltage V HG for applying the gamma compensation to the video green signal S GC and the reference voltage V LB , the reference voltage V MB and the reference voltage V HB for applying the gamma compensation to the video blue signal S BC are set so that an area from a minimum luminance (a minimum transmittance) to a maximum transmittance of a corresponding V-T characteristic can be fully used. In other words, for example, when the color liquid crystal display 1 has the V-T characteristic as shown in FIG. 22 (curve b), the reference voltage V LG is set to approximately 1.0V in order to obtain a maximum transmittance (a maximum luminance) instead of approximately 1.7V of the conventional voltage, and when the color liquid crystal display 1 has a V-T characteristic as shown in FIG. 24 (curve b), the reference voltage V LG is set to approximately 1.8V in order to obtain a maximum transmittance (a maximum luminance, a peak point). Similarly, for example, when the color liquid crystal display 1 has a V-T characteristic as shown in FIG. 22 (curve c), the reference voltage V LB is set to approximately 1.5V in order to obtain a maximum transmittance (a maximum luminance) instead of approximately 1.7V of the conventional voltage, and when the color liquid crystal display 1 has a V-T characteristic as shown in FIG. 24 (curve c), the reference voltage V LB is set to approximately 2.0V in order to obtain a maximum transmittance (a maximum luminance, a peak point).
In brief, the first embodiment is characterized in that each difference among a red V-T characteristic, a green V-T characteristic and a blue V-T characteristic in the color liquid crystal display 1 is considered and the reference voltage V LR , the reference voltage V MR , the reference voltage V HR , the reference voltage V LG , the reference voltage V MG , the reference voltage V HG , the reference voltage V LB , the reference voltage V MB and the reference voltage V HB are set so that a range from a maximum luminance to a minimum luminance of each V-T characteristic can be fully used.
Next, for example, when a non-active control signal S C1 is supplied from the CPU (not shown), the common terminals Tc of switch 28 1 to switch 28 3 shown in FIG. 3 are connected to the first selection terminals Ta, therefore, the fixed reference voltage V LRF , the fixed reference voltage V MRF and the fixed reference voltage V HRF supplied from the reference voltage supply source 26 are directly supplied to the gamma compensating circuit 21 1 shown in FIG. 1 as the reference voltage V LR , the reference voltage V MR and the reference voltage V HR . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video red signal S RC based on the reference voltage V LR , the reference voltage V MR and the reference voltage V HR in the gamma compensating circuit 21 1 independently of the video green signal S GC and the video blue signal S BC , and thereby a gradient is given. Then, the video red signal S RC is output as a video red signal S RG .
In addition, please refer to Japanese Patent Application Laid-open No. Hei 6-205340 disclosing details of the operation of the gamma compensating circuit 21 1 .
Similarly, for example, when a non-active control signal S C2 is supplied from the CPU (not shown), the common terminals Tc of switch 28 4 to switch 28 6 shown in FIG. 3 are connected to the first selection terminals Ta, therefore, the fixed reference voltage V LGF , the fixed reference voltage V MGF and the fixed reference voltage V HGF supplied from the reference voltage supply source 26 are directly supplied to the gamma compensating circuit 21 2 shown in FIG. 1 as the reference voltage V LG , the reference voltage V MG and the reference voltage V HG . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video green signal S GC based on the reference voltage V LG , the reference voltage V MG and the reference voltage V HG in the gamma compensating circuit 21 2 independently of the video red signal S RC and the video blue signal S BC , and thereby a gradient is given. Then, the video green signal S GC is output as a video green signal S GG .
Similarly, for example, when a non-active control signal S C3 is supplied from the CPU (not shown), the common terminals Tc of switch 28 7 to switch 28 9 shown in FIG. 3 are connected to the first selection terminal Ta, therefore, the fixed reference voltage V LBF , the fixed reference voltage V MBF and the fixed reference voltage V HBF supplied from the reference voltage supply source 26 are directly supplied to the gamma compensating circuit 21 3 shown in FIG. 1 as the reference voltage V LB , the reference voltage V MB and the reference voltage V HB . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video blue signal S BC based on the reference voltage V LB , the reference voltage V MB and the reference voltage V HB in the gamma compensating circuit 21 3 independently of the video red signal S RC and the video green signal S GC , and thereby a gradient is given. Then, the video blue signal S BC is output as a video blue signal S BG .
As another case, for example, when an active control signal S C1 and a reference voltage change data D RV are supplied from the CPU (not shown), the DAC 25 converts the reference voltage change data D RV into analog change voltage V 1 to analog change voltage V 9 and supplies to respective input terminal of adder 27 1 to adder 27 9 . With this operation, each of adder 27 1 to adder 27 3 adds each of the fixed reference voltage V LRF , the fixed reference voltage V MRF , the fixed reference voltage V HRF supplied to the corresponding first input terminal to each of change voltage V 1 to change voltage V 3 supplied to the corresponding second input terminal and applies each of the addition result (V LRF +V 1 ), the addition result (V MRF +V 2 ) and the addition result (V HRF +V 3 ), to each of the second selection terminals Tb of switch 28 1 to switch 28 3 . Further, since the common terminal Tc of switch 28 1 to switch 28 3 are connected to the second selection terminal Tb, the addition result (V LRF +V 1 ), the addition result (V MRF +V 2 ) and the addition result (V HRF +V 3 ) are supplied to the gamma compensating circuit 21 1 as the reference voltage V LR , the reference voltage V MR and the reference voltage V HR . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video red signal S RC in the gamma compensating circuit 21 1 based on the reference voltage V LR , the reference voltage V MR , the reference voltage V HR which are finely adjusted in order to change a change quantity (incline) of a voltage level of the video red signal S RG for the reference voltage V LR , the reference voltage V MR and the reference voltage V HR independently of the video green signal S GC and the video blue signal S BC , and thereby a gradient is given. Then, the video red signal S RC is output as a video red signal S RG .
Similarly, for example, when an active control signal S C2 and a reference voltage change data D RV are supplied from the CPU (not shown), the DAC 25 converts the reference voltage change data D RV into analog change voltage V 1 to analog change voltage V 9 and supplies them to respective input terminals of adder 27 1 to adder 27 9 . With this operation, each of adder 27 4 to adder 27 6 adds each of the fixed reference voltage V LGF , the fixed reference voltage V MGF and the fixed reference voltage V HGF supplied to the corresponding first input terminal to each of change voltage V 4 to change voltage V 6 supplied to the corresponding second input terminal and applies each of the addition result (V LGF +V 4 ), the addition result (V MGF +V 5 ) and the addition result (V HGF +V 6 ) to each of the second selection terminals Tb of switch 28 4 to switch 28 6 . Further, since the common terminals Tc of switch 28 4 to switch 28 6 are connected to the second selection terminal Tb, the addition result (V LGF +V 4 ), the addition result (V MGF +V 5 ) and the addition result (V HGF +V 6 ) are supplied to the gamma compensating circuit 21 2 as the reference voltage V LG , the reference voltage V MG and the reference voltage V HG . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video green signal S GC in the gamma compensating circuit 21 2 based on the reference voltage V LG , the reference voltage V MG and the reference voltage V HG which are finely adjusted in order to a change quantity (incline) of a voltage level of the video green signal S GC to the reference voltage V LG , the reference voltage V MG and the reference voltage V HG independently of the video red signal S RC and the video blue signal S BC , and thereby a gradient is given. Then, the video green signal S GC is output as a video green signal S GG .
Similarly, for example, when an active control signal S C3 and a reference voltage change data D RV are supplied from the CPU (not shown), the DAC 25 converts the reference voltage change data D RV into analog change voltage V 1 to analog change voltage V 9 and supplies to respective input terminals of adder 27 1 to adder 27 9 . With this operation, each of adder 27 7 to adder 27 9 adds each of the fixed reference voltage V LBF , the fixed reference voltage V MBF and the fixed reference voltage V HBF supplied to the corresponding first input terminal to each of change voltage V 7 to change voltage V 9 supplied to the corresponding second input terminal and applies each of the addition result (V LBF +V 7 ), the addition result (V MBF +V 8 ) and the addition result (V HBF +V 9 ), each of the second selection terminals Tb of switch 28 7 to switch 28 9 . Further, since the common terminals Tc of switch 28 7 to switch 28 9 are connected to the second selection terminals Tb, the addition result (V LBF +V 7 ), the addition result (V MBF +V 8 ) and the addition result (V HBF +V 9 ) are supplied to the gamma compensating circuit 21 3 as the reference voltage V LB , the reference voltage V MB and the reference voltage V HB . With this operation, the gamma compensation including the first gamma compensation and the second gamma compensation is applied to the video blue signal S BC in the gamma compensating circuit 21 3 based on the reference voltage V LB , the reference voltage V MB and the reference voltage V HB which are finely adjusted in order to change a change quantity (incline) of a voltage level of the video red signal S RG to the reference voltage V LG , the reference voltage V MB and the reference voltage V HB independently of the video red signal S RC and the video green signal S GC , and thereby a gradient is given. Then, the video blue signal S BC is output as a video blue signal S BG .
As above described, in the first embodiment, in gamma compensating circuit 21 1 to gamma compensating circuit 21 3 , each range from a maximum luminance to a minimum luminance of each of the red V-T characteristic, the green V-T characteristic and the blue V-T characteristic in the color liquid crystal display 1 are fully considered, the gamma compensation is independently applied to the video red signal S RC , the video green signal SR GC and the video blue signal S BC based on the reference voltage V LR , the reference voltage V MR , the reference voltage V HR , the reference voltage V LG , the reference voltage V MG , the reference voltage V HG , the reference voltage V LB , the reference voltage V MB and the reference voltage V HB which are fixed or finely adjusted, and a gradient is given. Accordingly, an optimal gamma compensation can be carried out and a reproduced image of a good gradation can be obtained. As a result, it is possible to meet a recent request of a high quality image. Furthermore, it is fully available to the color liquid crystal display 1 having a V-T characteristic of a high transmittance shown in FIG. 24 .
In addition, when a gradation batter occurs in a specific color among red, green and blue, the CPU (not shown) supplies reference voltage change data for changing reference voltage (any one of the reference voltage V L , the reference voltage V M and the reference voltage V H ) corresponding to a color range in which the gradation batter occurs (near the white level, near gray or near the black level) and the active control signal S C1 to the reference voltage generating circuit 22 , and thereby this gradation batter can be removed.
Second Embodiment
Next, explanations will be given of the second embodiment according to the present invention.
FIG. 6 is a block diagram showing an electrical configuration of a driving circuit for the color liquid crystal display 1 according to the second embodiment of the present invention. In FIG. 6 , same numerals are given to corresponding parts in FIG. 1 and the explanations thereof are omitted. In the driving circuit for the color liquid crystal display 1 shown in FIG. 6 , instead of the reference voltage generating circuit 22 shown in FIG. 1 , a reference voltage generating circuit 31 is provided.
FIG. 7 is a block diagram showing one example of an electrical configuration of the reference voltage generating circuit 31 . In FIG. 7 , same numerals are given to corresponding parts in FIG. 3 and the explanations thereof are omitted. In the reference voltage generating circuit 31 shown in FIG. 7 , instead of the DAC 25 and the reference voltage supply source 26 shown in FIG. 3 , a DAC 32 and a reference voltage supply source 33 are provided.
The DAC 32 converts a reference voltage change data D RV supplied from a CPU (not shown) into an analog change voltage V 1 , an analog change voltage V 2 , an analog change voltage V 3 , an analog change voltage V 5 , an analog change voltage V 6 , an analog change voltage V 8 and an analog change voltage V 9 and supplies them to respective first input terminals of an adder 27 1 , an adder 27 2 , an adder 27 3 , an adder 27 5 , an adder 27 6 , an adder 27 8 and an adder 27 9 . In the reference voltage supply source 33 , a resistor R 17 and a resistor R 18 lengthwise connected and a resistor R 23 and a resistor R 24 lengthwise connected are removed from the reference voltage supply source 26 shown in FIG. 3 . Seven voltages generating at connection points of seven pairs of resistors lengthwise connected are respectively supplied to second input terminals of the adder 27 1 ,the adder 27 2 , the adder 27 3 , the adder 27 5 , the adder 27 6 , the adder 27 8 and the adder 27 9 as a fixed reference voltage V LF , a fixed reference voltage V MRF , a fixed reference voltage V HRF , a fixed reference voltage V MGF , a fixed reference voltage V HGF , a fixed reference voltage V MBF , and a fixed reference voltage V HBF are applied to respective first selection terminals Ta of a switch 28 1 , a switch 28 2 , a switch 28 3 , a switch 28 5 , a switch 28 6 , a switch 28 8 ; and a switch 28 9 .
Further, in the reference voltage generating circuit 31 shown in FIG. 7 , an adder 27 4 and an adder 27 7 and an switch 28 4 and an switch 28 7 shown in FIG. 3 are removed, and a control signal S C4 is supplied from the CPU (not shown) to the switch 28 1 .
Next, in the second embodiment, reasons are given of the above-mentioned configuration. As understood from FIG. 22 and FIG. 24 , there are differences in a range in which a transmittance T is high concerning each of a red V-T characteristics, a green V-T characteristic and a blue V-T characteristic in the color liquid crystal display 1 , however, there is little difference in a range in which the transmittance T is low. So, in the second embodiment, in order to reduce a circuit scale, as gamma compensation for the video red signal S RC , gamma compensation for the video green signal S GC and gamma compensation for the video blue signal S BC corresponding to the range in which the transmittance T is low, a similar gamma compensation is applied to the video red signal S RC , the video green signal S GC and the video blue signal S BC using a common reference voltage V L . In addition, it is assumed that gamma compensation in the second embodiment includes a first gamma compensation and a second gamma compensation.
Further, operations are similar to those of the first embodiment except the gamma compensation using the common reference voltage V L , therefore, explanations thereof are omitted.
As above described, according to the second embodiment, in the range in which there is no difference of the V-T characteristic and the transmittance T is low, the gamma compensation is applied using the common reference voltage V L in order to give a gradient, therefore, a circuit scale can be reduced in addition to effects obtained from the configuration according to the first embodiment.
Third Embodiment
Next, explanations will be given of the third embodiment of the present invention.
FIG. 8 is a block diagram showing an electrical configuration of a driving circuit of a digital circuit configuration for a color liquid crystal display 1 according to the third embodiment of the present invention. In FIG. 8 , same numerals are given to corresponding parts in FIG. 20 and the explanations thereof are omitted.
In the driving circuit for the color liquid crystal display 1 shown in FIG. 8 , instead of a controlling circuit 11 , a gradation power supply circuit 12 and a data electrode driving circuit 13 shown in FIG. 20 , a controlling circuit 41 , a gradation power supply circuit 42 and a data electrode driving circuit 43 are provided.
The controlling circuit 41 is, for example, an ASIC, and supplies red data D R of eight bits, green data D G of eight bits, blue data D B of eight bits supplied from outside to the data electrode driving circuit 43 and generates a polarity inverting pulse POL for alternately driving a horizontal scanning pulse P H , a vertical scanning pulse P V and the color liquid crystal display 1 to supply the polarity inverting pulse POL to the data electrode driving circuit 43 and a scanning electrode driving circuit 14 . Further, the controlling circuit 41 independently applies gamma compensation to the red data D R , the green data D G and the blue data D B , and thereby supplies red gradation voltage data D GR , green gradation voltage data D GG and blue gradation voltage data D GB to the gradation power supply circuit 42 . In addition, it is assumed that the gamma compensation in the third embodiment includes a first gamma compensation and a second gamma compensation.
The gradation power supply circuit 42 , as shown in FIG. 9 , is mainly provided with a DAC 44 1 , a DAC 44 2 and a DAC 44 3 and voltage follower 45 1 to voltage follower 45 54 . The DAC 44 1 converts the red gradation voltage data D GR supplied from the controlling circuit 41 into analog red gradation voltage V R0 to analog red gradation voltage V R17 and supplies them to voltage follower 45 1 to voltage follower 45 18 . Similarly, the DAC 44 2 converts the green gradation voltage data D GG supplied from the controlling circuit 41 into analog green gradation voltage V G0 to analog green gradation voltage V G17 and supplies them to voltage follower 45 19 to voltage follower 45 36 . The DAC 44 3 converts the blue gradation voltage data D GB supplied from the controlling circuit 41 into analog blue gradation voltage V B0 to analog blue gradation voltage V B17 and supplies them to voltage follower 45 37 to voltage follower 45 54 . Voltage follower 45 1 to voltage follower 45 54 applies buffer to red gradation voltage V R0 to red gradation voltage V R17 , green gradation voltage V G0 to green gradation voltage V G17 and blue gradation voltage V B0 to blue gradation voltage V B17 for the gamma compensation and supplies them to the data electrode driving circuit 43 .
The data electrode drive circuit 43 , as shown in FIG. 9 , is mainly provided with a MPX 46 1 , a MPX 46 2 and a MPX 46 3 , a DAC 47 1 of eight bits, a DAC 47 2 of eight bits and a DAC 47 3 of eight bits and voltage follower 48 1 to voltage follower 48 384 . In addition, in a real data electrode driving circuit, a shift register, a data register, a latch, a level shifter and a like are provided at a front step of a DAC, however, there is no relationship between features of the present invention and these elements and operations, therefore, explanations thereof are omitted.
The MPX 46 1 switches a group of red gradation voltage V R0 to red gradation voltage V R8 over a group of red gradation voltage V R9 to red gradation voltage V R17 in red gradation voltage V R0 to red gradation voltage V R17 supplied from the gradation power supply circuit 42 based on the polarity inverting pulse POL supplied from the controlling circuit 41 and supplies any one of the groups to the DAC 47 1 . Similarly, the MPX 46 2 switches a group of green gradation voltage V G0 to green gradation voltage V G8 over a group of green gradation voltage V G9 to green gradation voltage V G17 in green gradation voltage V G0 to green gradation voltage V G17 supplied from the gradation power supply circuit 42 based on the polarity inverting pulse POL supplied from the controlling circuit 41 and supplies any one of the groups to the DAC 47 2 . The MPX 46 3 switches a group of blue gradation voltage V B0 to blue gradation voltage V B8 over a group of blue gradation voltage V B9 to the blue gradation voltage V B17 in blue gradation voltage V B0 to blue gradation voltage V B17 supplied from the gradation power supply circuit 42 based on the polarity inverting pulse POL supplied from the controlling circuit 41 and supplies any one of the groups to the DAC 47 3 .
The DAC 47 1 , based on the group of red gradation voltage V R0 to red gradation voltage V R8 or the group of red gradation voltage V R9 to red gradation voltage V R17 , applies the gamma compensation to the red data D R of eight bits supplied from the controlling circuit 41 so as to give a gradient to the red data D R , converts the red data D R into an analog data red signal and then supplies the analog data red signal to voltage follower 48 1 to voltage follower 48 382 . Here, FIG. 10 shows an example of a relationship between the red data D R (indicated by hexadecimal number (HEX)) of eight bits supplied to the DAC 47 1 and red gradation voltage V R0 to red gradation voltage V R8 or red gradation voltage V R9 to red gradation voltage V R17 . As understood from FIG. 10 , in order to apply the gamma compensation including the first gamma compensation and the second gamma compensation to the red data D R so as to give a gradient to the red data D R , the group of red gradation voltage V R0 to the red gradation voltage V R8 or the group of red gradation voltage V R9 to red gradation voltage V R17 which has a nonlinear voltage value is supplied to the DAC 47 1 .
Similarly, The DAC 47 2 , based on the group of green gradation voltage V G0 to green gradation voltage V G8 or the group of green gradation voltage V G9 to green gradation voltage V G17 , applies the gamma compensation to the green data D G of eight bits supplied from the controlling circuit 41 so as to give a gradient to the green data D G , converts the green data D G into an analog data green signal and then supplies the analog data green signal to voltage follower 48 129 to voltage follower 48 256 . Not shown, however, in order to apply the gamma compensation including the first gamma compensation and the second gamma compensation to the green data D G so as to give a gradient to the red data D G , the group of green gradation voltage V G0 to green gradation voltage VGB or the group of green gradation voltage V G9 to green gradation voltage VG G17 which has a nonlinear voltage value is supplied to the DAC 47 2 .
Similarly, The DAC 47 3 , based on the group of blue gradation voltage V B0 to blue gradation voltage V 38 or the group of blue gradation voltage VB 9 to blue gradation voltage VB 17 , applies the gamma compensation to the blue data D B of eight bits supplied from the controlling circuit 41 so as to give gradient to the blue data D B , converts the blue data D B into an analog data blue signal and then supplies the analog data blue signal to voltage follower 48 257 to voltage follower 48 384 . Not shown, however, in order to apply the gamma compensation including the first gamma compensation and the second gamma compensation to the blue data D B so as to give a gradient to the blue data D B , the group of blue gradation voltage V B0 to blue gradation voltage V B8 or the group of blue gradation voltage V B9 to blue gradation voltage VG B17 which has a nonlinear voltage value is supplied to the DAC 47 3 .
Voltage follower 48 1 to voltage follower 48 384 apply buffer to the data red signal, the data green signal and the data blue signal supplied from DAC 47 1 to DAC 47 3 and apply these signals to corresponding data electrodes of the color liquid crystal display 1 .
Next, explanations will be given of operations of the controlling circuit 41 , the gradation power supply circuit 42 and the data electrode driving circuit 43 which are features of the present invention in operations of the driving circuit for the liquid crystal display 1 .
First, the controlling circuit 41 supplies the red data DR of eight bits, the green data D G of eight bits and the blue data D B of eight bits supplied from the outside to the data electrode driving circuit 43 and supplies the red gradation voltage data D GR , the green gradation voltage data D GG and the blue gradation voltage data D GB which are considered in order to fully use a range of the V-T characteristic from the minimum luminance to maximum luminance for each of red, green and blue in the color liquid crystal display 1 to the gradation power supply circuit 42 . The gradation power supply circuit 42 analog-converts the red gradation voltage data D GR , the green gradation voltage data D GG and the blue gradation voltage data D GB , and then applies buffer to these data and supplies them to the data electrode driving circuit 43 as red gradation voltage V R0 to red gradation voltage V R17 , green gradation voltage V G0 to green gradation voltage V G17 and blue gradation voltage V B0 to blue gradation voltage VB 17 .
Accordingly, the data electrode driving circuit 43 , based on the group of red gradation voltage V R0 to red gradation voltage V R8 or the group of red gradation voltage V R9 to red gradation voltage V R17 , the group of green gradation voltage V G0 to the green gradation voltage V G8 or the group of green gradation voltage V G9 to green gradation voltage V G17 and the group of blue gradation voltage V B0 to blue gradation voltage V B8 or the group of blue gradation voltage V B9 to blue gradation voltage V B17 , applies the gamma compensation to the red data D R of eight bits, the green data D G of eight bits and the blue data D B of eight bits so as to give gradient to these data and analog-converts the data red signal, the data green signal and the data blue signal and then applies these signals to the corresponding data electrodes in the color liquid crystal display 1 after applying buffer.
As above described, according to the third embodiment, approximately similar effects of the first embodiment can be obtained, that is, in digital circuit configuration, it is possible to give a gradient by applying an optimal gamma compensation, to obtain a reproduced image of fine gradation and to use the color liquid crystal display 1 fully even if it has a V-T characteristic of a high transmittance.
Further, when a gradation batter occurs in a specific color among red, green and blue, the controlling circuit 41 supplies the gradation voltage data D G changed in order to change a gradation voltage (any one of the gradation voltage V 0 to the gradation voltage V 17 ) corresponding to a color area in which the gradation batter occurs (anyone of near white level, near gray and near black level) to the gradation power supply circuit 42 , and thereby the gradation batter can be removed.
Fourth Embodiment
Next, explanations will be given of the fourth embodiment of the present invention.
FIG. 11 is a block diagram showing an electrical configuration of a driving circuit of a digital circuit configuration for the color liquid crystal display 1 according to the fourth embodiment of the present invention. In FIG. 11 , same numerals are given to corresponding parts in FIG. 8 and the explanations thereof are omitted. The driving circuit for the color liquid crystal display shown 1 in FIG. 11 is provided with a controlling circuit 51 , a gradation power supply circuit 52 and the data electrode driving circuit 53 instead of the controlling circuit 41 , the gradation power supply circuit 42 and the data electrode driving circuit 43 in FIG. 8 .
The controlling circuit 51 , for example, is an ASIC, and as shown in FIG. 12 , is mainly provided with a controlling section 54 and gamma compensating section 55 1 to gamma compensating section 55 3 . The controlling section 54 generates a horizontal scanning pulse P H , a vertical scanning pulse P V and a polarity inverting pulse POL for alternatively driving the color liquid crystal display 1 and supplies them to the data electrode driving circuit 53 and a scanning electrode driving circuit 14 and supplies a control signal S CR , a control signal S CG and a control signal S CB for controlling gamma compensating section 55 1 to gamma compensating section 55 3 . The gamma compensating section 55 1 to gamma compensating section 55 3 applies the gamma compensation independently to red data D R , green data D G and blue data D B supplied from the outside by operational processes based on the control signal S CR , the control signal S CG and the control signal S CB supplied from the controlling section 54 and gives a gradient to these data, and then respective compensation results are supplied to the data electrode driving circuit 53 as a compensated red data D RG , a compensated green data D GG and a compensated blue data D BG . In addition, the gamma compensation in gamma compensating section 55 1 to gamma compensating section 55 3 includes the first compensation and second compensation, and further includes a second slight compensation caused by differences among red, green and blue not fully compensated by a gamma rough compensation (described later) common to red, green and blue in the second gamma compensation.
The gradation power supply circuit 52 , as shown in FIG. 12 , is provided with resistor 56 1 to resistor 56 19 lengthwise connected between reference voltage V REF and ground and voltage follower 57 1 to voltage follower 57 17 , each of an input terminal is connected to a connection point of the adjacent resistor. The gradation power supply circuit 52 applies buffer to gradation voltage V 0 to gradation voltage V 17 set for the second gamma rough compensation and supplies them to the data electrode driving circuit 53 .
The data electrode driving circuit 53 , as shown in FIG. 12 , is mainly provided with a MPX 58 , a DAC 59 of eight bits and voltage follower 60 1 to voltage follower 60 384 . In addition, in a real data electrode driving circuit, a shift register, a data register, a latch, a level shifter and a like are provided at a front step of the DAC, however, since there are no direct relationships between the features of the present invention and these elements and operations, the explanations thereof are omitted.
The MPX 58 switches the group of gradation voltage V 0 to gradation voltage V 8 and the group of gradation voltage V 9 to gradation voltage V 17 among gradation voltage V 0 to gradation voltage V 17 supplied from the gradation power supply circuit 52 based on the polarity inverting pulse POL supplied from the controlling circuit 51 and supplies it to the DAC 59 . The DAC 59 applies the second gamma rough compensation to a compensated red data D RG of eight bits, a compensated green data D GG of eight bits and a compensated blue data D BG of eight bits based on the group of gradation voltage V 0 to gradation voltage V 8 and the group of gradation voltage V 9 to gradation voltage V 17 supplied from the MPX 58 , converts these data into an analog data red signal, an analog data green signal and an analog data blue signal and supplies these signals to corresponding voltage follower 60 1 to corresponding voltage follower 60 384 . The voltage follower 60 1 to the voltage follower 60 384 apply buffer to the data red signal, the data green signal and the data blue signal supplied from the DAC 59 and apply these signals to the color liquid crystal display 1 .
In addition, the gamma compensation in the DAC 59 is the second gamma rough compensation common to red, green and blue in the second gamma compensation. As the second gamma rough compensation common to red, green and blue, for example, when the color liquid crystal display 1 has the V-T characteristic shown in FIG. 22 (curve a to curve c), the V-T characteristic curve obtained by averaging curve a to curve c is assumed, gradation voltage V 0 to gradation voltage V 17 are set so that the second gamma rough compensation suitable to the assumed V-T characteristic curve is applied to the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG . In this case, the gamma slight compensation is applied to differences between the assumed V-T characteristic curve and curve a to curve c in gamma compensating section 55 1 to gamma compensating section 55 3 .
Here, FIG. 13 shows an example of a relationship between the compensated red data D RG of eight bits, the compensated green data D GG of eight bits and the compensated blue data D BG of eight bits (indicated by hexadecimal number (HEX)) and gradation voltage V 0 to gradation voltage V 8 and gradation voltage V 9 to gradation voltage V 17 . As understood from FIG. 13 , in order to apply the second gamma rough compensation to the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG , the group of gradation voltage V 0 to gradation voltage V 8 or gradation voltage V 9 to gradation voltage V 17 which have nonlinear voltage values for the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG is supplied-to the DAC 59 .
Next, explanations will be given of operations in the controlling circuit 51 , the gradation power supply circuit 52 and the data electrode driving circuit 53 which are features of the present invention in the operations of the driving circuit for the color liquid crystal display 1 .
First, the controlling circuit 51 independently applies the first gamma compensation and the second gamma slight compensation to the red data D R of eight bits, the green data D G of eight bits and the blue data D B of eight bits supplied from the outside by an operational process to give a gradient to these data, and then each of compensation results are supplied to the data electrode driving circuit 53 as the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG . The gradation power supply circuit 52 applies buffer to gradation voltage V 0 to gradation voltage V 17 set for the second gamma rough compensation and supplies them to the data electrode driving circuit 53 .
Accordingly, the data electrode driving circuit 53 applies the second gamma rough compensation to the compensated red data D RG of eight bits, the compensated green data D GG of eight bits and the compensated blue data D BG of eight bits supplied from the controlling circuit 51 based on the group of gradation voltage V 0 to gradation voltage V 8 or the group of gradation voltage V 9 to gradation voltage V 17 , analog-converts these data into a data red signal, a data green signal and a data blue signal, and then applies buffer to these data so as to apply them to corresponding electrodes.
As above described, since the controlling circuit 51 executes the first gamma compensation and the second gamma slight compensation according to the fourth embodiment and the data electrode driving circuit 53 executes the second gamma rough compensation, two MPXs and two DACs can be reduced compared with the third embodiment and effects approximately similar to the third embodiment can be obtained and a circuit scale can be reduced.
Fifth Embodiment
Next, explanations will be given of the fifth embodiment of the present invention.
FIG. 14 is a block diagram showing an electrical configuration of a driving circuit of a digital circuit configuration for the color liquid crystal display 1 according to the fifth embodiment of the present invention. In FIG. 14 , same numerals are given to corresponding parts in FIG. 11 and explanations thereof are omitted. The driving circuit for the color liquid crystal display 1 shown in FIG. 14 is provided with a controlling circuit 61 and the data electrode driving circuit 62 instead of the controlling circuit 51 , the gradation power supply circuit 52 and the data electrode drive circuit 53 in FIG. 11 .
The controlling circuit 61 , for example, is an ASIC, and, as shown in FIG. 15 , is mainly provided with a controlling section 63 and ROM 64 1 to ROM 64 3 . The controlling section 61 generates a horizontal scanning pulse P H , a vertical scanning pulse P V and a polarity inverting pulse POL for alternatively driving the color liquid crystal display 1 and supplies them to the data electrode driving circuit 62 and the scanning electrode driving circuit 14 and supplies a control signal S CR , a control signal S CG and a control signal S CB for controlling ROM 64 1 to ROM 64 3 .
The ROM 64 1 to the ROM 64 3 are look-up tables , in order to give a gradient to data by applying gamma compensation independently to red data D R of eight bits, green data D G of eight bits and blue data D B of eight bits supplied from outside, previously memorized compensated red data D RG of ten bits, compensated green data D GG of ten bits and compensated blue data D BG of ten bits which are respective compensated results and, when the red data D R of eight bits, the green data D G of eight bits and the blue data D B of eight bits and the control signal S CR , the control signal S CG and the control signal S CB are supplied from the controlling section 63 , reads the corresponding compensated red data D RG of ten bits, the corresponding compensated green data D GG of ten bits and the corresponding compensated blue data D BG of ten bits using the red data D R , the green data D G and the blue data D B as referring addresses and supplies them to the data electrode driving circuit 62 . In addition, the gamma compensation in ROM 64 1 to ROM 64 3 includes the first gamma compensation and the second gamma compensation.
Here, FIG. 16 shows an example of a relationship between the red data D R of eight bits stored in the ROM 64 1 and the compensated red data D RG of ten bits. Not shown, however, ROM 64 2 and ROM 64 3 also memorize the green data D G , the compensated green data D GG of ten bits corresponding to the blue data D B and the compensated blue data D BG similarly to FIG. 16 .
The data electrode driving circuit 62 , as shown in FIG. 15 , is mainly provided with a gradation voltage supply source 65 , a MPX 66 , a DAC 59 of 10 bits and voltage follower 68 1 to voltage follower 68 384 . In addition, in the real data electrode driving circuit, a shift register, a data register, a latch, a level shifter and a like are provided at a front step of a DAC, however, since there are no direct relationships between the features of the present invention and these elements and operations, the explanations thereof are omitted.
The gradation voltage supply source 65 is provided with resistor 69 1 to resistor 69 5 lengthwise connected between a reference voltage V REF and a ground and supplies a gradation voltage V 0 , a gradation voltage V 8 a gradation voltage V 9 and a gradation voltage V 17 for converting the compensated red data D RG of ten bits, the compensated green data D GG of ten bits and the compensated blue data D BG often bits generating at connection points of adjacent resistors into an analog red signal, an analog green signal and an analog blue signal to the MPX 66 .
The MPX 66 switches the group of the gradation voltage V 0 and the gradation voltage V 8 and the group of the gradation voltage V 9 and the gradation voltage V 17 among the gradation voltage V 0 , the gradation voltage V 8 , the gradation voltage V 9 and the gradation voltage V 17 supplied from the gradation voltage supply source 65 based on the polarity inverting pulse POL supplied from the controlling circuit 61 and supplies it to DAC 67 .
The DAC 67 converts the compensated red data D RG of ten bits, the compensated green data D GG of ten bits and the compensated blue data D BG of ten bits into an analog red signal, an analog green signal and an analog blue signal based on the group of gradation voltage V 0 and the gradation voltage V 8 and the group of gradation voltage V 9 and the gradation voltage V 17 supplied from the MPX 66 and supplies these signals to corresponding voltage follower 60 1 to corresponding voltage follower 60 384 . The voltage follower 60 1 to voltage follower 60 384 applies buffer to the data red signal, the data green signal and the data blue signal supplied from the DAC 66 and apply these signals to the color liquid crystal display 1 .
Here, FIG. 17 shows an example of a relationship between the compensated red data D RG of ten bits, the compensated green data D GG often bits and the compensated blue data D BG often bits (indicated by hexadecimal number (HEX)) and gradation voltage V 0 to gradation voltage V 8 and gradation voltage V 9 to gradation voltage V 17 . As understood from FIG. 17 , the group of gradation voltage V 0 to gradation voltage V 8 or the group of gradation voltage V 9 to gradation voltage V 17 which have nonlinear data values for the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG is supplied to the DAC 67 .
Next, explanations will be given of operations in the controlling circuit 61 and the data electrode driving circuit 62 which are features of the present invention in the operations of the driving circuit for the color liquid crystal display 1 .
First, the controlling section 63 in the controlling circuit 61 supplies the control signal S CR , the control signal S CG and the control signal S CB , reads the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG of ten bits using the red data D R of eight bits, the green data D G of eight bits and the blue data D B of eight bits supplied from the outside as referring addresses and supplies them to the data electrode driving circuit 62 .
Accordingly, the data electrode driving circuit 62 analog-converts the compensated red data D RG of ten bits, the compensated green data D GG of ten bits and the compensated blue data D BG of ten bits supplied from the controlling circuit 61 based on the group of the gradation voltage V 0 and the gradation voltage V 8 or the group of the gradation voltage V 9 and the gradation voltage V 17 into a data red signal, a data green signal and a data blue signal, and then applies buffer to these data so as to apply them to corresponding electrodes.
As above described, since the controlling circuit 61 executes the first gamma compensation and the second gamma compensation according to the fifth embodiment and the gradation power supply circuit 52 can be omitted compared with the fourth embodiment and effects approximately similar to the fourth embodiment can be obtained and a circuit scale can be reduced.
Also, according to fifth embodiment, only the compensated red data D RG , the compensated green data D GG and the compensated blue data D BG read from ROM 64 1 to ROM 64 3 , therefore, it is possible to execute gamma compensation at higher speed than the gamma 25 compensation using the operational process as described in the fourth embodiment.
It is apparent that the present invention is not limited to the above embodiments but may be changed and modified without departing from the scope and spirit of the invention.
For example, in each of the above embodiments, the present invention is applied to a color liquid crystal display 1 of a normally white type, however, the present invention is not limited to this and may be applied to a color liquid crystal display of a normally black type in which a transmittance is low in a state that no voltage is applied. In this case, for example, in the third embodiment, not FIG. 10 but FIG. 18 shows a relationship between the red data D R of eight bits supplied to the DAC 47 1 and the group of red gradation voltage V R0 to red gradation voltage V RB and the group of red gradation voltage V R9 to red gradation voltage V R17 .
In another embodiment, the reference voltage and the gradation voltage, storage contents in ROM 64 1 to ROM 64 3 or a like may be changed so as to be suitable to the color liquid crystal display of the normally black type.
Also, in the above embodiments, the present invention is applied to the color liquid crystal display 1 of the active matrix driving type using TFT as a switch element, however, the present invention is not limited to this and may be applied any color liquid crystal display having any configuration and any function.
Also, the first gamma compensation and the second gamma slight compensation are applied by the operation process in the fourth embodiment and the first gamma compensation and the second gamma compensation are applied by reading data from the ROMs in the fifth embodiment, however, the present invention is not limited to this.
For example, in the fourth embodiment, the first gamma compensation and the second gamma slight compensation may be applied by reading data from a ROM and in the fifth embodiment, the first gamma compensation and the second gamma compensation may be applied by an operation process.
Also, Japanese Patent Application Laid-open Hei 10-313416 discloses that, concerning the first gamma compensation and the second gamma compensation, in the gamma characteristic of the color liquid crystal display 1 , a gamma compensation may be applied to a curve part by reading data from a ROM, a RAM and a like and a gamma compensation may be applied to a linear part by an operation process.
Also, in the second embodiment, concerning the driving circuit of the analog configuration, the gamma compensation is applied using the common reference voltage for the video red signal S RC , the video green signal S GC and the video green signal S BC corresponding no difference area in each of the red V-T characteristic, the green V-T characteristic and the blue V-T characteristic of the color liquid crystal display 1 , and therefore, circuit scale can be reduced. It is also possible to use this technique for a driving circuit of a digital circuit configuration.
For example, in the gradation power supply circuit 42 shown in FIG. 9 , since only one gradation voltage may be generated concerning a same voltage value in among red gradation voltage V R0 to red gradation voltage V R17 , green gradation voltage V G0 to green gradation voltage V G17 and blue gradation voltage V B0 to blue gradation voltage V B17 , scale of the DAC 44 and number of voltage followers 45 for generating two other gradation voltage can be reduced.
Also, in each of the above-mentioned embodiments, the first gamma compensation is that a gamma compensation is applied to give a luminance characteristic of a reproduced image to a luminance of an input image, however, in addition to the gamma compensation suitable to the gamma characteristic of the CRT display (gamma is approximately 2.2), a gamma compensation different from the gamma characteristic of the CRT display and suitable another gamma characteristic may be applied. For example, when various commodities are sold via a television broadcast or an internet, the first gamma compensation is applied so as to match a color and a design of a real commodity with those displayed on the liquid crystal display.
Furthermore, in each of the above-mentioned embodiments, the first gamma compensation always is applied, however, only the second gamma compensation may be applied. | A driving method for a color liquid crystal display which drives the color liquid crystal display based on a video red signal, a video green signal and a video blue signal by independently applying a gamma compensation to a clamped video red signal, a clamped video green signal and a clamped video blue signal in gamma compensating circuits in order to make suitable to a red transmittance characteristic, a green transmittance characteristic and a blue transmittance characteristic. With this operation, it is possible to carry out an optimal gamma compensation suitable to a characteristic of the color liquid crystal display and to remove a gradation batter occurring in a specific color. | 6 |
This application claims the benefit of Korean Patent Application No. 2000-54081, filed on Sep. 14, 2000, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a liquid crystal display device, and more particularly to a liquid crystal display device implementing in-plane switching (IPS) where an electric field to be applied to liquid crystal molecules is generated in a plane parallel to a substrate.
[0003] 2. Discussion of the Related Art
[0004] A liquid crystal display device uses the optical anisotropy and polarization properties of liquid crystal molecules to produce an image. Liquid crystal molecules have a definite orientational alignment as a result of their long, thin shapes. That orientational alignment can be controlled by an applied electric field. In other words, as an applied electric field changes, so does the alignment of the liquid crystal molecules. Due to the optical anisotropy, the refraction of incident light depends on the orientational alignment of the liquid crystal molecules. Thus, by properly controlling an applied electric field a desired light image can be produced.
[0005] While various types of liquid crystal display devices are known, active matrix LCDs having thin film transistors and pixel electrodes arranged in a matrix are probably the most common. This is because such active matrix LCDs can produce high quality images at reasonable cost.
[0006] Recently, liquid crystal display (LCD) devices with light, thin, and low power consumption characteristics are used in office automation equipment and video units and the like. Driving methods for such LCDs typically include a twisted nematic (TN) mode and a super twisted nematic (STN) mode. Although TN-LCDs and STN-LCDs have been put to practical use, they have a drawback in that they have a very narrow viewing angle. In order to solve the problem of narrow viewing angle, in-plane switching liquid crystal display (IPS-LCD) devices have been proposed. The IPS-LCD devices typically include a lower substrate where a pixel electrode and a common electrode are disposed, an upper substrate having no electrode, and liquid crystals interposed between the upper and lower substrates.
[0007] A detailed explanation about operation modes of a typical IPS-LCD panel will be provided referring to FIGS. 1 to 3 .
[0008] As shown in FIG. 1, upper and lower substrates 1 and 2 are spaced apart from each other, and a liquid crystal layer 3 is interposed therebetween. The upper and lower substrates 1 and 2 are called color filter substrate and array substrate, respectively. Pixel and common electrodes 4 and 5 are disposed on the lower substrate 2 . The pixel and common electrodes 4 and 5 are parallel with and spaced apart from each other. The pixel and common electrodes 4 and 5 apply a horizontal electric field 6 to the liquid crystal layer 3 . The liquid crystal layer 3 has a negative or positive dielectric anisotropy, and thus it is aligned parallel with or perpendicular to the horizontal electric field 6 , respectively.
[0009] [0009]FIGS. 2A and 2B conceptually illustrate operation modes of a conventional IPS-LCD device. When there is no electric field between the pixel and common electrodes 4 and 5 , as shown in FIG. 2A, the long axes of the liquid crystal molecules maintain an angle from a line perpendicular to the parallel pixel and common electrodes 4 and 5 . Herein, the angle is 45 degrees, for example.
[0010] On the contrary, when there is an electric field between the pixel and common electrodes 4 and 5 , as shown FIG. 2B, there is an in-plane horizontal electric field 6 parallel with the surface of the lower substrate 2 between the pixel and common electrodes 4 and 5 . The in-plane horizontal electric field 6 is parallel with the surface of the lower substrate 2 because the pixel and common electrodes 4 and 5 are formed on the lower substrate 2 . Accordingly, the liquid crystal molecules are twisted so as to align, for example, the long axes thereof with the direction of the horizontal electric field 6 , thereby the liquid crystal molecules are aligned such that the long axes thereof are parallel with the line perpendicular to the pixel and common electrodes 4 and 5 .
[0011] By the above-mentioned operation modes and with additional parts such as polarizers and alignment layers, the IPS-LCD device displays images. The IPS-LCD device has wide viewing angles since the pixel and common electrodes are together placed on the lower substrate. Moreover, the fabricating processes of this IPS-LCD device are simpler than those of other various LCD devices.
[0012] However in the IPS-LCD device, a color-shift which depends on the viewing angle still remains. It is already known that this color-shift cannot be acceptable for full color-image display. This color-shift is related to a rotational direction of the liquid crystal molecules under application of electric field when the applied voltage is greater than the threshold voltage. Moreover, this color-shift is caused by increasing or decreasing of an optical retardation (Δn·d) of the liquid crystal layer with viewing angle.
[0013] For the sake of discussing the above-mentioned problem of the IPS-LCD device, with reference to FIG. 3, the specific pixel structure of the IPS-LCD device is employed and will be described in detail.
[0014] As shown in FIG. 3, the pixel and common electrodes 7 and 8 have bend angle α. These bend electrode's structure allows the liquid crystal molecules 9 to rotate in opposite direction in each pixel when the voltage is supplied to the bend electrodes. Therefore, the bend electrodes 7 and 8 and the oppositely directed liquid crystal molecules 9 divide the pixel into two different regions with different viewing angle characteristics. And thus, the color-shift can be effectively compensated by this multi domain structure.
[0015] However, when the voltage is turned ON, extraordinary domains appear around the bottom edges of driving electrodes. These extraordinary domains degrade the picture quality and reliability of the IPS-LCD device having the bend electrodes. Namely, disclination appears at the edges of the pixel areas, and thus this disclination manifests as positional non-uniformities in the transmittance of light.
[0016] [0016]FIGS. 4A and 4B are enlarged partial plan views of pixel and common electrodes. These figures illustrate arrangement of the liquid crystal molecules and the electric field when the voltage is turned ON. As shown, a common electrode 11 is extended from a common line 23 , and a pixel electrode 21 is disposed parallel with the common electrode 11 . The common electrode 11 forms an acute angle with the common line 23 as depicted in a portion “A” of FIG. 4A while the pixel electrode 21 forms an obtuse angle with the common line 23 as shown in a portion “D” of FIG. 4A. When the voltage is supplied to the common and pixel electrodes 11 and 21 , the electric field occurs between the common and pixel electrodes 11 and 21 . However at this time, a distortion of the electric field appears around the acute and obtuse angels, the portions “A” and “D”. Thereupon, reverse rotational deformation is caused by this distortion of the electric field around the portions “A” and “D”.
[0017] Referring to FIG. 4B, when the voltage is applied to the pair of electrodes 11 and 21 , the liquid crystal molecule 41 located in the parallel electric field area turns clockwise while the liquid crystal molecule 51 located in the distorted electric field area turns counterclockwise. So the orientation direction of the liquid crystal is different between the parallel electric field area and the distorted electric field area, and thus the disclination occurs in the distorted electric field area. This disclination causes a decrease in the aperture ratio, and a change of the orientation direction causes traces of the extraordinary domains. These features also affect response characteristic of the liquid crystal layer, and an afterimage phenomenon occurs in the display area
SUMMARY OF THE INVENTION
[0018] Accordingly, the present invention is directed to an IPS-LCD device that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0019] An object of the present invention is to provide an array substrate for use in the IPS-LCD device having an increased aperture ratio.
[0020] Another object of the present invention is to provide the array substrate for use in the IPS-LCD device which suppresses the traces of extraordinary domains and afterimage phenomenon.
[0021] Another object of the present invention is to provide the array substrate for use in the IPS-LCD device which improves the response characteristics of the liquid crystal layer.
[0022] In order to achieve the above object, the first preferred embodiment of the present invention provides an array substrate for use in an in-plane switching liquid crystal display device including a plurality of gate lines on a substrate; a plurality of data lines over the substrate, each data line being perpendicular to each gate line; a common line on the substrate, the common line being parallel with and spaced apart from the gate line; a plurality of common electrodes extended from the common line and elongated along the data line, wherein each common electrode has a plurality of bend portions, and wherein each common electrode has a sawtooth-shaped base in contacting part where each common electrode meets the common line in order to form an obtuse angle with the common line; a plurality of pixel electrodes spaced apart from and elongated along the common electrodes, wherein each pixel electrode has a plurality of bend portions and corresponds to each common electrode; a connecting line contacting one end of each pixel electrode, the connecting line electrically connecting pixel electrodes; a switching element electrically connected with the gate and data lines, the switching element supplying voltage to the pixel electrodes.
[0023] Each pixel electrode has a sawtooth-shaped base in contacting part where each pixel electrode meets the connecting line, and makes an obtuse angle with the connecting line using the sawtooth-shaped base.
[0024] The connecting line overlaps a portion of each gate line and comprises a storage capacitor with each gate line. One of the common electrodes elongates along the data line and electrically communicates with adjacent pixels.
[0025] The common line crosses the one of bend portions of each common electrode, and electrically connects a plurality of common electrodes. Moreover, the common line elongates along the gate line and communicates with the other common lines that are located in the adjacent pixels.
[0026] The present invention also provides, in another aspect, an array substrate for use in an in-plane switching liquid crystal display device including a gate line on a substrate; a data line over the substrate, the data line being perpendicular to the gate line; a common line being parallel with and spaced apart from the gate line; a plurality of common electrodes extended from the common line, wherein each common electrode has a zigzag shape and a sawtooth-shaped base, and wherein each common line forms an angle of greater than 90° with the sawtooth-shaped base; a connecting line being parallel with the gate line; a plurality of pixel electrodes extended from the connecting line, wherein each pixel electrode has a zigzag shape and a sawtooth-shaped base, and wherein each common line forms an angle of greater than 90° with the sawtooth-shaped base; and a switching element electrically connected with the gate and data lines, the switching element supplying voltage to the pixel electrodes.
[0027] The aforementioned switching element is located in the crossing of the gate and data lines. This switching element includes a source electrode that is extended from the data line; a gate electrode that is extended from the gate line; a drain electrode that contacts one of the pixel electrodes through a drain contact hole; an active layer that is formed over the gate electrode and between the source and drain electrodes; and ohmic contact layers that are formed between the active layer and the source and drain electrodes.
[0028] One of the pixel electrodes has a bend end portion over the drain electrode. This bend end portion overlaps one end of the drain electrode and contacts the drain electrode through the drain contact hole
[0029] The connecting line overlaps a portion of the gate line, and the connecting line and the gate line comprise a storage capacitor. A plurality of the pixel electrodes and the connecting line can be made of a transparent conductive material. However, a plurality of the pixel electrodes and the connecting line can be made of an opaque metallic material.
[0030] A plurality of the common electrodes and the common line can be made of a transparent conductive material. However, the plurality of the common electrodes and the common line can be made of an opaque metallic material.
[0031] The present invention also provides, in another aspect, an array substrate for use in an in-plane switching liquid crystal display device including a gate line on a substrate; a data line over the substrate, the data line being perpendicular to the gate line, wherein each pair of gate and data lines defines a pixel area; a common line being parallel with and spaced apart from the gate line, wherein the common line is located in any region of the pixel area and elongates along the gate line; a plurality of common electrodes extended from the common line, wherein each common electrode has a zigzag shape and sawtooth-shaped base in the intersection where each common electrode crosses the common line, wherein each common line forms an angle of greater than 90° with the sawtooth-shaped base, and wherein one of the common electrodes elongates along the data line; a connecting line being parallel with the gate line; a plurality of pixel electrodes extended from the connecting line, wherein each pixel electrode has a zigzag shape and a sawtooth-shaped base, and wherein each common line forms an angle of greater than 90° with the sawtooth-shaped base; and a switching element electrically connected with the gate and data lines, the switching element supplying voltage to the pixel electrodes.
[0032] One of the pixel electrodes has a sharply bent end portion over the switching element that is located in the crossing of the gate and data lines. This switching element includes a source electrode that is extended from the data line; a gate electrode that is extended from the gate line; a drain electrode that is the bent end portion of one pixel electrode; an active layer that is formed over the gate electrode and between the source and drain electrodes; and ohmic contact layers that are formed between the active layer and the source and drain electrodes.
[0033] The drain electrode and the pixel electrodes can be separately formed on a different layers. Moreover, a substance of which the drain electrode is made can be different from that of the pixel electrodes. However, the data line, the connecting line, the pixel electrodes, and the source and drain electrodes can be made of the same material.
[0034] The connecting line overlaps a portion of the gate line, and the connecting line and the gate line comprise a storage capacitor. And the common line and each common electrode intersect in one bend portion of each common electrode. Moreover, the common line is connected with the other common lines that are located in the adjacent pixel areas in order to form a mesh shape.
[0035] One of the common electrodes is connected with the other common electrodes that are positioned in the adjacent pixel areas in order to form the mesh shape.
[0036] A plurality of the pixel electrodes and the connecting line can be made of a transparent conductive material. However, the plurality of the pixel electrodes and the connecting line can be made of an opaque metallic material.
[0037] A plurality of the common electrodes and the common line are made of a transparent conductive material. However, the plurality of the common electrodes and the common line are made of an opaque metallic material.
[0038] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
[0039] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0040] In the drawings:
[0041] [0041]FIG. 1 is a conceptual cross sectional view illustrating a typical IPS-LCD panel;
[0042] [0042]FIGS. 2A and 2B are conceptual perspective views illustrating operation modes of a conventional IPS-LCD device;
[0043] [0043]FIG. 3 is a partial plan view illustrating bend electrodes of the conventional IPS-LCD device;
[0044] [0044]FIGS. 4A and 4B are enlarged partial plan views of pixel and common electrodes according to the conventional IPS-LCD device;
[0045] [0045]FIG. 5A is a plan view illustrating a pixel of an array substrate for use in an IPS-LCD device according to a first preferred embodiment of the present invention;
[0046] [0046]FIG. 5B is a cross-sectional view taken along line V-V of FIG. 5A;
[0047] [0047]FIGS. 6A and 6B are enlarged plan views of a portion “B” of FIG. 5A when the voltage is turned ON;
[0048] [0048]FIG. 7A is a plan view illustrating a pixel of an array substrate for use in an IPS-LCD device according to a second preferred embodiment;
[0049] [0049]FIG. 7B is a cross-sectional view taken along line VII-VII of FIG. 7A; and
[0050] [0050]FIG. 8 is an enlarged plan view of a portion “C” of FIG. 7A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0052] [0052]FIG. 5A is a plan view illustrating a pixel of an array substrate for use in an IPS-LCD device according to a first preferred embodiment of the present invention, and FIG. 5B is a cross-sectional view taken along line V-V of FIG. 5A.
[0053] As shown in FIG. 5A, a plurality of gate lines 121 are transversely disposed on a substrate 110 (see FIG. 5B). A common line 123 is spaced apart from the gate lines 121 and disposed parallel with the gate lines 121 . A plurality of data lines 161 that are spaced apart from each other are disposed across and perpendicular to the gate and the common lines 121 and 123 . Each pair of gate and data lines 121 and 161 defines a pixel area.
[0054] Near the crossing of the gate and data lines 121 and 161 , gate and source electrodes 122 and 162 are positioned and electrically connected with the gate and data lines 121 and 161 , respectively. A drain electrode 163 is spaced apart from the source electrode 162 and overlaps one end of the gate electrode 122 . The source electrode 162 overlaps the other end of the gate electrode 122 . An active layer 140 is located over the gate electrode 122 and between the source and drain electrodes 162 and 163 and the gate electrode 122 .
[0055] A connecting line 181 is disposed parallel with the gate line 121 and overlaps a portion of the gate line 121 . And thus the connecting line 181 and the gate line 121 comprise a storage capacitor. First and second pixel electrodes 182 and 183 , which extend from the connecting line 181 , are disposed in substantially zigzag shapes roughly perpendicular to the connecting line 181 , and thus the first and second pixel electrodes 182 and 183 communicate with the connecting line 181 . One end of the second pixel electrode 183 bends over the drain electrode 163 and overlaps one end of the drain electrode 163 . This end of the second pixel electrode 183 electrically contacts the drain electrode 163 through a drain contact hole 171 .
[0056] First, second and third common electrodes 124 , 125 and 126 that have substantially zigzag shapes are disposed parallel with the pixel electrodes 182 and 183 . And one end of each common electrode 124 , 125 or 126 is electrically connected to the common line 123 . Each common electrode 124 , 125 or 126 is spaced apart from the adjacent pixel electrodes 182 and 183 . Although FIG. 5A shows three common electrodes and two pixel electrodes, the number of the common and pixel electrodes depends on a space between electrodes and on an angle of the bend portions of each electrode.
[0057] The common line 123 , the gate and data lines 121 and 161 , and the common electrodes 124 , 125 and 126 are an opaque metal, while the pixel electrodes 182 and 183 , and the connecting line 181 are a transparent conductive material. Preferably, the opaque metal is selected from a group consisting of chromium (Cr), aluminum (Al), aluminum alloy (Al alloy), molybdenum (Mo), tantalum (Ta), tungsten (W), and antimony (Sb), and the like, while the transparent conductive material is indium tin oxide (ITO) or indium zinc oxide (IZO). However, the common line 123 and the common electrodes 124 , 125 and 126 can be a transparent conductive material. Although not depicted in FIG. 5A, the gate line 121 , the gate electrode 122 , the common line 123 , and the common electrodes 124 , 125 and 126 are covered by a gate insulation layer (see reference element 130 of FIG. 5) that is formed of silicon nitride (SiNx) or silicon oxide (SiO2).
[0058] Still referring to FIG. 5A, portions of the pixel electrodes 182 and 183 contact the connecting line 181 and portions of the common electrodes 124 , 125 and 126 also contact the common line 123 , and at least one of these portions has an obtuse angle between each line and each electrode. Such obtuse angle portions are shown, for example at the portion “B” of FIG. 6A, described by a dotted circle. Namely, each electrode makes the obtuse angle with each line by employing a sawtooth-shaped base of that driving electrode. That is, the pixel electrodes 182 and 183 intersect the connecting line 181 at an obtuse angle and the common electrodes 124 , 125 and 126 intersect the common line 123 at an obtuse angle.
[0059] Although not depicted in FIG. 5A, the data line 161 can have a substantially zigzag shape as if the abovementioned pixel and common electrodes do.
[0060] Now referring to FIG. 5B, a fabricating process for the array substrate shown in FIG. 5A is provided. At first, the gate electrode 122 and the common electrodes 124 and 125 are formed on the substrate 110 . The gate line 121 of FIG. 5A is formed with the gate electrode 121 in the same layer, and thus the gate electrode 122 extends from the gate line 121 . If the gate electrode 122 and the common electrodes 124 and 125 are different materials, they are formed in different steps. Moreover, the common line 123 of FIG. 5A is formed with the common electrodes 124 and 125 in the same layer, and thus these common electrodes 124 and 125 that have substantially zigzag shapes extend from the common line 123 . After that, a gate insulation layer 130 is formed on the substrate 110 to cover the gate electrode 122 and common electrodes 124 and 125 . As mentioned before the gate insulation layer 130 is silicon nitride (SiNx) or silicon oxide (SiO2). Subsequently, an active layer 140 is formed on the gate insulation layer 130 , particularly over the gate electrode 122 . Ohmic contact layers 151 and 152 are formed on the active layer 140 , and thus the ohmic contact layers 151 and 152 are interposed between the active layer 140 and the source and drain electrodes that are formed in a later step. The active layer 140 includes an amorphous silicon layer (a-Si), while the ohmic contact layers 151 and 152 include a doped amorphous silicon layer (n+a-Si).
[0061] The source and drain electrodes 162 and 163 are formed on the ohmic contact layers 151 and 152 , respectively, and on the gate insulation layer 130 . Those source and drain electrodes 162 and 163 are made of the same material as the gate electrode 122 . At this time, the data line 161 is formed together with the source electrode 162 such that the data line 161 is connected to the source electrode 162 . The source and drain electrodes 162 and 163 are spaced apart from each other and respectively overlap both ends of the gate electrode 122 .
[0062] Thereafter, a passivation layer 170 is deposited over the entire surface of the substrate 110 , and then patterned to form the drain contact hole 171 that exposes a portion of the drain electrode 163 . The passivation layer 170 is made of silicon nitride (SiNx) or silicon oxide (SiO2). Next, the connecting line 181 , which overlaps the portion of the gate 15 line 121 , is formed on the passivation layer 170 . At this time, the first and second pixel electrodes 182 and 183 are simultaneously formed. And thus, one end of the second pixel electrode 183 contacts the drain electrode 163 through the drain contact hole 171 . These pixel electrodes 182 and 183 have substantially zigzag shapes and are parallel with the common electrodes 124 and 125 , as shown in FIG. 5A. Again, the pixel electrodes 182 and 183 are connected with the connecting line 181 . Although the connecting lines 181 and the pixel electrodes 182 and 183 are made of the transparent conductive material, such as ITO and IZO, as described above, they can be made of an opaque conductive material.
[0063] Subsequently, although not shown in FIG. 5B, an orientation film of polyimide or photoalignment material is formed on the pixel electrodes and on the passivation layer, and rubbed by a fabric or patterned by light.
[0064] [0064]FIGS. 6A and 6B are enlarged plan views of a portion “B” of FIG. 5A when the voltage is turned ON. These figures illustrate the structure of the electrodes and common lines according to the first embodiment. As shown in FIGS. 6A and 6B, the common electrode 124 has a sawtooth-shaped base in a contacting part between the common electrode 124 and the common line 123 . In other words, the common electrode 124 forms the angle of β, which is greater than 90°, with the sawtooth-shaped base that is a part of the common line 123 . Accordingly, the common electrode 124 has an obtuse angle (i.e., the angle of β) with the common electrode 123 . Here, when the voltage is applied to the common and pixel electrodes 124 and 182 , electric field 190 is then perpendicular to the common and pixel electrodes 124 and 182 . As shown FIG. 6B, not only liquid crystal molecules 211 , which are relatively far from the common line 123 , but also liquid crystal molecules 221 , which are relatively close to the common line 123 , turn clockwise, in contrast to the conventional art. Namely, the same rotational direction results in substantially the entire regions. Hence, the disclination does not appear, the traces of the extraordinary domains also do not appear, and the response characteristic of the liquid crystal layer is improved. Moreover, the afterimage phenomenon is not brought about in the display area.
[0065] Now, the reference will be explained in detail to a second preferred embodiment referring to FIGS. 7A to 8 . According to the second embodiment, the common line also forms an obtuse angle with the common electrodes although these common line and common electrodes are formed in a mesh shape in order to decrease electrical resistance.
[0066] [0066]FIG. 7A is a plan view illustrating a pixel of an array substrate for use in an IPS-LCD device according to the second preferred embodiment. As shown, a plurality of gate lines 121 are transversely disposed on a substrate 110 (see FIG. 7B). A plurality of data lines 161 that are spaced apart from each other are disposed across and perpendicular to the gate line 121 . Each pair of gate and data lines 121 and 161 defines a pixel area.
[0067] Near the crossing of the gate and data lines 121 and 161 , gate and source electrodes 122 and 162 are positioned and electrically connected with the gate and data lines 121 and 161 , respectively. The source electrode 162 overlaps one end of the gate electrode 122 . A connecting line 181 is disposed parallel with the gate line 121 and overlaps a portion of the gate line 121 . And thus the connecting line 181 and the gate line 121 comprise a storage capacitor. First and second pixel electrodes 182 and 183 , which are extended from the connecting line 181 , are disposed in substantially zigzag shapes perpendicular to the connecting line 181 , and thus the first and second pixel electrodes 182 and 183 communicate with the connecting line 181 . One end of the second pixel electrode 183 bends over the gate electrode 122 and overlaps the other end of the gate electrode 122 . This end of the second pixel electrode 183 is spaced apart from the source electrode 162 and acts as a drain electrode 163 . However, the drain electrode 163 and the second pixel electrode 183 can be separately formed with different materials. When the drain electrode 163 is formed in a different fabricating step with different material, the pixel electrode can contact the drain electrode 163 through a drain contact hole (not shown). Moreover, an active layer 140 is located over the gate electrode 122 and between the source and drain electrodes 162 and 163 .
[0068] A common line 127 is spaced apart from the gate lines 121 and transversely disposed parallel with the gate lines 121 . The common line 127 can be located in any region of the pixel area, and this common line 127 extends to the next pixels areas and is transversely connected with the other adjacent common lines, which are positioned in the next pixel areas, in order to form a mesh shape with one of common electrodes 124 .
[0069] Still referring to FIG. 7A, first, second and third common electrodes 124 , 125 and 126 that have substantially zigzag shapes are disposed roughly parallel with the pixel electrodes 182 and 183 , and extend from the common line 127 . Again, each common electrode 124 , 125 or 126 is electrically connected to the common line 127 in a respective bend portion of each common electrode. Each common electrode 124 , 125 or 126 is spaced apart from the adjacent pixel electrodes 182 and 183 . One of the common electrodes 124 , 125 or 126 , for example the first common electrode 124 , extends along the data line 161 such that this common electrode is electrically connected to the other common electrodes that are located in adjacent upper and lower pixel areas. Thus, one of common electrodes 124 forms a mesh shape with the common line 127 . Although FIG. 7A shows three common electrodes and two pixel electrodes, the number of the common and pixel electrodes depends on a space between electrodes and on an angle of the bend portions of each electrode.
[0070] In this second embodiment of the present invention, the common line 127 , the gate and data lines 121 and 161 , and the common electrodes 124 , 125 and 126 can be an opaque metal. The pixel electrodes 182 and 183 , and the connecting line 181 can be a transparent conductive material if they are formed separately from the drain electrode 163 . Preferably, the opaque metal is selected from a group consisting of chromium (Cr), aluminum (Al), aluminum alloy (Al alloy), molybdenum (Mo), tantalum (Ta), tungsten (W), and antimony (Sb), and the like, while the transparent conductive material is indium tin oxide (ITO) or indium zinc oxide (IZO). However, the common line 127 and the common electrodes 124 , 125 and 126 can be the transparent conductive material so as to provide a high aperture ratio. Although not depicted in FIG. 7A, the gate line 121 , the gate electrode 122 , the common line 127 , and the common electrodes 124 , 125 and 126 are covered up with a gate insulation layer (see reference element 130 of FIG. 5) that is formed of silicon nitride (SiNx) or silicon oxide (SiO2).
[0071] Still referring to FIG. 7A, portions at which the pixel electrodes 182 and 183 contact the connecting line 181 have obtuse angles between the connecting line 181 and each electrode 182 or 183 , as described in the first embodiment. Further, the intersections in which the common electrodes 125 and 126 cross the common line 127 also have obtuse angles, i.e., the portion “C” which is described by a dotted ellipse. Namely, each common electrode 125 or 126 forms an obtuse angle with the common line 127 by employing sawtooth-shaped bases of those driving electrodes.
[0072] Although not depicted in FIG. 7A, the data line 161 can have a substantially zigzag shape as if the abovementioned pixel and common electrodes do.
[0073] [0073]FIG. 7B is a cross-sectional view taken along line VII-VII of FIG. 7A. As shown, a fabricating process for the array substrate shown in FIG. 7A is provided. At first, the gate electrode 122 and the gate line 121 of FIG. 7A are formed on the substrate 110 in the same layer. And thus, the gate electrode 122 extends from the gate line 121 . After that, a gate insulation layer 130 is formed on the substrate 110 to cover the gate electrode 122 and the gate line 121 (see FIG. 7A). As mentioned before the gate insulation layer 130 is silicon nitride (SiNx) or silicon oxide (SiO2). Subsequently, an active layer 140 is formed on the gate insulation layer 130 , particularly over the gate electrode 122 . Ohmic contact layers 151 and 152 are formed on the active layer 140 , and thus the ohmic contact layers 151 and 152 are interposed between the active layer 140 and the source and drain electrodes that are formed in a later step. The active layer 140 includes an amorphous silicon layer (a-Si), while the ohmic contact layers 151 and 152 include a doped amorphous silicon layer (n+a-Si).
[0074] Next, the source and drain electrodes 162 and 163 are formed on the ohmic contact layers 151 and 152 , respectively, and on the gate insulation layer 130 . Those source and drain electrodes 162 and 163 can be made of the same material as the gate electrode 122 . The source and drain electrodes 162 and 163 are then spaced apart from each other and respectively overlap the gate electrode 122 . At this time, the data line 161 is formed together with the source electrode 162 such that the data line 161 is connected to the source electrode 162 . Moreover, the first and second pixel electrodes 182 and 183 , which have substantially zigzag shapes, are formed on the gate insulation layer 130 when the source and drain electrodes 162 and 163 are formed. Thus, they can be made of the same materal. Simultaneously, the connecting line 181 is formed in the same layer such that the first and second pixel electrodes 182 and 183 contact the connecting line 181 . The connecting line 181 on the gate insulation layer 130 overlaps a portion of the gate line 121 , and thus these gate and connecting lines 121 and 181 comprise the storage capacitor, with the gate insulation layer 130 as a dielectric layer.
[0075] At this point, since the drain electrode 163 is one end of the second pixel electrode 183 as described before, the drain contact hole (not shown) is not required. However, in case that the drain electrode 163 is formed separately from the pixel electrode and made of the different material from the pixel electrode, the step of fabrication needs additional steps and a drain contact hole is also required through a passivation layer that is formed in a later step.
[0076] Thereafter, a passivation layer 170 is deposited over the entire surface of the substrate 110 . The passivation layer 170 is made of silicon nitride (SiNx) or silicon oxide (SiO2). As shown in FIG. 7B, the drain contact hole is not depicted, contrary to the first embodiment. Next, the common electrodes 124 and 125 , which have substantially zigzag shapes and are roughly parallel with the pixel electrodes 182 and 183 , are formed on the passivation layer 130 . Moreover, the common line 127 of FIG. 7A is formed with the common electrodes 124 and 125 in the same layer, and thus these common electrodes 124 and 125 extend from the common line 127 . The common line 127 and the common electrodes 124 and 125 can be formed of the transparent conductive material, such as ITO and IZO, or an opaque conductive material.
[0077] Subsequently, although not shown in FIG. 7B, an orientation film of polyimide or photoalignment material is formed on the common electrodes and on the passivation layer, and rubbed by a fabric or patterned by light.
[0078] [0078]FIG. 8 is an enlarged plan view of a portion “C” of FIG. 7A and illustrates the structure of the pixel electrodes and the common line according to the second embodiment. As shown, the common electrodes 125 and 126 have sawtooth-shaped bases at the intersections of the common electrodes 125 and 126 and the common line 127 . In other words, the common electrodes 125 and 126 form obtuse angles, which are greater than 90°, with the sawtooth-shaped bases, which are part of the common line 127 . Accordingly, as shown FIG. 6B, when the voltage is applied to the pixel and common electrodes, electric field is then perpendicular to the common and pixel electrodes. The rotational direction of the liquid crystal molecules should be the substantially same even regions near the intersection of the common electrodes 125 and 126 ad the common line 127 .
[0079] Hence, as aforementioned, disclination does not appear in the intersection of the common electrodes and the common lines, traces of the extraordinary domains also do not appear, and the response characteristic of the liquid crystal layer is improved. Moreover, afterimage phenomenon is not brought about in the display area.
[0080] Further, preferred embodiments of the present invention include the following advantages.
[0081] First, since the in-plane switching liquid crystal display device (IPS-LCD) includes the substantially zigzag-shaped pixel and common electrodes, the IPS-LCD can have the wide viewing angle and can compensate color-shift.
[0082] Second, since the pixel and common electrodes form obtuse angles with the connecting and common lines, the same rotational direction of the liquid crystal molecules under application of electric field, when the applied voltage is applied, should result near the intersection of the pixel electrodes and the connecting line and near the intersection of the common electrodes and the common line. Therefore, disclination does not occur, traces of the extraordinary domains also do not appear, and the response characteristic of the liquid crystal layer is improved. Moreover, the afterimage phenomenon is not brought about in the display area.
[0083] It will be apparent to those skilled in the art that various modifications and variation can be made in the method of manufacturing a thin film transistor of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | This disclosure provides an array substrate for use in an IPS-LCD device which includes substantially zigzag-shaped pixel and common electrodes. The pixel electrodes and the common electrodes are connected with a connecting line and the common line, respectively. However, if each pixel and common electrode forms an acute angle with each connecting and common lines, liquid crystal molecules are strangely rotated and produce extraordinary domains in the intersection when the voltage is turned ON. Moreover, disclination occurs around the intersection. In order to overcome these problems, substantially sawtooth-shaped bases are employed of where the pixel and common electrodes meet the connecting and common lines, respectively. So each electrode forms an obtuse angle with each respective line, and thus the rotational direction of the liquid crystal molecules are the same in regions of the pixel area when the voltage is supplied. Accordingly, disclination is prevented, and the aperture ratio and the response characteristic are improved. | 6 |
This application claims the benefit under 35 U.S.C. 119(e) of the filing date of Provisional U.S. Application Ser. No. 60/856,520, entitled Roll-Up Sign Bracket, filed on Nov. 3, 2006. This provisional application is expressly incorporated herein, in its entirety, by reference.
BACKGROUND OF THE INVENTION
This application relates to signs and message display devices, and more particularly to adjustable brackets for attaching such signs to support stands for display to the public.
Signs used in the roadway construction field may be of the rigid type, constructed of metal, plywood, or the like, or may be of the flexible type, constructed of fabric or vinyl and designed to roll up for transport and storage when not in use. The signs may be of any shape, such as diamond, square, rectangular, or circular, and may be of varying sizes, depending upon the distance from which the signs must be viewed.
Portable, metallic sign stands are commonly used to support both rigid and flexible or roll-up types of signs. For example, the assignee of the present application, TrafFix Devices, Inc. of San Clemente, Calif., makes and sells several types of such sign stands, under, for example, the registered trademarks SUPER BUSTER, LITTLE BUSTER, BIG BUSTER, ECONO BUSTER, and the trademark TRI BUSTER. The TRI BUSTER sign stand is disclosed in co-pending and commonly assigned U.S. application Ser. No. 11/935,085, entitled Portable Sign Stand and filed on even date herewith, which application is herein expressly incorporated by reference.
Typically, rigid sign brackets may be left on the sign stand if a roll-up sign needs to be used. However, when a rigid sign is to be employed, the roll-up sign bracket must be removed from the sign stand. Removing the roll-up sign bracket in the event of the need to use a rigid sign often results in damage to or loss of the roll-up sign bracket.
SUMMARY OF THE INVENTION
The roll-up sign bracket of the present invention is designed to freely and easily rotate to a stowage position, without the need for removal from the sign stand, when it is desired to mount a rigid sign panel to the sign stand.
More particularly, a bracket is provided for mounting an article on a mast, which comprises a body, a clamp on the body for securing the bracket at a desired location on the mast, and a receptacle on the body for receiving a portion of the article. Forward portions of the bracket body comprise angled surfaces so that when the bracket body is secured to the mast in a particular orientations, no portions of the bracket body extend substantially forwardly of a forward side of the mast. The body preferably comprises opposing side walls and a rear wall, and the clamp extends through the rear wall.
The claim preferably comprises a bolt and nut combination and has a proximal handle for rotating the bolt. The angled surfaces, in a preferred embodiment, are on each of the side walls. The side walls each have a substantially horizontal lower edge, and the angled surfaces each extend upwardly from their respective lower edges toward a front end of the bracket body at a predetermined angle. In a preferred embodiment, the predetermined angle is between about 30° and about 60°. In a most preferred embodiment, the predetermined angle is about 45°. The receptacle comprises a slot in each of the opposing side walls.
In another aspect of the invention, there is provided a bracket for mounting an article on a mast, which comprises a body and a clamp on the body for securing the bracket at a desired location on the mast. A receptacle on the body is provided for receiving a portion of the article. The bracket body may be secured in first and second different orientations on the mast at the desired location, the first orientation being one in which the receptacle is positioned forwardly of a forward surface of the mast, for receiving the article portion, and the second orientation being one in which substantially no portions of the bracket body are positioned forwardly of the mast forward surface.
Preferably, the body comprises opposing side walls and a rear wall, and the clamp extends through the rear wall. The clamp comprises a bolt and nut combination and has a proximal handle for rotating the bolt. Each of the side walls include angled surfaces thereon. The side walls each have a substantially horizontal lower edge, and the angled surfaces each extend upwardly from their respective lower edges toward a front end of the bracket body at a predetermined angle. In a preferred embodiment, the predetermined angle is between about 30° and about 60°, and in a most preferred embodiment, the predetermined angle is about 45°.
Again, with reference to a preferred embodiment, the receptacle comprises a slot in each of the opposing side walls. The bracket body is moved from the first orientation to the second orientation by rotating the bracket body upwardly and rearwardly.
In still another aspect of the invention, there is disclosed a method of reorienting a bracket disposed on an upstanding mast from an operational orientation, for securing an article to the mast, to a non-operational orientation, without removing the bracket from the mast. The method comprises loosening a clamp which secures the bracket in the operational orientation, wherein a receptacle on the bracket is disposed forwardly of a forward surface of the mast for receiving a portion of the article. Then, the bracket is rotated rearwardly through a predetermined angle to the non-operational orientation, wherein no substantial portion of the bracket is disposed forwardly of the forward surface of the mast. The clamp is then re-tightened to secure the bracket in the non-operational orientation.
The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom view of a roll-up sign bracket constructed in accordance with the principles of the present invention;
FIG. 2 is a perspective view of the roll-up sign bracket of FIG. 1 ;
FIG. 3 is a side view of the roll-up sign bracket of FIGS. 1 and 2 ;
FIG. 4 is a front view of the roll-up sign bracket of FIGS. 1-3 ;
FIG. 5 is a perspective view of a sign stand on which the bracket of FIGS. 1-4 has been installed and on which a rigid sign is mounted;
FIG. 6 is a detail view of the portion of FIG. 5 denoted by the circle A;
FIG. 7 is a perspective view of a sign stand illustrating both a prior art roll-up sign bracket and a roll-up sign bracket in accordance with the present invention installed thereon, for comparison purposes;
FIG. 8 is a detail view of a portion of FIG. 7 denoted by the circle B;
FIG. 9 is a perspective view of a sign stand on which is disposed a roll-up fabric or vinyl sign and a roll-up sign bracket according to the present invention;
FIG. 10 is a perspective view, in isolation, of the roll-up sign bracket installed on the sign stand of FIG. 9 ;
FIG. 11 is a detail view of a portion of FIG. 9 denoted by the circle C;
FIG. 12 is a perspective view of a sign stand having a roll-up sign bracket in accordance with the present invention; and
FIG. 13 is a detail view of a portion of FIG. 12 denoted by the circle D.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, there is shown in FIGS. 1-4 a roll-up sign bracket 10 constructed in accordance with one embodiment of the present invention. The bracket 10 comprises a body 12 , comprised, preferably, of metal, such as steel. In a presently preferred embodiment, the body 12 is comprised of 0.080-0.100 inch thick galvanized steel. Of course, other suitable rigid, durable materials may be used, such as alternative metals or plastics. The body 12 comprises opposing side walls 14 , 16 and a rear wall 18 . A bolt 20 having threads 22 on one end thereof and a T-handle 24 on the opposing end extends through a hole 26 on the rear wall 18 , as well as a nut 27 , which is preferably welded to the wall 18 . Corresponding slots 28 , 30 are disposed on the front ends of each of the side walls 14 , 16 , as shown particularly in FIGS. 2 and 3 .
The slots 28 , 30 are adapted to receive the horizontal pultrusion for supporting a flexible sign, as will be described more fully below. Accordingly, frontwardly of the slots 28 , 30 are upstanding fingers 32 , 34 , each of which include upper hooks 36 , 38 , respectively, overhanging a portion of the respective slots 28 , 30 . The hooks 36 , 38 function to retain the pultrusion in the slots 28 , 30 .
An important feature of the present invention is that the bottom portion of each side wall 14 , 16 , respectively, cuts sharply upwardly toward the front edge thereof, to create an angled edge 40 , 42 , respectively. As shown in FIG. 3 , an angle θ between the angled edge 42 and a line extending from bottom edge 44 is approximately 45°, though the angle may actually fall within a range of approximately 30° to 60° and still be adapted to function effectively for the purposes of this invention. In the preferred embodiment, the angle θ for the other angled edge 40 , which is not specifically shown in the drawings, should be approximately the same as the illustrated angle θ.
Now referring particularly to FIGS. 5 and 6 , there is shown in FIG. 5 a portable sign stand 46 having a plurality of support legs 48 and a mast 50 . As shown, the sign stand 46 is supporting a rigid sign panel 52 . Importantly, even though a rigid sign panel 52 is deployed on the sign stand, the roll-up sign bracket 10 of the present invention remains installed on the sign stand. This will be discussed in more detail below.
FIGS. 7 and 8 illustrate a sign stand 46 , similar to that in FIGS. 5 and 6 , but in FIGS. 7 and 8 no sign panel is illustrated, for clarity. A roll-up sign bracket 10 , of the invention, is installed thereon, in a manner similar to that on FIGS. 5 and 6 . Also installed thereon is a typical prior art roll-up sign bracket 54 , for comparative purposes, to be discussed in more detail below.
Now referring to FIGS. 9-11 , there is shown yet another sign stand 46 of the type previously shown. In this instance, a roll-up fabric or vinyl sign panel 56 is deployed on the sign stand, as illustrated. The sign panel 56 is supported by crossed horizontal and vertical pultrusions 58 and 60 , respectively.
Both the top and bottom portions of the bracket 10 are open, except for an angled cross-member 62 ( FIG. 1 ), which is disposed at an angle approximately the same as angle θ. Thus, to mount the roll-up bracket 10 on the sign stand 46 , the bracket 10 is slipped over the mast 50 , as shown in FIGS. 9 and 11 , so that the mast is disposed in the space within the body 12 defined by the side walls 14 and 16 , the rear wall 18 , and the angled cross-member 62 . When the bracket 10 is located at a desired position along the mast 50 , such as the position shown in FIGS. 9 and 11 , the operator turns the T-handle 24 in a clockwise direction to advance the distal threaded end 22 of the bolt 20 toward the front end of the bracket 10 . Ultimately, with sufficient advancement of the bolt 20 , the mast will become clamped between the bolt 20 and the angled cross-member 62 , thus securing the bracket 10 in the desired position.
Once the bracket 10 is secured, the slots 28 and 30 are disposed on the front side of the mast 50 . At this juncture, the horizontal pultrusion 58 of the flexible sign 56 can be positioned within the two slots 28 and 30 , so that it lies horizontally through both slots and extending from each side, as shown.
In a preferred embodiment, the bracket 10 weights about 0.25 lb., and has overall dimensions of approximately 3.125 in.×3.250 in.×4.562 in. The slots 28 and 30 are sized to receive pultrusions having a thickness of up to 0.375 in. The bracket is adapted particularly to fit a mast 50 size of approximately 1 in.×1 in., which is a typical size. Masts are usually fabricated of hollow metallic square tubing. Of course, the bracket 10 can be adapted to fit any reasonably sized sign stand mast and sign frame pultrusion.
Now again referring to FIGS. 5 and 6 , when it is desired to place a rigid sign 52 on the stand 46 , rather than having to remove the bracket 10 from the mast 50 , the operator need only turn the T-handle 24 counter-clockwise sufficiently to loosen the bracket relative to the mast 50 , and then rotate the bracket backwards as shown, so that the slots 28 and 30 and the remainder of the front portion of the bracket 10 move upwardly to the orientation shown in FIG. 6 . The T-handle 24 can then be re-tightened to secure the bracket in this new orientation, with the mast 50 still clamped between the distal end of the bolt 20 and the angled cross member 62 . The rigid sign 52 can then be installed, using one or more rigid sign brackets or other suitable mounting means.
FIGS. 7 and 8 are included to visually illustrate a significant advantage of the present bracket 10 relative to prior art brackets, such as prior art roll-up sign bracket 54 . As shown, the prior art bracket 54 presents a front portion 64 thereof which extends frontally of the mast 50 at all times when the bracket 54 is installed. This bracket frontal portion prevents the rigid sign 52 from proper disposition on the sign stand. Accordingly, this type of bracket must be removed before the sign panel 52 is installed, with consequent additional labor and potential bracket loss or damage.
On the other hand, as discussed above, the inventive bracket 10 may merely be rotated backwardly, through approximately the angle θ, as shown. Because of the angled edges 40 and 42 , once rotated, the bracket lies substantially flush along the mast 50 , as shown, thereby permitting a rigid sign 52 to lie freely in front of the mast.
FIGS. 12 and 13 illustrate a different type of wind-yielding portable sign stand 46 , on which a rigid sign 52 is installed, by means of rigid sign brackets 66 . The inventive bracket 10 has been rotated backwardly to its storage position, as discussed above, to permit the sign panel 52 to be properly installed.
Accordingly, although an exemplary embodiment of the invention has been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention. | A bracket for mounting an article, such as a roll-up fabric sign, on a mast, includes a body and a clamp on the body for securing the bracket at a desired location on the mast. A receptacle on the body is provided for receiving a portion of the article. The bracket body may be secured in first and second different orientations on the mast at the desired location, the first operational orientation being one in which the receptacle is positioned forwardly of a forward surface of the mast, for receiving the article portion, and the second non-operational orientation being one in which substantially no portions of the bracket body are positioned forwardly of the mast forward surface. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to shaft coupling means, and more specifically pertains to a bearing interconnecting torque limiting overload coupling for preventing shaft rotation at forces exceeding the designed torque for the operating machinery.
A variety of styles of shaft coupling devices are available in the prior art, and usually are provided for coupling the drive shaft of a motor or speed reducer with a main driven shaft supporting the work component being turned. Many of these coupling devices are constructed in the category of flexible couplings, and any of a variety of connectors that are designed for providing a transmission of rotatable or torque forces from a drive shaft to the intended driven shaft, or the like. In addition, safety means has on occasion been designed into these type of couplings, functioning in the manner of safety devices to prevent the exertion of excessive torque forces upon the driven shaft from damaging the drive shaft and its prime mover, or even from causing damage to the tool actively performing work upon the machinery and exerting the torque in the first instance. Many of these safety devices have been designed in the category of mechanically activated torque couplers, and as can be seen in the United States patent to Schultz, U.S. Pat. No. 2,771,171, a variety of magnetic pole pieces are arranged within a rotor means and normally effect a revolving of a driven member and its axial shaft for furnishing force transmission for rotation of a pair of axial shafts, but yet in the event that excessive force is applied to one of the shafts then the magnetic means is disengaged for curtailing the rotation of the driven shaft. The shown magnetically operated torque coupler of this United States patent, while it may be effective in its operations, it is quite dissimilar from the mechanically actuated torque limiting means of the current invention.
An additional variety of magnetic coupling devices for preventing overload force from being exerted upon a driven shaft, and which finds significant usage in the textile industry, as when spindles of yarn are being wound, and thereby the tension upon the yarns becomes rather critical and when exceeded can cause a break down in its windings, are shown in the United States patents to Cowell, U.S. Pat. No. 3,221,389, and the United States patent to Gollos, U.S. Pat. No. 3,339,819. This latter patent is pertinent for disclosing a series of spherical projections that contact and intermesh with cups formed upon an opposing annular surface, these two separate components being held together through the agency of permanent magnerts.
Further type of magnetic torque limiting devices, and specifically for use in low force operating mechanisms, such as phonograph record players or sound recorders, are shown in the two United States patents to Tiffany, U.S. Pat. No. 1,136,739, and Cornwell, U.S. Pat. No. 2,300,778.
The combination of magnetic couplers having spring biasing to determine the degree of force necessary for disengaging a coupling has also been available in the prior art, as shown in the United States patent to Allen, U.S. Pat. No. 3,053,365. And, other forms of connectors, which generally have utilized the permanent magnet approach for effecting torque control are shown in the additional United States patent to Woolley, U.S. Pat. No. 3,277,669; the United States patent to Hornschuch, et al. U.S. Pat. No. 3,159,725; the U.S. patent to Spodig, U.S. Pat. No. 2,943,216; the United States patent to Beeston, Jr., U.S. Pat. No. 2,885,873; and finally, the United States patent to Hoad, U.S. Pat. No. 2,746,691, which utilizes a frictional connection between magnets for determining the degree of torque necessary to effect discoupling of its torque limiting device.
Various ball detent couplings are available in the art. Some are shown in the U.S. Pats. No. 3,701,404, No. 3,680,673, No. 3,893,553; No. 3,981,382, No. 3,979,925, No. 3,942,238, No. 3,927,537, No. 3,930,382, and No. 3,866,728.
While all of the foregoing disclosures may be effective for achieving their particular intended results within specific types of mechanical devices and apparatuses, the current invention, a hereinafter to be summarized, and described, embodies rather distinct structure that operates rather differently from any of these prior art, and attains rather precise torque limiting connection between not only a shaft to shaft connection, but also between a combination of shafts, flanges, and dials, depending upon the type of industrial machinery comprising the rotating part, and that which is to be rotated.
It is, therefore, the principal object of this invention to provide a totally mechanical torque limiting overload coupler that may be used intermediate rotating and rotatable parts, of different designs, for achieving precise, but yet adjustable, discoupling of such parts when the force of rotating torque exceeds that for which the machinery was designed.
Another object of this invention is the provision of a torque limiting device which incorporates spring means that may be varied in its quantity of usage so as to provide for major adjustments in the degree of torque that may be withstood by the coupler during its application.
In view of the foregoing, it is yet another object of this invention to provide a retainer in the form of a threaded nut that biases against the aforesaid spring means for furnishing a fine adjustment in the degree of torque being withstood by this coupler before its disengagement.
Yet a further object of this invention is the provision of the usage of a combination of bearing means, preferably in the form of ball bearings, and tapered pins, that function to insure connection of the rotating and rotatable parts of machinery together, but which bearings and pins flexurally disconnect from their seats when the maximum torque force is reached and exceeded.
Yet another object of this invention is the provision of an overload coupling which incorporates rather few functioning components, but yet is totally mechanically operative, and does not rely upon any other extraneous force means, such as a magnetic force, other than its purely mechanical coupling which disengages under the influence of excessively applied torque.
A further object of this invention is the provision of a torque limiting overload coupling which is relatively fascile in its adjustment for attaining precise settings for accommodating applied torque forces during usage of machinery.
A further object is to attain a precise repositioning in register between the rotatable and rotating components of a machine.
Another object is to attain a highly reliable operating coupler that is capable of functioning even in the presence of fretting.
These and other objects will become more apparent to those skilled in the art upon reviewing the summary of this invention, and upon undertaking a study of its preferred embodiment in view of the drawings.
SUMMARY OF THE INVENTION
This invention contemplates the construction of a torque limiting device for furnishing a totally mechanically operative overload coupling for, as previously mentioned, attaching rotating and rotatable parts of machinery together. And, due to the unique construction of the interrelated components of this invention, the coupling can be easily adjusted, to within relatively precise limits of the quantity of force or torque that may be accommodated by such machinery before disengagement of the coupling occurs, therefore functioning as a safety mechanism for industrial machinery and tools.
The invention is designed for interconnecting the shaft of a rotating part with the shaft of a rotatable part, or may interconnect a pair of similar type flanges or dials together, or may couple a combination of a shaft to flange or dial, or vice versa. In any event, and throughout the analysis of this invention, it is likely that the legend given to the rotating part, and the rotatable part, of this invention may be interchanged, in that a rotatable part may actually be driven by a prime mover for effecting a revolving of what may be herein described as the rotating component. In any event, the torque limiting coupler of this invention is reversible in its disposition of use within the scope of this invention.
The coupler includes first and second connecting mean that secure respectively to either the rotating and rotatable parts of standard machinery, such as of an indexing machine. It may be commented that the precision essentially derived from an indexing machine relies significantly upon the critical operation of its precisionally machined components, such as in its integral roller gear indexing drive, and if too much force or back pressure is exerted upon such a drive, it may have a tendency to distort or damage its fine construction, rendering it totally inoperative for its intended usage. Therefore, the torque limiting means of this invention, and its first and second connecting means, which are intervened and normally displaced apart by the agency of seated bearing means and cooperating tapering pins, furnishes a rather precisely regulated coupler that can be predetermined for disconnection when a fairly exact degree of torque is encountered. All this can occur without any relative displacement between the said connecting means. The invention has been designed wherein one of its connecting means is readily exposed for securement with either the drive shaft or flange of the prime mover, or from a speed reducer or indexing drive, with all of the other primary components of the coupler being associated with the other rotating or rotatable part of the machinery. Thus, the disassembly or separation of this coupler can easily be accommodated by a simple separation of the components, and without necessitating a piece-mean disassembly of its components, which ordinarily may be easily scattered, upon its disengagement. But, as previously explained, the one connecting means may be directly fastened with either the rotating or rotatable part of the machinery, while the other connecting means, having all of the operating components of this coupler associated therewith, connects wit the remaining machine rotating or rotatable parts.
The two connecting means of this coupler are intervened by an intermediate bearing means, as aforesaid, which includes a retainer having a series of apertures therein, and in which bearings, such as bail bearings, may be seated and held therein between the two said connecting means. The bearings may normally rest directly within mating seats formed within the adjacent surface of one of the connecting means, or within a special adapter formed having precision seats and into which their respective ball bearing may customarily be arranged during normal operation of machinery, with force transmission being effected routinely through this overload coupling device provided the torque limits for the coupler is not exceeded. And, the juxtaposed and other connecting means cooperates with a diaphragm, which may be more specifically identified as a bearing seating means which rests against this other connecting means, and which is biased through the agency of a clamp plate which is urged by a spring means for normally biasing the bearing means into a seating engagement within its respective seating means formed either within the first and second connector means, or their respectively associated bearing seat adapter and diaphragmed like bearing seat. And, since bearings alone seated intermediate two connectors normally do not furnish sufficient force resisting connection between components within an overload coupling for use within major machinery, it has been found desirable to incorporate additional force absorbing means, in the form of pins, that mate within aligned tapered apertures in the diaphragm bearinged seat so as to insure the simultaneous rotation between the rotating and rotatable parts of the machinery, and only when major forces, in the category of 2000 to 10,000 inch-pounds of force are encountered, does the diaphragmed bearinged seat gradually ease away from the bearings and the tapered pins for eventually furnishing rather precisely controlled decoupling of the overload device at a predetermined instance.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 discloses an isometric view of the torque limiting overload coupling of this invention;
FIG. 2 furnishes a right side view of the coupler shown in FIG. 1;
FIG. 3 is a partial sectional side view of the coupler;
FIG. 4 furnishes a vertical sectional view of the right side connecting means of the coupler shown in FIG. 3;
FIG. 5 is a left end view of the connecting means shown in FIG. 4;
FIG. 6 is an exploded view of the right side connecting means and the various coupler operating components that are disposed thereon during its assembly;
FIG. 7 provides an end view of the diaphragm means of the coupler;
FIG. 8 provides a partial vertical sectional view from the side of the diaphragm means shown in FIG. 7;
FIG. 9 provides a partial vertical sectional view from the side of a slightly modified coupler of this inventionl; and
FIG. 10 provides a right side end view of the coupler shown in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In referring to the drawings, and in particular FIGS. 1 through 3, there is shown the overload coupling 1 of this invention. This invention, as shown in this particular embodiment, connects with a pair of shafts 2 and 3, of an item of machinery, and which shafts may be identified as the rotating and rotatably parts interconnected through the agency of the coupling device of this invention. As previously explained, either the shaft 2 or the shaft 3 may comprise the rotating member, as being driven from a prime mover, while the other of said shaft may be the rotatable part, and which may connect to the item of machinery to be turned, such as, for example, an indexing table.
The shaft 2 is disposed for coupling by means of the bushing 4, to the connecting means 5, while the shaft 3 secures by means of the bushing 6 with the connecting means 7 of this coupler. A dowel pin 8 secures an adapter means 9 to the connecting means 5, and this adapter is provided with a series of seats, as at 10, spacedly around its circumference and which are designed for seating of the bearing 11 held by the retainer 12 around the circumference of the coupling device.
The connecting means 7 has a series of pins 13 spacedly arranged within apertures around its midcircumference, and these pins, at their forward ends, are tapered, as at 14, and normally, snugly seat within a corresponding aperture, as at 15, located within a diaphragm type of bearing seating means 16. This seating means 16 also includes a series of beveled cavities, as at 17, therein for seating of the ball bearings 11, as previously explained. Once again, since there are a variety of these ball bearing provided around the circumference of the coupling, there will be a corresponding bearing seat, as at 10, provided within the adapter means 9, and a bearing seat 17, furnished within the diaphragm means 16, for each of the bearing 11, held by the retainer 12, intermediate these two connecting means 5 and 7.
As can also be seen in this FIG. 3, a clamp plate 18 is contiguous against the multibearing seated diaphragm means 16, and a spring 19 urges the said plate forcefully against the said diaphragm and its bearings 11 and the pins 13. An adjustment nut 20 having a socket set screw 21 therein, for tightening purposes, is threaded onto the end of the connecting means 7, and thereby can adjustably bias against the spring 19 for urging it against its contiguous plate 18 and the bearing means of this invention.
As shown in FIGS. 4 and 5, the connecting means 7 includes the series of the spaced apertures, as at 22, and into which the pins 13 insert, with there being approximately eight of said spaced apertures provided around the circumference of this connecting means. Obviously, other number of apertures 22, and corresponding pins 13, may be provided within the operation of this coupler, and in practice, as few as four pins have been found effective in the operations of this coupler. In addition, a series of counterbored holes 23 are also spacedly provided around the circumference of this connector, and useful for connecting a dial means to the same which may be associated with the driving means or driven component of the machinery in which this coupler is utilized.
The disposition of these various components during their assembly onto at least the first connecting means 7 or this invention is shown more clearly in FIG. 6. As can be seen, the connector 7 is integrally formed having its threaded end 24, and onto which the adjustment nut 20 threadedly engages at the final assembly and force withstanding adjustment of this coupler. The series of spaced apertures 22 formed around the circumference of the connecting means 7 are each disposed for reception of the tapered pins, one as shown at 13. The adapter means 9 is next insertable onto the connecting means 7, and freely fits thereon so that when disengagement of this coupler is effected, this adapter means, which is rigidly fastened or pinned to one of the rotating or rotatable parts of the machinery, will be reasonably free to turn upon disconnection of the coupler, as when an excessive torque is encountered. This adapter 9 includes a series of bearing seats 10 therein, and also include the additional apertures 24a and into which the dowel pins 8 may insert for retention of this rotating or rotatably part therewith, as previously described. Disposed for next insertion upon the connecting means 7, but being freely rotatable with respect thereto, is the retainer 12, having the spaced apertures 25 and into which the bearing means 11 insert to be captured, having then one exposed side being retained normally within the aligned bearing seats 10, of the adapter 9, as previously explained. The next item that inserts onto the connecting means 7 is the diaphragm means 16 having integrally formed therein the series of aligned bearing seats 17 that provide for seating of the other side of the plurality of ball bearings 11 therein for embracing them intermediate these two components 9 and 16 as explained. The tapered apertures 15 are also shown provided upon this diaphragmed bearing seat means. The clamp plate 18 next inserts contiguously against the back side of the diaphragm means 16, and is urged thereagainst, and therefore, provides for normal retention of the bearings seated within their respective seats of the adapter 9 and the diaphragm 16 under normal operating conditions of this coupler. A plurality of the spring means 19 are held by the adjustment nut 20 against the clamp plate 18, and these spring means have preferably been designed in the form of disc springs, with the number of disc springs utilized depending upon the degree of force that is required to be sustained by the coupler before it separates under overload conditions. Obviously, other forms of spring could be utilized for this spring means 19 of the invention, but disc springs of this type have been found to operate desirably under load conditions, and are more susceptible for ease of adjustment in the quantity of force that may be sustained by this coupler during operation of machinery. Finally, the bushing 6 may insert within the threaded end 24 of the connecting means 7, and therein key either a driving shaft or driven shaft during installation of this coupler.
FIGS. 7 and 8 disclose in greater detail the configuration of the diaphragm means 16, and as can be seen, there are six bearing seats 17 provided around its perimeter, each one designed for holding and supporting a side of one of the ball bearings 11. And, there are eight tapered apertures 15 provided therethrough, and into which the tapered ends of the pins 13 are normally inserted for providing retention of the connector means 5 and 7 together during normal installation and operations of the machinery, and within the specified limits of the torque for which this coupler has been adjusted to sustain without disconnection. As previously explained, the usage of bearings alone would not provide sufficient resistance for the coupler to withstand forces in these quantities, and therefore, the supplemental reinforcement of the coupler through the use of the tapered pins 13, seated within the tapered apertures 15 of the diaphragm means, provides for enhancement in the forces withstood by this coupler during its functioning within an item of industrial machinery. Thus, as heavier forces are encountered by this coupler during machinery operation, such forces, as they reach the adjusted limits for the coupler, causes a gradual separation between the adapter means 9 and the diaphragm 16. As this occurs, the diaphragm 16 gradually rises up from its seating upon the pins 13 until that condition prevails when the bearings 11 are totally removed from their said seats, and held in this separate condition by means of their unseated location. Such bearings may also be slightly less in diameter than the length of the tapered and projecting portions 14 of the pins 13 extending from the connecting means 7. Thus, when that condition is reached and prevails, the coupler will have broken down, thereby reducing or preventing further rotation of the rotatable part by means of the rotating part of the machinery. But, in addition, it is necessary that the coupler function precisely during that time when the torque is less than its designed overload limit. Thus, all of the components of this coupler, and particularly its bearings and tapered pins, must snugly fit their mating surfaces under routine operating conditions as within their respective bearing seats and tapered apertures. To insure this, the coupler is preloaded in its assembly, so as to prevent any backlash during its routine operations. This is achieved by providing for a slight clearance, something in the vicinity of one-one thousandth of an inch, between the bearings and their seats 17 and 10 when the coupler is initially assembled but before any spring pressure from the spring means 19 is urged upon the bearings. And, when spring pressure is then applied, the adapter plate and diaphragm means are then snugly urged into contiguous contact with the various bearings 11 and the tapered pins 13, thereby insuring a very tight and snug contiguous relationship between these components when the coupler is finally assembled for routine usage. Thus, when finally assembled, under the preloaded conditions as explained, the diaphragm 16 adds an element of flexurality to the coupler, in that it is free to flex and gradually separate under load conditions that are approaching an overload force, but reseat within itself as the load forces may be lessened. But, it may finally achieve a total disconnection when that designed overload force is finally encountered. And, as previously explained, the number of disc springs 19 applied onto the connecting means 7, and biased together and against the diaphragm 16 by means of the adjustment of the nut 20, generally determines the rather precise force that may be withstood by this coupler before it breaks down.
FIGS. 9 and 10 disclose a slight modification in this invention, and wherein its normal operating components, such as the connector 7 having the retainer 12 with its bearings 11, are held intermediate the adapter means 9 and the diaphragm 16 as previously explained. The adapter means 9 includes a series of threads, as at 26, so that the flange portion 27 of a driving member or driven member may be connected therewith so as to provide a rigid connection between this flange 27 and the adapter 9, for the same purposes as previously explained with the manner of attachment of the connecting means 5 to the adapter 9. Thus, in this particular embodiment, the one connecting means will comprise the flange 27, which will be associated with the coupler as a component of the machinery, thereby replacing the type of shaft connection 2 as explained with respect to the machinery parts disclosed in FIG. 1.
Various modifications to the structure and operation of this invention may be envisioned by those skilled in the art upon reviewing the subject matter of this disclosure. Such modifications, if within the spirit and scope of this invention, are intended to be protected by any patent issuing upon this invention. The description of the preferred embodiment set forth is provided for illustrative purposes only. For example, more or less than six bearing means 11 may be utilized in this coupler. | A torque limiting overload coupling for use in connecting rotating and rotatable parts together, first and second connectors couple the drive shaft to another shaft, or flange or dial of a machine, such as an indexing machine, a series of bearings are seated intermediate the pair of connectors with an adapter cooperating with one of the connectors for providing a seating of the said bearing, as at one side, while a diaphragm type bearing seat cooperates with spring means for biasing against the bearings and furnishing their seating as against the other connector, and one or more pins interconnect between the first connector and the diaphragmed bearing seat for insuring the simultaneous rotation of both connectors, and their connecting shafts, flanges, or dials, as during normal operation of the designed machinery. | 5 |
BACKGROUND
[0001] Products such as nail polish or other cosmetics are often offered by manufacturers and retailers in a variety of types and colors in order to meet the needs of consumers in the marketplace. The various types and colors are typically produced by manufacturers in advance and then distributed to retail stores or offered to consumers through other distribution channels. This can lead to rows and rows of products sitting on shelves and large quantities being held in inventory. This also requires manufacturers and retailers to attempt to predict the needs of consumers. This can be cumbersome because of the ever-changing state of fashion and the wide variety of preferences and needs of consumers.
[0002] Therefore, there exists in the marketplace a need to provide a wide assortment of cosmetics, such as nail polish, to consumers in the marketplace without the drawbacks of present methods and practices. The present disclosure describes a device and method of use that permits a consumer or a retailer to create a vast assortment of cosmetics, including nail polishes, that can be prepared according the specific needs of a consumer without the disadvantages associated with traditional methods of distribution and manufacturing.
[0003] The present disclosure provides, in one example, a mixing device that permits the creation of customized cosmetics without the need for specialized or cumbersome manufacturing equipment.
[0004] In another example, the present disclosure provides a mixing device that can efficiently and effectively mix a variety of different materials and additives.
[0005] It is still another example the present disclosure describes a mixing device that permits the mixing of the contents of a container without the need to add or remove any components such that the process is cleaner than and presents less risk of contamination than known mixing devices and methods.
BRIEF SUMMARY
[0006] In one embodiment of the present disclosure a portable mixing device includes a base with a retention wall defining a recess. The base also includes a driver with a driving magnet. In the recess, the portable mixing device includes a mixing chamber with a mixing element that includes a footing, a paddle and a mixing magnet. The mixing element is magnetically coupled to the driver to induce rotation of the mixing element.
[0007] In another embodiment the footing of the portable mixing device may include a peripheral surface that is located adjacent an inner surface of an enclosure of the mixing chamber. The peripheral surface maintains the mixing element's central position inside the enclosure.
[0008] In another embodiment the base of the portable mixing device may also include an activation switch located in the recess that activates the driver when the mixing chamber is positioned inside the recess.
[0009] In still another embodiment, the portable mixing device may include a collar that fits within the recess that includes a border that defines a pocket. The pocket is smaller in volume than the recess such that different size mixing chambers can be used with the base.
[0010] In still another embodiment, the mixing chamber of the portable mixing device is a nail polish container that includes a lid and a brush.
[0011] In another embodiment, the driver of the portable mixing device may be located in a central position in the bottom of the recess and be made of a low-friction material such that when the mixing chamber is positioned and held in the recess, the driver can spin and induce the mixing element to spin in order to mix the contents of the mixing chamber.
[0012] In another example of the present disclosure, a mixing chamber may include a mixing element with a footing, a paddle and a mixing magnet. the mixing chamber may also include an enclosure with a floor in which the mixing element can be removably positioned. The mixing chamber may also include a cap that can be secured to the top edge of the enclosure.
[0013] In another example, the footing of the mixing chamber is disc-shaped and the paddles are perpendicular to the footing.
[0014] In an example method of the present disclosure, a method of mixing nail polish may include adding a color component to a nail polish mixture inside an enclosure of a mixing chamber that includes a mixing element. The method also includes the steps of positioning the mixing chamber inside a recess of a base that includes a driver and mixing the color component and the nail polish mixture by causing the driver to spin the mixing element by magnetic coupling of the driver and the mixing element. The method may also include removing the mixing chamber from the base.
[0015] In another example method, a user may also actuate a motor connected to the driver by pressing the mixing chamber on an actuation switch inside the recess of the base.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings, wherein:
[0017] FIG. 1 is an illustration of one embodiment of a mixing device of the present disclosure.
[0018] FIG. 2 is an exploded view of the embodiment shown in FIG. 1 .
[0019] FIG. 3 is an illustration of one embodiment of a mixing chamber of the present disclosure.
[0020] FIG. 4 is an illustration of one embodiment of a nail polish container of the present disclosure.
[0021] FIG. 5 is an illustration of one embodiment of a base of the present disclosure.
[0022] FIG. 6 is an exploded view of one embodiment of a mixing chamber of the present disclosure.
[0023] FIG. 7 is an illustration of one embodiment of a mixing element of the present disclosure.
[0024] FIG. 8 is an illustration of another embodiment of a mixing element of the present disclosure.
[0025] FIG. 9 is an illustration of another embodiment of a mixing element of the present disclosure.
[0026] FIG. 10 is an illustration of another embodiment of a mixing element of the present disclosure.
[0027] FIG. 11 is an illustration of another embodiment of a mixing element of the present disclosure.
[0028] FIG. 12 is an illustration of another embodiment of a mixing element of the present disclosure.
[0029] FIG. 13 is an illustration of another embodiment of a mixing element of the present disclosure.
[0030] FIG. 14 is an illustration of another embodiment of a mixing element of the present disclosure.
[0031] FIG. 15 is an illustration of another embodiment of a mixing element of the present disclosure.
[0032] FIG. 16 is an illustration of another embodiment of a mixing element of the present disclosure.
[0033] FIG. 17 is an illustration of another embodiment of a mixing element of the present disclosure.
DETAILED DESCRIPTION
[0034] For the purposes of promoting and understanding the principles disclosed herein, references are now made to the preferred embodiments illustrated in the drawings and specific language is used to describe the same. It is nevertheless understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated device and such further applications of the principles disclosed as illustrated herein are contemplated as would normally occur to one skilled in the art to which this disclosure relates.
[0035] One embodiment of a nail polish mixing device is shown in FIG. 1 . The mixing device 100 may include base 102 , collar 104 , mixing chamber 106 , cap 108 , mixing element 110 and paddle 112 . As further shown in FIGS. 2 and 5 , mixing chamber 106 fits into base 102 and base 102 includes driver 204 . Driver 204 is coupled to a motor (not shown) that is housed inside of base 102 that spins driver 204 and in turn, mixes the contents of mixing chamber 106 as will be further explained. Base 102 , in this example, is generally cylindrical in shape with a tapered portion toward the top. Base 102 can, however, be of any suitable size and shape that can hold the motor, electronic circuitry, power source and other required elements to provide the functionality as will be described. In one example, base 102 is an injection molded plastic component with a removable pedestal 114 . Pedestal 114 can be removed in whole from base 102 or include a door or other access point in order to provide access to the internal components of base 102 . In other examples, base 102 can be made of metals, alloys or other composite materials.
[0036] Referring back to FIGS. 2 & 5 , base 102 may also include activation switch 202 , driver 204 , and retention wall 208 . In this embodiment, base 102 includes upstanding retention wall 208 that defines recess 216 . When in use during the mixing process, mixing chamber 106 is placed inside recess 216 and is surrounded by retention wall 208 . The bottom of recess 216 may be a circularly-shaped flat surface as shown in FIG. 5 . In this embodiment, the bottom of recess 216 includes both the stationary annular portion that extends from the outer edge of the bottom that meets circularly-shaped driver 204 . In this arrangement, the stationary annular portion of the bottom of recess 216 and the surface of driver 204 define a substantially co-planar surface on which mixing chamber 106 can be placed.
[0037] As further shown in FIG. 5 , activation switch 202 can be positioned near the outer edge the bottom of recess 216 . Activation switch 202 can be any suitable toggle switch that is coupled to the motor and other electrical circuitry inside of base 102 such that when mixing chamber 106 is inserted into recess 216 and a force is applied in a downward direction, driver 204 spins and in turn, the contents of mixing chamber 106 are mixed.
[0038] Mixing device 100 may also include collar 104 . Collar 104 , as shown in FIG. 2 , in an element configured to be received in recess 216 of base 102 . In instances where the outer diameter of mixing chamber 106 is significantly smaller than the inner diameter of recess 216 , collar 104 can be used to occupy the space that otherwise would exist. Collar 104 maintains mixing chamber 106 in a substantially centralized position in recess 216 so that driver 204 and mixing element 110 are aligned. In instances where mixing chamber 106 is larger and the outer diameter of mixing chamber 106 is only slightly smaller than the inner diameter of recess 216 there is no need for collar 104 . As can be seen in the example in FIG. 2 , collar 104 may include border 218 that defines pocket 220 . In this example, collar 104 is a cylindrically-shaped element and border 218 is an upstanding wall configured to receive a complimentary sized mixing chamber 106 . Collar 104 can be made of any suitable material such as a metal, plastic, composite or the like.
[0039] FIGS. 3 and 6 show one embodiment of mixing chamber 106 . Mixing chamber 106 may also include cap 108 and mixing element 110 . Mixing chamber 106 can be any suitable enclosure that can be used to hold the mixture of components that are to be mixed, such as nail polish and additives. As shown, mixing chamber 106 is cylindrically shaped with a threaded top on which cap 108 can be secured.
[0040] Mixing chamber 106 may also include mixing element 110 . In one embodiment, mixing element 110 fits inside enclosure 206 of mixing chamber 106 . In this embodiment, mixing element 110 includes footing 210 , paddle 212 and mixing magnet 214 . Footing 210 may be a disc-shaped horizontal element that is the base platform of mixing element 110 from which vertical paddle 112 is secured. As can be appreciated, as footing 210 spins around its center, paddle 112 mixes the mixture with any additives that may be present in enclosure 306 . In order to maintain mixing element 110 in a central position in enclosure 306 , the peripheral surface 302 of footing 210 has a smaller outer diameter than that of enclosure 306 defined by inner surface 304 . In this embodiment, mixing chamber 106 has a consistent outer diameter such that mixing element 110 can be easily inserted and removed from mixing chamber 106 as shown in the exploded view in FIG. 6 . Other profiles of mixing chamber 106 can also be used.
[0041] A second embodiment of mixing chamber 106 is shown in FIG. 4 . As shown, mixing chamber 106 is nail polish container 400 . In this embodiment, mixing element 406 is similar to the mixing element previously described such that is can be interchangeable with different style mixing chambers. Nail polish container 400 includes lid 402 with brush 404 connected thereto. Nail polish container 400 is configured so as to be inserted into base 102 for the mixing of custom nail polishes. The included lid 402 and brush 404 permits the user to mix a custom nail polish and then easily apply the custom polish without the need to transfer the polish between containers.
[0042] As described above, the mixing element 110 of mixing chamber 106 may also include mixing magnet 214 . In one embodiment, mixing element 110 includes two mixing magnets 214 positioned diametrically across from each other under paddle 212 . In this embodiment mixing magnets 214 are disc-shaped magnets attached through footing 210 such that they extend through footing 210 as shown in FIG. 6 . Other configurations of mixing element 110 may also be used that use different shapes for mixing magnet 214 and different quantities of mixing magnets 214 . As shown in FIG. 6 , mixing magnet may be a single bar magnet that extends across footing 910 . As shown in FIG. 8 and in FIG. 10 , mixing element 110 may include three or four mixing magnets respectively.
[0043] Mixing element 110 may also include different profiles and shapes of paddle 212 . Paddle 212 may include a single double-fin shaped profile as shown in FIG. 6 or may include other profiles. FIGS. 7-17 show various profiles and arrangements of paddle 112 . The different profiles of paddle 112 and of footing 210 and of mixing magnets 214 provide different advantages such as mixing efficiency, ease of manufacture, compatibility with different mixing chambers, stability, and compatibility with different mixtures of various viscosities.
[0044] As discussed above, driver 204 includes a driving magnet 206 and mixing element 110 includes a mixing magnet 214 . The driving magnet 206 and the mixing magnet 214 are matched with each other such that when the mixing chamber 106 with mixing element 110 contained inside is place in base 102 , the matched driving magnet 206 of driver 204 in base 102 couples with the mixing magnet 214 . In this manner, when driver 204 spins, the magnetic coupling of the magnets induces mixing element 110 to spin inside of mixing chamber 106 . Other configurations of mixing magnet 214 and driving magnet 206 can be used so long as the arrangement causes mixing element 110 to spin inside of mixing chamber 106 to mix the mixture and additives.
[0045] As shown in FIG. 2 , when mixing chamber 106 is inserted into base 102 , at least a portion of floor 308 of mixing chamber 106 sits on top of driver 204 . In addition, mixing element 110 sits on top of floor 308 inside of enclosure 306 . In order to permit the movement of both driver 204 and mixing element 110 relative to mixing chamber 106 , these two component, in one embodiment, are made of a low-friction material. This permits these component to spin in their respective locations relative to mixing chamber 106 . In one example, driver 204 and mixing element 110 are made of nylon material. Other materials with low-friction properties can also be used.
[0046] As discussed above, base 102 may include a motor, power source and other elements that spin driver 204 . In other embodiments, base 102 may include gearing and mechanical coupling to driver 204 whereby a hand crank or other manual movements of a user can be used to spin driver 204 and in turn, spin mixing element 110 .
[0047] In still other embodiments, base 102 may include a programmable logic controller (PLC) or hardware or software that can be used to control the speed, direction and time that driver 204 is induced to spin. Various spin profiles can be created and stored for use in different situation and for use with different liquids, cosmetics and materials. In one example, the PLC is programmed to spin automatically spin at a certain rate for a specified length of time and then to reverse and spin at the certain rate for a second specified length of time. The PLC then stops movement of driver 204 until the spin profile is started again. In other examples, an external control mechanism such as a cell phone or other device can be used to interact, store and program the PLC for further customization of the spin profiles.
[0048] Mixing device 100 can be used to mix a variety of different materials. One example use, as briefly discussed earlier, is in connection with a custom nail polish. A base nail polish can be mixed with different color elements, with textures, and with other additives, such as glitter, to obtain custom nail polish. The mixing device can also be used to mix paints and other cosmetic products such as, but not limited to, lotions, perfumes, lip gloss, creams and the like.
[0049] Various methods of mixing cosmetics are contemplated in the present disclosure. In one example method, a mixing element 110 is inserted into mixing chamber 106 . A user could then deposit a certain quantity of a base nail polish into mixing chamber 106 . A color component could then be added to the base nail polish. In addition, glitter or some other textured component could also be added. Mixing chamber 106 with the base nail polish and additives can then be inserted into recess 216 of base 102 . When a force is applied to mixing chamber 106 , activation switch 202 is depressed that. in turn, activates driver 204 to spin with a spin profile according to a user's choosing. The magnetic coupling between driver 204 and mixing element 110 induces mixing element 110 to also spin according to the spin profile. When the mixing is complete, driver 204 automatically stops or a user would cease applying a force to mixing chamber 106 to deactivate activation switch 202 . The mixing chamber 106 could then be removed from base 102 and the mixed nail polish would be ready for use.
[0050] Other methods could also be employed to use mixing device 100 . Other example methods could include a variation of the steps described above or involve performing the steps above in a different order.
[0051] While the particular preferred embodiments have been shown and described, it is obvious to those skilled in the art that changes and modifications may be made without departing from the teaching of the disclosure. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as limitation. The actual scope of the disclosure is intended to be defined in the following claims when viewed in their proper perspective based on the related art. | A portable mixing device may include a base that has a retention wall defining a recess and a driver that includes a driving magnet. The portable mixing device may further include a mixing chamber that can be positioned into the recess and removed therefrom. The mixing chamber may also include a mixing element with a footing, a paddle and a mixing magnet. The mixing magnet may magnetically couple to the driving magnet of the driver to induce rotation of the mixing element in the mixing chamber. | 1 |
[0001] This application claims the benefit under 35 USC 119 (e) of Provisional Application 62/030136 filed Jul. 29, 2014 and of Provisional Application 62/037884 filed Aug. 15, 2014 the disclosures of which are hereby incorporated by reference.
[0002] This invention relates to markings containing reflective glass which can be used on roadways or on signs such as road signs or commercial signs.
BACKGROUND OF THE INVENTION
[0003] Road surface markings are used on a road surface in order to convey official information. They can also be applied in other facilities used by vehicles to mark parking spaces or designate areas for other uses. Road surface markings are used on paved roadways to provide guidance and information to drivers and pedestrians.
[0004] Paint can be used, sometimes with additives such as retro-reflective glass beads is generally used to mark travel lanes. It is also used to mark spaces in parking lots or special purpose spaces for disabled parking, loading zones, or time-restricted parking areas. Colors for these applications vary by locality. Paint is a low-cost marking and has been in widespread use since approximately the early 1950s.
[0005] The paint consists of three main components: pigments, resins or binders, and water or solvents. Pigments are finely grounded materials that give out colors or block out the surface beneath it. They may contain other materials such as UV stabilizer, and fillers which bring out the color pigments to the required level. Resins or binders are the glue of the paint to bind pigment and glass beads together to the road surface. The resins for the water based paints are polyvinyl acetate latex, methyl methacrylate or acrylic resin. The resins for solvent based paints are linseed or soya oils and alkyd resins. The pigments and resins are mixed with water for water based paints and solvents for solvent based paints so that they can be applied onto the road surface. Solvents that are use can be naphtha, toluene, methanol, methylene chloride, and acetone. Due to environmental concerns, some jurisdictions has some restriction on the solvent based paints.
[0006] Epoxy can also be used which contains two parts which are a pigmented resin base and catalyst. The two parts are mixed in a specialized truck for epoxy marking application. The epoxy is then heated prior to spraying onto road surface. Retro-reflective glass beads are applied using a separate bead gun behind the epoxy spray gun. Typically, epoxy markings last about 4 years. Epoxy has been in use since the late 1970s and has gained popularity over the 1990s as the technology has become more affordable and reliable.
[0007] In U.S. Pat. No. 6,045,069 (Steed) issued Apr. 4, 2000 is disclosed a rotary mill for reduction of recycled glass to ground glass particles. The rotary mill comprises a primary reduction chamber, a secondary reduction chamber and an outlet chamber. Glass entering the primary reduction chamber is deflected by an impact rotor, which shatters the material and sends the resulting particles into a plurality of shatter bars. The shatter bars further reduce these particles and deflect them back towards the rotor so that the reduced particles encounter newly shattered material, causing further attrition. In addition, the rotary mill includes an exhaust fan arranged to generate an airflow from the primary reduction chamber, through the secondary reduction chamber and into the outlet chamber. This airflow carries the reduced particles into the secondary reduction chamber wherein the particles are thrown against reduction means. The reduction means are positioned between the secondary reduction chamber and the outlet chamber such that only particles below a certain size enter the outlet chamber. Material of sufficiently reduced size enters the outlet chamber wherein it is separated into fine particles and heavier particles. Specifically, the heavier particles fall out of the airflow and gather at the base of the outlet chamber until a sufficient weight accumulates to open the balance door which expels the heavy material from the rotary mill.
[0008] The particles generated by the above system tend to be much finer than conventional grinding systems so that the reflectivity of the ground material is improved.
SUMMARY OF THE INVENTION
[0009] According to the invention there is provided a method for providing reflective visible markings on a surface comprising:
applying onto the surface a base material which is liquid in an initial state for application and sets or cures to form a solid layer after application; the base material containing a filler material of ground glass.
[0012] Preferably the ground glass is impregnated with a colorant.
[0013] Preferably the ground glass is impregnated with the colorant in a process subsequent to grinding.
[0014] Preferably the ground glass is impregnated with a colorant in a process including heating the glass in ground form.
[0015] Preferably the ground glass includes a mixture of particles of different size.
[0016] Preferably the glass is ground from recycled glass material for example from plate glass or vehicle glass, or similar non-colored glass, since neither has color which can interfere with the coloring of the glass in the present process, although bottles can be used in some cases.
[0017] Preferably the ground glass is mixed through the base material.
[0018] Preferably the base material is colorless so that the color of the road markings is provided by the impregnated colorant. However the base material may be tinted or partly colored at the same color provided the reflection from the ground glass inside the layer of base material is not impeded by the colorant in the base material.
[0019] Preferably the ground glass is mixed through the base material so as to increase the hardness of the base material.
[0020] Preferably the ground glass is applied to the road way as a common material simultaneously with the base material.
[0021] Preferably the base material is cured with a catalyst such as epoxy.
[0022] Preferably the ground glass is formed by a grinding process as shown in the above US patent.
[0023] Preferably the markings are applied to a road way on the surface. However, the material can be applied in other locations, such as signs at the road way or other commercial signs.
[0024] When applied over existing markings, the base material and the glass filler both are transparent or colorless to show through an underlying marking over which the material is applied. That is preferably the base material and the filler contain no pigment.
[0025] Preferably the material includes a U/V resistant material to prevent fading of an underlying marking over which the material is applied.
[0026] Preferably the base material is a clear paint or varnish.
[0027] The invention also relates to a roadway when coated in markings with a reflective colored material as defined above.
[0028] The invention also relates to a method of coating a roadway with a reflective colored material comprising applying a material as defined above.
[0029] The invention also relates to a sign with underlying markings when coated with a reflective material as defined above.
[0030] The invention also relates to method of coating a sign with a reflective colored material comprising applying a material as defined above.
[0031] According to a further aspect of the invention there is provided a material for application to a surface to provide visible markings comprising:
a base material which is liquid in an initial state for application and sets or cures to form a solid layer after application; and a filler layer of glass; wherein both the base material and the filler material are transparent or colorless to show through an underlying marking over which the material is applied.
[0035] That is preferably the base material and the filler contain no pigment.
[0036] Preferably material includes a U/V resistant material to prevent fading of an underlying marking over which the material is applied.
[0037] The filler can be ground glass of a very fine characteristic manufactured by the above process or the filler can be bead glass manufactured from recycled material by melting the glass and passing it through a beading process which is well known.
[0038] Preferably the glass is ground to provide finer material and coarser material where the finer material is mixed into the base material and the coarser material is applied at the surface of the base material. It has been found in this regard that the irregular outer surface of the ground particles provide a significantly increased bond to the base material relative to spherical beads, so that the particles remain bound into the base material for a much longer time period. This avoids the situation where the conventional round or spherical beads break away and leave the subsequent holes containing moisture which can make the surface very slippery. Also the rough particles provide an increased traction effect for the exposed surface of the road markings.
[0039] Preferably the coarser material is applied separately onto the surface of the base material.
[0040] Preferably the glass is ground in a rotary mill where the coarser material is collected at a bottom of a discharge chamber and at least some of the finer material is collected in an air stream at a top of the discharge chamber.
[0041] In this arrangement preferably the material collected from the bottom of the discharge material is separated into a medium grind material for mixing with the fine material in the base material, a coarse grind material for application separately onto a surface of the base material and a return material for return to the rotary mill.
[0042] Preferably the base material is a clear paint or varnish.
[0043] Preferably the ground glass includes a mixture of particles of different size.
[0044] Preferably the glass is ground from recycled glass material for example from bottles.
[0045] Preferably the ground glass is mixed through the base material so as to increase the hardness of the base material.
[0046] Preferably the ground glass is applied simultaneously with the base material.
[0047] Preferably the base material is cured.
[0048] Preferably the base material is epoxy but other materials can be used.
[0049] Preferably the ground glass is formed by a grinding process as shown in the above US patent but other processes can be used.
[0050] The invention also provides a sign for providing visible markings including a substrate, a layer of a marking material over the substrate containing visibly distinguishing markings viewable by a person looking at a front face of the substrate and a material as defined above applied over the markings.
[0051] This protects the underlying markings of the sign and also can provide a reflective character to the sign.
[0052] In some cases the underlying markings use a coating such as paint or can be a layer plastics layer such as vinyl cut to form the markings and adhesively attached to the substrate.
[0053] Preferably the sign includes a mast for presenting the substrate to passing viewers.
[0054] Preferably the substrate is aluminum although other base materials such as those typically used for signs can be used.
[0055] The coating of the markings on the sign can be carried out on existing signs while in situ or while temporarily removed or the coating can be applied on new signs during manufacture. The coating will protect the underlying marking material whether that is itself an applied coating or more typically a plastics cut out sheet applied onto the base substrate. In both cases fading or wear can be reduced particularly if the UV protectant is included. The addition of the reflective glass in the coating makes the sign reflective in a manner which cannot be achieved using conventional materials. Bead glass can be used if preferred. Both the base material and the glass filler should be sufficiently transparent to allow the underlying color of the markings to be visible through the coating layer.
BRIEF DESCRIPTION OF THE FIGURES
[0056] FIG. 1 is a side view in cross-section of a rotary mill for use in the present invention.
[0057] FIG. 2 is a cross-sectional view on an enlarged scale of the rotary mill of FIG. 1 showing the relationship between the tips of the rotor and the feed chute.
[0058] FIG. 3 is a schematic illustration of the system of the present invention.
DETAILED DESCRIPTION
[0059] Referring to the drawing, a rotary mill 1 comprises a housing 10 , a material delivery system 12 and an exhaust fan 14 . The housing 10 comprises a rotor 16 , a primary reduction chamber 18 , a secondary reduction chamber 20 and an outlet chamber 22 , as shown in FIG. 1 .
[0060] The primary reduction chamber 18 comprises an inlet opening 24 , an intake guide surface 26 and a plurality of shatter bars 28 . The inlet opening 24 provides access to the interior of the housing 10 for incoming material and for airflow generated by the exhaust fan 14 . In this embodiment, the inlet opening 24 is positioned beneath the material delivery system 12 . The intake guide surface 26 is arranged to direct material from the inlet opening 24 into the swept area of the rotor 16 . The plurality of shatter bars 28 are arranged to further reduce particles deflected by the rotor 16 and direct these particles back toward the rotor 16 as described below.
[0061] The secondary reduction chamber 20 is connected to the primary reduction chamber 18 by a curved portion 30 as described below. The secondary reduction chamber 18 includes reduction elements 32 positioned between the secondary reduction chamber 20 and the outlet chamber 22 , arranged such that particles above a given size are prevented from entering the outlet chamber 22 . The reduction elements 32 may comprise staggered bars, perforated metal plates, wire screens or combinations thereof.
[0062] The outlet chamber 22 comprises an outlet opening 34 in one wall of the chamber 22 , a fan control flap 36 and a lower material outlet 38 . The outlet 34 comprises the exit from the housing 10 for fine particles and for airflow generated by the exhaust fan 14 as described below which generates an airflow through the chambers by injecting air at the inlet 24 as indicated at 14 A. The lower material outlet 38 comprises a balanced door 40 situated at the base of the outlet chamber 22 for removal of heavy particles. Specifically, once a mass of material equal to the balance weight has gathered, the balanced door 40 opens and expels the material from the housing 10 . The fan control flap 36 comprises a movable baffle 42 located within the outlet chamber 22 for controlling airflow through the housing 10 so that the amount and size of particles drawn off at the outlet 34 and the lower material outlet 38 may be varied as described below.
[0063] The rotor 16 is arranged for rotation within the housing 10 and is driven by a motor, the details of which are not shown as these will be obvious to one skilled in the art. The rotor 16 includes peripheral impact hammers 44 and is situated below the intake guide surface 26 . While a rotor that exposes more blades will move more air, durable construction and suitable mass for reducing incoming material conflict with ideal air moving capabilities. However, generation of airflow by the rotor 16 is not an important consideration due to the airflow generated by the exhaust fan 14 . Thus, the rotor 16 is arranged so that the impact hammers 44 have the largest mass possible within the swept area of the rotor 16 . In this embodiment, the rotor 16 includes three impact hammers 44 , although it is of note that the construction of the rotor 16 may vary greatly.
[0064] The exhaust fan 14 is arranged to produce an airflow through the housing. Specifically, the exhaust fan 14 connected to the fan outlet such that the airflow generated by the exhaust fan 14 is drawn into the housing 10 via the inlet opening 24 and is drawn out of the housing 10 via the outlet 34 . The details of the exhaust fan 14 are not shown as these will be obvious to one skilled in the art.
[0065] The material delivery system 12 transports material to the rotary mill 1 . In this embodiment, the material delivery system 12 comprises a conveyor 46 . For reasons that will become apparent, the rotary mill 1 cannot be “choke” loaded. As a result, computerized control of the conveyor 46 may be used to provide a steady input volume regardless of input material size. Specifically, rotor speed and airflow may be monitored to determine loading efficiency and this information may be used to control the power source driving the conveyor 46 . In this manner, the mass of material within the rotary mill 1 may be closely controlled so that attrition of material occurs at a steady rate.
[0066] In operation, the material to be reduced is transported by the conveyor 46 to the inlet opening 24 . The material passes therethrough onto the intake guide surface 26 at a speed at or near free fall. The intake guide surface 26 directs the material into the swept area of the impact hammers 44 of the rotor 16 . Of note is that the intake guide surface 26 is positioned such that a maximum amount of the kinetic energy generated by the rotor 16 is transferred to the material with minimal strain on the rotor 16 , so that the rotor 16 needs only to tip or bump the incoming material. This transfer of kinetic energy shatters the material along natural fault planes, producing smaller particles. The smaller particles are accelerated away from the rotor 16 and into the shatter bars 28 where further reductions occur as a result of collisions between the shatter bars 28 and the smaller particles. Of note is that the shatter bars 28 do not have to be of massive structure or unusual hardness because of the reduced size of the particles. The shatter bars 28 also direct the smaller particles back towards the swept area of the rotor 16 where, in a continuous feed situation, the smaller particles encounter new particles produced by the impact hammers 44 of the rotor 16 striking newly introduced material and these secondary impacts between reflected material and recently shattered material result in further reduced particles. Of note is that the rotor 16 causes a localized increase in the pressure of the airflow generated by the exhaust fan 14 . This forces entrained particles, which are naturally quite abrasive, away from the housing 10 , thereby drastically reducing scrubbing and wear on the rotary mill 1 . Furthermore, the reduced particles are swept by the airflow drawn through the housing generated by the exhaust fan 14 around the curved portion 30 into the secondary reduction chamber 20 .
[0067] As noted above, the curved portion 30 is arranged such that the airflow generated by the exhaust fan 14 directs the reduced particles toward the reduction elements 32 in the secondary reduction chamber 20 . As noted above, the reduction elements 32 are arranged such that only particles below a given size, or fine particles, pass through the reduction elements 32 and enter the outlet chamber 22 while oversized particles are directed back into the flow of reduced particles leaving the rotor path. Thus, the reduction elements 32 provide the particle size control, forming a restriction in the path that material follows through the housing 10 . Furthermore, the close, staggered configuration of the reduction elements 32 causes the airflow generated by the exhaust fan 14 to change direction rapidly several times before being drawn out of the secondary impact chamber 20 . This turbulent airflow prevents particle build-up from occurring on the reduction elements 32 . Of note is that the position and orientation of the reduction elements 32 is not critical as they may be placed either vertically or horizontally with little or no change in their effectiveness.
[0068] Upon entry into the outlet chamber 22 , the fine particles remain in the airflow generated by the exhaust fan 14 and are drawn off through the outlet 34 while heavy particles fall to the lower material outlet 38 until a mass accumulates that equals the balance weight, which opens the balanced door 40 and releases the heavy particles. The balanced door 40 ensures that air is drawn into the rotary mill 1 only through the inlet opening 24 , thereby keeping a negative pressure on all parts of the housing 10 and serving as a form of dust control. Furthermore, the position of the movable baffle 42 within the outlet chamber 22 may be altered to vary the intensity of the airflow, thereby varying the amount and size of the particles drawn off through the outlet 34 . In cases where this fine product has value, the flow of fine particles may, for example, be blown into a bag house or cyclone or may be turned into a slurry by the addition of a water spray. Furthermore, the heavy material which exits the lower opening can be fed into any suitable classification machinery for further processing. Thus, this arrangement also serves as a simple means of material classification.
[0069] Of note is that the position of the rotor 16 within the housing 10 is quite critical. In this embodiment, a clearance of 0.125 inches is optimum, wherein clearance refers to the ideal spacing between the rotor 16 and the housing 10 as well as the clearance between the impact hammers 44 and the housing 10 . if too much clearance is allowed, turbulence occurs and entrained particles build up which greatly increase the wear on the rotary mill 1 .
[0070] The importance of having a constant and steady flow of incoming material can be shown when a large particle is introduced and allowed to pass through the rotary mill 1 alone. The resulting pile of reduced material consists of a light scattering of larger particles on the top and bottom of a cross section with the majority in the center finely pulverized, as there are few particles to carry out the attrition process. However, with a constant, regulated flow of input material, there is a steady impingement between fractured particles and the particle size distribution is more even.
[0071] Clearly, time of material residency is an important factor in the successful operation of the above-described rotary mill 1 . However, the tendency to return particles to the new product flow can cause a buildup of material in the system. This has been overcome by the addition of a supplementary airflow generated by the exhaust fan 14 . The exhaust fan 14 creates a path of steadily moving air from the inlet opening 24 to the outlet 34 . Furthermore, the airflow overcomes turbulence created by the rotor 16 and ensures that all material continues to follow the desired path through the rotary mill 1 .
[0072] The housing 10 thus provides the impact chamber 18 defined within the housing with the rotor 16 mounted in the impact chamber 18 of the housing 10 rotatable about a longitudinal axis 16 A of the rotor 16 . The impact chamber 18 of the housing has a peripheral wall 18 A which forms generally a cylinder surrounding the axis 16 A of the rotor.
[0073] The feed opening 24 in the peripheral wall 18 A of the impact chamber forms a space in the cylindrical wall defined by edges 18 B and 18 C. The feed opening is arranged for deposit of the feed material onto the rotor so that rotation of the rotor acts to throw the solid materials against the peripheral wall 18 A.
[0074] The rotor 16 has a plurality of axially extending, angularly spaced impact hammers 44 at its periphery for rotation about the axis 16 A of the rotor which is transverse to the feed opening 24 so that the materials are fed generally radially inwardly toward the axis.
[0075] The rotor 16 is positioned relative to the feed opening such that the impact hammers 44 impact and deflect the solid materials entering through the feed opening, thereby fragmenting the solid materials to form finer and coarser particles and throw the particles outwardly toward the plurality of shatter bars 28 located at the peripheral wall 18 A of the impact chamber arranged such that the shatter bars contact the deflected solid materials, thereby further fragmenting the solid material into said particles. The shatter bars extend parallel to the axis and are arranged at angularly spaced positions around the axis.
[0076] The second outlet chamber 22 is defined within the housing downstream of the rotor 16 with the first impact chamber and the second outlet chamber being connected by the chamber 20 and the separate elements 32 so that the particles pass from the first chamber 18 to the second chamber 22 .
[0077] The finer particle outlet duct 34 is connected to the outlet chamber 22 and is arranged to so that the airstream acts to extract the particles from the chamber 22 to a separator outside the outlet 34 . The coarser particles are collected at the bottom discharge 38 for allowing release of coarser particles from a bottom of the outlet chamber.
[0078] The guide surface 26 forms an inclined guide wall at the feed opening 24 starting at the edge 18 C in the peripheral wall of the impact chamber which is directed from the opening toward the rotor 16 . The guide wall 26 forms a planar surface 26 A which is inclined downwardly into the impact chamber 18 and transversely across the opening 24 so that the solid material falling from the conveyor 46 slides along the guide wall surface 26 A into the chamber to the rotor. A bottom edge 26 B of the guide wall is located closely adjacent the impact hammers 44 as they rotate with the rotor 16 so that the solid material is fed off the bottom edge onto the impact hammers. Each of the impact hammers has along its axial length a leading blade element 44 A carried on a support 44 B of the impact hammer 44 . The leading blade element, when viewed in the cross-section of FIG. 2 extends generally radially outwardly of the axis of the rotor from an inner edge 44 C to an outer edge 44 D which passes closely adjacent the edge 26 B. Thus the blade element 44 A forms a leading or front face 44 E so as to engage and carry the solid material angularly forwardly around the axis of the rotor as it falls from the bottom edge 26 B.
[0079] The leading blade elements 44 A are formed of a hardened steel material harder than the support 44 B of the impact hammer. As previously explained, the impact hammers 44 are arranged to form elements of a large mass so that the support of the impact hammer comprises a metal block extending longitudinally of the rotor and radially outwardly of the axis so that the leading blade element is mounted on a front face of the block.
[0080] The hardened steel material is an iron based steel overlay wear plate material with a near nanoscale submicron microstructure. This provides a 68 to 71 HRc single and double pass deposit and maintains a high hardness after exposure to high temperatures. This provides an exceptional resistance to severe sliding abrasion ad a toughness equivalent to 400 Brinell Q&T plate. It provides a forming or cutting response similar to standard chrome carbide plate. This is a steel alloy with a unique glass forming chemistry that allow high undercooling to be achieved during application. This results in a considerable refinement of the crystalline microstructure to a near nanosize range. It has a density of the order of 7.36 g/cm3.
[0081] Contents are as follows:
[0000]
Chromium 25%
Boron 10%
Molybdenum 10%
Niobium 10%
Manganese 5%
Silicon 5%
Carbon 2%
Iron balance
[0082] The leading blade element has a planar front face lying which is inclined relative to a bottom portion of the guide surface at the bottom edge at the location around the axis when the front face passes the bottom edge so that the outer edge 44 D of the front face is angularly advanced relative to the inner edge 44 C.
[0083] In order to improve the fracturing of the particles, the shatter bars are also formed of the same hardened steel material.
[0084] As shown in FIG. 3 , the above grinding machine is used to generate ground glass from waste glass materials 60 . This generates ground materials of different grade of particle size from the size of crystals to fine powder. This includes fine materials 61 , medium materials 62 , coarse materials 63 and oversize materials 64 . The materials fine and medium materials 61 , 62 are mixed in a chamber 65 with a base material from a supply 66 such as epoxy which is liquid in an initial state for application and sets or cures to form a solid layer after application.
[0085] In a process after the grinding as shown at 67 including heating in a suitable container, the ground glass is impregnated with a colorant.
[0086] The base material is colorless so that, when the ground glass is mixed through the base material, the color of the road markings is provided by the impregnated or applied colorant and the base material does not impede or hide the reflection of light from the glass particles within the base material.
[0087] The mixing of the ground glass through the base material acts to increase the hardness of the base material.
[0088] The base material with the ground glass admixed therein is applied simultaneously by a spray coating or brush coating process shown schematically at 68 onto a road surface and the base material 70 is cured.
[0089] Thus there is provided a coloring system 67 where the fine and medium ground glass 61 , 62 is impregnated or coated with a colorant and a second coloring system where the coarse material 63 is colored.
[0090] The mixing chamber 65 receives the colored materials 61 , 62 for mixing the particles into the base material 66 where the finer material is mixed into the base material. As shown at 71 , the colored coarser material 63 is applied on the surface of the base material 70 on the road surface.
[0091] As explained previously the coarser material 72 is collected at a bottom of a discharge chamber 22 and at least some of the finer material 61 is collected in an air stream at opening 34 at a top of the discharge chamber 22 .
[0092] The material 72 collected from the bottom of the discharge material is separated at a separator 1 into a medium grind material 62 for mixing with the fine material in the base material 66 and a coarse grind material 73 . The material 73 is fed to a second separator 2 where it is separated into the material 63 for application separately onto a surface of the base material and the oversize material 64 as a return material for return to the rotary mill.
[0093] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | Reflective visible markings on a road or sign surface are formed by applying onto the surface a base material which is liquid in an initial state for application and sets or cures to form a solid layer after application where the base material contains a fine/medium filler material of glass ground from recycled materials in a rotary mill. Coarse material from the grinder is separated out and supplied as a separate material to be applied onto the surface of the layer of base material and fine ground glass. The base material can be colored to provide the color required and the base material transparent or both can be transparent and the color provided by the underlying layer. | 1 |
FIELD OF THE INVENTION
This invention relates to marine structures and, more particularly, to an apparatus and method for supporting a marine structure on a soft, unconsolidated underwater floor during the installation of the structure.
BACKGROUND OF THE INVENTION
Various types of structures are used to extract oil and gas from offshore reservoirs. Most of these structures include a horizontal working platform that is supported at a safe distance above the water's surface by a support device. These support devices include floatation devices that are held in place with anchors, temporarily installed submergible devices, and permanently installed submergible devices. A typical permanently installed support device for an offshore platform consists of long piles that are driven into the underwater floor using a jacket.
The jacket of an offshore platform is that portion of the platform that rests on the underwater floor and through which piles are driven to permanently support the entire platform. It includes hollow pile sleeves that serve as guides for driving the piles and that assure that each pile will be properly placed. In addition to the pile sleeves, the jacket includes many horizontal, vertical, and diagonal supports that provide support for the piles against lateral loads.
Many offshore areas have very soft, unconsolidated underwater floors, which present challenging problems with regard to jacket installation. In particular, after the jacket has been lowered to the sea floor, it is often very difficult to perform the pile driving operations since the jacket tends to sink into the soft mud around the area of the jacket surrounding the pile that is currently being driven. This problem is typically resolved by attaching mudmats to the bottom of the jacket.
Mudmats are used to support the jacket structure of an offshore platform during installation of the platform. In particular, the mudmats have a large area and are thereby able to distribute the load of the jacket over that large area. This allows the jacket to stand on the soft underwater floor and remain stable during the pile driving operations, which typically last 3 to 4 days, but may last as long as three weeks during problematic installations. Mudmats, thus, are an integral part of the mudline framing plane, which is the lowest level of framing in the jacket.
Conventional steel mudmats consist of the major steel pipe members of the mudline framing plane, the mudmat skin or planking, and the integral mudmat framing beams (which support the mudmat planking and which arc typically steel wide flange beams, but may also be steel pipe). Conventional mudmat planking is typically flat steel plate, stiffened steel plate, or crimped steel plate or sheet piling.
There are several disadvantages to using conventional steel skinned mudmats. First, the steel skin for the mudmats is heavy (typically 15.3 psf in air and 13.3 psf submerged). Second, since conventional mudmats are made of steel, they must be protected cathodically. This need for cathodic protection is present despite the mudmats' short useful life since conventional mudmats continue to draft from the platform's cathodic protection after their usefulness has ended. Third, due to their need for cathodic protection, conventional steel mudmats require the placement of additional anodes even when the mudmats are no longer serving any useful purpose. Each additional anode increases the cost of the mudmat system by about $1500 and increases the weight of the jacket by about 900 pounds.
Thus, there is a need for a mudmat that is made of a non-corroding material and hence does not require as much cathodic protection. Further, such mudmats should preferably have a high flexural strength and be lightweight.
Accordingly, it is an object of the present invention to provide a mudmat that does not require as much cathodic protection, has a high flexural strength, and that is lighter than conventional mudmats.
SUMMARY OF THE INVENTION
In accordance with the present invention, a fiberglass mudmat assembly is provided that meets the requirements listed above. In an embodiment of the invention, a fiberglass mudmat is provided having at least one fiberglass plank, a mudline framing plane that is attached to and provides support for the fiberglass plank or planks, and has integral mudmat framing beams that are attached to and provide support for the fiberglass plank or planks.
The present invention also provides for a mudmat assembly for supporting a portion of a subsea offshore platform on a soft, unconsolidated underwater surface. The mudmat assembly includes a plurality of fiberglass planks; a plurality of supporting beams; a mechanism for attaching said fiberglass planks to said framing beams; a plurality of integral framing beams; and, a mechanism for attaching said fiberglass planks to said integral framing beams.
A method is provided for the construction of an assembly that supports a jacket on a soft unconsolidated underwater surface during the installation of an offshore platform. The steps of the method consists of providing a jacket with a plurality of pile sleeves, providing a plurality of fiberglass mudmats, and supporting the pile sleeves with fiberglass mudmats.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which like reference numbers indicate like features, and wherein:
FIG. 1 illustrates a top plan view of a fiberglass mudmat assembly according to the present invention;
FIG. 2 illustrates a bottom plan view of the fiberglass mudmat assembly of FIG. 1;
FIG. 3 illustrates a cross sectional view of a section of the fiberglass mudmat assembly taken along line 3 — 3 of FIG. 1;
FIG. 4 illustrates a cross sectional view of a section of the fiberglass mudmat assembly taken along line 4 — 4 of FIG. 1;
FIG. 5 illustrates a cross sectional view of a section of the fiberglass mudmat assembly taken along line 5 — 5 of FIG. 1;
FIG. 6 illustrates a side plan view of the fiberglass mudmat planking of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to a fiberglass mudmat assembly 10 that is used in the construction of offshore oil and gas platforms. The mudmat assembly 10 is constructed with fiberglass mudmat planking 12 that is supported by a mudline framing plane 14 , as illustrated in FIG. 1 . The framing plane 14 can be formed with edge steel pipes 16 and an optional center steel member 18 that supports the mudmat planking 12 and integral framing beams 20 . In one embodiment, the fiberglass planks 12 are supported by edge brackets 22 attached to edge pipes 16 , by bottom brackets 24 on framing beams 20 , and by center brackets 26 attached to center member 18 , as illustrated in FIG. 2 .
Although the framing plane 14 is illustrated as being generally rectangular in FIG. 1 and FIG. 2, many different configurations are possible with various (possibly non-rectangular) shapes and different numbers and types of edge and center pipes. Similarly, different configurations of the framing beams 20 can be used in accordance with the present invention. The dimensions of the mudmat assembly typically can range from about 10 feet×10 feet to 50 feet×50 feet. The weight of the fiberglass mudmat assembly is typically 12-15 psf in air and 10-15 psf submerged.
Edge brackets 22 and framing beams 20 provide support to planking 12 in which edge bracket 22 is attached to edge pipe 16 (FIG. 3 ). In one illustrated embodiment, the framing beam 20 provides an upper bracket 28 and a lower bracket 30 into which the planking 12 is inserted (FIG. 4 ). Also, as shown in FIG. 5, center pipes 18 can be provided with upper and lower brackets 32 , 34 respectively, in order to provide additional support for planking 12 .
The fiberglass mudmat plank 12 according to the present invention is formed from a coated plate fiberglass laminate. The fiberglass planking 12 can be manufactured by a pultrusion process known to one skilled in the art. A pultruded fiberglass structural shape consists of reinforcing fibers and resin. The fiber reinforcement provides structural stiffness, and the resin provides ultra-violet resistance, chemical resistance, impact resistance, and fire resistance, as well as resistance to other environmental factors. Resins typically contain fillers to assist in achieving an intended performance characteristic. Reinforcing fibers consist of continuous strand mat and continuous strand roving. The pultrusion process is complete once the reinforcing fibers are coupled with the resin and a surfacing veil. Typical structural shapes contain from 45% to 75% reinforcement by weight.
A variety of continuous and woven reinforcement fibers are commonly used in fiberglass pultrusions including primarily E-Glass, S-Glass, aramid, and carbon. The most commonly used reinforcement is E-Glass. Other reinforcements are more costly, and hence are less commonly used in construction. E-Glass has a density of 0.094 lbs/in 3 , a tensile strength of 500,000 psi, a tensile modulus of 10.5×10 6 psi, and a 4.8% elongation to break. S-Glass has a density of 0.090 lbs/in 3 , a tensile strength of 665,000 psi, a tensile modulus of 9.0×10 6 psi, and a 2.3% elongation to break. Aramid has a density of 0.053 lbs/in 3 , a tensile strength of 400,000 psi, a tensile modulus of 9.0×10 6 psi, and a 2.3% elongation to break. Carbon has a density of 0.064 lbs/in 3 , a tensile strength between 275,000 and 450,000 psi, a tensile modulus between 33×10 6 and 55×10 6 psi, and an elongation to break between 0.6% and 1.2%.
Continuous strand mat consists of long glass fibers that are intertwined and bound with a small amount of resin, called a binder. It provides the most economical method of obtaining a high degree of transverse or bi-directional strength characteristics. These mats are layered with roving, and this process forms the basic composition found in most pultruded products. The ratio of mat to roving determines the relationship of transverse to longitudinal strength characteristics. In continuous strand roving, each strand contains from 800 to 4,000 fiber filaments. Many strands are used in each pultrusion profile. This roving provides the high longitudinal strength of the pultruded product. The amount and location of these “rovings” can and does alter the performance of the product. Roving also provides the tensile strength needed to pull the other reinforcements through the manufacturing die.
Since pultrusion is a low-pressure process, fiberglass reinforcements normally appear close to the surface of the product. This can affect appearance, corrosion resistance, and handling of the products. Surface veils can be added to the laminate construction, and, when used, displace the reinforcement from the surface of the profile, thereby creating a resin-rich surface. The two most commonly used veils are E-Glass and polyester.
Resin formulations typically consist of polyesters, vinyl esters, and epoxies. Further, they can be chosen to be either fire retardant or non-fire retardant. Polyesters and vinyl esters are the two primary resins used in the pultrusion process. Epoxy resins are typically used wit carbon fiber reinforcements in applications where higher strength and stiffness characteristics are required. Epoxies can also be used with E-Glass for improved physical properties. Polyester resin has a tensile strength of 11,200 psi, an elongation of 4.5%, a flexural strength of 17,800 psi, a flexural modulus of 0.43×10 6 psi, a heat distortion temperature of 160° F., and a short beam shear of 4,500 psi. PULTEX® Series 1525 is a fire retardant polyester resin manufactured by Creative Pultrusions, Inc. of Alum Bank, Pa. It possesses a flame spread rating of 25 or less as determined by the ASTM E-84 Tunnel Test, while maintaining good chemical resistance combined with high mechanical and electrical properties. This product is commonly used offshore where fire resistance and moderate corrosion resistance are key elements in the design. For example, it is commonly used in fire retardant structures used offshore such as wellhead access platforms and cable trays.
The width and height of each mudmat plank 12 can vary according to the requirements of the jacket structure. In one preferred embodiment, a fiberglass mudmat plank 12 can be constructed having a width of generally about 10¼ inches across, a height of generally about 1⅞ inches, and various lengths as required by the designer. However, other widths and heights can be used. As illustrated in FIG. 6, each plank 12 has a horizontal planar surface 36 and a plurality of interior vertical surfaces 38 that are approximately normal to planar surface 36 and have flanged ends 40 . Each plank 12 has two exterior vertical surfaces 42 approximately normal to planar surface 12 and partially flanged ends 44 . The small flanges add strength and spread the load out over a greater contact area.
In one embodiment of the present invention, the fiberglass planking 12 has a flexural strength between 60 and 80 ksi. As a result, the fiberglass planking 12 is able to span a longer unsupported distance than unstiffened flat steel plate, thus requiring fewer integral framing beams 20 . This reduction in framing beams 20 results in a lower fabrication cost due to the decreased number of required connections. Further, the amount of steel tonnage used is reduced, which produces additional material cost savings.
Thus, the present invention provides a mudmat that does not require as much cathodic protection, has a high flexural strength, and that is lighter than conventional mudmats. Additionally, tremendous cost savings can be realized by using the fiberglass planking 12 , of the subject invention that is substantially lighter than conventional steel plate mudmat planking. For example, should the total lift weight of the entire jacket be on the “bubble” when determining a derrick barge's ability to lift and set the jacket, a substantial weight savings could mean that a smaller derrick barge could be used to install the jacket instead of the relatively larger derrick barge required for a conventional installation. This ability to use a smaller barge could result in cost savings up to one million dollars in some situations.
All of the methods and/or apparatus disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the devices and methods of this invention have been described in terms of specific embodiments, it will be apparent to those of skill in the art that variations may be applied to the methods and/or apparatus and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the invention. Therefore, all such substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims. | A mudmat assembly for supporting a portion of a subsea offshore platform on a soft, unconsolidated underwater surface is described. The mudmat assembly includes at least one fiberglass plank, a mudline framing plane that is attached to and provides support for the fiberglass plank, and integral framing beams attached to and providing support for the fiberglass plank. The fiberglass mudmat assembly of the present invention requires minimal cathodic protection, has a high flexural strength, and is lighter than conventional mudmats. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Australian Patent Application No. AU 2003903841, filed on May 24, 2003.
All of the foregoing applications, as well as all documents cited in the foregoing applications (“application documents”) and all documents cited or referenced in the application documents are incorporated herein by reference. Also, all documents cited in this application (“herein-cited documents”) and all documents cited or referenced in herein-cited documents are incorporated herein by reference. In addition, any manufacturer's instructions or catalogues for any products cited or mentioned in each of the application documents or herein-cited documents are incorporated by reference. Documents incorporated by reference into this text or any teachings therein can be used in the practice of this invention. Documents incorporated by reference into this text are not admitted to be prior art.
FIELD OF THE INVENTION
The invention relates to a fodder radish. More particularly, a fodder radish ( Raphanus species) suitable for use as a multiple grazing fodder crop for livestock is provided. The invention also relates to the seeds, and to the plants of the radish. It also relates to methods of producing a Raphanus plant type having the characteristics of recovery from grazing to give the potential for multiple grazings over many cycles.
BACKGROUND OF THE INVENTION
Animal producers worldwide use fodder crops as an inexpensive means of feeding animals during times of forage shortfall, usually during dry summer periods or during cold winter periods. Fodder crops which can be grazed many times rather than once only have potential to lower the cost of production for many farmers.
Plants of Raphanus are used widely throughout the world for many purposes.
For example, Raphanus sativus , domestic radish is used as a vegetable for human consumption, predominantly the root but also to a lessor extent of the leaves, stems and pods.
Raphanus sativus can also be used as an oilseed crop where the seed is harvested and oil extracted. The sprouted seed may also be consumed as a sprout by humans.
Raphanus sativus is also used as a biofumigant in crop rotations to suppress pathogens such as fungal diseases, or cyst nematodes in subsequent crops particularly with Sugar Beet ( Beta vulgaris ) in Europe. These crops are frequently ploughed under but may also be grazed once.
Raphanus sativus may be used as a single grazing fodder crop. However, the cultivars used will usually not recover sufficiently from grazing to allow multiple grazings. Many of these cultivars are relatively early to flower, bolting with 3 months of sowing. The cultivars usually also have hairy leaves and stems which on occasion can be prickly and rejected by grazing animals.
Raphanus sativus with large bulbs may be grown for animal fodder, notably in South Africa. The cultivars used are relatively early flowering and will usually bolt to flower within 3 months of sowing.
The nutritive value of fodder radish for animal feed is known to be high and the species possesses some valuable characteristics for livestock farming. However it is clear that there are a number of features of existing cultivars which have limited its ability to provide a flexible source of grazing on farms.
The typical radish used for grazing purposes is an annual which bolts to flower very readily and rapidly. This limits its use to a single grazing before flowering as the nutritional value declines considerably at flowering. Later flowering forms would provide more flexibility on farm by allowing farmers to keep the feed until needed. This is very apparent in the related Brassica species fodder rape ( Brassica napus ), turnip ( Brassica rapa ) and kale ( Brassica oleracea ) where both annual and biennial forms exist. As a result in these species the biennial forms are more widely used for animal fodder than the annual forms. The delayed flowering of the biennials allows the energy they assimilate to accumulate into storage organs such as bulbs, leaf or stems. From this perspective later flowering or biennial radishes with a long growing period would be valuable for grazing over the summer, or kept until autumn and winter in a nutritious vegetative state.
When typical fodder radish crops are grazed by animals the growing point of the plant is above ground and it is damaged, limiting any regrowth. It would be valuable for a plant to have multiple low growing points to avoid grazing damage and allow maximum recovery.
The majority of traditional fodder and vegetable radish forms of Raphanus sativus are covered in short prickly hairs or trichomes and this feature can render the plant less palatable to livestock than glabrous types. Raphanus plants which lack trichomes are preferred by grazing livestock.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a better fodder radish plant for livestock grazing which can be grazed more than once or to at least provide the public with a useful choice.
The invention provides a fodder Raphanus plant which can be grazed more than once by livestock.
The invention also provides seeds, pollen, ovules and vegetative propagules of the plant.
The fodder radish is preferably Raphanus species.
Within this specification the term “Raphanus” is intended to include any radish species including but not limited to Raphanus sativus, Raphanus maritimus, Raphanus landra and Raphanus raphanistrum.
The Raphanus is preferably very late flowering or biennial in habit which allows grazing over a longer period than more rapidly flowering or annual crops.
The Raphanus preferably has a low crown to allow recovery from grazing by livestock.
The Raphanus preferably has multiple growing points to enhance the ability to recover from grazing by livestock.
The Raphanus preferably has minimal leaf and stem trichomes (or hairs) to enhance the palatability of the plant to grazing livestock.
The invention also provides fodder radish which can be multiply grazed and which has at least one of the following characteristics:
a) palatable and nutritious; b) able to establish quickly under diverse field conditions; c) provide a useful amount of fodder into a drought period; d) tolerant or resistant to common pests, viruses and diseases affecting Brassica crops; e) persistent over a number of grazing cycles; f) provide a useful amount of fodder during the winter period; g) have a yellow seed coat; h) have minimal anthocyanin expression anywhere on the plant; or i) recovers to produce a useful amount of herbage.
The Raphanus species may contain genetic introgression from other species such as Brassica.
The invention provides the plant or its parts producing seed, pollen of the plant, an ovule of the plant and vegetative propagules of the fodder species adapted for multiple grazing.
In particular the invention provides a Raphanus seed designated PG545.
The invention also provides a Raphanus plant having all the physiological and morphological characteristics of the Raphanus plant derived from the seed of the Raphanus PG545.
The invention also provides a method for producing a hybrid Raphanus seed which seed produces a plant capable of being multiple grazed, comprising crossing a first parent Raphanus sativus plant with a second parent Raphanus plant and harvesting the resultant hybrid Raphanus.
The invention also provides a hybrid seed produced by the method above.
The invention also provides a hybrid plant or its parts produced by growing said hybrid Raphanus seed above.
The invention also provides vegetative propagules of the fodder Raphanus species.
The invention also provides a method for the production of Raphanus with the ability to regrow after grazing to be suitable for multiple grazing which comprises:
a) crossing or backcrossing Raphanus sativus with Raphanus maritimus to produce hybrid plants b) selecting for low crown and improved recovery from grazing in the progeny over subsequent generations
The invention also provides a method of the production of Raphanus cultivars with glabrous leaves which comprises:
a) crossing or backcrossing the common phenotype with trichomes on the leaves of Raphanus with Raphanus plants containing genes for glabrous leaves to produce hybrid plants b) selecting for the presence of glabrous leaves in the progeny of subsequent generations
The invention also provides a method of the production of Raphanus with an extremely late flowering behaviour which comprises:
a) crossing or backcrossing the common early flowering Raphanus with extremely late flowering Raphanus plants to produce hybrid plants b) selecting for late flowering in the progeny of subsequent generations
The invention further provides the plant or its parts producing tetraploid seed or pollen for the production of tetraploid seed of the fodder Raphanus which can be multiply grazed by livestock.
The invention further provides an ovule of the tetraploid plants and vegetative propagules of the tetraploid plants.
The invention also provides a tetraploid Raphanus plant having all the physiological and morphological characteristics of a Raphanus plant derived from the seed of the Raphanus which can be multiply grazed by livestock.
The invention also provides a method for producing a tetraploid hybrid Raphanus seed comprising crossing a tetraploid first parent Raphanus plant with a second parent tetraploid Raphanus plant and harvesting the resultant hybrid Raphanus seeds, wherein said first or second parent Raphanus plant a tetraploid Raphanus plant which can be multiply grazed by livestock.
The invention also provides a tetraploid hybrid seed produced by any method above.
The invention also provides a tetraploid hybrid plant or its parts produced by growing hybrid Raphanus sativus seed produced by any method above.
The invention also provides vegetative propagules of tetraploid plants.
Preferably the fodder Raphanus plant is grown from the seed PG545. It may be grown however from any seed having these characteristics such as, for example PG534 and PG560.
The invention will now be described by way of example only with reference to the following embodiments.
BRIEF DESCRIPTION OF THE FIGURES
The following Detailed Description, given by way of example, but not intended to limit the invention to specific embodiments described, may be understood in conjunction with the accompanying Figures, incorporated herein by reference, in which:
FIG. 1 shows plants of the multiple graze radish in the second summer after sowing, showing the survival alongside winter forage cultivars of rape ( Brassica napus ) and leaf turnip ( Brassica rapa ), both of which had failed to survive into the second summer.
FIG. 2 shows a cow grazing multigraze forage radish.
FIG. 3 shows a clipped plant of multiple grazing radish showing the many stems developing from a large crown.
FIG. 4 shows a single crown of multigraze radish showing the multiple regrowth sites after five grazing cycles.
FIGS. 5 and 6 show roots of the multigraze radish showing the branched nature of the root and large crown with many emerging stems.
FIG. 7 shows a plant of multiple grazing radish showing the multiple stems developing from a large crown after five grazing cycles.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the terms “comprises”, “comprising”, and the like can have the meaning ascribed to them in U.S. Patent Law and can mean “includes”, “including” and the like.
In order to develop a multiple grazing fodder radish it was necessary to obtain a series of parental germplasm lines which contained the range of necessary features, or “phenotypes”. The necessary features were available in 2 different Raphanus species:
Feature
Raphanus maritimus
Raphanus sativus
Very Late flowering
+
Mostly − few +
Multiple growing points
+
−
Deep crown
+
−
Forked root
+
−
Persistent for 2 years
+
−
Regrowth from grazing
+
−
Trichomes (unpalatable hairs)
−
Mostly − few +
Dehiscent pods
−
+
Harvestable seed
−
+
Raphanus maritimus occurs on the sea coast of Europe and southern England. It has features which are of valuable for multiple grazing purposes such as a very low crown and a deep forked root. It is also very late to flower and may survive up to 2 or more years. It also has useful amounts of salt tolerance. However, it can not be used directly for grazing due to the extreme prickly nature of the trichomes (leaf hairs) on the leaves and stem and the silique or pods are non-dehiscent and do not release the seed and must be sown as pod pieces making it difficult to domesticate the plant for modem agriculture. In order to take advantage of the desirable features it is necessary to first cross this species with domesticated Raphanus sativus to combine the useful features into one population. These two species had previously been successfully crossed, indicating that no crossing barrier existed between the species (McNaughton 1976).
Raphanus sativus used for production have dehiscent pods enabling a high seed yield. They are also rapid to establish and many cultivars have a high forage yield for a single grazing. These features are of value for a multiple grazing radish.
Within Raphanus sativus there is a variation in the number of plant trichomes (hairs on the leaf and stem). Glabrous forms are more palatable to grazing animals and are desirable in a multiple grazing fodder radish. The glabrous form Biser was used as a source of this feature in crosses. This feature of Biser originated as a result of introgression from cabbage ( Brassica oleracea ) (Bonnet 1979). Although this source was used it would be possible to use other glabrous sources of germplasm.
Within Raphanus sativus there is a large variation for flowering time. Most forms are early flowering but less common late flowering forms requiring a degree of vemalisation also exist. For a multiple grazing fodder radish late flowering forms are desirable and a selection for very late flowering within Long Black Spanish were used as a basis of late flowering in subsequent crosses. Although this source was used it would be possible to use other late flowering sources of germplasm.
To obtain all the necessary features of Raphanus sativus which are of value for a multiple grazing fodder radish it was necessary to cross 2 populations together and select for the desirable features. The very late flowering selection from Long Black Spanish was crossed with the glabrous line Biser. This gave a late flowering glabrous radish suitable for crossing with Raphanus maritimus.
Further selection over 4 cycles gave a very late flowering glabrous radish. The population resulting from 3 cycles of selection was crossed with Raphanus maritimus and selected over 3 cycles for glabrous leaves and late flowering. However, this population still had a proportion of non-dehiscent pods so was crossed back to the 4 th cycle of selection from the late flowering selection from Black Spanish cross Biser.
This population was then selected for all the features required in a multiple grazing radish, including the following:
Late flowering habit with a long vegetative period A deep large forked root with a low crown Multiple growing points Recovery from grazing over many cycles Glabrous leaves A dehiscent pod or silique for ease of seed harvest High forage yield The ability to survive for more than 1 year in suitable environments High disease and pest resistance Rapid establishment Yellow seed coat Low expression of anthocyanin pigment on all parts of the plant
This resulted in 3 multiple grazing radish lines PG534, PG545 and PG560. Seed of these are deposited in the Margot Forde Germplasm Centre at AgResearch, Palmerston North, New Zealand. Seed of PG534, PG545 and PG560 were also deposited under the terms of the Budapest Treaty with the Agricultural Research Service Culture Collection (NRRL), 1815 North University St., Peoria, IL. Deposited seed will be irrevocably and without restriction or condition released to the public during the term of any patent issued from this application.
The invention has resulted from a series of complex crosses and selection from a range of germplasm sources and species over 16 years, as outlined in the breeding history of Table 1. All crosses were carried out in the field by placing a few plants of one parent among many plants of the other parent. A high selection pressure was maintained with between 1000 and 1 million plants being planted in each generation. Each cycle of selection resulted in 7 to 20 parents, which were allowed to interpollinate together in isolation.
The resulting selections have a complex origin incorporating germplasm from three species in the approximate proportions as determined by pedigree; Raphanus sativus (86.7%), Raphanus maritimus (7.5%) and Brassica oleracea (5.8%).
Although this Figure outlines the crosses and selections undertaken to develop the multiple grazing fodder radish it would be possible to develop such types using slightly different materials and methods. It would be important to use germplasm lines which contain all the desirable features as outlined above and then cross between them and to select for a combination of these features over many cycles of selection.
Whilst the invention has been described with reference to specific embodiments, it will be appreciated that numerous modifications and variations can be made to these embodiments without departing from the scope of the invention as described in this specification and the following claims.
The invention is further described by the following numbered paragraphs:
1. A fodder Raphanus plant which can be grazed more than once by livestock. 2. A fodder Raphanus plant according to paragraph 1 that is a Raphanus species selected from the group Raphanus sativus, Raphanus maritimus, Raphanus landra and Raphanus raphanistrum. 3. A fodder Raphanus plant according to paragraph 1 that is very late flowering or biennial in habit which allows grazing over a longer period than more rapidly flowering or annual crops. 4. A fodder Raphanus plant according to paragraph 1 that has a low crown to allow recovery from grazing by livestock. 5. A fodder Raphanus plant according to paragraph 1 that has multiple growing points to enhance the ability to recover from grazing by livestock. 6. A fodder Raphanus plant according to paragraph 1 that has minimal leaf and stem trichomes (or hairs) to enhance the palatability of the plant to grazing livestock. 7. A fodder radish that can be grazed many times and which recovers to produce a useful amount of herbage. 8. A fodder radish that can be multiply grazed and which has at least one of the following characteristics:
a) palatable and nutritious; b) able to establish quickly under diverse field conditions; c) provide a useful amount of fodder into a drought period; d) tolerant or resistant to common pests, viruses and diseases affecting Brassica crops; e) persistent over a number of grazing cycles; f) provide a useful amount of fodder during the winter period; g) have a yellow seed coat; h) have minimal anthocyanin expression anywhere on the plant;
9. A fodder radish according to paragraph 8 that contains genetic introgression from other species such as Brassica . 10. Seeds, pollen, ovules, vegetative propagules of the fodder Raphanus plant according to any one of paragraphs 1-9. 11. Raphanus seed designated PG545. 12. Raphanus seed having all the physiological and morphological characteristics of the Raphanus plant derived from the seed of the Raphanus PG545. 13. A method for producing a hybrid Raphanus seed which seed produces a plant capable of being multiple grazed, comprising crossing a first parent Raphanus sativus plant with a second parent Raphanus plant and harvesting the resultant hybrid Raphanus. 14. Hybrid seed produced by the method of paragraph 13. 15. A hybrid plant or its parts produced by growing hybrid seed of paragraph 14. 16. A method for the production of Raphanus with the ability to regrow after grazing to be suitable for multiple grazing which comprises:
a) crossing or backcrossing Raphanus sativus with Raphanus maritimus to produce hybrid plants b) selecting for low crown and improved recovery from grazing in the progeny over subsequent generations
17. A method of the production of Raphanus cultivars with glabrous leaves which comprises:
a) crossing or backcrossing the common phenotype with trichomes on the leaves of Raphanus with Raphanus plants containing genes for glabrous leaves to produce hybrid plants b) selecting for the presence of glabrous leaves in the progeny of subsequent generations
18. A method of the production of Raphanus with an extremely late flowering behaviour which comprises:
a) crossing or backcrossing the common early flowering Raphanus with extremely late flowering Raphanus plants to produce hybrid plants b) selecting for late flowering in the progeny of subsequent generations
19. A plants or its parts producing tetraploid seed or pollen for the production of tetraploid seed of the fodder Raphanus which can be multiply grazed by livestock. 20. An ovule of the tetraploid plants and vegetative propagules of the tetraploid plants of paragraph 19. 21. A tetraploid Raphanus plant having all the physiological and morphological characteristics of a Raphanus plant derived from the seed of the Raphanus which can be multiply grazed by livestock. 22. A method for producing a tetraploid hybrid Raphanus seed comprising crossing a tetraploid first parent Raphanus plant with a second parent tetraploid Raphanus plant and harvesting the resultant hybrid Raphanus seeds, wherein said first or second parent Raphanus plant a tetraploid Raphanus plant which can be multiply grazed by livestock. 23. A tetraploid hybrid seed produced by any method of paragraph 22. 24. A tetraploid hybrid plant or its parts produced by growing hybrid Raphanus sativus seed produced by the method of paragraph 22. 25. Vegetative propagules of tetraploid plants according to paragraph 24. 26. A Raphanus plant grown from the seed PG545 or any seed having these characteristics such as, for example PG534 and PG560.
TABLE 1 Grazing radish pedigree
REFERENCES
Bonnet A 1979 Inheritance of some characters in radish ( Raphanus sativus ). Cruciferae Newsletter 4: 31 George R A T, Evans D R 1981 A classification of winter radish cultivars Euphytica 30: 483-492 Johnston T D 1963 The fodder radish. Welsh Plant breeding Station Annual Report 1963: 135-139 Johnston T D 1977 Breeding aspects of Raphanus and Brassica. Cruciferae Newsletter 2: 13 McNaughton I H 1976 The possibility of leafy, biennial radishes from hybridisation of Raphanus sativus (fodder radish) and R. maritimus (sea radish). Cruciferae Newsletter 1: 21-22 Rethman N F G, Heyns G 1987 Grazing of Raphanus sativus L (Japanese radish) Journal of the Grassland Society of South Africa 4:154 Verschoor A, Rethman N F G 1992 Forage potential of Japanese radish ( Raphanus sativus ) as influenced by planting date and cultivar choice. Journal of the Grassland Society of South Africa 9:176-177 | The invention relates to a fodder radish. More particularly, a fodder radish ( Raphanus species) suitable for use as a multiple grazing fodder crop for livestock is provided. The invention also relates to the seeds, and to the plants of the radish. It also relates to methods of producing a Raphanus plant type having the characteristics of recovery from grazing to give the potential for multiple grazings over many cycles. | 0 |
This application is a continuation in part of Ser. No. 07/742,087, now U.S. Pat. No. 5,105,801 of Aug. 2, 1991, which is a continuation application of U.S. application Ser. No. 07/545,519 of Jun. 28, 1990, abandoned.
FIELD OF THE INVENTION
The invention essentially relates to a method and device for improving in particular the reproducibility and efficiency of pressure waves generated during the electric discharge from a capacitance between two electrodes, by interposition of an electrically conductive liquid between the electrodes, and a shockwave generating apparatus using such a method or device, particularly for hydraulic lithotripsy.
BACKGROUND OF THE INVENTION
An apparatus is known from U.S. Pat. No. 2,559,227 of RIEBER, for generating high frequency shockwaves, which apparatus comprises a truncated ellipsoidal reflector in which shockwaves are generated by discharge or electric arc between two electrodes converging to the first focal point of the ellipsoid, the object being to destroy a target situated in the second focal point of the ellipsoid, which is external to the truncated reflector (see FIG. 3 and col. 7, line 51 to col. 9, line 30).
Electrodes are produced in a highly conductive material such as copper or brass and are mounted on an insulator which is supported in pivotal manner by means of a device, so as to adjust the spacing between said electrodes (see col. 4, lines 42 to 53 and col. 8, lines 40 to 47).
With the RIEBER apparatus or any similar apparatus, the discharge or electric arc is produced between the electrodes and due to the sudden discharge of a capacitor, by closing a high voltage switch (see FIG. 2B). According to the RIEBER apparatus, the circuit between the electrodes comprises a capacitor, with an associated self-inductance. It has been noted that the capacitor discharge is of damped oscillatory type. In other words, the capacitor is going to discharge and to re-charge in reverse at a lower voltage than the initial voltage which is very high, until depletion of the charges contained in the capacitor.
Simultaneously, an electric arc and a plasma are established between the two electrodes of which the current will also be, by way of consequence, of damped oscillatory type, as can be understood with reference to FIGS. 1a, 1b and 1c. Accordingly, FIG. 1a illustrates the chronogram of voltages, while FIG. 1b illustrates the chronogram of currents established in the RIEBER type discharge circuit. It is found that when the circuit is closed at time t 1 , the voltage at the terminals of the electrodes rises suddenly to the value of the voltage at the terminals of the capacitors (see FIG. 1a). A low current is established between the two electrodes (FIG. 1b) due to the fact that, first the liquid in which the electrodes are immersed, and which is usually water, is still slightly electrically conductive, and second, that for reasons of safety and of arc ignition, a high resistance is provided in parallel to the capacitor supplying the electrodes.
After a certain time, namely after time t 2 , called latency time, the arc is established between the electrodes. At that moment, the current increases suddenly by several KA as clearly illustrated in FIG. 1b. It is a known fact that the arc is constituted by a plasma whose resistance is extremely low (about 1/100 or 1/1000 Ohm) and it is the low value of this resistance which explains the importance of the oscillations of current (FIG. 1b) and of voltage (FIG. 1a) during the discharge of a capacitor in an RL type circuit.
The energy contained and dissipated by the arc contributes to the vaporization of the liquid in which the electrodes are immersed, and which is normally water, to the creation of a steam bubble and consequently to the formation of the shockwave. The quicker this energy is dissipated, the more efficient will be the shockwave.
It is thus found that, due to the oscillatory nature of the current, as illustrated in FIG. 1b, the supply of energy to the external medium is progressive, as clearly illustrated in FIG. 1c.
This explains how, the quicker is the vaporization of the liquid, in particular water, the stronger will be the pressure wave and the shorter will be its pressure-rising time.
Thus, a great quantity of energy will have to be delivered to vaporize an important quantity of liquid, and in particular water.
Yet, virtually all the currently known devices use discharges which are all of damped oscillatory type, as illustrated in FIGS. 1a and 1b, resulting in a progressive dissipation of the energy with time (FIG. 1c).
In their prior document EP-A-0 296 912, the Applicants have proposed a first solution for delivering suddenly or in a relatively short time, most of the energy stored by the charge of the capacitor of the discharge circuit between two electrodes. It was proposed to this effect, to increase the electric resistance on the path of the electric arc at least between the electrodes by interposition of a high resistance insulating element, between the arc-generating electrodes. This solution is fully satisfactory when generating shockwaves whose initial pressure wave is substantially spherical.
However, said prior solution is difficult to implement mechanically because of the small dimensions of the electrodes and of the mechanical strength towards shockwaves. Moreover, the latency time problem is not solved in that the main aim of this particular solution is only to improve the discharge rate when electric arc is established, which does not improve the reproducibility of the discharge, hence of the shockwave.
Accordingly, the main object of the invention is to solve the new technical problem consisting in providing a solution permitting instant delivery in a relatively short time of most of the energy stored by the charge of the capacitor of the discharge circuit between two electrodes, by eliminating completely or substantially the latency time normally necessary for generating an electric discharge between the electrodes.
Another object of the invention is to solve the new technical problem consisting in providing a solution permitting complete or substantially complete elimination of the latency time when generating an electric discharge between two electrodes while considerably improving the reproducibility of the shockwave due to an important improvement in localizing the generation of the discharge current.
Yet another object of the present invention is to solve the new technical problem consisting in providing a solution permitting the complete or substantially complete elimination of the latency time when generating an electric discharge between the electrodes, while producing an electric discharge of critical damped type which will cause an instant delivery or a delivery in a relatively short time of most of the energy stored by the charge of the capacitor of the discharge circuit between the electrodes.
A further object of the present invention is to solve said new technical problems while providing a solution permitting a reduction of the wear of the electrodes, and limiting the extent of the alterations to be made on the existing prior apparatuses.
Yet another object of the invention is to solve the aforesaid new technical problems in an extremely simple manner which can be used on an industrial scale, particularly with reference to extracorporeal lithotripsy.
All said new technical problems have been solved for the first time by the present invention in a satisfactory manner, for little costs, and at industrial level, particularly with reference to extracorporeal lithotripsy.
Thus, in a first aspect, the present invention provides a method for improving the electric discharge rate produced in a liquid medium such as water, between at least two electrodes, generating such a discharge, characterized in that it consists in considerably reducing the resistance to the passage of the electric discharge at least between the electrodes in order to bring it to a resistance value near to the critical resistance by interposing at least between the electrodes, an electrically conductive liquid medium contained in an essentially closed reservoir surrounding the electrodes.
Said reservoir is produced in a material which will not substantially affect the propagation of the shockwaves. Examples of such materials are a latex, a silicon, or a metal strip, which are well known to skilled in the art.
According to another advantageous embodiment, the electrodes support the reservoir and are removable. They can therefore be supplied with the reservoir, the assembly then being usable and disposable, thus reducing maintenance costs compared with the prior solutions.
According to a particularly advantageous embodiment, the electrically conductive liquid medium used has an electrical resistance which is less than 1/10, and preferably at least 1/100 of the electrical resistance value of the ordinary ionized water used as reference. Preferably still, the electrical resistance of the electrically conductive medium according to the invention, as expressed in linear resistivity, is less than about 15 Ohm.cm. The electrically conductive liquid media can be constituted by an aqueous or non-aqueous electrolyte. A suitable aqueous electrolyte is water containing ionizable compounds, notably salts such as halide salts, for example NaCl, NH 4 Cl, sulfates or nitrates with alkaline or alkaline earth metals or transition metals such as copper. A currently preferred electrically conductive aqueous liquid medium is constituted by water salted at the rate of 100 or 200 g/l, having respectively a linear resistivity value of 10 and 5 Ohm.cm.
More preference is given to an electrically conductive aqueous liquid medium containing about 10% by weight of NaCl (about 100 g/l) and between 0.5 and 2% by weight of phosphate salt, particularly disodium phosphate (Na 2 HPO 4 , 12H 2 O). The linear resistivity of such an electrically conductive medium is about 8 Ohm.cm. Advantageously, a dye, such as methylene blue, is added in the proportion of 2 mg/l in order to reveal any leaks in the reservoir.
Suitable non-aqueous conductive liquid media include the conductive oils, rendered conductive by the addition of conductive particles such as metallic particles, which are well known to those skilled in the art.
According to a second aspect, the present invention also provides a device for improving the rate of electrical discharge produced in a liquid medium such as water, between at least two electrodes generating such a discharge, characterized in that it comprises means for reducing the resistance to the passage of an electric discharge at least between the electrodes so as to bring it to a resistance value near to the critical resistance, comprising an essentially closed reservoir surrounding the electrodes, and filled with an electrically conductive medium. The material making up said reservoir is selected not to substantially affect the propagation of the shockwaves. In particular, said reservoir can be made of latex, silicon, or metallic strip. It can take the form of a membrane around the electrodes.
According to a third aspect, the present invention further relates to an apparatus generating shockwaves by electric discharge between at least two electrodes immersed in a liquid discharge medium, notably of extracorporeal type, characterized in that it comprises a device for improving the discharge rate as described previously. According to an advantageous embodiment, said apparatus comprises a truncated ellipsoidal reflector having an internal focal point where the shockwaves are generated by electric discharge between at least two electrodes and a focus, external to the reflector, in which the shockwaves are focussed, said truncated ellipsoidal reflector being filled with a liquid coupling medium. In this case, there is an essentially closed reservoir, as indicated hereinabove, which surrounds the electrodes and therefore the internal focus, which reservoir is filled with electrically conductive medium, while outside said reservoir, another liquid medium, notably water, is used inside the truncated ellipsoidal reflector.
Other characteristics of the electrically conductive medium according to the invention have been described with reference to the method and are obviously applicable to the device.
According to the invention, the discharge is produced through an electrically conductive medium, thus eliminating completely or substantially completely the latency time. Moreover, a considerable increase of the reproducibility of the shockwave generated between the electrodes is obtained. This is mainly due to the fact that in the conventional case, the arc is ignited at random in time and in space, inducing the formation of an inaccurately localized steam bubble, which is not the case according to the present invention. Also, according to the invention, the presence of an oscillating current is eliminated, so that the discharge is of critical damped type, as will be more readily understood from the description given with reference to the appended drawing.
Also according to the invention, the presence of the reservoir filled with electrically conductive liquid, enables the quantity of electrically conductive liquid used to be considerably reduced, and this liquid is not in contact with the patient. Moreover, the electric discharge takes place in a confined domain, thereby limiting electrical risks.
The invention therefore provides all the technical advantages indicated hereinabove, which were unexpected and non-obvious to the man skilled in the art.
Other aims, characteristics and advantages of the invention will also appear to the man skilled in the art from the following explanatory description made with reference to the accompanying drawings, particularly showing a presently preferred embodiment of the invention, given by way of example and non-restrictively
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b and 1c respectively show the curves of voltage, current and energy during the conventional discharge of an electric arc generated between two electrodes using a discharge circuit according to U.S. Pat. No. 2,559,227 of RIEBER;
FIG. 2 illustrates diagrammatically, in partial cross-section, an apparatus generating shockwaves, particularly for extracorporeal lithotripsy, comprising an electric discharge device according to the present invention, which comprises a substantially closed reservoir filled with an electrically conductive liquid medium in which the electrical discharge is generated between two electrodes; and
FIGS. 3a3b, 3c respectively illustrate, similarly to FIGS. 1a, 1b, 1c the curves of voltage, current and energy obtained according to the present invention, using an electrically conductive liquid medium interposed at least between the electrodes, according to FIG. 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 2, this shows an apparatus generating shockwaves such as for extracorporeal lithotripsy, comprising a truncated ellipsoidal reflector designated by the general reference 10 which is of the type of that described in U.S. Pat. No. 2,559,227 of RIEBER. Said reflector is provided with two discharge electrodes 12, 14 disposed in facing relationship, in this case, according to a cage-like structure as is known from document DE-A-2 635 635. These two discharge electrodes 12, 14 converge towards the internal focus point symbolized by reference F.
The second focal point of the ellipsoid is situated outside the truncated ellipsoidal reflector 10 and it is with that second focus point that the target to be destroyed will be made to coincide, as described in detail in RIEBER's U.S. patent. Said target, of course, can be constituted by a concretion. The electrode 12 is for example on ground as illustrated in the figure, and connected also to one side of a capacitor C. The other electrode 14 is connected to the capacitor C via a switching device I, such as for example a gas discharge arrester or "spark gap", which is intermittently switched off by a control symbolically designated by reference 20. A high value resistor R or a self is provided in parallel to capacitor C. The capacitor is charged with a high voltage, between 10,000 and 20,000 V, from a source of power as described for example in FIG. 1 of Applicants' document EP-A-0 296 912, this circuit not being illustrated here.
According to the prior art, the ellipsoidal reflector 10 is filled with a shockwave transmitting liquid, usually water, whose resistance to the passage of an electrical current is significant. Said electrical resistance value of ordinary ionized water such as tap water, as expressed in linear resistivity value, is, in average, about 1500 Ohm.cm. In the case of oils, which are very insulating, such as in the case of RIEBER's U.S. Pat. No. 2,559,227, the linear resistivity value is about 3 to 5M. Ohm.cm.
When producing an electric discharge in such a prior art circuit, where the liquid medium between the electrodes 12, 14 is constituted by normally ionized water, a discharge chronogram such as illustrated in FIGS. 1a, 1b and 1c, is obtained for which there is a significant latency time while the discharge rate is of the oscillatory type, this delivering the energy progressively to the external medium.
According to the present invention, an essentially closed reservoir 30 is used, which is filled with an electrically conductive medium 32, thus enabling the resistance to the passage of the electric discharge between the electrodes 12, 14 to be brought near to or advantageously below the critical resistance this constituting a solution which is quite the opposite to that recommended in Applicants' document EP-A-0 296 912 which proposes on the contrary to considerably increase the electrical resistance between the electrodes by interposing an insulating element between the electrodes.
This reservoir 30 is itself surrounded by a liquid coupling medium 34 filling the truncated ellipsoidal reflector 10, particularly water, this enabling the patient's skin to be in contact with ordinary water.
This reservoir is produced in a material which does not substantially affect the shockwaves generated by the electric discharge between the electrodes 12, 14. Such materials are wellknown of the man skilled in the art. Particular examples of such materials are a latex, a silicon, a metallic strip. Practical embodiments take the form of a membrane fixed in appropriate manner, for example on the electrically conductive external element 12a supporting the electrode, as understood by the man skilled in the art.
Advantageously, the electrodes are designed to support the reservoir, and are removable, as illustrated in FIG. 2. They can therefore be supplied with the reservior 30, the electrodes and reservoir assembly being then usable and disposable, thereby reducing maintenance costs compared with the prior solutions.
According to an advantageous embodiment of the invention, the electrically conductive liquid medium 32, contained in the reservoir 30, has an electrical resistance which is less than 1/10 and preferably less than 1/100 of the value of the electrical resistance of ordinary ionized water, used as reference, and which is usually of about 1500 Ohm.cm as expressed in linear resistivity. Preferably, the electrical resistance of the electrically conductive medium according to the invention, as expressed in linear resistivity, is less than about 15 Ohm.cm.
Any aqueous or non-aqueous electrically conductive liquid can be used as electrically conducting medium according to the invention. A suitable aqueous electrically conductive liquid is an aqueous electrolyte constituted from pure water to which ionizable soluble compounds are added, such as salts like halides, in particular chlorides, sulfates, nitrates. A particularly preferred aqueous electrolyte is water with addition of NaCl or of NH 4 Cl. The medium given more preference is water salted at 100 or 200 g/l whose respective linear resistivity is from 10 to 5 Ohm.cm.
More preference is given to an aqueous electrically conductive medium which contains about 10% by weight of NaCl and between 0.5 and 2% by weight of disodium phosphate (Na 2 HPO 4 ,12H 2 O) and which has a linear resistivity of about 8 Ohm.cm at 25° . The NaCl/phosphate proportion is not critical and enables the resistivity to be adjusted to up to 10 Ohm.cm. A dye can also be added to the electrically conductive medium, so as to reveal any leaks in the reservoir 30.
Suitable non-aqueous electrolytes are electrically conductive oils, namely oils which have been made conductive by addition of electrically conductive particles such as metallic particles.
According to the invention, when using an electrically conductive medium, a discharge chronogram is obtained, such as illustrated in FIGS. 3a, 3b, 3c. It is found that, as soon as the electrodes are charged at time t 1 , the generation of the arc is quasi-instantaneous. Moreover, said discharge is of critical damped type, and is no longer of the oscillatory type. Also, the energy is delivered to the external medium for a much shorter time than in the case of an oscillating rate, or in the case of prior rates with latency times.
The result is a considerable increase of the reproducibility of the pressure wave owing to the fact that the discharge is no longer ignited at random in time and in space, but on the contrary at time t 1 and induces the formation of a perfectly localized steam bubble. The chronogram shown in FIG. 3 was obtained by using water salted at 200 g/l as electrically conducting medium for immersing the electrodes 12, 14, as well as a capacitor having a capacitance of 100 nF, a spacing between the electrodes of 0.4 mm, the discharge circuit of FIG. 2 having a total self inductance L of 80 nH.
In the description and claims, it will be recalled that the critical resistance is the value of the resistance between the electrodes for which the relation: ##EQU1## is substantianlly met. In the formula L is the value of internal self-inductance of the dischage circuit of capacitor C, and C is the capacitance value of the capacitor.
It will be noted that according to the invention, using an electrically conductive liquid medium, an excellent reproducibility of the shockwaves is obtained, the dispersion coefficient being less than 5%, particularly if salted water is used, whereas said mean deviation is about 30% if ordinary ionized water such as tap water is used. The invention therefore provides all the aforesaid non-obvious and unexpected technical advantages and as a result solves all the aforesaid technical problems. The invention also provides the possibility of implementing the aforedescribed method.
Finally, the invention also covers an apparatus generating shockwaves by generating an electric arc between two electrodes, characterized in that it uses a method or device for improving the discharge rate such as described hereinabove. In particular, said apparatus for generating shockwaves is characterized in that it comprises a truncated ellipsoidal reflector comprising a reservoir filled with an electrically conductive liquid, as previously described, as well as another liquid coupling medium surrounding the reservoir and filling the reflector. A particular application is extracorporeal lithotripsy. | The present invention relates to a method and a device for producing an electric discharge between two electrodes. This method characterized in that the resistance to the passage of the electric arc, at least between the electrodes, is considerably reduced so as to bring it to a resistance value near to or slightly higher than the critical resistance, by interposing at least between the electrodes, an electrically conductive electrolyte contained in an essentially closed reservoir surrounding the electrodes. The invention makes it possible to improve the rate of discharge of an electric current produced between the electrodes, by eliminating substantially completely the latency time. | 6 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to a viscous isolator, and more particularly to a vibration isolator and damper for isolating a reaction wheel assembly on a supporting structure while permitting a mounting base to be moved relative to the supporting structure along multiple axes of freedom.
2. Description Of The Prior Art
Spacecraft reaction wheel assemblies used for pointing control systems, as on a telescope, can emit vibrations into the spacecraft structure that result in blurred images in optical sensors carried by the spacecraft. A reaction wheel assembly produces vibration disturbances when it rotates due to imperfections in the electromagnetics and their drive electronics, unbalance of the rotor, and imperfections in the spin bearings. Since the reaction wheel assemblies provide a desired control torque for positioning the optical elements in the absence of a chemical reaction propulsion system, the isolation system provide attenuation above specific natural frequencies and must have peaking factors in one or more degrees of freedom without impairing transmission of the desired control torques. To maintain accuracy, vibrations must be isolated between the supported structure and the supporting system during both ground loading (one G) and in orbit (zero G).
One system for isolating vibrations is disclosed in U.S. Pat. No. 3,540,688, wherein a supporting system employs pivoted single-axis isolators arranged into a bipod and a tetrahedron in which the isolators are supported by means of universally rotatable joints to provide a kinematic mount system.
U.S. Pat. No. 4,848,525 discloses an active 6 degree-of-freedom pointing and isolation system having a magnetically suspended positioning system mounted above a hexapod of linear actuators.
Critical to the above isolation systems is the design of the isolator element. Typically, the prior art isolator elements have been designed for relatively high frequencies, of the order of 15 Hz or greater; therefore, deflections due to one G ground loading and launch vibrations were relatively small and not a limiting factor. However, in some applications the vibration isolator is required to provide specific natural frequencies and peaking factors in one or more degrees of freedom. Thus, for an application with a magnetically suspended wheel the radial translation motion was required to be isolated at a relatively low frequency (4.0 Hz), and very tightly controlled frequencies and peaking factors were specified for all six degrees of freedom to avoid interaction with the magnetic suspension control system. Moreover, the isolator was required to operate in both ground and orbit environments. Where the prior art applications utilized a ridgedly attached isolator the radial translational frequency at 4 Hz could not be accurately controlled.
Moreover, viscous damped isolators are designed to produce damping in their axial direction by fluid shear through a controlled annulus. Damping in the radial direction is typically very low as compared to axial damping and not accurately controlled. Therefore, the peaking factor of the radial translational isolator frequency could not be accurately controlled. Further, radial deflection was limited to the radial clearance of the annulus which must be relatively small to achieve good axial and radial damping. A low frequency radial translational isolator requires a larger value of radial motion than can be provided by the prior art isolators. Still further, the small radial gap coupled with the low radial stiffness precludes operation in the radial direction at one G, and results in the isolator chattering between its stops during launch vibration with the resultant transmittal of impact loads to the reaction wheel assembly.
The present invention avoids the foregoing limitations by providing a hexapod of isolation elements pivoted at each end to carry only axial loads. Travel limiting stops are build into the structure so as to avoid transmitting the loads caused by impact during launch to the isolator elements. A tunable viscous damper is provided which may be peaked at a desired resonant frequency.
SUMMARY OF THE INVENTION
The present invention overcomes the problems of the prior art by providing a vibration isolating and damping apparatus that passively isolates vibrations between a supporting structure and a supported structure while permitting movement of the supported structure over six degrees of freedom with respect to the supporting structure, wherein the supported structure contains a torque producing device for developing a control torque.
Three sets of isolators, skewed at a predetermined angle, are grouped into bipods or pairs which are attached to the supported structure in the plane of the payload mass center. Each of the isolator elements is pivoted at each end so that only axial loads are carried by the elements during rotation and translation of the payload. Travel limiting stops may be build into the apparatus so as to maximize the allowable deflection of the supported structure and avoid transmitting impact loads through the isolator angular pivots.
More particularly, the invention comprises a cradle for supporting the supported structure, a plurality of isolators each having a body, a first end secured in a flexible manner to the supporting structure and a second end flexibly secured to the cradle, the isolator supporting the cradle with respect to the supporting structure in a relatively movable fashion. The isolators are arranged in pairs on a common base on the cradle and skewed by a given angle with respect to the supporting structure, the pairs of isolators being substantially parallel to an azimuthal axis passing through the centers of the supporting structure and the cradle. The isolators are further arranged in substantially equiangularly disposed pairs about the azimuthal axis and provided with a flexible joint which provides at least two degrees of freedom at each of the ends of the isolators so that opposite ends of each isolator are relatively movable axially and each of the isolators being movable relative to each other along their respective longitudinal axes while maintaining the supported structure in a kinematic relation with the supporting structures. The isolators are designed to provide a complex mechanical impedance as a function of vibration frequency which allows transmission of the control torque producing frequencies of the torque producing device while suppressing transmission of undesired vibration frequencies of the reaction wheel assembly to other spacecraft structures.
More particularly, the isolator pairs are arranged substantially 120 degrees apart with each isolator member being inclined substantially at 38.3 degrees relative to the plane of the supporting structure. Mounting surfaces of the supporting structure are distributed so as to support the second ends of the isolators whereby the plane of the flexible joints thereof contains the center of mass of the supported structure. In a preferred environment, the apparatus includes means for limiting the maximum movement of the cradle relative to the supporting structure in which the allowable movement is less than the maximum movement of the cradle relative to the supporting structure provided for by the isolators. These constraints are provided by a pair of coaxial metallic tubes being joined at a first end proximal to the azimuthal axis and disposed in parallel to the plane of the cradle and radial to the azimuthal axis passing through the cradle. The outer tube is preferably fixed to the supporting structure at the first end of a pair of isolators and the cradle is provided with an aperture having a predetermined clearance for a stop arm extending radially and outwardly, the stop arm being affixed to the inner tube and disposed for constraining motion of the cradle so that the deflection of the cradle induced by vibration of the reaction wheel assembly will cause the stop arm resiliently to apply a predetermined counterforce to the cradle, thereby restraining the isolator from deflection greater than a predetermined value.
In a further preferred environment, the viscous vibration and damping isolator comprises a base member having an inner and outer face and provision for attaching the outer face to the supporting structure. A first bellows is joined to the inner face of the base member and forms a fluid seal, the other end of the first bellows being joined to a first face of an axially aligned piston, so that the base member, the first bellows, and the piston provide a first fluid chamber which is filled with damping fluid. The first bellows is expansible and contractible in an axial direction. A hollow main cylindrical housing has a closed first end and an open second end and is aligned axially with the piston and joined at its circumference to a second face of the piston. A second bellows is received within the main cylindrical housing and axially aligned with the first bellows. It is joined at a first end to a second opposing face of the piston and at a second end to a second hollow cylindrical housing which is coaxially disposed within the main cylindrical housing. The second bellows is also expansible and contractible in an axial direction and has an outer diameter which exceeds the inner diameter of the main cylindrical housing and has an inner diameter which is greater than the outer diameter of the second cylindrical housing. Thus, the second hollow cylindrical housing, the second bellows, and the piston comprise a second fluid chamber which is also filled with damping fluid and communicates with the first fluid chamber through an axial bore in the piston. The second hollow cylindrical housing is further provided with closed ends and an exterior centrally located flange which forms a fluid seal with the second bellows. The piston is provided with an axial bore in which an axial shaft is slideably disposed. At its distal end, the axial shaft is joined to the inner face of the base member and at its proximal end the axial shaft is joined to the first end of the second cylindrical housing. The axial bore forms a radial gap with the axial shaft and the radial gap provides fluid coupling between the first and second chambers. Stiffness of the damper is augmented by a tuning spring that is placed between the base and the piston and arranged in plurality about the first bellows. The isolator is further provided with a stem, connected to the main cylindrical housing at its closed end, which is adapted to move the piston axially when force is applied to the stem and to damp reciprocation of the stem by utilizing viscous resistance of the fluid when the stem moves in the axial direction of the main cylindrical housing as induced by vibration of the supported structure.
Preferably, temperature compensation is provided by a thermal compensator bellows disposed within the second cylindrical housing, which forms a fluid seal with an end cap defined by a closed end of the second cylindrical housing. A compensator spring is disposed within the bellows for establishing positive pressure, the bellows and second cylindrical housing defining a third fluid chamber which is filled with fluid and fluidly coupled through a fluid passage in the axial shaft to the radial gap into the first and second fluid chambers, thereby allowing an exchange of fluid between the temperature compensator and the first and second fluid chambers to effect a constant fluid pressure to be maintained in the system with temperature variations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the multiaxis isolation system of the present invention as used in an earth-orbiting spacecraft.
FIG. 2 is a schematic drawing showing the hexapod geometry of the present invention.
FIG. 3 is a cross-sectional view of a vibration isolator element constructed in accordance with this invention.
FIG. 4 is a prospective view of the multiaxis pivot as shown in FIG. 3.
FIG. 5 is a conceptual side elevation view of one embodiment of the motion limiter elements used to predetermine the allowed deflection of the cradle.
FIG. 6 is a side elevation view of the motion limiter stops of FIG. 5.
FIG. 7 is an enlarged end view of the stop assembly of FIG. 6.
FIG. 8 is a cross-sectional view corresponding with the stop limiter of FIG. 6.
FIG. 9 is a plan view of a further embodiment of the stop structure of the present invention.
FIG. 10 is an end view of the structure of FIG. 9.
FIG. 11 is a graph showing transmission loss as a function of frequency for translation along the X-axis.
FIG. 12 is a graph showing transmission loss as a function of frequency for translation along the Y-axis.
FIG. 13 is a graph showing transmission loss as a function of frequency for rotation about the X-axis of the preferred embodiment of the invention.
FIG. 14 is a graph showing transmission loss as a function of frequency for rotation about the Y-axis.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings and particularly to FIGS. 1 and 2, a preferred embodiment of an isolating system constructed in accordance with the present invention comprises a base or supporting structure 10 and a frame or cradle 12 which is suspended from the supporting structure by a plurality of viscous isolators 14. Cradle 12 is provided with a plurality of angularly spaced apart members 16 in the shape of a "Y", with each arm 16 being spaced from another arm 16 substantially by 120 degrees. A plurality of mounting surfaces 13 are distributed laterally and equilaterally upon the cradle 12 for mounting the reaction wheel assembly. A member 18 extends distally and at right angles to each arm of the cradle for supporting the stem ends of the isolators. Each isolator is provided with a flexible joint 20 which permits free translation of an associated isolator through at least two dimensions. Such joints may be formed from either spherical bearings or two-axis flexures. In this manner, the plane of the flexible joints supporting the stems is arranged to contain the center of mass of the reaction wheel assembly. One isolator stem 22 is provided with a lateral offset so as to clear the stem 24 of the associated isolator. The cradle 12 also carries an associated cable and connector 28 for providing electrical connections to the supported structure.
Provision is made by a stop assembly 26 for limiting the maximum movement of the cradle 12 relative to the supporting structure 10 so that the allowable relative displacement of the cradle is less than that provided for by the design of the isolators. In one embodiment, shown in FIGS. 5-8 the stops to limit isolator motion are shown located at each isolator pair between the supporting structure 10 and cradle 12. This arrangement places the stops in parallel with the isolator elements and as a result the stop contact forces will not be applied through the isolator element and the pivot flexures. The stop location can be chosen to accommodate the expected translational motion due to acceleration in the azimuthal direction with allowance for tolerances. Particulars of the stop design are described below.
Referring now to FIG. 2, the invention is comprised of a system of six identical single degree of freedom isolation elements 14 arranged in a symmetrical pattern of three isolator pairs, in which each pair of elements is connected with a point A, B, or C, 120 degrees apart. The elements are grouped in three sets of pairs or bipods, which are attached to the cradle at a radius R in the plane of the reaction wheels' mass center. The elements in each isolator pair are skewed by angle from the Z or azimuth axis extending longitudinally and at right angles to the XY plane, with the angle measured about the line connecting the attachment point A, B, or C to the center of mass M. In the preferred embodiment, the base 30 of each pair of isolator elements is formed by the supporting structure 10. In the preferred embodiment, each isolator member of each isolator pair is inclined substantially at 38.3 degrees relative to the Z axis.
The viscous isolator of the present invention will now be described with respect to FIG. 3. The isolator 14 includes a base member 32 having outer and inner faces and in which the outer face is coupled to a supporting structure (not shown) by a lower pivot member 20. A lower bellows 33 is joined at the first end to the inner face 34 of base 32 and bonded to provide a fluid seal and structural integrity. At its upper end lower bellows 33 is bonded to a piston 35, also to provide a fluid seal and structural integrity. The bellows 33 is expansible and contractible in an axial direction, and in combination with the base member 32 and piston 35 defines a first fluid chamber which is to be filled with a suitable damping fluid, such as silicone. An upper cylindrical housing 36 has a closed end 37 which is structurally affixed to the offset stem 22. Cylindrical housing 36 is axially aligned with piston 35 and joined structurally to piston 35 at the open end 38 of housing 36. A second bellows 40 is axially aligned with bellows 33 and disposed within upper cylindrical housing 36. Bellows 40 is joined at a first end in common with piston 35 and with the open end of cylindrical housing 36. A second end of bellows 40 distal to piston 35 is joined to a second cylindrical housing 42 which is coaxially disposed within the upper cylindrical housing 36. Bellows 40 is also expansible and contractible in an axial direction of the upper cylindrical housing 36 and is provided with an outer diameter somewhat less than the inner diameter of cylindrical housing 36 and has an inner diameter greater than the cylindrical housing 42 so as to define a second fluid chamber between the exterior of the second cylindrical housing 42 and bellows 40 and joined with piston 35 so as to define a second fluid chamber also filled with damping fluid.
Piston 35 is provided with an axial bore. The cylindrical housing 42 is closed at lower end with the upper end having an end cap provided with an annular bore and having an exterior located flange to form a fluid seal with the second bellows. An axial shaft 43 is positioned within the bore of piston 35 to form a radial gap therebetween, the radial gap providing fluid coupling between the first and second fluid chambers. Shaft 43 is joined at its lower end to the inner face 34 of base member 32 and its upper end to cylindrical housing 42 and it is provided with an annular bore for fluid coupling to a third fluid chamber, whose function is to be described below.
Since the bellows are designed with low stiffness, a plurality of tuning springs 44 are disposed between the inner face of base 32 and piston 3 and approximately equiangularly disposed about the circumference of the first bellows 33. Coil springs are placed in parallel with the main bellows and adjusted to obtain the required stiffness, approximately one-third of which being allocated to the multiple bellows and two-thirds to the springs.
One isolator in each pair further includes a stem 22 which may be offset as shown and which is affixed to housing 36 so as to move piston 35 axially when the force is applied to upper pivot 20, while the offset allows the stem of and adjacent isolator to move freely while minimizing the space requirements of the supports.
A third bellows 45 is used to provide a redundant seal over first bellows 33 and provides a fluid seal between the base 32 and piston 35. Piston 35 and base 32 are provided with a fluid passage to allow pressure communication between bellows 45 and the enclosure defined by the cylindrical housing 36 and cylindrical housing 42. Its purpose is to allow atmospheric pressure equalization and to allow evacuation, thus simulating space conditions. A vent port 46 is used for this purpose. Fluid port 47 is used to fill the fluid chambers with a damping fluid.
Fluid volume variation with temperature change is compensated for by a spring-loaded piston acting to pressurize the damping fluid. A small fluid passage in the axial shaft joins the compensator volume to the main fluid volume at the midpoint of the annular passage where the fluid pressure is maintained substantially constant with temperature. This temperature compensation is provided by a thermal compensator bellows 48 disposed within cylindrical housing 42 and sealed by lower end cap 50 and enclosed by the upper end cap of cylindrical housing 42. Temperature compensator spring 52 is arranged to apply a predetermined pressure on lower end cap 50 so as to pressurize the damping fluid effectively to one half the peak pressure obtained in operation. Fluid expansion due to temperature increase causes temperature compensator bellows 48 to contract thereby allowing additional space for the expanded fluid while maintaining the predetermined pressure by temperature compensator spring 52, thereby relieving an over-pressure condition in the first and second fluid chambers and damping gap of the isolator to maintain a substantially constant system pressure. The axial force maintained on thermal compensator bellows 48 by preload spring 52 establishes a positive pressure on the damping fluid over a wide range of temperature conditions.
Affixed to the base 32 of isolator 14 is a lower pivot 20 and affixed to the stem 22 is an upper pivot 20 of identical construction. By providing these freely moving joints at both ends of the isolator element, an impact or vibratory load in any direction applied to cradle 12 is translated into only axial load in its movement of the isolator elements. The springs and dampers therefore can be optimized for performance along one degree of freedom. FIG. 4 is a perspective view of a preferred embodiment of the flexure pivot. The pivots at each end of the isolator have two angular degrees of freedom. Since they consist of two right angle bending elements, machined into a solid cylinder, they introduce no friction into the system. Having relatively low stiffness, the flexures preclude significant bending loads on the isolator.
The operation of isolator 14, constructed in this manner, will now to be described. When lower pivot 20 moves in an axial direction such that base 32 is pushed toward fluid chamber 54, some of the damping fluid in fluid chamber 54 flows into fluid chamber 53 via the radial gap formed in the annular bore of piston 35. As the damping fluid flows through piston 35 in this manner, a damping force is produced by the viscous resistance of the fluid with axial shaft 43. As a result, piston 35 is subjected to this resistance and compresses bellows 40. At the same time, the fluid in fluid chamber 53 is compressed in accordance with the depth of compression of lower pivot 20. Accordingly, bellows 33 and bellows 45 contract, thereby reducing the capacity of fluid chamber 54, so that the force exerted by the fluid therein increases. If lower pivot 20 moves in a direction such that it extends out from main cylinder housing 36, on the other hand, some of the fluid in fluid chamber 53 flows into fluid chamber 54 between the base 32 and piston 35. Also, in this case, bellows 40 extends and the fluid flows past the restrictive radial gap in piston 35 so that motion of stem 22 is damped.
In response to the movement of lower pivot 20 in the extending direction fluid chamber 54 increases in capacity, so that bellows 33 and 45 extend. Thus, as lower pivot 20 repeatedly extends and contracts relative to stem 22, or stem 22 extends and contracts relative to lower pivot 20, the isolator serves as both shock absorber, vibration absorber, and damper.
Referring now to FIGS. 5-8, there are shown the structures limiting the device which protects the isolator elements from excessive excursions imposed during launch and in zero gravity space. FIG. 5 is a conceptual plan view showing schematically the supporting structure 10, cradle 12, motion limiting aperture 26, and motion stops 60 and 61. In the structure illustrated, the stops 60 and 61 are supported from the cradle; however, in an alternate embodiment stops 60 and 61 may be joined to supporting structure 10 and operatively limiting apertures provided in the cradle 12. This alternate structure is shown in FIG. 9 and FIG. 10. With continued reference to FIG. 5, member 62 is affixed to base structure 10 and provided with motion limiter apertures 26 which are configured to allow free motion of stops 60 and 61, respectively, within predetermined limits. Referring now to FIG. 6, the stop assembly is shown in side view. Member 62 has defined within an aperture therein motion limiter 26. Stop member 60 is comprised of a coaxial tube assembly 63 which in this view is supported from the cradle 12, including a bearing assembly 64, within which a portion of tube assembly 63 is allowed to rotate, and a crank 65 to which is affixed stop member 66. An end view taken through 7--7 of FIG. 6 is shown in FIG. 7. Tube assembly 63 supports crank arm 65 which is affixed to stop number 66. Tube assembly 63 is seen to be supported by bushing 64.
Referring now to FIG. 8, a detailed view of the tube assembly is shown. Tube assembly 63 is comprised of first and second coaxial tubes 66, 67 disposed in parallel to the plane of the cradle 12 and are joined at end 68 by welding, braising, or other similar means. Outer tube 66 is secured to the base structure 10 at one end. The free end of inner tube 67 is provided with a shaft 69 which extends through support bearing 64 to crank arm 65. Crank arm 65 is in turn provided with stop member 60 at right angles to shaft 69. In response to deflection of cradle 12 induced by motion of the supported structure, stop member 60 will be caused to engage aperture 26 after a predetermined deflection of the cradle. This will cause free arm 65 to apply a torque to inner tube 67 and resiliently apply a predetermined counterforce to cradle 12 thereby restraining the isolator elements from deflection greater than a predetermined value which is established from the spring constant of the tube assembly 63, and using the dimensions of stop number 60 and motion limiter aperture 26.
FIGS. 9 and 10 show an alternate embodiment of the motion limiting structure. Cradle 12 is provided with slots to receive a stop 60 which again engages crank arm 65 to produce a limiting force from the coaxial tube assembly 63, here secured to base 10.
It may be seen from the foregoing that the deterministic design of the isolators allows calculation to establish the required amount of damping and the required stiffness of the elastic members when given the force, direction of force, frequency range, amplitudes and directions of vibrations to be expected. The kinematic structure is adaptable to deformation of the supporting structure as well as mounting errors of the flexure joints connecting the isolator elements to the structures without applying undesired constraints. Element design requirements can be derived from the system frequency and peaking (Q) requirements. The element stiffness (K), damping constant (C), and skew angle (α) can, for example, be selected to match the X/Y translational frequency (fx), the X/Y rotational frequency (fx) and the X/Y translational peaking frequency (Qx). The steady state frequency response can be computed from the known constants and transfer functions as shown in FIGS. 11-14. It is also possible to select the skew angle (α) for isoelastic stiffness where Kx=Ky=Kz. By arranging the isolator elements inclined relative to the azimuth axis, the system may be provided with significantly increased stiffness with respect to the movement of the cradle along the Z axis. More specifically, the axial restraint attributable to the stiffness of the suspension elements about their axes varies with the cosine squared of the angle. Consequently, the axial stiffness of the system will decrease as the angle (α) is increased.
FIG. 11 shows that the translation transmissibility along the X axis reaches a peak at 4 Hz and attenuates rapidly thereafter. Y axis translation follows a similar characteristic as shown in FIG. 12. FIGS. 13 and 14 show the corresponding rotation transmissibility characteristics along the X rotation axis and the Y rotation axis, reaching a peak at approximately 9 to 10 Hz. A resonant frequency of 9 to 10 Hz is required for X and Y axis rotation in order to provide rigidity for the magnetic suspension control torques to be effectively applied. Thus, substantial isolation is obtained over a large frequency range in the X and Y coordinates, while allowing transmission of the desired control torque frequencies about the X, Y, and Z axes.
Stop stiffness is set to provide a compromise between the peak deflections under the launch conditions and the peak impact loads. The isolator element design also permits the use of a nonlinear damping technique to provide a higher damping constant during launch than in operation. Higher damping would reduce the impact loads without the necessity of increasing the stroke.
The novel use of tuning springs provides a low cost, convenient technique to tune the stiffness of the isolator element to provide a very tightly controlled frequency response. The tuning springs are positioned in a way that does not increase the interface dimensions. The upper and lower bellows are designed to provide approximately one third of the needed element stiffness, the tuning springs and the redundant seal bellows providing the remainder. A metal bellows is preferred over synthetic rubber or other polymers because of the better dimensional and stiffness controls offered. The damping coefficient can be changed significantly by using a different viscosity damping fluid. Thus, the design offers significant flexibility in optimizing performance.
While the present invention has been adapted to provide a complex mechanical impedance as a function of frequency which allows transmission of control torque producing frequencies while suppressing undesired vibration frequencies, it is clear that the isolator structure is also applicable for providing vibration isolation and damping in the absence of such control torques. Moreover, while the isolator elements have been skewed at a predetermined angle with respect to the Z axis, with the base of the isolator pairs and the upper joints of the isolators at a common radius R from the Z axis, other attitudes of the isolators may be desirable where the base and upper joints are constructed at differing radii to favor a desired transnational or rotational axis transmissibility characteristic.
While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than words of limitation and that changes may be made within the preview of the appended claims without departing from the true scope and spirit of the invention in its broader aspects. | A system for isolating a supported structure from transmitting vibrations to a supporting base in a spacecraft provides six degrees of freedom in a kinematic mounting. Six isolator elements in a symmetric arrangement of three skewed isolator pairs provides viscous damping and vibration and shock attenuation during launch and operation in space. The isolators employ two degrees of freedom flexure joints at each mounting point to assure primarily axial deflection and minimize bending moments, and have tuning springs to optimize performance. The system permits deterministic design and allows calculation of all loads from the nominal geometry and the isolator axial stiffness. Limit stops are provided between the supporting structure and the supported structure to limit excursions of the isolator members. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 12/791,780, filed Jun. 1, 2010, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/182,673, filed May 29, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OR PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not applicable.
SEQUENCE LISTING
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention relates generally to electric motors, and more particularly to a electromagnetically driven motor and electric power generator.
[0008] 2. Discussion of Related Art including information disclosed under 37 CFR §§1.97, 1.98:
[0009] Optimal mechanical efficiency and power conservation in electric motors and electric power generators is an implicit and tacit objective, yet it is of paramount importance. Indeed, it is in the very nature of such machines to be efficient. To that end, a well known means of improving efficiency in motors has been through the reduction of friction between moving parts in contact with one another. Most often that is achieved by introducing a lubricant between the parts.
[0010] Another objective, now also of paramount importance, is that of being environmentally clean. To that end, it is increasingly desirable to employ only those engines and motors that provide motive force, and electrical power generators that provide electrical energy, without the consumption of fossil fuels.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention harnesses the energy contained in the magnetic fields of permanent magnets to assist in driving an electric motor. More specifically, the present invention provides a way to exploit the motive force available when two magnets having identical polarity are brought into proximity. In the present invention, this is accomplished by circumferentially positioning an array of permanent magnets (“drive magnets”) on a rotor and positioning a series of electromagnets on a platform surrounding the drive magnets. The electromagnets are energized and provided with a repulsive polarity only at the exact time and position necessary to repel a corresponding drive magnet on the rotor so as to drive the rotor in one direction. The rotor includes one or more other circumferentially disposed arrays of permanent magnets (electrostatic “induction magnets”), as well, but these other sets of magnets are employed to induce current in circumferentially disposed wire coils in proximity to the induction magnets.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1A is a schematic upper perspective view showing a first preferred embodiment of the electromagnetically driven motor and electric power generator of the present invention;
[0013] FIG. 1B is a schematic exploded view thereof; and
[0014] FIG. 2 is a schematic upper perspective view of a second preferred embodiment of the electromagnetically driven motor and electric power generator of the present invention;
[0015] FIG. 3 is a schematic exploded upper perspective view of a third preferred embodiment of the motor and electric power generator of the present invention;
[0016] FIG. 4 is an upper perspective view thereof;
[0017] FIG. 5 is a lower exploded perspective view showing the lower portion of the apparatus without the stators shown; and
[0018] FIG. 6 is an upper perspective view showing an alternative embodiment of the apparatus of FIGS. 3-5 , in which the ring of electromagnets has been replaced by a linear induction motor ring.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring next to FIGS. 1A and 1B , there is shown a first preferred embodiment of the electromagnetically driven motor and electric power generator of the present invention. This embodiment in its entirety bears reference number 1000 herein. Collectively, these figures show that the inventive apparatus comprises generally cylindrical upper and lower inner stators 1010 , 1015 , respectively, each having a proximal end 1020 , 1025 , a distal end 1030 , 1035 , an annular structural ring formed in the distal end 1040 , 1045 , an outer circumferential dimension 1050 , 1055 , and a plurality of coil windings 1060 , 1065 embedded in the annular structural ring or otherwise affixed to the body of its respective inner stator in an array of columns or rows such that both the inner and outer surfaces 1070 , 1075 , and 1080 , 1085 , respectively, of the coil containers are exposed or only lightly protected by a thin layer of non-ferrous material.
[0020] Next, the inventive electromagnetic electric generator apparatus includes a substantially cylindrical rotor 1100 having an inside diameter and an outside diameter (not indicated by reference numbers), the inside diameter slightly larger than the outside diameter or outside circumferential dimension of the upper and lower inner stators, such that the inner stators insert into the rotor with an acceptable clearance for free rotation, and optimal magnetic levitation relative to both the upper and lower outer stators 1200 , 1205 (the latter elements to be described in detail below), and optimal induction during operation (also to be described below). The rotor has an upper end 1110 and a lower end 1120 , and a circumferential midline 1130 . An upper and lower row of permanent magnets 1140 , 1150 are each arrayed in rows on the upper and lower sides, respectively, of the circumferential midline. Upper and lower structural rings 1160 , 1170 integrally connect with a medial circumferential ring 1180 with vertical slats 1190 to form the framework within which the magnets are disposed.
[0021] Next, it will be seen that a plurality of permanent magnets 1000 are circumferentially disposed around the circumferential midline 1130 and medial ring 1180 of the rotor. The magnets are oriented with exposed poles angled rearwardly relative to the direction of rotation of the rotor. An axially oriented spindle 1310 having a center axle 1320 spans the distance from the upper to lower edges of the rotor and is affixed to the medial ring with radially extending spokes or a concentrically disposed solid plate or disk (not shown) which connects to the inner wall of the rotor at the circumferential midline.
[0022] Next, the inventive electromagnetically driven electric generator includes substantially cylindrical upper and lower outer stators 1200 , 1205 . Each outer stator in the assembly includes an inside diameter and an outside diameter (not indicated by reference numbers), the inside diameters being slightly larger than the outside diameter of the rotor, such that the rotor inserts into the outer stators with an acceptable clearance for free rotation of the rotor within the outer stators, and for optimal magnetic levitation of the rotor relative to the outer stators, and for optimal induction during operation. The upper and lower outer stators each include a proximal end 1210 , 1215 and a distal end 1220 , 1225 , and an inwardly projecting ring or cap 1230 , 1235 disposed at the respective distal ends and to which the upper and lower inner stators are affixed in a spaced apart relationship such that the rotor is disposed between the inner stators and outer stators with a small clearance.
[0023] Each of the upper and lower outer stators also includes either cross members 1240 , 1245 or end plates having, both possible structures including a center bearing or bushing 1325 in which each end of axle 1320 is journalled. A plurality of outwardly extending arches 1350 connect to the upper cap 1230 of the upper outer stator 1200 and arc downwardly to a terminus 1155 generally coplanar with the cap 1235 on lower outer stator 1205 .
[0024] A support ring 1260 is attached or integrally affixed to the arches for structural support and to provide a structural element for affixing a plurality of electromagnets 1270 , which angle away from the direction of rotation of the rotor so as to orient the magnetic pole 1275 (which is opposite the exposed pole of permanent magnets 1300 on rotor 1100 ), such that the permanent magnets 1300 on rotor 1100 are repelled and driven by the electromagnets 1270 in support ring 1260 .
[0025] The upper and lower outer stators each include a row 1290 , 1295 , respectively, of coil windings 1292 , 1297 , circumferentially disposed around the stators and having exposed sides, in the same manner as those of the inner stators. Thus, when the rotor is inserted between the upper and lower inner and outer stators and the axle journalled in the upper and lower bushings, the rotor circumferential midline 1130 is concentric with the support ring 1260 , thereby bringing the rotor's permanent magnets 1360 , into concentric alignment with electromagnets 1270 , and the upper and lower inner and outer stators are held in a spaced apart relationship, the former to accommodate and allow movement of the center plate or spokes 1390 extending from spindle 1310 , and the latter to accommodate and allow free movement of the rotor. The space or gap 1299 between the upper and lower outer stators is shown in FIG. 1A .
[0026] Referring now to FIG. 2 , there is shown a second preferred embodiment 1360 of the inventive electromagnetically driven motor and electric power generator of the present invention. In this embodiment all of the structural and operative elements are identical to those of the second preferred embodiment, except that electromagnets 1270 are replaced by a high speed linear synchronous motor or linear induction motor ring (LSM ring) 1365 comprising a plurality of electromagnets configured in an annular array. In effect, this is the same device as that shown in FIGS. 1A-1B , but includes a substantially continuous ring of electromagnets rather than an array of a relatively small or limited number of spaced apart magnets.
[0027] In either of the second and third embodiments shown in FIGS. 1 through 2 , respectively, the electromagnets may be pulsed (that is, turned on and off) in a sequence. Additionally, they can be provided with power in a precise manner so as to control the rotation speed of the rotor. The electric pulses can be timed by a circuit that includes optical infrared sensors disposed around the circumferential LSM ring 1365 or support ring 1260 , and which sense the proximity of a surface of magnets 1300 , adjusting the pulse timing according to the then current speed of the rotor.
[0028] Referring next to FIGS. 3-5 , there is shown a fourth preferred embodiment of the electromagnetically driven motor and electric power generator of the present invention, generally denominated 1400 herein. In this embodiment, the inventive apparatus includes generally cylindrical upper and lower stators 1420 , 1425 , respectively, each having a proximal (upper) edge or end 1570 , 1575 (as viewed from the top down), a distal (lower) edge or end, 1580 , 1585 an annular structural mounting ring, 1590 , 1595 , first and second sets 1650 , 1655 , respectively, of coil windings, 1660 , 1665 , circumferentially disposed around the upper and lower stator drums, 1593 , 1597 , respectively, and having exposed sides, or sides lightly covered with a thin layer of non-ferrous material. Each stator in the assembly includes an inside diameter and outside diameter (not indicated by reference numbers), the stator inside diameters being slightly larger than the outside diameter of the rotor 1410 , such that the rotor inserts into the stators with an acceptable clearance for free rotation of the rotor within the stators, and for optimal induction during operation. As is shown, each of the upper and lower stator coil rings, 1660 , 1665 are affixed to their respective stator drum, which is, in turn, attached to a structural mounting ring, 1590 , 1595 , the upper of which attaches to top plate, 1600 , and the bottom of which attaches to base plate, 1605 .
[0029] The supportive frame for this embodiment includes an upper (top) plate 1605 and lower (base) plate 1605 , each including a center bearing or bushing 1608 , in which a bearing 1610 on center axle 1550 is seated. A plurality of outer columnar supports 1620 connect at connection points 1625 upper and lower plates, 1600 , 1605 . A plurality of levitation magnets 1680 are disposed in the distal (lower) end 1450 of the rotor 1410 and in an annular channel 1603 in the base plate 1605 , and the absence of bearings or other surface contacts allows the rotor to spin on center axle with greatly reduced friction.
[0030] The substantially cylindrical rotor, 1410 , has an inside diameter and an outside diameter (not indicated by reference numbers), the outside diameter being slightly smaller that the inside diameter of the upper and lower stator mounting rings, 1590 , 1595 . The rotor 1410 has an upper end, 1440 and a lower end, 1450 , and a circumferential midline, 1460 . An upper and lower set of permanent magnets, 1470 , 1480 are each circumferentially arrayed in rows on the upper and lower sides, respectively, of the circumferential midline, 1460 . Upper and lower structural rings, 1490 , 1500 integrally connect with a medial circumferential ring 1510 with vertical slats 1520 to form framework within which the rows of magnets 1470 , 1480 are disposed.
[0031] As in the earlier embodiments, this embodiment includes an electromagnetic drive assembly that includes a plurality of drive magnets 1530 , which are also permanent magnets, and which are circumferentially disposed around the circumferential midline, 1460 and medial ring, 1510 of the rotor. The magnets are oriented with exposed poles angled rearwardly relative to the direction of rotation of the rotor. An axially oriented spindle 1540 having a center axle, 1550 spans the distance from the upper to lower edges of the rotor and is affixed to the medial ring with radially extending spokes (not shown) or a concentrically disposed solid plate or disc (not shown) which connects to the inner wall of the rotor at the circumferential midline.
[0032] Upper and lower support rings, 1630 , 1635 are attached or integrally affixed to the supports 1620 to provide a structural base and ceiling for securing and sandwiching a plurality of electromagnets 1640 , which angle away from the direction of rotation of the rotor so as to orient the magnetic pole 1645 (which is identical in polarity from the exposed pole of permanent magnets 1530 on rotor 1410 ), such that the permanent magnets 1530 are repelled and driven by the electromagnets 1640 in support rings 1630 , 1635 when energized.
[0033] A sensor mounting ring 1390 has a plurality of electromagnet tripping sensors 1380 (photo coupled interrupter modules) mounted thereon. The tripping sensors are connected to a power supply circuit. The sensor mounting ring is affixed to the upper plate 1600 , such that each tripping sensor corresponds to a single electromagnet, 1640 . Next, a propeller vane, 1370 having photo interrupter blades 1375 corresponding in number to the number of permanent magnets 1530 in medial ring 1510 , is positioned on center axle 1550 , such that when blades 1375 interrupt the beams from sensors 1380 , the power supply circuit causes a corresponding electromagnet 1640 to be energized, thereby creating an identical polarity to the outward facing pole of the most proximate permanent magnet 1530 , and thus creating magnetic repulsion which causes rotor 1410 to spin.
[0034] As will be readily appreciated by those with skill, the principle of operation of the above-described third preferred embodiment is in all material respects identical to that of the first through third embodiments.
[0035] In each embodiment, the structural and operative elements are configured to enable the motor and generator to run independently of the power supply when the rotor has achieved sufficient angular momentum. In this respect, the power supply may be conceived of as a motor starting circuit which selectively and periodically energizes the electromagnet as long as necessary for the system to become self-powering and at which point the permanent magnets are the sole motive force operating on the rotor to sustain rotation. In certain systems, a shunt circuit can be connected to the output of the wire coils to function as a charging circuit. Such a circuit includes a plurality or a bank of capacitors that taps into the output circuit when the rotor is at optimal operating speed, and delivers current in pulses to the capacitors, but with a frequency that does not impose too significant a load on the rotor so as to drag it to a stop. Rather, the charging circuit is controlled so as to permit the rotor to rebuild to optimal speed after current is siphoned off. The capacitors periodically discharge into batteries.
[0036] In FIG. 6 there is shown a fourth preferred embodiment of the inventive electromagnetically driven electric power generator. In this instance, the medial assembly of electromagnets shown in FIGS. 3-5 is replaced by a linear synchronous motor or linear induction motor ring (LSM ring) 1710 comprising a plurality of electromagnets configured in an annular array. Again, this is essentially the same device as that shown in FIGS. 3-5 , but includes a substantially continuous ring of electromagnets rather than an array of a relatively small or a limited number of spaced apart electromagnets.
[0037] The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiments of this invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like.
[0038] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which shall be defined by the claims filed concurrently with a successor non-provisional, regular national utility patent application. | Method and apparatus for powering an electric motor by circumferentially positioning an array of drive magnets on a rotor and positioning a series of electromagnets on a platform surrounding the drive magnets. The electromagnets are energized and provided with a repulsive polarity at exact time and position necessary to repel a corresponding drive magnet on the rotor so as to drive the rotor in one direction. The rotor includes arrays of permanent magnets that induce current in wire coils circumferentially disposed in one or more stators around and in close proximity to the induction magnets. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 09/976,277, filed Oct. 15, 2001, which is now U.S. Pat. No. 7,184,389. This application also claims the benefit of Korean Patent Application No. 2000-69018 filed on Nov. 20, 2000, in the Korean Industrial Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical recording medium and a reproducing apparatus and method, and more particularly, to a recording medium storing information regarding data in the current sector as data in a linking loss area, and an apparatus and method linking data.
2. Description of the Related Art
Since basic recording units of a digital versatile disc-rewritable (DVD-RW) are positioned one after another in a continuous series, in contrast to those of a DVD-Random Access Memory (DVD-RAM) which are divided by physical identifier (PID) areas or buffer fields (extra areas allocated to correspond to a requirement for controlling a spindle motor accurately), it is required that a recording-start point of each basic recording unit in a DVD-RW is precisely located. Here, the basic recording unit of the DVD-RAM may be a sector and the basic recording unit of the DVD-RW may be an error correction code (ECC) block.
Since the basic recording units of the DVD-R and the DVD-RW, which have the same physical formats, are positioned in a continuous series as described above, when data transmission or recording is momentarily discontinued or subsequently recommenced, the DVD-R and the DVD-RW use a linking scheme in which an extra area of a next recording-start point is allocated. The sizes of a linking area which is applied to the linking scheme are 0 kilo bytes (KB), 2 KB, and 32 KB.
FIGS. 1A through 1C are schematic diagrams showing conventional data linking methods. FIG. 1A shows the data structure of a 2 KB linking method, FIG. 1B shows the data structure of a 32 KB linking method, and FIG. 1C shows the data structure of a 0 KB linking method. In the conventional linking methods as shown, if the data type in sector information is ‘1b’, this indicates that the next sector is a linking loss area. The linking loss area has no effective data and only stores dummy data, that is, ‘00h’. Therefore, main data recorded in a subsequent area is replaced with ‘00h’ regardless of reproducing data, and therefore correction of an ECC block can be improved.
FIG. 1A shows a data structure in which the size of a linking loss area is 2 KB, and FIG. 1B shows a data structure in which the size of a linking loss area is 32 KB. If user data does not fill an entire first ECC block, padding data is recorded in the remaining part of the first ECC block. If the data type of the last sector of the first ECC block is ‘1b’, the first sector (2 KB) of the second ECC block or an entire second ECC block (16 sectors=32 KB) becomes a linking loss area according to a linking type and padding data is recorded in the linking loss area.
FIG. 1C shows a data structure, in which 0 KB linking is performed after performing 32 KB linking. That is, FIG. 1C shows 0 KB link recording in the second ECC block (the 32 KB linking loss area) of FIG. 1B , and user data is recorded from the first sector of the second ECC block in which 0 KB linking is performed. However, if the data type is ‘1b’ in the last recording sector of the first ECC block of FIG. 1C , the next sector, that is, the first sector of the second ECC block, may be taken for a linking loss area and user data can be replaced with ‘00h’. Therefore, an error may occur in this sector, and as a result an ECC error occurs in the entire second ECC block and data in the second ECC block cannot be reproduced.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a recording medium having sectors where data is recorded, in which data in a sector is regarded as data in a linking loss area according to data type information.
It is another object of the present invention to provide a method of linking data, depending on effectiveness of data in a sector, which is determined by using data type information.
It is yet another object of the present invention to provide an apparatus linking data, depending on effectiveness of data in a sector, which is determined by using data type information.
Additional objects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
The foregoing and other objects of the present invention are achieved by providing a recording medium having sectors where data is recorded, in which each sector has a data identification area, in which information identifying the type of data recorded in the sector is recorded, and the data identification area indicates at least whether or not data recorded in the sector is linking data.
The above and other objects of the present invention may also be achieved by providing a method of linking data, the method having the operations of (a) dividing an error correction code block having a predetermined size into a plurality of sectors and checking data type identification information which indicates whether or not data in each sector is linking data; and (b) replacing main data of a sector with predetermined data according to the result of checking the data type identification information.
The above and other objects of the present invention may also be achieved by providing an apparatus linking data in a process recording and/or reproducing optical data, the apparatus having a checking unit checking and outputting the type of data if no error occurs in an error correction code block having a plurality of sectors, each sector having data type identification information which indicates that data recorded in the sector is linking data; and a replacing unit that replaces main data of a sector with predetermined data according to the data type output from the checking means.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIGS. 1A , 1 B, and 1 C are schematic diagrams of the data structure in a conventional data linking method;
FIG. 2 is a block diagram of a digital versatile disc-recordable/rewritable (DVD-R/RW) apparatus;
FIG. 3 is a block diagram of the configuration of an apparatus providing linking data according to the present invention;
FIG. 4 is a schematic diagram showing the data structure of a data identification area, in which data type information is stored, according to the present invention; and
FIGS. 5A , 5 B, and 5 C are schematic diagrams of a data structure explaining a data linking method according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
The DVD-R/RW apparatus shown in FIG. 2 has a disc 20 , a pickup 21 , an auto laser power control (ALPC) 22 , a radio frequency-amplifying unit 23 , a data processor 24 , a host interface 25 , a host 26 , a servo processor 27 , a motor and driver 28 , and a microcomputer (MICOM) 29 .
The ALPC 22 controls the power of a laser beam emitted from the pickup 21 , and the radio frequency-amplifying unit 23 amplifies a minute signal picked up from the disc 20 . The data processor 24 processes link data in accordance with data types, performs detection, insertion, protection, modulation and demodulation of a synchronization signal, and generates various control signals for error correction and for controlling the radio frequency-amplifying unit 23 . The host interface 25 connects the optical recording apparatus with a host 26 . The servo processor 27 controls various motors and servos related to the disc 20 to perform tracking and focusing, etc. The motor and driver 28 performs a function of rotating the disc 20 and driving motors, and the MICOM 29 controls the overall operation of the optical recording apparatus.
FIG. 3 is a block diagram of the configuration of an apparatus linking data according to the present invention, and is a detailed diagram of the data processor 24 shown in FIG. 2 . The data processor 24 of FIG. 3 has a data converting unit 24 - 1 , a non-return-to-zero (NRZ) converting unit 24 - 2 , a sync detecting unit 24 - 3 , a demodulating unit 24 - 4 , an identification error detection (IED) checking unit 24 - 5 , a data type checking unit 24 - 6 , and a data replacing unit 24 - 7 .
The data converting unit 24 - 1 converts an analog signal, which is amplified and output by the radio frequency-amplifying unit 23 , into non-return-to-zero inversion (NRZI)-type digital data. The NRZ converting unit 24 - 2 converts NRZI-type data, which is output from the data converting unit 24 - 1 , into NRZ-type data. The sync detecting unit 24 - 3 performs detection, protection, and insertion of various synchronization signals contained in NRZ data. The demodulating unit 24 - 4 demodulates the modulated 16-channel bits into 8 bits. The IED checking unit 24 - 5 checks whether or not an error exists in a data identification area in the demodulated data.
If the IED checking unit 24 - 5 indicates that there is no error in the data identification area, the data type checking unit 24 - 6 checks data type information in the data identification area.
FIG. 4 is a schematic diagram showing the data structure of a data identification area, in which data type information is stored, according to the present invention. The data identification area is formed with a sector information field and a sector number field. The sector information field is formed of a sector format type field, a tracking method field, a reflectance field, a reserve field, an area type field, a data type field and a number-of-layers field.
That is, sector format type information of bit position b 31 indicates a constant linear velocity (CLV) or zone constant linear velocity (ZCLV) as follows:
0b: CLV format type 1b: Zoned format type, specified for Rewritable discs
Tracking method information of bit position b 30 indicates pit tracking or groove tracking as follows:
0b: Pit tracking 1b: Groove tracking, specified for Rewritable discs
Reflectance information of bit position b 29 indicates whether or not reflectance exceeds 40% as follows:
0b: Reflectance is greater than 40% 1b: Reflectance is less than or equal to 40%. Bit position b 28 indicates a reserve bit.
Area type information of bit positions b 27 and b 26 indicates a data area, a lead-in area, a lead-out area, or a middle area for a read-only disc as follows:
00b: Data area 01b: Lead-in area 10b: Lead-out area 11b: Middle area of read-only discs
Data type information of bit position b 25 indicates read-only data, or the linking data as follows:
0b: Read-only data 1b: Linking data
Layer number information of bit position b 24 indicates the number of layers in a single layer disc or a dual layer disc as follows:
0b: Layer 0 of dual layer disc or single layer disc 1b: Layer 1 of dual layer disc
A data identification area for storing data type information, as shown in FIG. 4 , is recorded on a recording medium, such as an optical disc 20 .
If data type information in bit position b 25 of FIG. 4 is ‘1b’, the data replacing unit 24 - 7 replaces main data in the corresponding sector, that is, the current sector, with ‘00h’ and outputs ‘00h’ to an external or internal memory (not shown).
FIGS. 5A , 5 B, and 5 C are schematic diagrams of a data structure explaining a data linking method according to the present invention, showing a 2 KB link method, a 32 KB link method and a 0 KB link method, respectively.
In the linking method of the present invention, shown in FIGS. 5A , 5 B, and 5 C, if the data type contained in sector information is ‘1b’, this indicates that the current sector is a linking loss area. A linking loss area has no effective data and only dummy data is recorded in the linking loss area. Therefore, main data recorded in the current sector is replaced with ‘00h’ regardless of data to be reproduced, and correction of an ECC block can be improved.
FIG. 5A is a data structure in which the size of a linking loss area is 2 KB (1 sector), and FIG. 5B is a data structure in which the size of a linking loss area is 32 KB (16 sectors). If user data does not fill the entire first ECC block, padding data is recorded in the remaining part of the first ECC block. In the prior art, if the data type is ‘1b’, the next sector is allocated as a linking loss area. However, in the present invention, the current sector is allocated as a linking loss area, and therefore the sector marked by ‘*’, in which the last user data is recorded, has no meaning in the present invention. If the data type of the current sector of the second ECC block is ‘1b’, the current sector is allocated as a linking loss area and main data in the current sector is replaced with dummy data ‘00h’.
FIG. 5C shows a data structure in which 0 KB linking is performed after performing 32 KB linking. That is, FIG. 5C shows 0 KB link recording in the second ECC block (the 32 KB linking loss) of FIG. 5B , and user data as main data is recorded in the first sector in which 0 KB linking is performed. Also in FIG. 5C , if the user does not fill the entire first ECC block, padding data is recorded in the remaining part of the first ECC block. In the prior art, if the data type is ‘1b’, the next sector is allocated as a linking loss area. However, in the present invention, the current sector is allocated as a linking loss area, and therefore the sector marked by ‘*’, in which the last user data is recorded, has no meaning in the present invention. In addition, even if user data is recorded as 0 KB in the second ECC block, which is linked by 32 KB, the data type in the current sector is checked and the current sector can be allocated as a linking loss area. Therefore, the problem of error occurrence is solved. That is, since the data type of the current sector is ‘0b’, main data is determined as user data and is not replaced with dummy data ‘00h’.
According to the method of the present invention, data type information is checked to determine whether or not to replace main data of the current sector with dummy data. By doing so, error occurrence of the prior art can be prevented and block error correction is more effectively carried out.
Although a few embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. | An optical recording medium storing information for regarding data in the current sector as data in a linking loss area, and an apparatus and method providing linking data. The data link method includes dividing an error correction code block having a predetermined size into a plurality of sectors and checking data type identification information which indicates whether or not data in each sector is linking data; and replacing main data of a sector with predetermined data according to the result of checking the data type identification information. According to the above method, data type information is checked to determine whether or not to replace main data of the current sector with dummy data. By doing so, error occurrence of the prior art can be prevented and block error correction is carried out more effectively. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of U.S. patent application Ser. No. 08/525,804, filed Sep. 8, 1995 and entitled "Adjustable Torque Clutch for Remote Controlled Circuit Breakers" now abandoned.
FIELD OF THE INVENTION
This invention relates generally to a clutch assembly and, more specifically, to an adjustable torque clutch assembly for use in a circuit breaker motor operator.
BACKGROUND OF THE INVENTION
Circuit breakers may be controlled remotely by a motor operator. These motor operators typically utilize a torque limited module to couple a drive motor to a circuit breaker operating mechanism. Such a torque limited module includes a clutch that is centered on a drive shaft. One such clutch is disclosed in U.S. Pat. No. 4,921,083 entitled "Clutch Module with Predetermined Torque". This clutch is precisely loaded by means of a centering and spacing ring in the form of a cylinder. Upper and lower module plates embrace the spacer ring, which houses friction elements being loaded by a pair of springs. The friction elements include a pair of friction discs, separated by a spacer or slip disc, and a drive plate. The springs control the clutch frictional force between the friction elements thereby controlling the torque of the clutch assembly. The motor is supplied with a current pulse of duration longer than the time required to fully operate the circuit breaker. The friction elements slip when the circuit breaker operation is completed thereby permitting the motor to overrun without damage.
With such prior art clutches, the torque of the clutch assembly is determined by the height of the centering ring, the thickness of the friction elements and the spring rate of the springs inside the centering ring. In order to achieve a pre-determined torque, these clutch components are designed for and must be precisely fabricated to tight tolerances. This type of clutch design has the disadvantages of increased cost because of the high tolerance requirement and the inability to adjust the clutch torque at assembly time for any reason, particularly if out-of-tolerance components are to be accommodated. Accordingly, there exist a need for a clutch assembly which provides the desired pre-determined torque without requiring tight manufacturing tolerances, and also permits the clutch torque to be precisely adjusted at the time the clutch is assembled.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a clutch for limiting the torque applied in a circuit breaker operating mechanism.
It is a more specific object of the present invention to provide an adjustable torque clutch, which provides the ability to adjust the torque at the time the clutch is assembled.
It is another object of the present invention to provide a method for assembling an adjustable torque clutch such that the torque is adjusted at the time the clutch is assembled.
These objects are realized according to this invention by providing a novel clutch assembly having a gasket and a method of assembling to provide a clutch assembly with the desired torque without requiring the components to be manufactured to tight tolerances.
In accordance with a preferred embodiment the clutch assembly includes a cylinder ring which is disposed between upper and lower clutch plates and houses a pair of friction discs, a drive plate disposed between the friction discs, and a spring for forcing the friction discs together to create a frictional coupling force between the drive plate and the pair of friction discs. The exact amount of frictional force is determined by the distance between the upper and lower plates. Torque adjustment means in the form of a rubber gasket is disposed between the housing and one of the pair of clutch plates for adjusting the distance therebetween, thereby allowing the frictional force, and hence the overall clutch torque to be adjusted. A plurality of screws are provided to secure the clutch plates together once the frictional force is adjusted to a desired amount.
The present invention also provides a method for assembling a clutch assembly to take advantage of the adjustable torque mechanism. The method includes sequentially placing the housing, the pair of plates, the drive plate, the friction disc, the spring and the rubber gasket into an assembly fixture. Next, a load is applied to the pair of plates thereby compressing them together. The frictional force is adjusted until a pre-determined frictional force is achieved and then the pair of plates are secured together.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will be apparent from the following detailed description and the accompanying drawings in which:
FIG. 1 is a block diagram of a circuit breaker remote control arrangement using a motor operator to drive a circuit breaker through a clutch assembly;
FIG. 2 is an exploded view of a clutch assembly in accordance with the present invention;
FIG. 3 is a partial view showing the assembled clutch assembly; and
FIG. 4 is a side view of an assembly fixture and the clutch assembly showing the method of assembling the clutch assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a better understanding of the present invention together with other and further advantages, and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings.
Referring first to FIG. 1, there is shown a remotely control circuit breaker arrangement 1 which uses a drive motor 2 to operate through a clutch assembly 4 to drive a circuit breaker 6. The motor 2 is activated by a control signal and its driving motion is transmitted to the clutch assembly 4 through a motor shaft 8 coupling the motor 2 to the clutch assembly 4. The clutch assembly 4 transfers the rotation of the motor shaft 8 through a drive shaft 9 to the circuit breaker 6 in order to realize the necessary remote control thereof. In particular, the drive shaft 9 is used to rotate an operating mechanism arm (not shown) of the circuit breaker 6 through a limited angle for opening (or closing) electrical circuits completed therethrough. The clutch assembly 4 limits the torque applied to the drive shaft 9 and its use in motor operators for driving remote controlled circuit breakers is well known. For instance, U.S. Pat. No. 4,921,083 entitled "Clutch Module with Predetermined Torque", which is also assigned to the assignee of the present application covers an illustrative motor operator arrangement, and the disclosure therein is incorporated herein by reference.
Referring now to FIG. 2, there is shown an improved clutch assembly 10 is according to a preferred embodiment of the present invention having a novel rubber gasket 12 for providing the ability to adjust the torque of the clutch assembly 10. The other components of the clutch assembly 10 are not believed to be necessary for the understanding of the present invention, however, the reader may refer to U.S. Pat. No. 4,921,083 which has been previously incorporated by reference.
The clutch assembly 10 components are bounded by an upper clutch plate 14 and a lower clutch plate 16. The upper and lower clutch plates 14, 16 are secured by a plurality of circularly disposed screws 18 which pass through appropriate holes 20 in the upper clutch plate 14 and into threaded apertures 22 in the lower clutch plate 16. The rubber gasket 12 is disposed adjacent to the lower clutch plate 16 and a cylindrical centering ring 24 is disposed between the rubber gasket 12 and the upper clutch plate 14. Friction elements are disposed inside the centering ring 24 which comprise a drive plate 25 disposed between a pair of annular friction discs, a top friction disc 26 and a bottom friction disc 28. The drive plate has a central opening which is adapted for engagement with the drive shaft 9. An annular slip or spacer disc 30 separates the friction elements from a set of Belleville washers or springs 32.
FIG. 3 illustrates the assembled clutch assembly 10 wherein the various clutch components are squeezed together between the upper and lower clutch plates 14, 16, by virtue of the spring force of the Belleville springs 32 and tightening of the screws 18, to fit wholly within the confines of the centering ring 24 and the rubber gasket 12. The rubber gasket 12 is disposed between the centering ring 24 and the lower clutch plate 16 and acts as a resilient spacer thereby allowing the distance between the upper and lower clutch plates 14, 16 to be adjusted. During assembly of the clutch assembly 10, this arrangement allows the centering ring 24 to be pressed against the rubber gasket 12 until the desired torque is achieved. After the desired torque is achieved, the screws 18 are tightened to a range of 15-20 lb-in. thus forcing all of the clutch components within the confines of the centering ring 24 and rubber gasket 12. As a result, the centering ring 24 not only serves to maintain the various clutch components in alignment, it establishes, in combination with the rubber gasket 12, a consistent torque load for the clutch assembly 10.
The torque that the clutch provides is defined by the frictional force between the friction elements. The frictional force is defined by the amount of compression of the springs 32 which is defined by the distance between the upper and lower clutch plates 14, 16. The rubber gasket 12 is provided to allow this distance to be adjusted, and also functions as a seal to prevent any contaminants from entering into the clutch assembly 10.
The height of the centering ring 24 is such that when the upper and lower clutch plates 14, 16 are squeezed together, without the rubber gasket 12 disposed between the centering ring 24 and the lower clutch plate 16, the resulting torque would be too high. The height of the rubber gasket 12 is sized such that the combination of the centering ring 24 and the rubber gasket 12, in a non-compressed state, the resulting torque would be too small. The optimal torque is achieved when the centering ring 24 is pressed into the rubber gasket 12. The method that is utilized to achieve the optimal torque will be discussed hereinbelow.
The rubber gasket 12 is preferably made of a buna-n material having a hardness in the range of 65-75 Durometer Shore A. The rubber gasket is available as part number 035S (or equivalent) from Wolf Creek Rubber Company of Beaman, Iowa.
The operation of the friction elements is similar to that disclosed in U.S. Pat. No. 4,921,083. By virtue of the force imposed by the Belleville springs 32 on the friction elements, frictional forces are developed between the surfaces of the friction discs 26, 28 and the drive plate 25. The friction discs 26, 28 and the Belleville springs are selected to develop a pre-determined torque in a pre-determined range. The minimum torque is the minimum amount of torque applied to the drive shaft 9 (FIG. 1) that is able to rotate the circuit breaker operating mechanism arm (not shown). The maximum torque is the highest torque value that may be applied to the circuit breaker operating mechanism arm before damage occurs to the circuit breaker 6. For this application the pre-determined torque range is 380-640 lb-in. At torques greater than the predetermined torque, the friction elements slip and rotation of the of the motor shaft 8, does not result in rotation of the drive shaft 9. For loads less than the pre-determined torque, rotation of the motor shaft 8 causes rotation of the drive plate 25 thereby causing rotation of the drive shaft 9. The rotation of the drive shaft 9 angularly rotates the operating mechanism arm of the circuit breaker 6. When the circuit breaker operating mechanism arm reaches its fully open or fully closed position, the load imposed on the drive shaft 9 becomes greater than the frictional force or torque of the clutch assembly 10 and the friction elements slip thereby permitting the motor to overrun without causing damage to the motor or the circuit breaker.
FIG. 4 shows an assembly fixture 60 according to the present invention for torque adjustment and assembly of the clutch assembly 10. The assembly fixture 60 includes two sidewalls 62, a top fixture plate 64, a bottom fixture plate 66, a hydraulic cylinder 68, a valve 69, a pump 70, a torque analyzer 71, a torque transducer 72, a motor 73, and a torque tester shaft 74. The pump 70, valve 69 and hydraulic cylinder 68 are available as model nos. TS-10251, VC-20L and PAC-3002SB, respectively, from Enerpac of Butler, Wis. The torque analyzer 71 and the torque transducer 72 are available as model nos. 4AC and TT150, respectively, from Sturtevant Richmont of Franklin, Ill. The motor is available as model no. PAM02 from Square D Co. of Cedar Rapids, Iowa.
Each of the sidewalls 62 has a slot 76 to slidably accommodate the top plate 64. The bottom fixture plate 66 is coupled to the cylinder 68 which is coupled to and controlled by the pump 70 through the valve 69. The bottom fixture plate 66 has a plurality of slots 78 spaced to correspond to the threaded apertures 22 in the lower clutch plate 16 to accommodate without any interference the screws 18 projecting therethrough. The top fixture plate 64 is shaped similar to the upper clutch plate 14 and has a center hole 80 and a plurality of clearance holes 82 spaced in corresponding relationship to the holes 20 in the upper clutch plate 14 to allow access to the screws 18. The center hole 80 allows the torque tester shaft 74 to pass therethrough and engage the drive plate 25 (FIG. 7). The shaft 74 is coupled to both the motor 73 and the torque transducer 72. The motor 73 rotates the shaft 74 and the torque transducer 72 measures the torque provided by the torque assembly 10. The torque analyzer 71 has a digital display 84 and is coupled to the torque transducer 72 through a cable 86.
The preferred method for assembly and torque adjustment, according to this invention, will now be described with reference to the clutch assembly 10. The top fixture plate 64 is first removed from the assembly fixture 60 by sliding it out of the slots 76. The lower clutch plate 16 is then inserted into the assembly fixture 60 followed sequentially by the rubber gasket 12, the centering ring 24, the pair of Belleville springs 38, the third Belleville spring 56, the spacer disc 30, the bottom friction disc 28, the drive plate 25, the top friction disc 26, the upper clutch plate 14 and the screws 18. The top fixture plate 64 is then slid into the slots 76 and over the clutch components. As shown in FIG. 4, the clutch assembly 10 is now sandwiched between the top fixture plate 64 and the bottom fixture plate 66. Next, the shaft 74 is inserted into the clutch assembly 10 until it engages the drive plate 25 (FIG. 2). The valve 69 is opened and the hydraulic cylinder 68 is supplied with a pre-determined amount of air/oil from the pump 70 so that the cylinder 68 applies a pre-determined load to the lower clutch plate 16 thereby pressing the centering ring 24 into the rubber gasket 12. Next, the motor 73 rotates the torque tester shaft 74 and the torque transducer 72 measures the frictional force or torque of the clutch assembly 10. The torque analyzer 71 reads the measured torque value from the torque transducer 72 through the cable 86 and displays the torque value on the display 84. If the measured torque value is lower than 380 lb-in., the pump 70 is adjusted so that the cylinder 68 applies a greater load to the clutch assembly 10. If the measured torque value is greater than 640 lb-in., the pump 70 is adjusted so that the cylinder 68 applies a decreased load to the clutch assembly 10. The torque that the clutch assembly 10 applies to a load is adjusted by changing the load that the cylinder 68 applies until the measured torque is in the range of 380-640 lb-in. After the desired torque is achieved, the screws 18 are tightened to a range of 15-20 lb-in. This range provides a sufficient amount of hold force to hold the clutch assembly 10 together while not further pressing the centering ring into the rubber gasket. After the screws 18 are tightened, the clutch assembly 10 is removed from the assembly fixture 60 and a glue is applied to threads of the screws exposed below the lower clutch plate 16 thereby further locking them in place. The glue is part no. TL-290 GREEN from Loctite Corporation which is available from Globe Machinery & Supply of Cedar Rapids, Iowa.
While there have been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. For example, enhancements may be made to the assembly fixture to automate the adjustment process, such as, automating the process with a programmable logic controller. Additionally, the position of the rubber gasket may be changed such as by positioned adjacent to the upper clutch plate rather than the lower clutch plate. | An adjustable torque clutch assembly is provided for use in a motor operator. The clutch assembly includes a cylinder ring disposed between upper and lower clutch plates and houses a pair of friction discs, a drive plate disposed between the friction discs, and a spring for forcing the friction discs together to create a frictional coupling force between the drive plate and the friction discs. The exact amount of frictional force is determined by the distance between the upper and lower plates. A rubber gasket is disposed between the housing and one of the clutch plates for allowing adjustment of the distance between the clutch plates, thereby allowing the frictional force, and hence the overall clutch torque to be adjusted. A plurality of screws are provided to secure the clutch plates together once the distance between them, and hence the frictional force has been adjusted to a desired amount. | 5 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to the manufacture of integrated circuits in general, and in particular, to a method of preventing tungsten (W) coating on the back side of a wafer during chemical vapor deposition (CVD) of W by growing a thin oxide layer on the wafer back side.
(2) Description of the Related Art
Photolithographic limits in semiconductor manufacturing determine the level of integration that is possible in very large and ultra large scaled integrated circuit, VLSI and ULSI, respectively, technologies. One unwanted contribution to the so-called detrimental de-focus issue of photolithography comes from the environment in which the manufacturing processes are performed. Namely, during the multitude of processes employed in fabricating a semiconductor device on the polished surface of a wafer, the back side (unpolished side) of the wafer can be inadvertently exposed to the same processes as directed upon the front side. In many instances, such exposure is inconsequential since following process operations are tolerant or remedial of such exposure. However, in other process steps, the result of such exposure is detrimental and can prove troublesome in those subsequent processes and can ultimately limit the yield of good semiconductor devices from the wafer. If for example, a particular process step causes large particles to exist on a wafer, the depth-of-field limitations of submicron optical-lithography tools, such as of the well-known stepper, will prevent the patterning of features to the maximum resolution required.
Of the conventional deposition methods, chemical vapor deposition (CVD) is known to generate particulates that collect on the unprotected back side of wafer, especially when depositing tungsten (W) on the front side. As is well known in the industry, tungsten is usually used for metallization of the substrate, where tungsten fluoride (WF 6 ) is reacted with hydrogen (H 2 ) to form W on the front side of the wafer. However, when hydrogen reduction is used for the tungsten process, hydrogen fluoride (HF) vapor is formed, which inadvertently flows to regions at the back side of the wafer. There, additional WF 6 reacts with silicon (Si) or polysilicon to form a nucleation layer of tungsten (W) as well as silicon fluoride (SiF 4 ). Continued back side reaction of tungsten fluoride with hydrogen deposits tungsten and produces additional hydrogen fluoride. The HF then reacts with the native oxide which causes additional polysilicon to be exposed to tungsten fluoride (WF 6 ).
Some of these partially coated back side materials become detached in subsequent processes and form particulates which can cause fatal defects in the evolving semiconductor devices. Also, excessive uneven buildup of adhering deposited material on the back side of the wafer can deplanarize the back side, rendering the back side ineffective as a planar datum to assure accurate processing of the front side, such as maintaining a consistent depth of focus during a photolithographic exposure operation.
It is generally known in the art of deposition of metals onto dielectrics that especially adhesion of CVD-tungsten to dielectrics pose difficult problems. It is common practice, therefore, to deposit by sputtering, a “glue” layer. However, while the glue is being deposited onto the front side of the wafer, clips hold the wafer's edge, leaving “clip-marks” on the wafer. Thus, the wafer back side, the wafer edge, and “clip-marks” remain essentially as uncoated dielectric. As a result, subsequently deposited CVD-tungsten material tends to flake off from such uncoated areas in the course of further processing, thereby contaminating processing apparatus and interfering with desired processing. Manocha, et al., in U.S. Pat. No. 5,084,415 address this problem by forming an adhesive or glue layer on the dielectric, forming metal layer, forming a protective layer on a portion of the metal layer, and etching to remove metal not covered by the protective layer, including the edges, back side of the wafer. In a modified approach in U.S. Pat. No. 4,999,317, Lu, et al., propose, prior to metal deposition, first removing the dielectric from the back side, edge, and “clip-mark” areas of the wafer, and second, depositing an adhesive or glue layer on remaining dielectric on the front side, or face, of the wafer. Removal of dielectric material is by etching in the presence of a protective layer on the face of the wafer.
It is also possible to strip the back side of the wafer of the undesirable deposited materials, which is usually a complicated process. Alternatively, it is disclosed in the present invention a method where the back side is protected from the deposition process by forming a thin oxide layer.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method of preventing the forming of a de-focusing step on the back side of a substrate or a semiconductor wafer in order to improve the photolithographic process steps in semiconductor manufacturing.
It is another object of this invention to provide a method of forming an oxide layer on the back side of a substrate or a semiconductor wafer in order to prevent the forming of a de-focusing step.
These objects are accomplished by providing a substrate having a front side and a back side; forming a silicon dioxide layer on said back side; forming a polysilicon layer on said front side; forming an unwanted said polysilicon layer on said layer of silicon dioxide on said back side; forming a metal layer on said front side; forming islands of unwanted said metal layer on said polysilicon layer on said back side; forming an oxide layer on said unwanted polysilicon layer on said back side; forming a photoresist mask over said metal layer on said front side; patterning said metal layer on said front side using said photoresist mask; and removing said photoresist mask on said front side by using a photoresist stripper (PRS) without etching into said oxide layer and underlying polysilicon layer as well as the silicon dioxide layer on said back side, thus enabling the next photolithographic step of the manufacturing process without the effect of a defocusing high step on said back side of said substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a semiconductor substrate showing the forming of a film stack of materials formed on the front side of a substrate or wafer of prior art.
FIG. 2 a is a partial cross-sectional view of a semiconductor substrate showing the forming of an unwanted island of metal over an unwanted layer of polysilicon formed on the back side of a substrate, as practiced in the present manufacturing line.
FIG. 2 b is a partial cross-sectional view of a semiconductor substrate showing the etching of the unprotected portion of the polysilicon layer on the back side of the substrate of FIG. 2 a , as practiced in the present manufacturing line.
FIG. 2 c is a partial cross-sectional view of a semiconductor substrate showing the etching of the unprotected portion of the silicon dioxide layer on the back side of the substrate of FIG. 2 b , thus forming a high ledge or “step” as practiced in the present manufacturing line.
FIG. 3 is a partial cross-sectional view of a semiconductor substrate showing the forming of a protective thin oxide layer over the polysilicon layer on the back side of a substrate, according to the present invention.
FIG. 4 is a partial cross-sectional view of a semiconductor substrate showing the forming of a shallow “step” on the back side of a substrate during the various process steps performed on the front side of the substrate, according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now the drawings, FIG. 1 shows a typical set of process steps, including that of forming a metal layer step, that are performed on the front side of a substrate or a wafer in the present manufacturing line. FIGS. 2 a - 2 c show the back side of the same substrate where some of the unwanted materials are also deposited, and the resulting ledge or step that is formed subsequent to various etch steps. The presence of a high step causes defocusing problems with the photolithographic equipment, such as the well-known steppers. FIG. 3, on the other hand, shows the forming of an oxide layer that prevents the forming of a high step, and therefore, the elimination of the problem of defocusing during photolithographic process steps.
More specifically, in FIG. 1, substrate ( 10 ), preferably silicon, is shown where, during normal semiconductor processing, various layers are formed on the front side thereof. The layers are shown schematically to indicate as to how they would stack up over an area, not necessarily over a device area, as they are formed at each step in forming a memory cell, for example. These process steps are well known in the art and as they are not together significant to the invention, they are not described in detail here in order not to unnecessarily obscure the present invention. Also for simplicity, the actual structure of the cell is not shown, except for the film stacking of the various layers. However, those steps that are significant to the invention will be disclosed in detail.
Gate oxide layer ( 11 ) is formed, usually by a thermal oxidation process at a temperature between about 850° C. to 1100° C. Alternatively, the oxide can be formed by an atmospheric or low pressure chemical vapor deposition process as is well known. The preferred thickness of gate oxide is between about 10 to 1000 Å.
A first polysilicon layer ( 12 ) is next formed through methods including but not limited to Low Pressure Chemical Vapor Deposition (LPCVD) methods, Chemical Vapor Deposition (CVD) methods and Physical Vapor Deposition (PVD) sputtering methods employing suitable silicon source materials, preferably formed through a LPCVD method employing silane SiH 4 as a silicon source material at a temperature range between about 600 to 650° C., and to a thickness between about 200 to 5000 Å. First polysilicon layer is usually patterned to form the floating gate of the memory cell.
The patterning is accomplished by first depositing a nitride layer ( 13 ) and using it as a hard mask. Nitride layer is formed by reacting dichlorosilane (SiCl 2 H 2 ), or silane (SiH 4 ), with ammonia (NH 3 ) in an LPCVD at temperature between about 600 to 800° C. and at a flow rate between about 80 to 120 sccm. Preferably, the thickness of the nitride layer is between about 300 to 3000 Å. Openings (not shown) are formed in nitride layer ( 13 ) with an etch recipe comprising gases O 2 , SO 2 , CF 4 and He at flow rates between about 10 to 250, 10 to 80, 0 to 50 sccm and 40 to 80 sccm, respectively, or in a high density plasma (HDP) etcher in CF 4 —O 2 plasmas. The first polysilicon layer underlying the opening in the nitride layer is also etched using plasma etching, for example in a reactive ion etcher (RIE), with an etchant gas such as hydrogen bromide (HBr), or chlorine (Cl 2 ) and a carrier gas, such as argon (Ar). This results in the selective etching of the polysilicon down to gate oxide layer ( 11 ). At a later step, metal will be formed in the openings so formed to serve as contacts to the substrate.
Spacers (not shown) are next formed in the openings by forming an oxide layer ( 14 ) and then etching anisotropically. This is followed by the forming of an inter-poly oxide layer ( 15 ), preferably, oxide-nitride-oxide (ONO) at a temperature between about 600 to 800° C., and to a thickness between about 500 to 3000 Å. This is followed by the forming of second polysilicon layer ( 16 ) shown in FIG. 1, which is then patterned to form the control gate of the memory cell.
Usually metallization of the substrate—to form interconnections between the devices themselves and the circuits at large—is the next step in the fabrication of integrated circuits in semiconductor manufacturing. Metallization is sometimes referred to as “intralevel” when the connections are made between the semiconductor devices themselves, and as “interlevel” when the interconnections are between different levels of wiring in a multi-level substrate. Intralevel connections can be metal or polysilicon, while the interlevel connections are usually metal only. In the present state of the manufacturing line, aluminum, aluminum-copper, and more recently copper alone are the preferred metals for planar metallized layers that are patterned into wiring connections while tungsten is the preferred metal for making vertical connections between the wiring layer. Tungsten is formed by hydrogen reduction methods where tungsten fluoride (WF 6 ) is reacted with hydrogen (H 2 ) to form tungsten (W) to a thickness between about 2000 to 8000 Å.
A film stack of the various materials, including tungsten layer ( 17 ), that are formed on the front side of substrate ( 10 ) with a relatively high ledge, or, “step” ( 18 ) is shown in FIG. 1 . Some of these materials, depending upon the method of deposition, also deposit on the back side of the substrate. This is especially true with polysilicon and tungsten deposition. FIG. 2 a schematically represents the case of an unwanted layer of polysilicon ( 30 ) having been deposited on the back side of substrate ( 10 ). The thickness of layer ( 30 ) can be between about 200 to 2000 Å. This polysilicon layer is formed over an already formed silicon dioxide layer ( 20 ) with a thickness between about 1000 to 3000 Å. Some unwanted tungsten islands ( 40 ) are also formed on polysilicon layer ( 30 ) on the backside of substrate ( 10 ), as shown in FIG. 2 a . This is caused by the suction of tungsten fluoride (WF 6 ) to the back side of the wafer where the fluoride reacts with the polysilicon to form a nucleation layer of tungsten (W) as well as silicon fluoride (SiF 4 ). Continued back side reaction of tungsten fluoride with hydrogen deposits tungsten and produces additional hydrogen fluoride (HF). The HF then reacts with the native oxide which causes additional polysilicon to be exposed to tungsten fluoride, and so on.
After the tungsten metallization ( 17 ) on the front side of the wafer and after the forming of the tungsten islands ( 40 ) on the back side of the wafer, photo resist stripper (PRS) is used to remove the photoresist mask (not shown) that is used to pattern the metallization layer. This also removes the polysilicon layer ( 30 ) that is not protected by the tungsten island ( 40 ) on the back side of the substrate, as shown in FIG. 2 b . Further, silicon dioxide layer ( 20 ) is next removed on the back side when wet etch is performed to form openings in insulators for vias and contacts on the front side of the wafer. This results in a very high ledge or “step” ( 25 ) with a thickness between about 3000 to 7000 Å, as shown in FIG. 2 c with the attendant problem of causing defocusing of the photolithographic equipment in the subsequent manufacturing steps.
A main feature and key aspect of the present invention is a method of avoiding the etching of the polysilicon and silicon dioxide layers, namely, layers ( 20 ) and ( 30 ) in FIGS. 2 a - 2 c , while performing the necessary process steps required on the front side of the substrate. This feature comprises a thin oxide layer that is grown on the polysilicon layer in an oxygen, O 2 , plasma chamber. Thin oxide layer ( 50 ) has a thickness between about 8 to 15 Å, as shown in FIG. 3 . It is important that the oxide growth is performed in a chamber with oxygen flow rate between about 20 to 200 sccm, pressure between about 1 to 100 torr, and temperature between about 80 to 200° C. for a duration between about 30 seconds to 5 minutes. Thus, oxide layer ( 50 ) protects the underlying polysilicon layer ( 30 ) from the photo resist stripper (PRS) during photoresist removal. During the wet etch, the thin oxide layer will be lost, however, only polysilicon layer will be etched during the subsequent via etching step, thus leaving a very shallow ledge, or, step ( 25 ′) shown in FIG. 4, which will not cause any problems in the focusing of photolithographic equipment. The step height of the disclosed method is between about 50 to 1000 Å.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | A method is provided to prevent the forming of a high de-focusing ledge or step on the back side of a substrate or a semiconductor wafer in order to improve the photolithographic process steps in semiconductor manufacturing. In semiconductor manufacturing, various processes are performed to form various dielectric and metal layers on the front side of wafers. However, some of these materials deposit on the back side of the wafer as well. These unwanted deposits result in contaminants that break off from the back side, causing reliability problems. Those that do stay on, on the other hand, cause irregular topology, thus affecting the focusing of stepper equipment during photolithographic processes. It is disclosed in the present invention a method of forming an oxide layer which prevents the forming of such de-focusing steps on the back side of a wafer. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to repeater circuits, such as but not limited to those suitable for use with single track handshaking wires.
2. Background Art
A repeater circuit can be used with single track handshaking wires and other transmission mediums to facilitate transmitting signals from one location on a “left” side of the repeater to another location on a “right” side of the repeater. One optional and commonly used configuration may include the repeater pulling up/down the right side if an external circuit pulls up/down the left side and/or pulling down/up the left side if an external circuit pulls down/up the right side. This type of an arrangement may be suitable for use with GasP, other single wire handshake communication protocols, and other circuits where a request signal is used to pull up the left side of the repeater and a subsequent acknowledge signal is used to pull down the right side after the repeater relays the request signal to the right side, i.e., after the right side is pulled up.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-6 illustrate a number of repeater circuits.
DETAILED DESCRIPTION
FIG. 1 illustrates a repeater circuit 10 configured to duplicate signal transitions on either a left side state conductor L or a right side state conductor R to the other. The repeater circuits 10 is predominately described with respect to duplicating a request transition on the left side L to the right side R and duplicating or simulating an acknowledge request from the right side R to the left side L. This methodology may be employed in systems having asynchronous hand-shaking protocols, such as but not limited to GasP systems, and other systems where receipt of a request signals is typically replied to with an acknowledge signal. Of course, the repeater circuit 10 is not intended to be so limited and fully contemplates its use and application to any type of circuit arrangement.
The state conductors L, R may be connected to any type of external elements suitable for use with the repeater 10 . The external circuits may be configured to indicate the request signals with a falling transition, or low, and the acknowledge signal with a rising transition, or high. The transitions may be generally described as changing the state of the conductors, i.e., from a high to low or from a low to high. Upon the left side L receiving the falling transition, a NOR gate Nr 1 receives a low input from the left state conductor L and another low input from a state node S, which in turn causes the NOR gate Nr 1 to activate n-type transistor Nr to pull the right state conductor R low, thereby duplicating the falling transition on the left state conductor L to the right state conductor R.
A master clear or other feature (not shown) may be included to initially set the state node S to a desired high or low value depending on the transitioning state of the left and right state conductors. If the left and right terminals are high at start-up, then the state node S should be cleared to low. The terminal, in this case the left terminal L that connects to the input of the NOR gate Nr 1 , must receive the first transition and it must be a rising transition. Once the request signal is duplicated to the right state conductor R, the P-type transistor Ps is activated to pull the state node S from its previous low state to a high state. A keeper circuit may be include to maintain this state until the repeater 10 receives the next transition signal. After each transition occurs, the state of node S changes. The purpose of this state node S is to remember the last transition that is repeated and to enforce what the next transition must be, i.e. after a rising transition on the left terminal L is repeated to the right terminal R, the next transition to be repeated must originate on the right terminal R, be repeated to the left terminal L, and be a falling transition. The transition of the state node after duplicating the rising transition to the right state conductor and maintaining the transition state of the state node allows for maintaining state.
The external circuit associated with the right state conductor R may instigate a transition on the right state conductor R in order to acknowledge receipt of the request signal, which in this case requires transitioning the right state conductor from a low to a high. The high transition of the right side state conductor R and the high value at the state node S activates a NAND gate Nd 1 to activate a P-type transistor P 1 , which in turns pulls the left side state conductor L high, thereby duplicating the rising transition on the right state conductor R to the left side state conductor L. The high transition on the left side state conductor L then activates an n-type transistor Ns to pull the state node S back low, thereby setting the repeater 10 to subsequently duplicate another falling transition from the left side state conductor L to the right side state conductor R.
FIG. 2 illustrates a repeater circuit 20 configured to copy a request transition on a left state conductor L to right state conductors R 1 and R 2 . The repeater 20 may be further configured to wait for acknowledge transitions on both of the first and second right state conductors R 1 and R 2 before instigating the acknowledge transition on the left state conductor L.
A transistor n 1 may be included for transitioning the left conductor L from a high state to a low state in order to communicate an acknowledge signal from the right side. The pull of the transistor n 1 is opposite to the pull of the associated external element that pulls the left conductor L from low to high when sending the request signal. Transistors p 1 , p 2 may be included for respectively transitioning the right state conductors R 1 , R 2 from a low to high when communicating the request signal from the left side. The pull of the transistors p 1 , p 2 is opposite to the pull of the associated external element that pulls the conductors R 1 , R 2 from high to low when sending the acknowledge signal.
A state node S and keeper circuit k may be included to add state to the repeater 20 . The state of the state node may be used to selectively enable the transistors n 1 , p 1 , and p 2 . The transistor n 1 may be used to transition the first state conductor to indicate an acknowledge signal from either one of the right side state conductors R 1 , R 2 if the state node is low and the external elements transition both the state conductors R 1 , R 2 to send the acknowledge signal. The transistors p 1 , p 2 may be used in a similar manner to transition the right state conductors R 1 , R 2 to indicate the request signal from the left side if the state node S is high and the external element transitions the left state conductor L to communicate the request signal.
State transistors Ns, Ps may be included to manage the state of the state node s. The transistors Ns, Ps may be configured to pull the state node S between its high and low states. The state transistor Ps may be used to pull the state node to the high state if the transistor n 1 transitions the left state conductor. The state transistor Ns may pull the state node S low if the transistors p 1 , p 2 transition the right state conductors R 1 , R 2 .
FIG. 3 illustrates a repeater circuit 30 configured such that transitions caused by one of the external elements on the left state conductor are alternately toggled to the two right state conductors R 1 , R 2 , such as to communicate the request signal from the left to the right side of the repeater 30 . This may, for example, include communicating the request signal to state conductor R 1 and then alternately communicating the next request signal to the state conductor R 2 . The acknowledge signals associated with each request signal may be communicated to the left state conductor L from the toggled to conductor R 1 , R 2 such that only the conductor R 1 , R 2 receiving the request signal is used to communicate the acknowledge signal.
Transistors n 1 , n 2 , p 1 , and p 2 may be included for transitioning the conductors L, R 1 , and R 2 . The transistor n 1 may be used to pull the left conductor L from high to low in order to communicate the acknowledge signal from one of the right conductors R 1 , R 2 . The pull of the transistor n 1 is opposite to the pull of the associated external element that pulls the left conductor L from low to high when sending the request signal. Transistor p 1 , p 2 may be included for respectively transitioning the right state conductors R 1 , R 2 from a low to a high in order to communicate the request signal. The pull of the transistors p 1 , p 2 is opposite to the pull of the associated external element that pulls the conductors R 1 , R 2 from high to low when sending the acknowledge signal.
State nodes S 1 , S 2 and keeper circuits k 1 , k 2 may be included to add state to the repeater 30 . The state of the state nodes S 1 , S 2 may be used to selectively enable the transistors n 1 , p 1 , p 2 . The transistors and state nodes may be configured such that the transistors n 1 , n 2 only transition the left state conductor to communicate the acknowledge signal if the state node S 1 is low and the toggled to state conductor R 1 , R 2 , i.e., the conductor receiving the request signals, is transitioned by the external element used to the send the acknowledge signal. This allows the repeater 30 to require the acknowledge signal from the toggled to conductor R 1 , R 2 receiving the request signal and not the other conductor R 1 , R 2 that does not receive the request signal.
The transistor n 1 may be used to pull the left conductor L low if the state node s 1 is low and the external element transitions the conductor R 1 . The transistor n 2 may be used to pull the left conductor L low if the state node S 1 is low and the external element transition the conductor R 2 . The transistor p 1 may be used to transition the conductor R 1 if the state nodes S 1 , S 2 are high and the external element transitions the conductor L high. The transistor p 2 may be used to transition the conductor R 2 if the state node S 1 is high, the state node S 2 is low, and the external element transitions the conductor L high.
Transistors n 3 a , n 3 b , p 3 , p 4 , and n 4 may be included to manage the state of the state nodes S 1 , S 2 . The transistors may be configured to pull the state nodes S 1 , S 2 between high and low states. The transistor p 3 may be used to pull the state node S 1 high if either of the transistors n 1 , n 2 transitions the left conductor L. The transistor n 3 a , n 3 b may be used to pull the state node S 1 low if with of the conductors R 1 , R 2 are pulled high. The transistor p 4 may be used to pull the state node S 2 high if the transistor p 2 transitions the conductor R 2 . The transistor n 4 may be used to pull the state node S 2 low if the transistor p 1 transitions the conductor R 1 . This repeater 30 may provided the following order of events: L high, R 1 high, R 1 low, L low, L high, R 2 high, R 2 low, L low.
FIG. 4 illustrates a repeater circuit 40 configured such that a transition caused by the external element on the conductor L is duplicated to the conductor R and a second subsequent transition caused by the external element on the conductor L results in immediately transitioning of the conductor L without transitioning the conductor R. This arrangement may be used to communicate a request from the left to the right, receive a corresponding acknowledge from the right and communicate it to the left, then receive a second request on the left and immediately communicate an acknowledge to the left without ever communicating the request to the right upon receipt of the next request.
Transistors n 1 , n 2 , and p 3 may be included for transitioning the conductors L, R. The transistors n 1 , n 2 may be used to pull the left conductor L low when communicating the acknowledge signal. The pull of the transistor n 1 is opposite to the pull of the associated external element that pulls the left conductor L high when sending the request signal. Transistor p 3 may be included for transitioning the conductors R from a low to a high when communicating the request signal. The pull of the transistor p 3 is opposite to the pull of the associated external element that pulls the conductors R 1 , R 2 low when sending the acknowledge signal.
State nodes S 1 , S 2 , optionally with the assistance of keeper circuits k 1 , k 2 , may be included to hold state of the repeater 40 . The state of the state nodes S 1 , S 2 may be used to selectively enable the transistors n 1 , n 2 , p 3 . The transistor n 2 may be used to pull the conductor L low if the state node S 1 is low and external element pulls the conductor R low. The transistor n 1 may be used to pull the conductor L low if the state nodes S 1 and S 2 are high and conductor L is high, which pulls the conductor L low without requiring the conductor R to communicate the acknowledge signal. The transistor p 3 may be used to pull the conductor R high if the conductor L and state node S 1 are high and the state node S 2 is low. The state of the state nodes S 1 , S 2 , and in particular, S 2 , controls whether the conductor R receives the request signal and whether the acknowledge signal is received without transitioning the conductor r.
Transistors p 2 , n 3 , n 6 , and n 7 may be included to manage the state of the state nodes S 1 , S 2 . The transistors may be configured to pull the state nodes S 1 , S 2 between high and low states. The transistor p 3 may be used to pull the state node S 1 high if either one of the transistors n 1 , n 2 pulls the conductor L low. The transistor n 3 may be used to pull the state node S 1 low if the conductor R is transitioned with an acknowledge signal. The transistor n 6 may be used to pull the state node S 2 low if the transistor n 1 is used to transition the conductor L. The transistor p 7 may be used to pull the state node S 2 low if the transistor p 3 is used to transition the conductor R.
The use of the state nodes S 1 , S 2 and the configuration of the various transistors allows the repeater 40 to operate in a system when each request must be answered with an acknowledgment. The repeater 40 is helpful in that each request is answered but only every other request is actually communicated to the right side. FIG. 5 illustrates a repeater circuit 50 having two the repeater 50 describer above with respect to FIG. 4 . The additional repeater 50 adds an additional cycle to the cycle described above such that only every fourth request is communicated from the additional repeater circuit 50 .
FIG. 6 illustrates another repeater circuit 60 configured to include a condition bit. The state of the condition bit can be used to allow or prohibit transitions caused by one of the external elements on one of the state conductors to be duplicated to the other state conductor.
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary and they may be embodied in various and alternative forms. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art.
While embodiments have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the embodiments. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the embodiments. | A repeater circuit configured to duplicate or otherwise coordinate signal transitions between state conductors, such as for use in asynchronous communication systems. The repeater circuit may include a state node or other feature to facilitate enforcing or otherwise ordering transitioning of the state conductors. | 7 |
FIELD OF INVENTION AND PRIOR ART
This invention relates to a tube assembling device for coupling or plugging square tubes in the assembly of cages, furniture, and the like.
Tube coupling devices are known which comprise a base member having projecting coupling members. Such devices are commonly made of plastic moldings in which the base member and the coupling members are hollow. Tubular members are fastened thereto by friction, adhesive, or by sheet metal screws. However, such devices are not adequate for rugged structures, such as animal cages and the like.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a new and improved tube coupling device. It is a further object of the invention to provide such devices which are especially adapted for making rugged structures. It is a further object of the invention to provide such devices in which the tubes can be secured thereto in a sure and certain manner. It is a further object of the invention to provide such devices which can be made in plastic molding machines simply and effectively.
Further objects of the invention are to avoid the disadvantages of the prior art and to obtain such advantages as will appear as the description proceeds.
BRIEF DESCRIPTION OF THE INVENTION
The invention relates to a tube assembling device for coupling or plugging square tubes. In a preferred form, it comprises a hollow base member; a first square-shaped, hollow coupling member projecting from the base member and having side walls substantially coincident with the walls of the base member; the hollow of the base member and the hollow of the first coupling member comprising a common bore which is open only at the free end of the first coupling member; a second coupling member comprising parallel side walls integral with and projecting from the base member to and integral with an end wall; and an axial partition parallel with the end wall and integral with and connecting the mid-portions of the side walls; the side and end walls of the second coupling member and the axial partition extending to and terminating in parallel planes which are normal to the base member, and the partition having a thickness, at least in the transverse or axial mid-portion thereof, preferably in both, which is substantially greater than the thickness of the side and end walls.
For the purpose of this description, the axis of the coupling device is to be considered the center line extending through the bore and the term axial means oriented in the same direction, i.e., parallel to the axis, and transverse means oriented crosswise of the axis.
Advantageously, the portions of the axial partition located adjacent the side walls and between the axial mid-portion are thinner than the axial mid-portion and have substantially the same order of thickness as the side and end walls. In such a structure, the axial and transverse mid-portions form a cross.
In a preferred form of the invention, either the transverse or axial mid-portion of the axial partition is integrally-connected to the base member and to the end wall by transverse or axial partitions. Advantageously, these partitions are transverse and are connected to the transverse mid-portion, are parallel to the afore-mentioned planes, and are integrally-connected with the mid-portions of the side walls. It is of advantage, too, if these partitions have a thickness which is in substantially the same order of thickness as the side and end walls.
In a preferred form of the invention, the base member is cube-shaped and each coupling member projects from a face thereof with its sides parallel to the edges of that face and spaced therefrom a distance equal to the thickness of the tubes to be coupled thereby, whereby, when the coupling device is inserted in a tube, any side face of the base member which does not have a coupling member projecting therefrom will lie in a common plane with a face of the tube fitted thereon.
In assembling a structure from the tube coupling device of the invention, a tube is fitted on the second coupling member and fastened thereto by fasteners which extend through the wall of the tube and into a mid-portion of the axial partition. This mid-portion is intentionally made thicker than the thickness of the walls in order to accommodate a sheet metal screw, or like fastener. Advantageously, the fastener is fastened into the end of the axial mid-portion of the second coupling member juxtaposed to a wall of the tube. Thus, when the second coupling member is inserted in the tube, the side walls are juxtaposed to opposed walls of the tube and the open portions are juxtaposed to the other two walls of the tube. Each of these latter will have the ends of the axial mid-portion in contact therewith. Thus, in a preferred form of the invention, the fastener projects through a tube wall into the end of the axial mid-portion which is juxtaposed thereto. It will be understood, however, that it could be passed through an adjacent side wall into a juxtaposed side wall of the second coupling member and then into the transverse mid-portion of the axial partition.
In order to effect a sturdy connection with the first coupling member which, in a broader aspect of the invention, need be the only coupling member associated with the base member, there is provided a hollow plug which can be inserted therein before the tube is fitted thereon. The plug, preferably, is hollow so that it can be rapidly molded in a molding machine; and is short, compared with the depth of the bore in the first coupling member. Stop means is provided to limit the distance it can be inserted into this bore and to keep the main portion of the plug adjacent the free end. The stop means can be either an extension of the plug which abuts the bottom of the bore, or it can be a rim at the top thereof which abuts the open end, or a complementary tapering of the bore and the plug. Before the plug is in place, the base member can be fastened to a fixed support, such as a wall, by passing a suitable fastener through the end wall thereof, provided, of course, it it does not have a coupling member thereon, and into the fixed support. When the plug is in place, a tube is slid over the first coupling member and a suitable fastener is passed through the tube wall, the wall of the coupling member, and into the plug, where it is anchored.
The coupling device of the invention as described provides not only for rigid and sturdy structures, but also for ease in molding. In any plastic operation, it is necessary to design the object so as to require a minimum of plastic. This is not so much on account of the plastic saved, but on account of the time required for effecting the molding. That is why, in the prior art devices, the first coupling member had a large bore which extended into the base member and the other coupling members similarly large bores which extended up to the base member. Thus, thin-walled construction is provided throughout and fast seal casting is obtained. These advantages are obtained, however, at the expense of sturdiness in the finished structure. The tube coupling device of the invention obtains these advantages in ease of molding and yet provides for markedly increased sturdiness in the final structure.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an isometric view of a tube coupling device according to the invention;
FIG. 2 is a plan view of the tube coupling device of the invention;
FIG. 3 is a side elevation is section taken along line III--III of FIG. 2;
FIG. 4 is a side elevation in section taken along line IV--IV of FIG. 2;
FIG. 5 is an isometric view of a corner of a cage according to the invention;
FIG. 6 is a cross-section taken along line VI--VI of FIG. 5;
FIG. 7 is a cross-section taken along line VII--VII of FIG. 5; and,
FIG. 8 is a cross-section of a modified form of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now particularly to FIGS. 1, 2, 3, 4, and 8, there is shown a tube coupling device in the form of a corner having a base member 10, a first coupling member 12, a second coupling member 14, and a third coupling member 16. The base member 10 is in the shape of a cube and the coupling members 12, 14, and 16 project from faces of that cube and are centered in the faces to provide a margin 18 along each edge of the cube face, which has a dimension equal to the thickness of the tube which is fitted over the coupling member. Thus, when a tube 20 is fitted on a coupling member, as shown in FIG. 5, the exposed faces 22 and 24 of the base member will lie in the same plane as the sides 26 and 28, respectively, of the tube 20.
The base member 10 is hollowed out to provide side walls 30 and end wall 32. The first coupling member 12 similarly is hollowed out to provide side members 34 with the hollow thereof constituting, with the hollow of the base member 10, a common bore 36. The bore 36 is square in cross-section to provide relatively thin walls 34 and 30. It also tapers toward the bottom 30 to provide facile removal of the mold components.
According to the structure desired, there may be provided a second, third, fourth, fifth, or sixth coupling member, or none at all, as shown in FIG. 8, in which case, the base member 10 and the coupling member 12 constitute a plug for insertion into the tube to form a foot, or to provide an anchor for anchoring the tube to a wall, or the like. In the latter case, the base member 10 would be fastened to the wall by a screw, or like fastener, passing through the end wall 32.
In order to firmly and securely fasten a tube to the coupling member 12, there is provided a tubular insert 38, shaped to fit in the upper portion of the bore 36, as shown in FIG. 3. The plug 38 has a leg 40 which acts as a stop to hold the plug 38 in the end portion of the coupling member 12, as shown in FIG. 3. When tube 42 is fitted over the coupling member 12, as shown in FIG. 5, it can be fastened thereto by sheet metal screw 44, which passes through the wall 46 of the tube 42, through the wall 34 of the coupling member 12 and into the hollow plug 38. It will be understood that the plug 38 need not be hollow except as it facilitates the molding or casting thereof.
In the modification shown in FIG. 8, the plug 38a has a cap 47, the lip 49 of which engages the end of the wall 34 to hold the plug in the position shown. Thus, the lip 49 functions as a stop to limit the insertion of the plug 38a, just as the leg 40 acts as a stop in the modification of FIG. 3. It will be understood that the leg 40 and the lip 49 can be eliminated where the bore 36 tapers appropriately, and the plug 38 or 38a has a corresponding taper which would prevent it from being inserted beyond the position shown in FIGS. 3 and 8. In that case, the taper functions as a stop means for limiting the insertion of the plug.
The other coupling members are constructed in the manner shown in FIGS. 1, 2, 3, and 4. Thus, they have side walls 48 and 50 which project from a face of the base member 12 and extend parallel to each other and normal to that face, to an end wall 52. The side walls 48 and 50 terminate in parallel planes which are normal to the face from which they project.
Spanning the mid-portions of the walls 48 and 50 and normal thereto is an axial partition 54. The axial mid-portion 56 of the axial partition 54 is enlarged to a thickness substantially greater than, say, about two times that of the side walls 48 and 50.
This enlarged axial mid-portion 56 is best seen in FIG. 3, where the section is taken on line III--III of FIG. 2. The portions 58 and 60 adjacent the walls 48 and 50, respectively, have a thickness substantially the same as the thickness of the walls 48 and 50.
The transverse mid-portion 62 is similarly enlarged. This is best seen in FIG. 4, where the section is taken along line IV--IV of FIG. 2. Thus, the axial partition 54 is embossed in the form of a cross formed by the mid-portions 56 and 62, one of which is axial and the other of which is transverse.
The purpose of the enlarged portions 56 and 62 is to provide a secure anchor for a sheet metal screw, as shown in FIGS. 5 and 6. Thus, when a tube 64 is fitted on a coupling member of the second type, as shown in FIG. 6, the ends of the axial mid-portion 56 are juxtaposed to and in contact with the sides 66 and 68 thereof. The tube 64 is thus secured to the coupling member by a sheet metal screw 70 which passes through the side 66 and into the enlarged axial mid-portion 56. It will be understood that, if desired, the sheet metal screw can be passed through the side 72 or 74 through the side wall 58 or 60 and into the enlarged transverse mid-portion 62.
The transverse mid-portion 62 is connected to the face 75 by a transverse partition 76, which is normal to the side walls 48 and 50. Similarly, the transverse mid-portion 62 is connected to the end wall 52 by a corresponding transverse partition 78. If desired, the partitions 76 and 78 can be omitted or, they can be made parallel to the sides 48 and 50, that is, axial, though such construction is not as sturdy and rigid as that shown. Also, it is to be understood that the sides 48 and 50 can be rotated 90 degrees, so that the enlarged mid-portion 56 becomes transverse, instead of axial, and the enlarged mid-portion 62 becomes axial, instead of transverse. Such a structure is not so advantageous as that shown, because it requires additional parts for molding. It will be understood also, that the parts previously described, except the plugs 38 and 38a, are integral parts of a unitary casting.
The coupling device of the invention thus provides for the construction of rugged and durable frames of hollow, square tubing particularly suited for animal cages or the like. Thus, a rectangular framework can be constructed, as shown in FIG. 5, with hardware cloth or like screening fastened thereto by suitable fasteners.
It is to be understood that the invention is not to be limited to the exact details of construction, operation, or exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art, and the invention is therefore to be limited only by the full scope of the appended claims. | The invention relates to a device for coupling or plugging square tubes, which comprises a hollow base member having a hollow coupling member projecting therefrom and, if desired, one or more other coupling members projecting from the base member. The other coupling members have axial partitions in the mid-portions thereof, at least the mid-portion of which is thick enough to receive a sheet metal screw and, if desired, there is provided a plug for the hollow coupling member for receiving a sheet metal screw. | 8 |
BACKGROUND OF THE INVENTION
Warp-knitted lace strips are used as border ornament of the underwear and outerwear for women. As shown in FIGS. 8 and 9, such lace strip 10 is generally provided with sinuate parts called scallops B consisting of repeated recesses and protrusions on the edge thereof and a large number of parts, each being called picot P, formed of U-bent yarns protruding from the scallops B. Conventional lace fabric of such kind has been knitted, in the direction shown by the arrow in the annexed drawing, chiefly by the raschel knitting machine, and in this case a plurality of units of lace strip have been knitted in the form of one piece of fabric that extending over the full width l of needle-row on the knitting machine and separated into units 10 in the later process.
Separation of the fabric piece into unit strips depends on cutting of the part 11 constituting only ground fabric construction interposed between adjacent two lace fabrics 10, 10 as shown in FIG. 8A along the sinuate line of scallops B by means of cutter 12 operated manually or mechanically. It also depends on such a method that a blasting yarn 14 for connecting picots P, P of adjacent lace fabrics 10, 10 as shown in FIG. 9 is beforehand knitted into the fabric and removed therefrom after completion of all-out knitting, when separate units of lace strip 10 are obtained.
However, these methods have been followed by drawbacks that separation by the use of cutter is low in operation efficiency when performed manually, correct cutting along sinuate line of the scallops is difficult in practical work, and moreover yarn ends 14 remain at the cut-end of the ground fabric, preventing fine finish of the outer edge of scallops B and clear protrusion of picot P, as shown in FIG. 8. In the case of mechanical cutting for separation, remaining of yarn ends at the outer edge of scallops B is similar to that in the previous case and prevents fine finish despite increased operation efficiency. Therefore, lace strips obtained by these methods have been extremely low in commercial value as border ornament.
Separation of the piece into units 10 according to release of basting yarn from the fabric is not followed by such drawbacks as those using the cutter but, on the other hand, followed by disadvantages as inferior ornamental properties resulting from the fact that: since the basting yarn 14 is knitted-in from sinuate scallops 10 to protruding picot P, agreement of protruding ends of picots P, P of adjacent lace fabrics 10, 10 with each other is required, which causes sinuation of the scallops to be weaker than that in the case of FIG. 8, particularly so and nearly straight at the protrusions B' of scallops; and picots can not be provided in the resesses B" of scallops.
SUMMARY OF THE INVENTION:
This invention has been intended for elimination of the above-described drawbacks.
The 1st object of this invention is to provide an entirely warp-knitted lace strip comprising knitting sinuate scallops to be formed of scallops-forming yarns on the edge of ground fabric and a large number of U-shaped picots protruding from the edge of scallops.
The 2nd object of this invention is to provide a material fabric for manufacturing warp-knitted lace strips in which the ground fabric, scallops to be knitted in the sinuate form on the edge of said ground fabric, and picots to protrude from the scallops are all knitted of insoluble yarns; and the protruding portion of picot is knitted-in into the soluble fabric portion formed in a series with and adjacently to the scallop.
The 3rd object of this invention is to provide a method of manufacturing warp-knitted lace strip from which the drawbacks as described above are eliminated by forming sinuate scallops and picots on the edge of insoluble fabric portion upon dissolving and removing the soluble fabric portion by the application of water or the like to the material fabric obtained in such a way as abovesaid.
The 4th object of this invention is to provide a material fabric for manufacturing warp-knitted lace strip in which the above-described insoluble fabric portion and soluble one are arranged alternately with each other along the direction of needle-row on the warp-knitting machine.
The 5th object of this invention is to provide a method of obtaining knitted lace strip in which insoluble fabric portions and soluble ones are knitted in an arrangement of alternation with each and soluble fabric portions are removed by dissolution after completion of all-out knitting, when insoluble fabric portions are separated into individual units, each unit being provided with sinuate scallops on the edge thereof as well as picots appearing on the scallops.
The 6th object of this invention is to provide a material fabric for manufacturing warp-knitted lace strips in which insoluble basting yarns are knitted-in between adjacent insoluble fabric portions so as to connect the two at the time of knitting of insoluble fabric portions and soluble ones in an arrangement of alternation with each other in the direction of needle-row on the warp-knitting machine.
The 7th object of this invention is to provide a method of manufacturing knitted lace strip wherein: when insoluble fabric portions and soluble ones are knitted into one piece in an arrangement of alternation with each other in the direction of needle row on the warp-knitting machine, adjacent insoluble fabric portions are adapted to be inseparable from each other, by knitting-in of insoluble basting yarns between these insoluble fabric portions, even after dissolution of soluble fabric portions so as to make easy the processing as drying after dissolving process; and individual lace strips are obtained when the fabric is separated by removal of said basting yarns after finishing process.
The above-described and other objects of this invention will be more apparent from the following descriptions quoted on the basis of annexed drawing as hereunder.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sketch of a part of warp-knitted lace strip according to this invention;
FIG. 2 is a view of knit structure of the part shown in FIG. 1 and enclosed by dotted line Z;
FIG. 3 is a view of knit structure of the part in FIG. 2 after removal of soluble texture by dissolution;
FIG. 4 is a view of an example of modified knit structure with respect to soluble warps shown in FIG. 2;
FIG. 5 is a schematic view of the fabric constituted of insoluble fabric portions and soluble ones in an alternation arrangement;
FIG. 6 is a view of knit structure showing the state wherein a basting yarn connects adjacent two isoluble two fabric portions with each other which are shown in FIG. 5;
FIG. 7 is a view of knit structure remaining after the soluble fabric portion shown in FIG. 6 has been removed by dissolution;
FIG. 8 is a sketch showing a part of a unit of lace strip according to conventional method. This strip has been cut off from the original material fabric along scallops by means of cutter;
FIG. 8A is a sketch schematically showing the state in which a piece of fabric consisting of a plurality of knitted units is being cut by the cutter for obtaining lace strips as shown in FIG. 8; and,
FIG. 9 is a sketch showing a part of the knitted piece separable into units of lace strip by removal of basting yarn.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the reference numeral 10 represents a unit of warp-knitted lace strip according to this invention. A warp-knitted lace strip of this kind is knitted along the direction of the arrow shown in the drawing and, in practice, continuous in both upward and downward directions in the drawing though not illustrated for simplification. This lace fabric 10 is composed of a multitude of lines of stitches, formed of a number of warps 1 and other warps 2 for connecting the lines of stiches with each other, thereby turning into marquisette ground fabric A on which the yarn for patterning are knitted-in by means of the Jacquard apparatus for producing the pattern A'. In the drawing of the lace fabric 10, scallops B in the shape of repeated sinuation are formed of the scallops-forming yarns 3 on the right-hand edge portion (will be called merely "edge" hereinafter). The numeral 4 denotes thick hemming yarns knitted-in into the scallops B. The reference character P indicates picots provided in large number on the edge of scallops B and formed by adapting the picot-forming yarns knitted-in into the scallops B in the shape of U to protrude from the scallops.
Then, a description will be made on a number of embodiments of structures and methods of knitting described above. In the description of FIGS. 2 through 7, any item corresponding to that in FIG. 1 is denoted by the same reference character and numeral as those refered to in FIG. 1 as far as possible.
FIG. 2 is a view of knit structure almost corresponding to the part Z enclosed by dotted line in FIG. 1, A denoting the foundation texture, B the scallops, and P positions at which picots are formed. The character N shows the position of needle. The ground fabric is knitted of warps 1 and 2. For this knitting, needle N 1 -N 9 are used. Each needle N forms chain stitches in every course of warp 1, and another warp 2 is interlaced between chain stitches adjacent to each other in the transverse direction, where a ground fabric A is formed. Describing this structure more detailedly with respect to needles N 1 and N 2 , the warp 2 is inserted through consecutive three courses on the stitch-line formed by the needle N 1 , transferred to the adjacent needle N 2 , inserted into consecutive three courses on the stitch-line formed by the needle N 2 just like the previous procedure, and then returned to the initial needle N 1 . Repetition of such processes with respect the needles N 1 -N 9 form a marquisette structure, i.e. ground fabric A. Application of other structures than marquisette to knitting is not limited. As apparent from the description of FIG. 1, some appropriate pattern (not illustrated) is knitted-in onto the ground fabric A.
Nine ends in total of scallops-forming yarns denoted as 3 are shifted corresponding to sinuation of scallops B while forming stitches by means of respective nine pieces of needles. That is to say, nine ends of scallops-forming yarns are threaded on nine pieces of needles, N 10 -N 18 , at the 1st course (the lowest position in the drawing), overlapped at this needle-position so as to form chain stitches in line corresponding to the number of courses, shifted to left side at the course a at the rate of one needlepitch, i.e. to other nine needles, N 9 -N 17 , for next overlapping, form chain stitches in line corresponding to the required number of courses, at the position to which they are shifted, and, further, shifted to left side at the course b at the same rate as the previous one, i.e. one needle-pitch, or to needle N 8 -N 16 . When these yarns 3 reach the course C after repetition of above-described performance, they are shifted to right side at the rate of one needle-pitch and the overlapping positions thereof are shifted to right side step by step. As a result of repetition of such action as described above, sinuate scallops are formed. The yarns represented as 4 are hemming yarns for scallops, two end thereof being arranged on the outer edge, i.e. right side of FIG. 1, of the scallops B whereas one strand being on the inner edge, i.e. left side in FIG. 1, of the scallops, and are inserted into chain stitches in line of the scallops-forming yarns 3 for formation of knit structure while curving correspondingly to sinuation of the scallops B.
The above-described warp yarns 1 and 2 for composing the ground fabric A as well as 3 for scallops B, hemming yarns 4, and picot forming yarn 6 which will be described later are all water-insoluble and compose the whole of insoluble fabric portion I.
In contrast with this, a position in which soluble yarns 5 are knitted-in is indicated by the character D. These warp yarns 5 are drawn through a guide bar commonly used for the warp 1 and, in the embodiment shown in the drawing, ten ends in total thereof 5 are threaded on respective ten pieces of needles, N 11 -N 20 , which are arranged over the width D ranging from the wale (II j ) lying at a pitch of one gauge outside the wale (II i ) that corresponds to the bottom of scallops B to the wale (II n ) lying at a pitch of two gauges outside the wale (II m ) that corresponds to the end of scallops B protrusion. These warps 5 compose the soluble fabric portion II by forming chain stitches in all the wales in the same number as that of courses. Incidentally, the scallops-forming yarns 3 are overlapped on soluble warps 5 in some knitting area. The line of chain stitches formed of the warp 5 in this overlap area is not illustrated for simplification. As embodiments of soluble yarn 5 and insoluble one 1, used are vinylon yarn and nylon filament yarn, respectively.
The yarns represented as 6 are picot-forming yarns to be knitted-in into the scallops B, inserted into chain stitches formed in line of soluble yarns, being protruded in the same length as that of two gauges from the scallops edge at the required course, and returned to repeated insertion to the scallops B to produce a multitude of the U-shaped protrusions.
In this way, protruding parts of picots are fixed in the soluble fabric portion II.
When the fabric thus obtained is immersed into the water in which the soluble fabric portion II is dissolved for removal, the edge of insoluble fabric portion I appears as sinuate scallops B provided with picots P as shown in FIG. 3.
Formation of sinuate scallops B of insoluble yarns on the edge of insoluble fabric portion I, formation of picots of similar insoluble yarn in the shape of protrusions from the scallops, and removal of soluble fabric portion by dissolution after knitting-in of picots into soluble fabric portion ensure not only clear appearance of picots but stronger sinuation of scallops, and, further, enable easy setting of the lengthes of picot protrusions as much as desired or varying said lengthes stepwise. Therefore, tasteful lace strips furnished with scallops and picots diversified in the shape can easily be manufactured.
FIG. 4 is a view showing an example of modified knitting mode of soluble yarns 5, wherein the same reference marks as those corresponding to respective items in the other drawings are used. A point different from that in FIG. 2 is that the soluble warps 5 are knitted along sinuate line of the scallops B. When thus knitted, the width of the part D in which the warps 5 are arranged, namely, soluble fabric portion II, can be made smaller than that required for knitting the warps 5 in straight line along the direction of wale as shown in FIG. 2. For example, in the case of this drawing, threading of five ends of warp yarns 5 on respective five needles, N 19 -N 23 , may satisfy the purpose.
In this way, significant decrease in consumption of soluble yarn is obtained, which leads to a great degree of economy.
What has been hitherto described refers to the case in which a unit of lace fabric is knitted. However, a plurality of separated units of insoluble lace fabric 10 can be manufactured at a time by dissolving the soluble fabric portions II when the whole of the fabric is immersed into the water, the fabric being knitted into a piece constituted of insoluble fabric portions I and soluble ones II in which two different portions are arranged alternately with each other. In this case, separation of said piece into units without use of cutter and, in addition, formation of clear sinuate scallops and picots on the edge of each separate lace fabric are all possible.
FIG. 6 shows an example of modification of knit structure and knitting method shown in FIG. 5. Insoluble fabric portions I and soluble ones II are knitted in an arrangement of alternation with each other so as to form a piece containing a plurality of these portions, and adjacent insoluble portions I, I are connected with each other by insoluble basting yarn 7. This basting yarn 7 is knitted-in along sinuate line of the edge portion and connects the tip of the U-shaped protrusion formed of picot-forming yarn 6 with adjacent insoluble fabric portion I. Though not shown, adjacent insoluble fabric portions I, I may be connected with each other by two basting yarns, one of which is 7 as described above and the other is knitted-in between the abovesaid one 7 and adjacent insoluble fabric portion I. From the fabric knitted in this way, insoluble fabric portions II are removed by dissolution during immersion of the whole of the fabric. A fabric from which soluble yarns have been removed by dissolution is shown in FIG. 7. A plurality of lace strips 10 are manufactured by separating the fabric, which has soluble yarn thereof dissolved, taken out from the water, and dried up, into units of insoluble fabric portions I upon releasing the basting yarn 7 from the fabric. In this way, insoluble fabric portions are made inseparable from each other even after the dissolution of soluble fabric portions II, which makes easy drying operation after dissolution and ensure the manufacture of a multitude of lace strips at higher rate of efficiency. | This invention is concerned with a new textile product in the form of a lace strip which is entirely warp-knitted with sinuate scallops. The scallops are manufactured from bent scallop-forming yarns and picots of which one end protrudes outwardly in a U-shape configuration.
The novel lace strips are manufactured by forming chain stitch lines in step-like indentation by overlapping the scallop-forming yarns and passing the yarns in turn through a plurality of needles. Simultaneously picot-forming yarns are transversely positioned to produce protrusions from the scallops. In order to separate the scallops and their picots, the parts of the knitted fabric to be readily separated, said scallops and attached picots are knitted to soluble yarns which are subsequently dissolved to facilitate separation. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to an absorption heat pump system.
Generally, a refrigeration cycle has a heat absorption side and a heat radiation side. When the heat absorption side is utilized, the system serves as a refrigerator, whereas, when the heat radiation side is utilized, the system serves as a heat pump. All heat pumps follow this concept regardless of whether they are of compression type or absorption type.
The absorption heat pump system of the invention, however, is an absorption type system workable only as a heat pump and, hence, is not the same as that of the above-mentioned concept. More specifically, the invention is concerned with an absorption heat pump system in which a refrigerant is evaporated by heat utilizable at a low temperature level and a warmed water of a comparatively high temperature is produced by the heat of absorption which is generated when the vapor of the refrigerant is absorbed by an absorbent, i.e., the type in which the evaporation temperature and the vapor pressure of the refrigerant in the evaporator are higher than the condensation temperature and the vapor pressure of the refrigerant in the condenser and the absorption temperature of the refrigerant is higher than the temperature at which the refrigerant is generated.
FIG. 1 shows a basic arrangement of the absorption heat pump of the kind described. As will be seen from this Figure, the absorption heat pump has an evaporator 1 and an absorber 2 accommodated by an upper section constituting the high-pressure side and a generator 3 and a condenser 4 accommodated by a lower section which constitutes the low-pressure side. These constituents are connected hermetically through a refrigerant line 6 having a first refrigerant pump 5, a refrigerant line 8 having a second refrigerant pump 7, a concentrated solution line 10 having a solution pump 9, a U-shaped dilute solution line 11 and a solution heat exchanger 12 so as to constitute an absorption heat pump cycle. Heating medium tubes 13 and 14 are provided in the evaporator 1 and the generator 3, respectively, while the condenser 4 and the absorber 2 are provided with cooling water tubes 15 and heated water tubes 16, respectively.
In the absorber 2, heat of a temperature level higher than the heating medium ciculated through the heat medium tubes 13 is produced by the energy possesed by the refrigerant gas evaporated by the heat derived from the heat medium tubes 13 and also by the reaction heat which is generated when the refrigerant gas is absorbed by the solution. According to this arrangement, therefore, it is possible to obtain warmed water or vapor of water of a temperature level higher than the low-temperature heat source is obtained in a heat exchanger 16' of the absorber 2, and to supply the warm water or the water vapor to the load 19. This system will be referred to as "hot fluid production type absorption heat pump system".
For instance, by the use of lithium bromide as the absorbent and water as the refrigerant, while using waste steam of 98° C. as the low-temperature heat source and circulating cooling water of about 25° C. through the condenser, it is possible to obtain water vapor of about 130° C. from the heat exchanger 16' of the absorber 2.
In the described operation of the absorption heat pump system, the steady supply of the warm water or water vapor of constant temperature is achievable only under an ideal condition of operation. Namely, any fluctuation in the rate of supply of the evaporated refrigerant flowing from the evaporator 1 into the absorber 2 or in the refrigerant temperature tends to appear as a large fluctuation in the amount of heat energy supplied to the load 19. For instance, assuming that a heat pump system exhibits a thermal output fluctuation as shown in FIG. 2, this heat pump system is considered as having a capacity smaller than the average value M of the thermal output fluctuation, rather than the average value M, from the view point of heat capacity demanded by the load 19. This means that the efficiency of operation of the heat pump system is extremly low.
More practically, referring to FIG. 2 in which the vertical axis represents the output temperature and the horizontal axis represents the time, all of the thermal output at temperature levels below that is demanded by the load 19 cannot be used practically, unless the output temperature is raised by a suitable auxiliary heater which is not shown. In such a case, the heat pump system is materially unable to supply the heat to the load over most part of the operation period, i.e. the apparent output is drastically lowered, because of the fluctuation in the heating capacity even though the system inherently has sufficiently large heating capacity.
In connection with the described basic arrangement of the absorption heat pump system, it has been obliged to make an on-off control of the operation of the second refrigerant pump 7 in accordance with a signal derived from a level detector disposed in a refrigerant reservoir disposed at the lower side of the condenser 4. Moreover, in the absorption heat pump system, there is a tendency that a cavitation of the second refrigerant pump 7 takes place because of lowering of the liquid level in the liquid refrigerant reservoir attributable to a reduction in the amount of the condensed refrigerant in the condenser 4 as a result of a reduction in the rate of generation of the refrigerant vapor in the generator 3 which in turn takes place when the rate of energy supplied by the heat source is decreased, i.e. when there is a reduction in the rate of supply or the temperature of the heat source fluid such as waste warm water or steam from factories or power plants, warm water heated by solar energy and so forth. In order to avoid the cavitation, such an on-off control of the second refrigerant pump 7 is conducted in accordance with the signal from a level detector for detecting the level of liquid refrigerant in the liquid refrigerant reservoir in such a manner that, when the liquid level has come down below a predetermined level, the second refrigerant pump 7 is stopped but the same is started again as the level of the liquid refrigerant has been increased beyond the predetermined level.
This conventionally adopted on-off control, however, imposes various problems. For instance, when the second refrigerant pump is started again, a large amount of condensate liquid refrigerant of low temperature is introduced from the condenser 4 to the evaporator 1 of high-pressure and temperature side, so that the pressure and temperature in the upper section are drastically lowered to inconveniently lower the temperature of the warm water supplied by the heat pump system. Namely, a so-called hunting of the output temperature inevitably takes place in response to the repeated starting and stopping of the second refrigerant pump 7.
In the conventional absorption heat pump system of the type described, the pressure differential between the upper section of high pressure and the lower section of low pressure is decreased as the temperature of the cooling water circulated through the condenser 4 is raised or as the heat input to the evaporator 1 is reduced, whereas the discharge pressure of the second refrigerant pump is not changed substantially. In consequence, the rate of supply of the liquid refrigerant from the condenser 4 to the evaporator 1 is increased to cause a drastic lowering of the liquid level in the liquid refrigerant reservoir 18. Since the on-off control of the second refrigerant pump 7 is conducted in response to this drastic change in the liquid level, the output temperature, i.e. the temperature of warm water produced in the system, is unstabilized. In addition, the efficiency of operation of the absorption heat pump system is decreased due to escape of the refrigerant liquid into a solution reservoir 20 below the absorber 2, partly because a rise in the liquid level in the unevaporated refrigerant reservoir 19 under the evaporator due to a decrease in the rate of evaporation of refrigerant caused by a reduction in the heat input to the evaporator 1, and partly because a large amount of condensate refrigerant liquid is introduced at once from the condenser 4 into the evaporator 1. As a result, the capacity of the system for supplying the warm water, i.e. the warm water output of the system, is further decreased.
Another problem in the hot fluid production type absorption heat pump system is that, when the temperature or flow rate of the liquid refrigerant introduced from the condenser to the evaporator is decreased, the rate of evaporation of the refrigerant is decreased as a result of lowering of the refrigerant temperature in the evaporator, because of the fact that the condensation temperature of the refrigerant in the condenser is lower than the evaporation temperature of the same in the evaporator.
As a countermeasure for obviating this problem, it is of course advisable to control directly the major factors, i.e. the temperature and flow rate of the heat source medium supplied to the evaporator and the generator.
In the heat pump system of the hot fluid production type, however, the waste heat fluid of a comparatively low temperature level, discharged from production equipments such as factories, chemical processes or the like is used as the heat source fluid supplied to the evaporator and generator. Under this circumstance, there is a practical limit in controlling the temperature and flow rate of the heat source fluid supplied to the evaporator and the generator, from the view point of the operation efficiency of the production equipment from which the heat source fluid is derived. The same problem, i.e. the difficulty in effecting direct control of the flow rate and temperature of the heat source fluid, is encountered also when a geo-thermal heating medium such as hot water or steam in springs is utilized as the heat source medium.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a heat pump system of hot fluid production type, improved to permit a stable production of heated fluid at a constant rate and at a temperature above a predetermined temperature. Particularly, it is quite important that this object be achieved without necessitating any direct control of temperature or flow rate of the heat source fluid in the evaporator and the generator.
To this end, according to the invention, there is provided an absorption heat pump system having a generator, a condenser, an evaporator and an absorber connected hermetically to form closed cycles for a refrigerant and an absorbent, wherein a heat source fluid is circulated through the generator to separate the vapor of the refrigerant from the absorbent in the generator, and the vapor refrigerant from the generator is condensed and liquefied in the condenser by a cooling fluid circulated through the condenser, while the heat source fluid is circulated through the evaporator to evaporate the liquid refrigerant coming from the condenser to develop a higher temperature in the evaporator than in the condenser, whereby a heated fluid of a temperature level higher than that of the heat source fluid is obtained from the absorber by the heat which is produced when the vapor refrigerant coming from the evaporator is absorbed by the solution, characterized by comprising a control means disposed in the refrigerant passage leading from the condenser to the evaporator and adapted to continuously controlling the temperature or flow rate of the liquid refrigerant, thereby to stabilize the temperature in the evaporator.
Namely, according to the invention, the fluctuation of the temperature of liquid refrigerant in the evaporator is prevented by the control of temperature or flow rate of the liquid refrigerant flowing from the condenser to the evaporator so that the rate of evaporation of the refrigerant in the evaporator and, hence, the rate of absorption of the refrigerant by the absorbent in the absorber are stably maintained to ensure a stable production of the heated fluid at a temperature above the predetermined temperature in the absorber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the basic arrangement of an absorption heat pump system of the hot fluid production type;
FIG. 2 is an illustration of expected fluctuation of heat output from the absorption heat pump system shown in FIG. 1;
FIG. 3 is an illustration of the basic circuit arrangement of an absorption heat pump system in accordance with an embodiment of the invention;
FIG. 4 is a view similar to that in FIG. 3, showing the circuit arrangement of an absorption heat pump system in accordance with another embodiment of the invention;
FIG. 5 is a diagram showing an absorption refrigeration cycle incorporated in an absorption heat pump system in accordance with still another embodiment of the invention;
FIGS. 6 and 7 are diagrams similar to that shown in FIG. 5, but showing further embodiments of the invention; and
FIGS. 8 to 10 are schematic illustrations of refrigerant heating sections in still further embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be fully described hereinunder with specific reference to the accompanying drawings showing some preferred embodiments of the invention. Throughout the Figures showing the embodiments of the invention, the same or like reference numerals are used to denote the same or like parts as those in the basic arrangement explained before.
(1) FIG. 3 shows a preferred embodiment of the invention in which an evaporator 1 and an absorber 2 are formed in the upper section of high pressure while a generator 3 and a condenser 4 are formed in the lower section of low pressure. These constituents are connected by the refrigerant line 8, solution lines 10,11 and so forth to form an absorption heat pump cycle so as to deliver warm water of a temperature above a predetermined temperature from the warm water discharge tubes 16, as in the case of the basic arrangement explained before in connection with FIG. 1. A refrigerant control valve 21 is disposed in the refrigerant line 8 through which the condensate liquid refrigerant is introduced from the liquid refrigerant reservoir 18 under the condenser 4 in the lower section to the evaporator 1 formed in the upper section of the high pressure. A level detector 17 for detecting the level of the condensate liquid refrigerant in the liquid refrigerant reservoir 18. The arrangement is such that the opening degree of the refrigerant control valve 21 is controlled in accordance with the signal from the level detector 17, through the operation of a control circuit 22.
If the heat energy of the heat source fluid supplied to the generator 3 and/or the evaporator 1 is decreased, i.e. if the heat input to the absorption heat pump system or the cooling power supplied to the condenser 4 is decreased, the level of the liquid refrigerant in the liquid refrigerant reservoir 18 starts to come down. Upon detection of the lowering of the level of liquid refrigerant by the level detector 17, the opening degree of the refrigerant control valve 21 is decreased so that the flow rate of the refrigerant from the condenser 4 to the evaporator 1 is decreased. It is thus possible to avoid any abrupt reduction of the liquid level in the condensate liquid refrigerant reservoir 18, while eliminating unfavourable phenomena such as cavitation of the second refrigerant pump 7 and the invasion of the solution reservoir 20 by the liquid refrigerant, thereby to ensure a safe and stable operation of the absorption heat pump system.
To the contrary, as the heat input and/or the cooling power applied to the system is increased, the level of the liquid refrigerant in the condensate liquid refrigerant reservoir 18 starts to rise. The rise of the liquid level is detected by the level detector 17 and the opening degree of the refrigerant control valve 21 is increased in accordance with the signal from the level detector thereby to increase the rate of flow of the refrigerant from the condenser 4 to the evaporator 1.
In the described embodiment, the absorption heat pump system has a detection mechanism, i.e. the detector 17 for detecting the level of the condensate liquid refrigerant level detector, capable of detecting the level of the condensate liquid refrigerant which varies in accordance with a change in the heat energy supplied to the generator 3 and/or the evaporator 1, i.e. the heat input or the cooling power applied to the system, and a control mechanism, i.e. the refrigerant control valve 21, adapted to control the rate of supply of the refrigerant from the condenser 4 to the evaporator 1 in response to the signal derived from the detection mechanism. The liquid level detection mechanism and the control mechanism cooperate with each other in controlling the rate of supply of the refrigerant to the evaporator 1 linearly or in a stepped manner in proportion to a change in the level of the liquid refrigerant. In the absorption heat pump system of the described embodiment, therefore, it is possible to prevent the undesirable hunting of the output water temperature, which unavoidably takes place in the conventional heat pump system of the kind described in response to frequent starting and stopping of the second refrigerant pump 7, is avoided to ensure the supply of stable temperature of the warmed water produced in the system.
Insteadly of using the level detector 17 in FIG. 5 for detecting the level of the condensate liquid refrigerant, it is possible to use, as the detection mechanism mentioned before, temperature detectors 23 and 24 or flow-rate detectors 23' and 24' in the heat source medium supply tubes 13 and 14 as indicated by on-dot-and-dash lines. Alternatively, it is possible to use a cooling water temperature detector in combination with a cooling water flow rate detector although these detectors are omitted from the drawings. Such detection mechanisms are superior to that of the described embodiment consisting solely of the level detector 17, in that they permit direct and prompt detection of the fluctuation in the heat energy supplied to the generator 3 and/or the evaporator 1, i.e. a fluctuation in the heat input or the cooling power applied to the absorption heat pump system. The detection mechanism used in the described embodiment, i.e. the level detector 17, is superior to other mechanisms such as the temperature detectors 23 and 24 in that it permits a direct and prompt detection and control of the flow rate of the refrigerant flowing from the condenser 4 to the evaporator 1. The detection mechanism need not always be such one as to adapted to detect the temperature of the heat source fluid or the level of the condensate liquid refrigerant but may be such one as adapted to detect any change in the physical amount caused by a change in the heat input to the absorption heat pump system or the cooling power applied to the applied to the same. For instance, a change in the heat input to the absorption heat pump system causes a change in the rate of generation of the vapor refrigerant in the generator 3 and rate of evaporation of the refrigerant in the evaporator 1 which in turn cause changes in vapor pressures in the upper and lower sections of the system, as well as a change in the evaporation temperature of the refrigerant sprayed in the evaporator 1 and a change in the temperature of the concentrated solution regenerated in the generator 3. The temperature of the unevaporated refrigerant sprayed in the evaporator 1 is also changed which in turn changes the temperature and flow rate of the dilute solution. It is, therefore, possible to use, as the detection mechanism, a pressure detector 25 for detecting the vapor pressure in the evaporator 1 and the absorber 2, i.e. the pressure in the upper section, a temperature detector 26 for detecting the temperature of the refrigerant sprayed in the evaporator 1, a temperature or flow rate detector 27 for the dilute solution, or a detector 28 for detecting the concentrated solution. When the physical amount detected by such a detector is increased or decreased in accordance with a change in the heat input to the absorption heat pump system or the cooling power applied to the same, the detector produces a signal which serves to decrease or increase the opening degree of the refrigerant control valve 21 through the action of the control circuit 22. It is also possible to use, as the detection mechanism, a level detector 30 for detecting the level of the unevaporated refrigerant in the unevaporated refrigerant reservoir 29. In such a case, the opening degree of the refrigerant control valve 21 is decreased or increased in accordance with a raising or lowering of the level of the unsaturated refrigerant.
FIG. 4 shows another embodiment of the invention in which, as the means for controlling the rate of conveyance of heat from the condenser 4 to the evaporator 1, i.e. the flow rate or temperature of the refrigerant, a variable speed refrigerant pump 7' is disposed in the refrigerant line 8 to work in place of the refrigerant control valve 21.
The speed of the variable speed refrigerant pump 7' is controlled through the operation of the control circuit 22, in accordance with a signal derived from the detection mechanism which may be any one of the detectors mentioned before, i.e. the condensate liquid refrigerant level detector 17, heat source temperature detectors 23,24, heat source flow rate detector 23',24', detector 25 for detecting the pressure in the upper section, a refrigerant temperature detector 26, thin solution temperature detector or dilute solution flow rate detector 27, concentrated solution temperature detector 28 or the unevaporated refrigerant level detector 30, thereby to control the flow rate of the condensate liquid refrigerant in response to the change in the heat input to the absorption heat pump system.
As has been described, the absorption heat pump systems of the present invention explained hereinbefore in connection with FIGS. 3 and 4 are adapted to evaporate a refrigerant by the heat derived from a heat source of a low temperature level and hot water of high temperature is generated by the heat which is discharged when the vapor refrigerant is absorbed by the concentrated solution. Each of these systems has a detection mechanism for detecting a change in a physical amount attributable to the change in the heat input to the absorption heat pump system or the cooling power applied to the same, and a control mechanism for controlling the flow rate of the refrigerant from the condenser to the evaporator in response to the signal delivered by the detection mechanism. It is, therefore, possible to avoid the hunting of the output warm water temperature, which inevitably takes place in the conventional system in response to the frequent starting and stopping of the refrigerant pump, thereby to ensure a high stability of the output warm water temperature. It is to be noted also that the reduction in the operation efficiency of the system, attributable to the mixing of the refrigerant in the solution, is eliminated advantageously.
(2) FIG. 5 shows still another embodiment in which the upper part including the evaporator and the absorber and the lower part including the condenser and the generator are constructed in separate bodies, unlike the embodiments explained in connection with FIGS. 3 and 4 in which the upper and lower parts are constructed in one body.
The absorption heat pump system of the embodiment shown in FIG. 5 has a generator 105, condenser 106, evaporator 102, absorber 103, and a heat exchanger 112 in which the absorbent returned from the absorber 103 to the generator 105 heats the absorbent of low temperature which flows from the generator 105 to the absorber 103. The absorbent coming out of the heat exchanger 112 is introduced to a heater 120 to heat the liquid refrigerant which is supplied from the condenser 106 to the evaporator 102. A control valve 121 is adapted to control the flow rate of the absorbent introduced to the heater 120 upon comparing the temperature of the liquid refrigerant coming out of the heater 120 and the temperature of the refrigerant in a liquid refrigerant reservoir 113 attached to the evaporator, in such a manner that the liquid refrigerant is maintained substantially at the same level as the temperature in the evaporator 102.
By raising the temperature of the refrigerant just flowing into the evaporator 102 to a level approximating the temperature in the evaporator 102, the degree of change in the evaporating condition in the evaporator 102 caused by the refrigerant flowing into the evaporator 102 through a pipe 125 is decreased. The fluctuation of the output (amount of heat output or temperature attained) shown in FIG. 2 is increased as the temperature of the refrigerant coming into the evaporator approaches the predetermined temperature of the evaporator, i.e. the evaporator temperature in rated operation, so that the level of the minimum output point is raised to raise the apparent output of the absorption heat pump system correspondingly, as will be seen from broken-line curve in FIG. 2.
Namely, also in the absorption heat pump system of the type described, the rate of evaporation of the refrigerant in the evaporator 102, as well as the rate of generation of the refrigerant in the generator 105, is limited in accordance with a reduction in the level of the load, because in this absorption heat pump system the capacities of the pumps 107, 109, 114, heat feeders 115, 116, heat exchangers 117, 118 and so forth are designed in conformity with the maximum load condition. Therefore, if the rate of discharge from the pump 107 is not changed substantially, the average rate of circulation of the refrigerant through the system is decreased by the discontinuous operation of the pump. The temperature of the liquid refrigerant in the condenser 106, however, is considerably low as compared with the temperature of the liquid refrigerant circulated through the evaporator 102 by the pump 114, so that the temperature in the evaporator 102 and, hence, the rate of evaporation of the refrigerant in the evaporator 102, are drastically changed as the supply of the liquid refrigerant to the evaporator 102 is made or interrupted due to repeated starting and stopping of the pump 107, resulting in a large fluctuation in the heat generation in the absorber 103 or the output of the absorption heat pump system as a whole, i.e. the temperature of the warm water or steam outputted from the system or the amount of heat derived from the system per unit time to seriously deteriorate the operation efficiency of the absorption heat pump system. This problem, however, is suppressed or obviated in the absorption heat pump system of this embodiment in which the refrigerant which is to be supplied to the evaporator 102 is pre-heated to a temperature of a level approximating that in the evaporator 102, before it enters the evaporator. In addition, it is to be noted that, since the absorbent circulated through the absorption heat pump system is used as the heat source for heating the refrigerant, it is possible to use the heating energy at any desired time, and the amount of heat consumed in the heating can be suitably controlled by equipment for controlling the operation of the heat pump. Therefore, no substantial loss of energy takes place even if the energy input control for heating the refrigerant is made in a simplified manner.
FIGS. 6 and 10 schematically show arrangements for heating the refrigerant in connection with the closed cycle of absorbent in heat pump systems in accordance with different embodiments of the invention.
In the embodiment shown in FIG. 6, the heat exchanger 120 is so arranged as to effect a heat exchange between the dilute absorbent flowing from the absorber 103 to the heat exchanger 112 and the refrigerant. In this embodiment, it is possible to attain, with a heater of a reduced size, a substantially equivalent effect to that achieved by the heater shown in FIG. 5, because the greater temperature difference is available than in the embodiment shown in FIG. 5. FIGS. 7 and 8 in combination show an embodiment in which a heater 120 is provided in connection with the concentrated absorbent flowing from the generator 105 into the absorber 103, while FIG. 9 shows an embodiment in which heat is supplied to the refrigerant heater 120 by means of a circulation heating pipe 126 in which a heat medium such as freon is confined. A reference numeral 127 designates a control valve for controlling the heating rate through the control of the heating medium. Finally, FIG. 10 shows an embodiment in which heat is delivered to the refrigerant heater 120 by means of a heat pipe 128. All of the embodiments shown in FIGS. 6 through 10 achieve the same effect as that performed by the absorption heat pump system shown in FIG. 5.
In FIG. 4, a reference numeral 216 designates a temperature detector disposed in the cooling water pipe 215 at the cooling water outlet side of the condenser 204. The opening degree of the control valve 217 provided in the cooling water pipe 215 is controlled in accordance with the signal from the detector thereby to control the flow rate of the cooling water. It is also possible to use a by-pass pipe 218 connected to the cooling water pipe 215 and by-passing the control valve 217 for controlling the flow rate of the cooling water. In this case, an electromagnetic stop valve 219 is provided in the by-pass pipe 218.
In operation, as the cooling water temperature comes down due to a change in the ambient air temperature or the like reason, the temperature detector 216 produces a signal for decreasing the opening of the cooling water flow rate control valve 217 thereby to decrease the flow rate of the cooling water, so that the predetermined cooling water temperature is recovered in the condenser 4. To the contrary, as the cooling water temperature starts to rise, the opening degree of the cooling water flow rate control valve 217 is increased to lower the cooling water temperature to the predetermined level immediately.
According to this arrangement, it is possible to stably maintain the optimum pressure in the lower section of the system to ensure a stable balance of the force for circulating the solution. It is thus possible to stably obtain the warm water from the absorption heat pump system, overcoming the problems of the prior art.
In the event that the temperature of the cooling water circulated through the condenser 4 is lowered far from the predetermined set temperature due to, for example, a large drop of the ambient air temperature as in the winter season, the control valve 217 for controlling the flow rate of the cooling water is fully closed to prevent excessive lowering of the pressure in the lower section of the system. In such a case, the control is made while observing and detecting the rise of temperature in the cooling water by-pass pipe 218, in such a manner that the control valve 217 starts to open as the cooling water temperature is raised to the predetermined level. From a view point of design, a pipe of a suitable small diameter is used as the material of the cooling water by-pass pipe 218.
By providing the cooling water by-pass pipe 218 in the manner described, it is possible to detect the cooling water temperature and to stably control the pressure in the lower section of the system, even if the cooling water flow rate control valve 217 is kept fully closed. The temperature detector 216 may be provided in the cooling water by-pass pipe 218. | An absorption heat pump system having a generator, a condenser, an evaporator and an absorber connected hermetically to form closed cycles for a refrigerant and an absorbent, comprising a control means disposed in the refrigerant passage leading from said condenser to said evaporator and adapted to continuously controlling the temperature or flow rate of the liquid refrigerant, thereby to stabilize the temperature in said evaporator. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of pending U.S. patent application Ser. No. 10/644,641 filed Aug. 10, 2003, and entitled “FILTERED IN-BOX FOR VOICE MAIL, E-MAIL, PAGES, WEB-BASED INFORMATION, AND FAXES,” which claims the benefit of priority to U.S. patent application Ser. No. 09/386,762 filed Aug. 31, 1999, and entitled “FILTERED IN-BOX FOR VOICEMAIL, E-MAIL, PAGES, WEB-BASED INFORMATION, AND FAXES,” both incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to a method for organizing, prioritizing, and displaying incoming message information on a wireless device.
BACKGROUND OF THE INVENTION
[0003] In recent years, the functionality of wireless devices has expanded far beyond simple voice or pager communications. Wireless devices can now receive a variety of incoming messages including pages, e-mails, faxes, voicemails, and short message services such as weather or sports updates. In some cases the actual message, for example a voicemail, is not delivered directly to the wireless device due to memory, bandwidth, or other limitations, but rather a notification message is sent to the wireless device to notify the user that a message has arrived and is being stored at a remote location. These type of notification messages are known in the art as shown in U.S. Pat. No. 5,797,103, “Method and Apparatus For Informing A Remote Unit Of A Feature-Originated Call,” incorporated herein by reference. The notification messages, as well as some actual messages, are generally stored within the wireless device. However, most wireless devices are only equipped with a small screen that displays a few short lines of text or small graphics. To view each item that has been sent to the wireless device, the user generally must scroll through a series of screens or menus and may be forced to examine all of the items of a particular type, or sometimes all of the items regardless of type in order to find the message of interest. Most wireless devices can be set to alert the user that a new message has arrived, but this feature is not very useful if it is alerting the user every few moments that something new has arrived. The user is likely to begin ignoring the alert or simply turn it off. This may result in important messages going unnoticed among a large number of unimportant messages.
[0004] For example, a user may subscribe to a number of services for his wireless device, including paging, a sports score service, and e-mail. With all of these services active on a typical evening when a variety of sporting events are in progress, the user may be receiving several messages every few minutes. If during this time the user receives an important page or e-mail from his or her boss, the message may go unnoticed among all the other messages and the user may miss an important work assignment.
[0005] The user of a wireless device can be easily overwhelmed when trying to keep track of and prioritize the myriad pieces of information that are arriving at any given time. It would be desirable for the wireless device to be able to organize the incoming information in such a way that the user can quickly and easily recognize and distinguish between important and unimportant items.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method for automatically organizing and prioritizing the incoming messages on a wireless communication device and displaying the messages accordingly. A predetermined set of rules is used to perform the organization and prioritization of the incoming messages. When a message arrives, it is analyzed to determine certain classification information about the message. This classification information is then used to organize the incoming message among the messages that are already being stored on or referenced on the wireless device. This information is also used to determine the priority of the incoming message. Depending on the level of priority assigned to the incoming message, the wireless device may alert the user that the new message has arrived or may just store the message for the next time the user chooses to check for messages. The wireless device may also update its display to reflect the various classification information that has been gathered about the messages presently being stored.
[0007] The present invention allows the user of a wireless communication device to subscribe to any number of services that send messages to the device, but the user maintains control over the way the incoming messages are handled to prevent being overwhelmed with information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a wireless network such as may be used with an embodiment of the present invention.
[0009] FIG. 2 is a flowchart illustrating one possible implementation of the method of the present invention. FIG. 3 is a flowchart illustrating an alternative implementation of the method of the present invention.
DETAILED DESCRIPTION
[0010] The present invention could be implemented within a wireless network similar to that depicted in FIG. 1 . A wireless device 101 communicates with a wireless infrastructure 102 that is connected to a variety of public and private networks including the Public Switched Telephone Network (PSTN) 103 and the Internet 104 . The user of the wireless device subscribes to a variety of information services that send messages of various formats or types to the wireless device via one of the networks to which wireless infrastructure 102 is connected. These services can include, but are not limited to, email, paging, voice mail, fax, and short message services (including short message based information services). These messages can originate from a variety of equipment such as telephone 105 , fax machine 106 , computer terminal 107 , or network server 108 depending on the type of message. The equipment that sends the message will vary based on the type of message and some messages may pass through more than one type of equipment before delivery to the wireless device. For example, an individual may leave a voicemail message for the user of the wireless device from telephone 105 , but the voicemail will likely be stored on Private Branch Exchange equipment 109 or telephone company equipment 110 and the device storing the voicemail will send a notification message to the wireless device to inform the user that the voicemail has arrived. Additionally, some types of messages can be sent from more than one type of equipment. For example, faxes may be sent from either fax machine 106 or computer terminal 107 if it is equipped with fax software.
[0011] FIG. 2 illustrates one possible way of implementing the present invention where much of the processing of the incoming messages is performed in the wireless infrastructure. A message for the user of wireless device 101 is received by wireless infrastructure 102 (step 201 ). The wireless infrastructure then retrieves a set of rules corresponding to the user for which the message is intended from a database either co-located with the wireless infrastructure or at a remote location and accessible to the wireless infrastructure via a computer network (step 202 ). Using these rules, the wireless infrastructure analyzes the message and determines classification information about the message (step 203 ). Based on this classification information, the wireless infrastructure can assign a priority to the message if desired; and if this priority is not very high the wireless infrastructure may elect not to send the alert message to the device, instead saving the alert message for later retrieval (step 204 , 205 ). If the priority is sufficiently high, the wireless infrastructure sends an alert message to the wireless device containing the classification information about the received message (step 206 ). This alert message can optionally contain part or the entire contents of the original message along with the classification information. Once the wireless device receives the alert message, it organizes and prioritizes the incoming message with the messages already stored on the wireless device using the classification information and pre-assigned priority information (if available) associated with the incoming message and the classification information that was previously determined for and associated with each of the stored messages (step 207 ). The wireless device then checks to see if the incoming message has been designated of a sufficient priority level to alert the user of the wireless device that it has arrived (step 208 ). If so, the wireless device can select a customizable or user-defined alert type such as ringing, beeping, or vibrating, based on the classification information (step 209 ). The wireless device alerts the user using the selected method (step 210 ). The display of the wireless device may also be updated to reflect that a new message has arrived such as by the display of standard or user-defined icons or sounds, the display of summarized message counts by type, or the display of the actual message itself as determined by the message priority and user-defined settings (step 211 ).
[0012] The method of the present invention as illustrated in FIG. 2 could also be implemented in another device on the network to which the wireless infrastructure could route the incoming messages for processing before passing them on to the wireless device.
[0013] Alternatively, all of the processing could be done on the wireless device itself as illustrated by the flowchart in FIG. 3 . The wireless device receives an incoming message from the wireless infrastructure (step 301 ). The wireless device then retrieves a predetermined set of rules corresponding to the user of the wireless device from its own memory or alternatively from a database somewhere else in the network (step 302 ). The incoming message is then analyzed using the predetermined set of rules to determine classification information (step 303 ). Using this classification information, the wireless device organizes the incoming message with the messages already stored on the wireless device (step 304 ). The wireless device also employs the predetermined rules to determine whether the incoming message is of sufficient priority to alert the user that it has arrived (step 305 ). If it is of sufficient priority, then the wireless device alerts the user using well known methods (step 306 ). In either case, the wireless device updates its display to reflect the incoming message (step 307 ).
[0014] The rule sets of the present invention used to determine the classification information are typically predetermined by the user of the wireless device. The user can input and modify these rules using any of a variety of well-known systems including calling into an interactive voice response system or a system that responds to touch-tone key presses, using software carried on the wireless device itself, or using a computer interface via the Internet or World Wide Web. These rules could be very simple in nature, with the user's choices limited to a few very general rules based on a few criteria, for example, message type or message origin. Alternatively, the user could be given the option of creating sophisticated rules that would allow the incoming messages to be searched for key words or phrases, or that would use different rules depending on time of day, day of the week, source of message, etc. The present invention could also be implemented with nested categories. For example, all email messages could be grouped under an “email” category and within that category the email messages could be grouped again as “work” or “personal” email.
[0015] For example, one potential rule would analyze an incoming email message and extract the email address of the originator. This address could then be cross-referenced with a built-in address book on the wireless device to locate the category that the individual corresponding to the email address has been classified under in the address book. The email message could then be classified under the same category.
[0016] The kind of classification information that can be obtained from the incoming message will vary based on the type or format of the message, but typical information may include type, origin, time received, and size. Certain message formats, such as email, can provide further information including, for example, full text searching of the content of the message. More sophisticated systems could be implemented to search voicemail messages for keywords through the use of voice recognition technology. Those of skill in the art will easily be able to determine additional kinds of information that can be extracted from incoming messages for use as classification information based on the type of message.
[0017] The display of the wireless device can be updated to inform the user of the results of the classification, organization, and prioritization steps in a variety of ways. The display of the wireless device could show the number of messages under each of the categories defined by the rule sets. Alternatively, the display could organize the messages by priority level, time received, or any other externally defined or user-defined item of classification information.
[0018] The method of the present invention can be implemented using any well known programming language and techniques. The implementation on the wireless device may be particularly suited to using Wireless Application Protocol (WAP) Forum defined standards, such as Wireless Markup Language (WML). The use of rule sets to organize messages is well known in the field of email software. Products like Microsoft Outlook 97 employ rules to direct incoming email messages to particular folders within the user's email box. Those of skill in the art will recognize how to implement the rule sets of the present invention to function in a similar fashion but without being limited to any one type of message.
[0019] The present invention is not limited to the specific embodiments described. It is expected that those skilled in the art will be able to devise other implementations that embody the principles of the present invention and remain within its scope. | The present invention is directed to a system for displaying, organizing, and prioritizing the incoming information on a wireless device. Using the present invention the wireless device can display the number of voice mails, e-mails, pages, and Internet information alerts that have been received by the wireless device during a specified time period. The invention also allows the incoming information to be separated by any number of user-specified criteria such as the originating sender, or divided by work related and personal messages. The present invention allows the wireless device user to see at a glance what kind of information has been received and is being stored on the wireless device. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 USC 119(e) of provisional patent application No. 60/759,756, filed Jan. 17, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates generally to luggage and more specifically to the weighing of luggage.
BACKGROUND OF THE INVENTION
[0003] Often at airports and other such locations there is a weight limit for each piece of luggage. If one or more pieces of a customer's luggage exceed this weight limit, then additional fees are assessed. Also, the traveler must then either find a way to reduce the weight and contents of the luggage or pay for an additional piece of luggage. In addition to the inconvenience experienced by the traveler and the additional fees, the traveler may have to miss a scheduled flight and as a result suffer even greater inconvenience and expense.
[0004] Placing luggage bags on a typical home scale, such as a bathroom scale, is a clumsy and difficult process. Oftentimes the display of the scale is covered by the luggage, which may be much larger and bulkier in size than the scale. It is also difficult to place luggage on a home scale and to keep it steady without holding it and thereby affecting the weight measurement. Each time the luggage needs to be weighed with a conventional home scale, the suitcase or bag must be closed before attempting to place it on the small-sized scale. What is needed is a method by which a customer can weigh luggage as it is being packed, to make sure that it fits within required weight limits before it taken to the airport or location for transport. The present invention meets this need.
SUMMARY OF THE INVENTION
[0005] The present invention provides airline travelers with a method of determining baggage weight compliance while traveling, prior to having baggage rejected or additional fees assessed at the baggage check counter at the airport. In a first aspect, a scale is disclosed that comprises first and second attachment points, wherein the scale indicates a relative force applied to the attachment points. In a second aspect, a scale is disclosed which comprises two independent attachment points wherein the scale can display the total force applied to the attachment points.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a suitcase with a handle, attachment fittings and a scale located in the handle in accordance with the present invention.
[0007] FIG. 2 is a detailed illustration of the handle of the suitcase in accordance with the present invention.
[0008] FIG. 3 illustrates a second embodiment of a handle
[0009] FIG. 4 illustrates a third embodiment of a handle
DETAILED DESCRIPTION
[0010] The present invention relates to generally to luggage and more specifically to the weighing of luggage. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features described herein.
[0011] The present invention provides an individual with a method for determining the weight of a piece of luggage (a suitcase, for example) without using a standalone utility scale.
[0012] FIG. 1 shows a suitcase 10 in accordance with the present invention. The suitcase 10 includes a body portion 11 and a handle 12 . The suitcase 10 further includes attachment fittings 14 a and 14 b which attach the handle 12 to the suitcase, and a weight scale 16 located in the handle in accordance with the present invention.
[0013] FIG. 2 is a partially expanded illustration of the handle 12 of the suitcase in accordance with the present invention. The handle 12 includes attachment points 14 a and 14 b , a spring or compression scale 102 , a window 210 with an indicator scale 112 . Attachment points 14 a and 14 b are used to attach the handle 12 to the suitcase or piece of luggage (not shown). The attachment points 14 a - 14 b may be permanently connected to the body 11 of the suitcase or they may be detachable, allowing the handle 12 to detach from the suitcase body 11 . The attachment points 14 a - 14 b connect to a spring or compression scale 102 which is contained within the handle shell 104 . The handle 12 is fitted with an opening 108 and a spring or compression scale 102 within the handle shell 104 .
[0014] As is seen in FIG. 2 , a window 110 with an indicator scale 112 fits within the opening 108 in the handle shell, thereby covering the spring scale 102 and the scale pointer 106 . The window 110 could be made from any kind of clear material such as plastic, glass, or any other transparent material. The indicator scale 112 has markings on it which indicate weight in pounds, ounces, a metric scale, or other measurement scales, and is calibrated to include the total weight of the suitcase and handle/scale combination, so that an accurate weight reading may be determined. When a person lifts the suitcase from a surface so that the suitcase is supported only by the person holding the suitcase, the scale pointer 106 will point to markings on the indicator scale 112 which indicate the weight of the suitcase. In this way a person may determine the weight of the suitcase.
[0015] The markings on the indicator scale, as indicated above, may be displayed in pounds, ounces, the metric system, or in any other desired weight measurement system. It would also be possible to utilize markings on the indicator scale which indicate weight limits imposed by specific airlines, transport companies, mailing systems or the like.
[0016] FIG. 3 illustrates a second embodiment of a handle. The handle is coupled to a body portion of a suitcase, for example the handle comprises a handle shell ( 300 ). Within the shell is a mechanism ( 301 , 302 , 303 ) coupled to the body portion. Each attachment point ( 301 a , 301 b ) moves independently causing an indicator ( 305 ) to move a distance proportionate to the weight suspended by the mechanism and causing a scale ( 306 ) adjacent to the indicator to move a distance proportionate to the weight suspended. In abstract, a device used to weigh items at two attachment points where the item being weighed has a variable center of gravity, which include a handle 300 and two attaching points 301 a and 301 b . Enclosed within the handle is a pair of cams 302 and followers 303 whereby the vertical force applied to the attachment points 301 a and 301 b is converted to a lateral force and movement of the cam followers 303 a and 303 b . Variations in weight attached and suspended at attachment points 301 a and 301 b result in a change in the lateral displacement of followers 303 a and 303 b and a resultant change in the relative positions of 305 and 306 . The relative measurement of force suspended at attachment points ( 301 a or 301 b may be observed by an offset distance change between 305 and 306 . The combined movements of the independent mechanisms result in a totalized weight indication suspended at the attachment points.
[0017] FIG. 4 illustrates a third embodiment of a handle. The handle is coupled to a body portion of a suitcase, for example the handle comprises a shell ( 400 ); within the shell is a mechanism ( 401 , 402 , 403 , 404 ) coupled to the body portion; where each attachment point moves independently; causing pressure to be transferred by a link(s) ( 405 a & 405 b ) and a transducer ( 408 ) sends a relative signal to a microprocessor ( 407 ). The microprocessor provides an indication of the totalized weight on a LCD ( 406 ). In abstract, a device used to weigh items at two attachment points where the item being weighed has a variable center of gravity, which include a handle 400 and two attaching points 401 a and 401 b . Enclosed within the handle is a pair of cams 402 and followers 403 a and 403 b whereby the vertical force applied to the attachment points 401 a and 401 b is converted to a lateral force and movement of the cam followers 403 a and 403 b . Variations in weight attached and suspended at attachment points 401 a and 401 b result in a change in force applied to a pressure transducer or strain gauge 408 . The relative measurement of force suspended at attachment points 401 a and 401 b may be observed as a digital value displayed on an electronic display screen 406 . The combined pressure of the independent mechanisms result in a totalized weight indication suspended at the attachment points.
[0018] Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Although two attachment points are utilized in the preferred embodiment, one of ordinary skill in the art readily recognizes that a plurality of attachment points could be utilized and that they would be within the spirit and scope of the present invention. Additionally, one of ordinary skill in the art readily recognizes that the scale could utilize a digital readout, and be within the spirit and scope of the present invention.
[0019] Although a suitcase is shown as a preferred embodiment, one of ordinary skill in the art readily recognizes that other types of pieces of luggage may be utilized, such as bags or containers of various kinds, and that they would also be within the spirit and scope of the present invention.
[0020] Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | The present invention provides airline travelers with a method of determining baggage weight compliance while traveling, prior to having baggage rejected or additional fees assessed at the baggage check counter at the airport. In a first aspect, a scale is disclosed that comprises first and second attachment points, wherein the scale indicates a relative force applied to the attachment points. In a second aspect, a scale is disclosed which comprises two independent attachment points wherein the scale can display the total force applied to the attachment points. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional patent application Ser. No. 60/071,299, filed Jan. 16, 1998, entitled Kinematic Coupling Nest Switch, the disclosure of which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
BACKGROUND OF THE INVENTION
In a semiconductor wafer processing environment, semiconductor wafers must be protected from contaminants and physical agitation. Such wafers are used to manufacture electronic components such as computer memory and microprocessors, and require certain physical characteristics so that electronic circuit elements may be fabricated onto the wafer surface. Manufacturing imperfections, such as those which can arise from dust, dirt, bumping, and jarring, can render a wafer unusable.
Accordingly, such wafers are often stored and transported in a sealable container called a wafer pod, or cassette. Such cassettes have a series of interior ridges on opposing sides to support a batch of wafers horizontally, and a removable door to allow access to the contents. Typically an automated, apparatus, such as a robotic arm or conveyor system, is used to transport these cassettes to minimize human manipulation which can lead to dropping and bumping of a loaded cassette, and further to damage and loss of wafer stock. Such an apparatus transports cassettes between different processing stations during various phases of the wafer manufacturing and treatment process.
At each processing station, the cassette is placed on a support platform which includes an arrangement of pins having beveled tops called a nest, which mate with corresponding beveled receptacles on the bottom of the cassette. The beveled tops allow precise, consistent placement while affording some tolerance of movement when placing the cassette on the pins. A typical prior art pin assembly is shown in FIGS. 1a, 1b. Typically three pin assemblies are used to support a cassette, of which a single traditional pin assembly 10 is shown in FIG. 1a. The beveled edges 12 mate with a corresponding beveled surface 14 on a cassette 16 at a contact area 18, as shown in FIG. 1b.
Removal of the cassette from the nested position on the pin assemblies can involve insertion of a robotic arm, or paddle, under the cassette between the pin assemblies, and lifting upwards. Traditional pin arrangements, however, incorporate cassette sensing pads which reside under the cassette in the area between the pins to sense the presence of a cassette by being displaced downward. Such pads, therefore, interfere with insertion of the paddle underneath the cassette.
A typical cassette receptacle and pin assembly arrangement is shown in FIGS. 2a, 2b, respectively. Two triangular orientations are commonly used. On the bottom side of a cassette 56, a larger, outer pin assembly receptacle orientation 42 is used to support a cassette nested at a processing station, while an inner pin assembly receptacle orientation 44 is used by a robotic paddle arm to transport cassettes between processing stations. The corresponding pin assembly orientations on the processing station 48 are shown in FIG. 2b. The inner set of pins 54 is mounted on a paddle 46, while the outer set 52 corresponds to placement at the processing station 48. Referring to FIGS. 2a, 2b, paddle 46 can effect removal of cassette 56 by being inserted between the outer set of pins 52 beneath the cassette 56, and lifting upward such that inner pins 54 engage inner receptacles 44.
Prior art cassette detection methods using cassette sensing pads 58 are incompatible with the use of the paddle 46 in FIG. 2b. As such pads reside within the paddle exclusion zone 60, they can interfere with the insertion of the paddle 46 between the outer set of pins 52 beneath the cassette 56. Alternative sensor placement is undesirable due to the need to maintain compliance with industry standards, and alternate non-interfering insertion paths of the paddle can complicate design of new systems and may not be suitable for existing paddle systems.
BRIEF SUMMARY OF THE INVENTION
A cassette sensing mechanism for detecting the presence of a wafer pod, or cassette, nested on a pin assembly arrangement allows cassette detection without interfering with insertion of a robotic paddle arm beneath the cassette to remove it for transport. Cassettes so nested reside on an arrangement of beveled pins which mate with corresponding beveled receptacles on the underside of the cassette. One or more pin assemblies supporting the cassette has a spring biased, hollow outer cylinder which slides up and down around a center post. When a cassette is placed on the pin assemblies, the outer cylinder of each pin assembly is displaced downwards against the spring bias a sufficient distance to trigger a sensor, thereby indicating the presence of a cassette. Upon removal of the cassette, the outer cylinder is displaced upwards by the spring, thereby resetting the sensor to indicate no cassette is present.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1a shows the prior art pin assembly shape;
FIG. 1b shows a cassette nested on a prior art pin assembly;
FIG. 2a shows a schematic illustration of prior art receptacle and sensor arrangements;
FIG. 2b shows a typical prior art pin assembly arrangement for a processing station and paddle;
FIG. 3a shows a cross sectional view of the novel pin assembly as disclosed herein;
FIG. 3b shows a cross sectional view of a pin assembly before a cassette is placed;
FIG. 3c shows a cross sectional view of a pin assembly with a cassette nested on top;
FIG. 4a shows a top view of alternative pin assembly and receptacle mating arrangements;
FIG. 4b shows a cross sectional view of alternative pin assembly and receptacle mating arrangements;
FIG. 5 shows the paddle arm and processing station as a cassette is transferred;
FIG. 6a shows an exploded view of a first embodiment of a pin assembly as defined by the present invention;
FIG. 6b shows a cross section view of the pin assembly in FIG. 6a at rest;
FIG. 6c shows a cross section view of the pin assembly in FIG. 6a when supporting a cassette;
FIG. 7a shows an exploded isometric view of a second embodiment of a pin assembly;
FIG. 7b is a top or plan view of the pin assembly in 7a;
FIG. 7c is a cross section of the pin assembly in 7b along line 7c;
FIG. 8a shows an exploded isometric view of a third embodiment of a pin assembly;
FIG. 8b shows a top or plan view of the pin assembly in 8a;
FIG. 8c shows a cross section view of the pin assembly in 8b along line 8c;
FIG. 9a shows an exploded isometric view of a fourth embodiment of a pin assembly;
FIG. 9b shows a top or plan view of the pin assembly in 9a;
FIG. 9c shows a cross section view of the pin assembly in 9b along line 9c;
FIG. 10a shows an exploded isometric view of a fifth embodiment of a pin assembly;
FIG. 10b shows a top view of the pin assembly in FIG. 10a.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, a pin assembly arrangement is used to support a wafer pod, or cassette, at various stages through a wafer fabrication sequence. Referring to FIG. 3a, a pin assembly 24 of the present invention includes a hollow outer cylinder 20 oriented coaxially around a center post 22. Referring to FIG. 3b, a pin assembly 24 is in the unladen position as outer cylinder 20 is shown biased upward by spring 26 just prior to engagement with cassette receptacle 28. Outer cylinder 20 remains slightly below the top of center post 22 by tolerance 30 such that a flat object placed on the pin assembly 24 will not displace the outer cylinder downward. Referring to FIG. 3c, cassette 16 has been placed on pin assembly 24, and outer cylinder 20 has been displaced downwards by travel distance 32. A detectable element, shown by arrow 33 in FIG. 6a, is disposed by movement of the outer cylinder. A sensor 66 is provided to sense the detectable element to thereby detect the downward displacement of the outer cylinder.
Various receptacle configurations on the bottom of the cassette for mating with the pins are shown in FIGS. 4a-4b. Cassette receptacles can be rectangular 34, triangular 36, or square 38. Typically, the outer cylinder 20 has a straight bevel contour, although cylinder 20 could be curved 40, rather than straight beveled, as long as the outer cylinder 20' moves relative to the center post 22' when a cassette is placed thereupon. Square receptacle 38, however, requires that the top of outer cylinder 20" be slightly above the top of center post 22", rather than slightly below in order to act as a switch. However, as only two pins are needed to assure that a payload is present and nested, such a square receptacle need not cause travel of the outer cylinder 20".
As shown in FIG. 5, the novel pin assembly arrangement can be used with an automated paddle 46 having inner pin assemblies 54 which can be inserted beneath the cassette 56 between outer pin assemblies 52, as no cassette sensing pads, 58 in FIGS. 2a and 2b, are used.
Referring to FIG. 6a, a hollow outer cylinder 20 is mounted coaxially on a center post 22 over a spring 26 on a base 62. A small flag 64 is attached to the bottom surface 76 of outer cylinder 20, extends outward from the center post 22, and is aligned with photosensor 66. Photosensor 66 has a pair of prongs 68, 70 which contain a light, or flux, source 72 and receptor 74, respectively. A dowel pin 75 extends from the bottom surface 76 of the hollow outer cylinder 20 into dowel aperture 78 in the base 62. Dowel pin 75 is of a sufficient length so as to slidably engage hollow outer cylinder 20, in alignment with dowel aperture 78 throughout the range of travel of outer cylinder 20, thereby preventing rotation of the outer cylinder 20. A top plate 79 is affixed to the base 62 to contain the pin assembly.
FIG. 6b shows the sensor in FIG. 6a in an untriggered state with the outer cylinder 20 displaced upwards, and photosensor beam 80 of light source 72 uninterrupted by flag 64. As shown in FIG. 6c, as cassette 16 approaches pin assembly 24 and cassette receptacle 28 engages outer cylinder 20, outer cylinder 20 is driven downward, thereby displacing flag 64 into the path of photosensor beam 80. Rotation of outer cylinder 20 is prevented by dowel pin 75 remaining inserted in dowel aperture 78, thereby keeping flag 64 aligned with photosensor prongs 68, 70.
Referring to FIG. 7a, a second embodiment is disclosed which shows a cantilevered member 82 fixed at distal end 83 and having a downward protruding tab 84. The outer cylinder 20 has a protruding annular ring 86 around its base which extends over the end of the cantilevered member 82. The protruding annular ring 86 avoids the need to prevent rotation of outer cylinder 20. As outer cylinder 20 is driven downward, protruding ring 86 displaces cantilevered member downward causing protruding tab 84 to break the beam 80 between photosensor prongs 68, 70 as shown in FIG. 7c. Spring 26 biases outer cylinder 20 and cantilevered member 82 upward such that protruding tab 84 is removed from the path of the beam 80 when the cassette is removed.
A third embodiment is shown in FIG. 8a in which the cantilevered member 82 itself provides the upward force. Outer cylinder 20 moves downward around center post 22 when displaced by a cassette. The protruding ring 86 therefore causes cantilevered member 82 to flex downward such that protruding tab 84 breaks the beam 80 between sensor prongs 68, 70 as shown in FIG. 8c. Cantilevered member 82 is biased sufficiently to drive outer cylinder 20 upward and return to the unflexed position when the cassette is removed, thereby removing protruding tab 84 from the path of the beam 80.
A fourth embodiment is shown in FIG. 9a in which the detectable element 90 is rotated, rather than driven linearly, from the downward movement of the outer cylinder 20. Referring to FIGS. 9a-9c, the rotating detectable element 90 is pivotally mounted with pivot pin 94 along an axis 92 orthogonal to the movement of the outer cylinder 20. An annular groove 96 is formed on the lower side of the outer cylinder 20 which accepts a cam extension 98 of detectable element 90. Downward movement of outer cylinder 20 displaces cam extension 98 such that detectable element 90 pivots around axis 92 into beam path 80, thereby triggering sensor 66. Spring 26 biases outer cylinder 20 upward such that outer cylinder 20 is displaced upward and detectable element 90 is removed from beam path 80 when the cassette is removed.
A fifth embodiment is shown in FIGS. 10a-10b in which a photosensor 100 is oriented in such manner so as to reflect light from the cylinder and complete the beam path 80 when the outer cylinder 20 is displaced downward. Outer cylinder 20 has a reflective ring 102 around its bottom perimeter. As outer cylinder 20 is displaced downward, reflective ring 102 intersects beam emitted by sensor light source 72. Sensor light source 72 and sensor receptor 74 are oriented relative to reflective ring 102 such that the beam 80 is reflected to sensor receptor 74 when the reflective ring 102 is displaced into beam 80, as shown in FIG. 10b. Outer cylinder 20 is again biased upwards by spring 26, thereby causing outer cylinder 20 and reflective ring 102 to travel upwards and out of the path of beam 80 when the cassette is removed.
The cassette positioning and detection mechanism incorporates a pin assembly arrangement in which at least one of the pin assemblies comprises the novel pin assembly as described herein. Other pin assemblies may be of the fixed type or novel type, depending on factors such as the expected receptacle configuration on the cassette, sensor redundancy, and manufacturing costs. Also, one of ordinary skill will appreciate that other arrangements for detecting the downward movement of the cylinder can be used. For example, the detectable element could comprise a portion of the cylinder which occludes a light beam upon displacement downwardly. Alternatively, electrical contacts could be positioned to close a circuit, or magnetic portions of the cylinder oriented proximate to sensors so as to sense a magnetic field.
As various extensions and modifications will be apparent to those skilled in the art, the present invention is not intended to be limited to the above embodiments but rather only by the spirit and scope of the following claims. | An apparatus for detecting the presence of a wafer cassette, or pod, resting on an arrangement of pins allows cassette detection without interfering with insertion of a robotic paddle arm beneath the cassette to remove it for transport. A cassette resides on an arrangement of beveled pins which mate with corresponding receptacles on the underside. Pins supporting the cassette have a spring biased, hollow outer cylinder coaxially mounted around a center post. A cassette placed on the pins displaces the outer cylinder downward a sufficient distance to trigger a sensor. Upon removal of the cassette, the outer cylinder is displaced upwards, resetting the sensor. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of an earlier filed co-pending application by the same inventor, Ser. No. 732,657, filed May 10, 1985 now abandoned, entitled variable volume Ejector.
FIELD OF THE INVENTION
This invention relates to fluid ejectors generally and, in particular, to variable volume ejectors in which the variation in ejected volume of a fluid is controlled by varying the flowrate of the motive fluid. The design is unique in that the flow of the motive fluid is further controlled by the use of a fluid pulsing mechanism.
BACKGROUND AND OBJECTS OF THE INVENTION
Ejectors have been in use for many years, sharing the basic functions of exhausting fluids or evacuating fluid-filled containers. They are known generally as ejectors or jet pumps and operate on the principle of one fluid (a motive fluid) entraining a second fluid. The functions being basically the same, the distinction within the art lies primarily in the design and construction of these ejectors or jet pumps.
All ejectors have three common features: an inlet, a port which allows the induction of the motive or operating medium (fluid) under pressure; suction or quasi-suction, a functional aspect which begins the entrainment process; and discharge, the stage wherein motive fluid energy is imparted to the fluid which is to be exhausted or pumped.
Pressurized pumping medium, hereinafter known as motive fluid, enters the inlet and travels through a nozzle or constricting aperture into the suction chamber. The purpose of the nozzle is to condition the motive fluid, generally by converting the pressure of the motive fluid into a high velocity stream which passes from the exit side of the inlet nozzle immediately to the inlet side of a discharge or ejector tube.
Ejecting or pumping action begins when an entrainment fluid in the suction chamber is captured or entrained by the high velocity stream emerging from the inlet's downstream nozzle. The venturi phenomenon effects lowering of the pressure in the suction chamber. The resulting action causes the entrainment fluid in the suction chamber to flow towards the discharge or ejector tube outlet urged by, and with, the motive fluid.
In the general ejector case, the entrained fluid from the suction chamber mixes with the motive fluid and acquires part of its energy in the downstream, discharge tube section. Normally, a diffuser section is provided adjacent and downstream of the discharge tube. Part of the velocity of the motive-entrained fluid mixture is converted to a pressure greater than the suction pressure, but lower than the motive fluid pressure. It is finally discharged at the diffuser exit port.
The amount of entrainment fluid which can be entrained by the motive fluid is dependent upon the amount of suction produced in the suction chamber from the discharge of the motive fluid through the suction chamber. Limitations on conventional ejector efficiency occur when large quantities of entrained fluid are elicited from a relatively small ejector unit. Because the vacuum produced by Venturi effect in these units is very limited in the amount of entrainment fluid which it may capture, the only reasonable way to increase the entrainment capacity of an ejector is to increase its size. Conventional ejectors possessing a single inlet nozzle and discharge nozzle are thus limited in the range of fluid flow volume that may be expected.
Compounding the disadvantageous low volume capability of most ejectors is their inherent lack of ability to compress the entrained fluid to high pressures. This derives from the fact that entrainment is essentially a boundary layer phenomenon. The motive fluid captures the entrained fluid between its boundary and the walls of the discharge tube. There is generally a mixture of the two fluids as energy is transferred from the motive to the entrained. This phenomenon is dependent upon many factors, not the least of which is solubility of the entrained fluid in the motive fluid or vice versa. In fact, if the two fluids are immiscible, a great deal of the efficiency of the ejector is lost. To act as a high pressure compressor, as most pumps are capable, the ejector or jet pump art obviously depart from the conventional entrainment principles that are employed today.
It is therefore an object of this invention to provide a variable volume ejector which can function relatively free from the limitations of size.
It is also an object of this invention to provide a variable volume ejector which will provide efficient operation over a wide range of fluid flows.
It is another object of this invention to provide an ejector which may be used to pump gaseous fluids as well as liquid fluids.
It is yet another object of this invention to provide an ejector which is capable of entraining a greater quantity of fluid than do conventional ejectors of comparable size.
It is a major object of this invention to make use of a principles of ejection by positive displacement means rather than conventional entrainment.
Finally, it is an object of this invention to provide means by which the aforesaid positive displacement (of entrained fluids) can be achieved; such a method contemplates the urging of entrained fluid by use of the momentum and confinement of hydraulic slugs rather than boundary layer entrainment.
I have described the operation of certain conventional fluid pumps--jet pumps and ejectors--in order to set out the standard of current art. I shall describe my invention hereinafter in terms of specified embodiments which shall be set forth in general form. The objects of the invention, having been set forth in part herein, will be readily seen or may be learned by practice with the invention.
SUMMARY OF THE INVENTION
The present invention accomplishes the above objects by providing an ejector inlet having motive fluid pulsing means so that the working or motive fluid is formed into piston shapes, termed hydraulic slugs.
The hydraulic slugs formed in the ejector inlet are passed then through a variable flow control actuator which, by changing inlet exit orifice cross sectional area, varies the diameter of the hydraulic slug which is allowed to pass therethrough. The flow control actuator means used in the preferred embodiment comprise one or more iris valves. Immediately downstream of the flow control actuator means is an extension of the inlet exit orifice, comprising two or more concentric cylindrical passageways which terminate in the suction chamber with constrictive cross-sectional areas termed concentric nozzles.
The suction chamber, in the preferred embodiment, is termed so because the fluid pressure therein is much lower than the motive fluid pressure which, during operation, is continuously entering the suction chamber from the inlet exit port nozzle(s). Means are provided for regulating the flow of entrained fluid being drawn into the suction chamber by either its lower relative pressure or from some pressurizing means external to the suction chamber which is to provide that entrainment fluid. For certain applications, backflow prevention means are also provided with or in lieu of these entrainment fluid flow control means.
The discharge mechanism of the variable volume ejector comprises one or more concentric cylindrical chambers which are coaxial with the inlet chamber and its exit port nozzles. This coaxial registry is necessary so that the concentric discharge cylinders are aligned with their respective inlet exit port nozzles in order to receive the motive fluid discharges therefrom. Thereafter, the downstream ejection mechanism of this invention resembles the conventional jet pump or ejector.
Of significant importance in the present invention is the fluid pulser provided for forming hydraulic slugs of the motive fluid. This inventional object has been achieved by introducing first a high pressure motive fluid into the inlet means, thereafter providing valving which has the capability of opening abruptly, i.e., near-instantaneously, to allow the highly pressurized motive fluid to fill the inlet chamber. Subsequently, the inlet chamber is constricted either immediately prior to, or concurrent with, its registry with the variable flow controlled actuating means. It is the combination of these three factors: introduction of high pressure motive fluid; near-instantaneous valving; and constriction, which, novel in their combination relative to ejectors and fluid pumps, cooperate to form the hydraulic slugs. The slugs, in turn, dissipate part of their momentum by pushing quanta of fluid (entrained) through the ejector tube(s).
Finally, other apparatus may be utilized in the varied embodiments of this ejector such as backflow preventers in conjunction with the diffuser portions, as well as baffling and state-of-the-art fluid separators.
In the first actual reduction to practice, I was able to achieve initial success using water as a motive fluid which had been pressurized to 25 psi with an electric motor pump. What I shall later describe as a cylindrical pulser, composed of brass, a plexi-glass separation chamber and galvanized steel tubing were also employed. The entrained fluid was air which was pumped, and thus compressed, into an enclosed separation chamber, to 5 psi.
It will be understood that the foregoing general description and the following detailed description, as well, are illustrative or the invention but are not restrictive thereof. Thus, while I relied on a pulser mechanism constructed within the ejector inlet chamber, those versed in the particular art will recognize that I have merely chosen this method to embody the concept of forming hydraulic slugs, as a motive force, in order to operate an ejector on the principle of positive displacement rather than the conventional boundary layer entrainment of traditional ejectors and jet pumps.
The accompanying drawings, referred to herein and made a part hereof, illustrate preferred embodiments of the invention, and together with the description, serve to explain the principles of my invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Of the drawings;
FIG. 1 is a bi-part illustration depicting, as FIG. 1A and in cross section, a constant volume ejector with motive fluid pulsing means and, in FIG. 1B, an elevational view of the pulser mechanism;
FIG. 2 is a bi-part illustration depicting, as FIG. 2A, a cross-sectional representation of a variable volume fluid ejector with motive fluid pulsing means and, in FIG. 2B, a front elevational view of a fluid flow control iris regulator in partial first stage open mode;
FIG. 3 is a cross-sectional view of a constant volume fluid ejector utilizing cylinder-within-cylinder motive fluid pulse actuation means; and
FIG. 4 is a variable volume ejector utilizing pulsing mechanisms of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4 of the accompanying drawings, there are illustrated ejector mechanisms capable of constant volume operation (FIGS. 1 and 3), and variable volume operation (FIGS. 2 and 4). It should also be understood that the principle of positively displacing the entrained fluid by means of hydraulic slugs is the principle mode of operation and, consequently, all embodiments contain this mechanism.
As preferably embodied in FIG. 1A, the constant volume pulsing ejector comprises an inlet area 10, a pulser 12, slug formation chamber 14, inlet area exit port 16, suction chamber 18, and ejector section 20. The ejector section 20 comprises a venturi-type inlet 22, what is commonly referred to as the parallel section 24 and a diffuser-discharge port 26. Illustrated in this embodiment only is the ejector portion 20, passing from the suction chamber 18 through, into and terminating within the fluid separator means 28. The fluid separator means 28 functions as both a means for separating the entrained fluid from the motive fluid and a confinement means, thus allowing compression of the entrained fluid.
FIG. 1B, depicting one form of a pulser mechanism, illustrates the superposition of two similarly apertured plates 12, 12', which are positioned in the inlet throat of the ejector as depicted in FIG. 1A. The downstream plate 12' is fixed, while the upstream plate 12 is caused to rapidly rotate by power means applied to shaft 30. In FIG. 1B, rotating plate 12, the upstream plate, is depicted approximately one third of the way through a closing cycle. Note that downstream plate 12', denoted by the shaded area, is visible through approximately one third of the upstream plates' apertures. As mentioned earlier, downstream plate 12' is fixed while upstream plate 12 is motivated by power means coupled through shaft 30. The motive means for driving shaft 30 are not herein depicted but those versed in the art will readily acknowledge that such motive means may encompass those obtained by any rotary drive mechanism available today. As the applicant pointed out in the summary of this invention, he gained initial success using an electric motor to drive said shaft.
Referring once again to FIG. 1A, there is also illustrated, contiguous to suction chamber 18, a number of inlet ports 32, 32' which may be fitted with entrained fluid flow control and/or backflow preventer valves. (not herein depicted).
I should like now, to briefly explain with reference to FIG. 1, how I have achieved ejection and compression of a gaseous fluid by means of a highly pressurized motive fluid, with such apparatus. A highly pressurized liquid fluid (water) was introduced into the ejector apparatus via the inlet chamber 10. With pulser plate 12, 12' superimposed in an open position (to allow free flow from inlet chamber 10 to its downstream exit chamber 14) by holding upstream pulser plate 12 rigid through shaft actuation means 30, the motive fluid was initially allowed to pass out of exit port nozzle 16 through the suction chamber 18 and into ejector means 20. This created a low pressure chamber which was immediately filled by gaseous fluid (air) passing into suction chamber 18 through induction port 32, 32'. The creation of the Venturi effect allowed the air to be entrained with the water and carried into separator 28. As air pressure began to build slightly within the separator (which was not evacuated), back pressure soon caused the ejector to fail. Motive fluid began to exit at induction ports 32, 32'.
Switching to the operative mode, I increased the motive fluid pressure, while simultaneously applying motive means, that is, connection of an electric motor, to pulser plate actuator shaft 30. The effect was as anticipated; with each opening, and corresponding closing, of the pulser (plates 12, 12'), downstream exit chamber 14 was abruptly filled at high pressure with the motive fluid. The slight constriction afforded by the geometry of the downstream exit chamber 14 and its nozzle means 16 are required to compensate for the sudden loss of cross-sectional area as the motive fluid transitions the pulser plate(s). This construction literally forms the hydraulic slug. The head of the slug presents a "wall of water" as it begins to transition the suction chamber 18 space between exit nozzle 16 and ejector tube intake 22. Gaseous fluid which has entered through induction port 32, 32' has filled the void of suction chamber 18 as well as the ejector tube 20. Meanwhile, the pulser plates have closed and the tube of water exiting chamber 14 has the physical appearances of a liquid piston. The hydraulic slug or liquid piston rams the inlet portion 22 of ejector tube 20, forcing the gaseous fluid therein through the tube into the separator-compression chamber 28. As described earlier in this specification, diffuser means 26 assists in the separation of motive fluid from entrained fluid; however, as pointed out, my invention does not utilize the traditional entrainment means, but rather employs a positive displacement technique. Therefore, it can be seen that the conventional diffuser has limited utility in this application. The conventional diffuser means can be replaced by a backflow climinator or check valve apparatus, which would be more functional in certain applications, e.g., low rate of operation.
Referring now to FIG. 2, specifically FIG. 2A, I have depicted the invention of FIG. 1 in its variable volume configuration. This is done by what I term "multi-coring" the hydraulic slug prior to its transition through the suction chamber. This is done by interposing, immediately downstream of the constricting inlet exit chamber 14, an iris valve 34. Immediately downstream of the iris valve, the remaining portion of chamber 14 is concentrically partitioned by emplacement, within the stream, of one or more concentric tubes; here, concentric tube 36 forms the partition with corresponding nozzles 38 and 40 for chambers labeled Stage I 42 and Stage II 44, respectively. In this embodiment, the hydraulic slug or piston is cylindrically bifurcated and the slug entering the transitional area in suction chamber 18 appears to be a cylindrical toroid surrounding a solid cylinder. Thereafter, operation is essentially the same as in FIG. 1.
Under initial operating conditions, iris valve 34 is at the position depicted in FIG. 2B, that is, set at its first stage opening position thereby covering toroidial chamber 44. As can readily be seen, the hydraulic slug formed would traverse only section 42, transitioning the suction chamber and entering ejector tube 20. I have illustrated hydraulic slugs B, B' in order to detail this configuration. It is important to note that, in this configuration, backflow preventer means are necessitated at ejector exit ports.
When greater volume is desired, iris valve 34 is opened to its second stage position, denoted in FIG. 2B, by phantom outline 48. At this time, both chambers 42 and 44 shape the slug configuration described above, and the resultant slugs B and A would be realized. Thus, there is presented herein, the description of a variable volume ejector which has motive fluid pulsing means for the formation of hydraulic slugs or pistons. It should also be understood that the technique for achieving flow variation may be employed to further increase such variation. One can conceive of a series of concentric slug separators (referred to earlier as a "bifurcator") with corresponding concentric ejector tubes. The iris valve regulating means would then be constructed to open in one, two, . . . x stages. Of course, as mentioned above, check means or back flow eliminator means must be utilized at various ejector tube exhaust ports if the invention is to be employed as a ejector-compressor. This reasonably follows since, in such an embodiment, if one were to use only first stage operation, it would be necessary to curtail backflow through the other "one plus" stages. It is also conceivable that, in multi-chamber (variable) ejector operation, ejector exit port takeoffs could be placed at differing locations along the center flow lines. For example, given the two exit ports 26 and 46, depicted in FIGS. 2A, I have contemplated a separator-within-separator configuration; the inner would receive ejecta from tube 20 and the outer would receive ejecta from tube 46.
In FIG. 3, I have introduced a pulsing means which can be used without apparent downstream constriction and still form the desired piston or hydraulic slug 68' of motive fluid. Referring particularly now to FIG. 3, there is illustrated a high pressure motive fluid container 50 enveloping the pulser section 52. Pulser actuation shaft means 30 remains essentially unchanged in this embodiment. As a practical matter, as I have noted earlier, an electric motor may be used to provide shaft 30 drive means. The framework 54, including bearing 56 may be constructed integrally with ejector tube 58 proper, or can be fitted to the high pressure motive reservoir 50.
In this embodiment, the pulser 52 comprises a cylinder 60 driven by shaft means 30 and residing within cylindrical housing end 62 of the ejector 58. The pulser inner cylinder 60 and the outer cylindrical ejector end 62 are placed wholly within the envelope 50, also referred to as the high pressure motive fluid reservoir. Both of these cylindrical geometrics 60, 62 are apertured; here, the outside cylindrical body apertures 64 and the inside rotational cylinder apertures 66 are positioned 90 degrees from each other. In operation, inner cylinder 60 is caused to rotate and, as inside apertures 66 align with outside apertures 64, high pressure motive fluid 68 would enter the ejector's apparent inlet side. Constrictive means 70 induce the formation of a hydraulic slug. It must be realized, however, that although it is a design of this embodiment, discrete constriction is not necessary to the formation of the hydraulic slug. Notably, in this embodiment, if apertures 64 and 66 have a total cross-sectional area exceeding the cross sectional area of ejector tube 58, constriction will have effectively taken place. Therefore, it must be taught that required constriction means relative constriction, i.e., cross-sectional area out should be somewhat less than cross-sectional area in.
When formed, the hydraulic slug will traverse ejector tube 58. The void 72' between slugs is filled by entrainment fluid 72 entering at induction port 74 through backflow preventer and control valve 76. One familiar with the operation of ejectors and jet pumps will realize that the entrainment fluid induction method, as well as the suction chambers of both of the herein described embodiments, though appearing diagrammatically different, are physically the same embodiment. This fact may be seen more clearly in FIG. 4.
FIG. 4, inculcating the method and mechanics of the variable volume ejector shown in FIG. 2A, contains an innovation designed to eliminate backflow preventer means 76 of FIG. 3. The apparatus downstream of air induction ports 76' operates on the same principle (after hydraulic slug formation) as iris valve 34 and chambers 42 and 44 of FIG. 2A. Therefore, the inlet-pulsing means embodied herein will be discussed.
Attention is now called to FIG. 4 at the point of induction of motive fluid 68. The familiar cylinder-within-cylindrical chamber pulser is used in a slightly different configuration. Inlet apertures 64, 66 are larger than those of FIG. 3. This is because the constriction 70 of FIG. 3 has been eliminated so that a rotating inner pulser cylinder 60 may employ induction ports 76 and terminate at iris valve 34 while maintaining a consistent cross-sectional area with stage 11 ejector tube chambers 42/44. Although a discrete constriction has not been employed, nonetheless constricting is effected by using motive fluid intake aperturing having greater cross-sectional area than the downstream inlet-ejector tubing (relative constriction, ibid.)
The latter design alternative may, in fact, be employed in any of the aforementioned embodiments. Suprisingly enough, the theory itself, i.e., use of hydraulic slugs is adaptable to generally all jet pumps and ejectors in use today. The basic principle that is applied is a presentation of a "solid" hydraulic front to a constraining (tubular) chamber, having first filled the chamber with some fluid which is to be ejected or pumped. Analogously, if one were to pass intermittently a flowing jet of water from a high enough pressure source past the mouth of a conventional liquid funnel, that person would observe a series of water slugs or "spurts" (quite well defined), leaving the nozzle end of the funnel. Each slug or spurt would be preceeded by a quantum of entrapped (literally, entrained) air.
It is evident, therefore, that the invention in its broader aspects is not limited to the specific embodiments herein shown and described, but that departures may be made therefrom within the scope of the accompanying claims, without departing from the principles of the invention and without sacrificing its major advantages. | A method and apparatus for ejecting fluids through use of a high pressure liquid motive fluid by forming hydraulic slugs from said motive fluid and conducting it through conventional ejection mechanisms, entraining a fluid which is to be ejected and depositing it into containment of user's choice. A pulser apparatus is employed which embodies the concept of abruptly starting and stopping high pressure motive flow, contemporaneously constricting the downstream flow through use of either inlet or instream interruption means, and entraining quanta of fluid to be ejected, said entrainment being the urging of said discrete quanta by the momentum of a series of hydraulic slugs formed by the aforementioned method. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a division of application Ser. No. 10/122,424 filed Apr. 12, 2002 now U.S. Pat. No. 6,883,611. The disclosure of this earlier application is incorporated herein in its entirety by this reference.
BACKGROUND
The present invention relates generally to operations performed in conjunction with subterranean wells and, in an embodiment described herein, more particularly provides a method of forming sealed wellbore junctions.
Many systems have been developed for connecting intersecting wellbores in a well. Unfortunately, these systems typically involve methods which unduly restrict access to one or both of the intersecting wellbores, restrict the flow of fluids, are very complex or require very sophisticated equipment to perform, are time-consuming in that they require a large number of trips into the well, do not provide secure attachment between casing in the parent wellbore and a liner in the branch wellbore and/or do not provide a high degree of sealing between the intersecting wellbores.
For example, some wellbore junction systems rely on cement alone to provide a seal between the interior of the wellbore junction and a formation surrounding the junction. In these systems, there is no attachment between the casing in the parent wellbore and the liner in the branch wellbore, other than that provided by the cement. These systems are acceptable in some circumstances, but it would be desirable in other circumstances to be able to provide more secure attachment between the tubulars in the intersecting wellbores, and to provide more effective sealing between the tubulars.
SUMMARY
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a method of forming a wellbore junction is provided which both securely attaches tubulars in intersecting wellbores and effectively seals between the tubulars. The method is straightforward and convenient in its performance, does not unduly restrict flow or access through the junction, and does not require an inordinate number of trips into the well.
In one aspect of the invention, a method is provided for forming a wellbore junction which includes a step of expanding a member within a tubular structure positioned at an intersection of two wellbores. This expansion of the member may perform several functions. For example, the expanded member may secure an end of a tubular string which extends into a branch wellbore. The expanded member may also seal to the tubular string and/or to the tubular structure.
In another aspect of the invention, the tubular string may be installed in the branch wellbore through a window formed through the tubular structure. An engagement device on the tubular string engages the tubular structure to secure the tubular string to the tubular structure. For example, the engagement device may be a flange which is larger in size than the window of the tubular structure and is prevented from passing therethrough, thereby fixing the position of the tubular string relative to the tubular structure.
In yet another aspect of the invention, a whipstock may be used to drill the branch wellbore through the window in the tubular structure. Thereafter, the whipstock is used to install the tubular string in the branch wellbore. After installation of the tubular string, the whipstock may be retrieved from the parent wellbore, thereby permitting full bore access through the wellbore junction in the parent wellbore. The tubular string may be installed and the whipstock retrieved in only a single trip into the well using a unique tool string.
In still another aspect of the invention, the window may be formed in the tubular structure prior to cementing the tubular structure in the parent wellbore. To prevent cement flow through the window, a retrievable sleeve is used inside the tubular structure. After cementing, the sleeve is retrieved from within the tubular structure.
Various types of seals may be used between various elements of the wellbore junction. For example metal to metal seals may be used, or elements of the wellbore junction may be adhesively bonded to each other, etc.
These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a method of forming a wellbore junction which embodies principles of the present invention and wherein a tubular structure has been cemented within a parent wellbore;
FIG. 2 is an enlarged cross-sectional view of the method wherein a branch wellbore has been drilled through the tubular structure utilizing a whipstock positioned in the tubular structure;
FIG. 3 is a cross-sectional view of the method wherein a tubular string is being installed in the branch wellbore;
FIG. 4 is an enlarged cross-sectional view of the method wherein a sleeve is being expanded within the tubular structure to thereby secure and seal the tubular string to the tubular structure;
FIG. 5 is a cross-sectional view taken along line 5 — 5 of FIG. 4 , showing the sleeve expanded within the tubular structure;
FIGS. 6 & 7 are cross-sectional views of the sleeve in its radially compressed and expanded configurations, respectively;
FIGS. 8–13 are cross-sectional views of a second method embodying principles of the present invention;
FIGS. 14–17 are cross-sectional views of a third method embodying principles of the present invention;
FIGS. 18–20 are cross-sectional views of a fourth method embodying principles of the present invention;
FIGS. 21–25 are cross-sectional views of a fifth method embodying principles of the present invention;
FIGS. 26 & 27 are cross-sectional views of a sixth method embodying principles of the present invention;
FIGS. 28 & 29 are cross-sectional views of a seventh method embodying principles of the present invention;
FIG. 30 is a cross-sectional view of an eighth method embodying principles of the present invention; and
FIGS. 31–35 are cross-sectional views of a ninth method embodying principles of the present invention.
DETAILED DESCRIPTION
Representatively illustrated in FIG. 1 is a method 10 which embodies principles of the present invention. In the following description of the method 10 and other apparatus and methods described herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used only for convenience in referring to the accompanying drawings. Additionally, it is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of the present invention.
As depicted in FIG. 1 , several steps of the method 10 have already been performed. A parent wellbore 12 has been drilled and a tubular structure 14 has been positioned in the parent wellbore. The tubular structure 14 is part of a casing string 16 used to line the parent wellbore 12 .
It should be understood that use of the terms “parent wellbore” and “casing string” herein are not to be taken as limiting the invention to the particular illustrated elements of the method 10 . The parent wellbore 12 could be any wellbore, such as a branch of another wellbore, and does not necessarily extend directly to the earth's surface. The casing string 16 could be any type of tubular string, such as a liner string, etc. The terms “casing string” and “liner string” are used herein to indicate tubular strings of any type, such as segmented or unsegmented tubular strings, tubular strings made of any materials, including nonmetal materials, etc. Thus, the reader will appreciate that these and other descriptive terms used herein are merely for convenience in clearly explaining the illustrated embodiments of the invention, and are not used for limiting the scope of the invention.
The casing string 16 also includes two anchoring profiles 18 , 20 for purposes that are described below. The lower profile 20 may be an orienting latch profile, for example, a profile which serves to rotationally orient a device engaged therewith relative to the window 28 . The upper profile 18 may also be an orienting latch profile. Such orienting profiles are well known to those skilled in the art.
A tubular shield 22 is received within the casing string 16 , and seals 24 , 26 carried on the shield are positioned at an upper end of the tubular structure 14 and at a lower end of the anchoring profile 20 , respectively. The shield 22 is a relatively thin sleeve as depicted in FIG. 1 , but it could have other shapes and other configurations in keeping with the principles of the invention.
The shield 22 serves to prevent flow through a window 28 formed laterally through a sidewall of the tubular structure 14 . Specifically, the shield 22 prevents the flow of cement through the window 28 when the casing string 16 is cemented in the parent wellbore 12 . The shield 22 also prevents fouling of the lower profile 20 during the cementing operation, and the shield may be releasably engaged with the profile to secure it in position during the cementing operation and to enable it to be retrieved from the casing string 16 after the cementing operation, for example; by providing an appropriate convention latch on the shield.
The shield 22 prevents cement from flowing out to the window 28 when cement is pumped through the casing string 16 . Other means may be used external to the tubular structure 14 to prevent cement from flowing in to the window 28 , for example, an outer membrane, a fiberglass wrap about the tubular structure, a substance filling the window and any space between the window and the shield 22 , etc.
At this point it should be noted that the use of the terms “cement” and “cementing operation” herein are used to indicate any substance and any method of deploying that substance to fill the annular space between a tubular string and a wellbore, to seal between the tubular string and the wellbore and to secure the tubular string within the wellbore. Such substances may include, for example, various cementitious compositions, polymer compositions such as epoxies, foamed compositions, other types of materials, etc.
At the time the casing string 16 is positioned in the wellbore 12 , but prior to the cementing operation, the tubular structure 14 is rotationally oriented so that the window 28 faces in a direction of a desired branch wellbore to extend outwardly from the window. Thus, the tubular structure 14 is positioned at the future intersection between the parent wellbore 12 and the branch wellbore-to-be-drilled, with the window 28 facing in the direction of the future branch wellbore. The rotational orientation may be accomplished in any of a variety of ways, for example, by engaging a gyroscopic device with the upper profile 18 , by engaging a low side indicator with the shield 22 , etc. Such rotational orienting devices (gyroscope, low side indicator, etc.) are well known to those skilled in the art.
After the tubular structure 14 is positioned in the wellbore 12 with the window 28 facing in the proper direction, the casing string 16 is cemented in place in the wellbore. When the cementing operation is concluded, the shield 22 is retrieved from the casing string 16 .
Referring additionally now to FIG. 2 , an enlarged view of the method 10 is representatively illustrated wherein the shield 22 has been retrieved. A whipstock 30 or other type of deflection device has been installed in the tubular structure 14 by engaging keys, lugs or dogs 32 with the profile 20 , thereby releasably securing the whipstock in position and rotationally aligning an upper deflection surface 34 with the window 28 .
The whipstock 30 also includes an inner passage 36 and a profile 38 formed internally on the passage for retrieving the whipstock. Of course, other means for retrieving the whipstock 30 could be used, for example, a washover tool, a spear, an overshot, etc.
As depicted in FIG. 2 , one or more cutting devices, such as drill bits, etc., have been deflected off of the deflection surface 34 and through the window 28 to drill a branch wellbore 40 extending outwardly from the window. As discussed above, the term “branch wellbore” should not be taken as limiting the invention, since the wellbore 40 could be a parent of another wellbore, or could be another type of wellbore, etc.
Referring additionally now to FIG. 3 , the method 10 is representatively illustrated wherein a tubular string 42 has been installed in the branch wellbore 40 . The tubular string 42 may be made up substantially of liner or any other type of tubular material.
As depicted in FIG. 3 , the tubular string 42 includes an engagement device 44 for engaging the tubular structure 14 and securing an upper end of the tubular string thereto. The tubular string 42 also includes a flex or swivel joint 46 for enabling, or at least enhancing, deflection of the tubular string from the parent wellbore 12 into the branch wellbore 40 . Alternatively, or in addition, the swivel joint 46 permits rotation of an upper portion of the tubular string 42 relative to a lower portion of the tubular string in the rotational alignment step of the method 10 described below. The tubular string 42 is deflected off of the deflection surface 34 as it is conveyed downwardly attached to a tool string 48 .
The tool string 48 includes an anchor 50 for releasable engagement with the upper profile 18 , a running tool 52 for releasable attachment to the tubular string 42 , and a retrieval tool 54 for retrieving the whipstock 30 . The running tool 52 may include keys, lugs or dogs for engaging an internal profile (not shown) of the tubular string 42 . The retrieval tool 54 may include keys, lugs or dogs for engagement with the profile 38 of the whipstock 30 .
When the anchor 50 is engaged with the profile 18 , the tubular string 42 is rotationally aligned so that the engagement device 44 will properly engage the tubular structure 14 as further described below. In addition, the anchor 50 is preferably spaced apart from the engagement device 44 so that when the anchor is engaged with the profile 18 and a shoulder 56 formed on a tubing string 58 of the tool string 48 contacts the anchor, the engagement device is properly positioned in engagement with the tubular structure 14 .
Specifically, the tubing string 58 is slidably received within the anchor 50 . When the shoulder 56 contacts the anchor 50 , the engagement device 44 is a predetermined distance from the anchor. This distance between the anchor 50 and the engagement device 44 corresponds with another predetermined distance between the profile 18 and the tubular structure 14 . Thus, when the tubular string 42 is being conveyed into the branch wellbore 40 , the engagement device 44 will properly engage the tubular structure 14 as the shoulder 56 contacts the anchor 50 .
The running tool 52 may then be released from the tubular string 42 , the tool string 48 may be raised into the parent wellbore 12 , and then the retrieval tool 54 may be engaged with the profile 38 in the whipstock 30 to retrieve the whipstock from the parent wellbore. Note that the installation of the tubular string 42 and the retrieval of the whipstock 30 may thus be accomplished in a single trip into the well.
The engagement device 44 is depicted in FIG. 3 as a flange which extends outwardly from the upper end of the tubular string 42 . The engagement device 44 includes a backing plate or landing plate 60 which is received in an opening 62 formed through a sidewall of a guide structure 64 of the tubular structure 14 . Preferably, the opening 62 is complementarily shaped relative to the plate 60 , and this complementary engagement maintains the alignment between the tubular string 42 and the tubular structure 14 . For example, engagement between the plate 60 and the opening 62 supports the upper end of the tubular string 42 , so that an annular space exists about the upper end of the tubular string for later placement of cement therein.
The guide structure 64 is more clearly visible in the enlarged view of FIG. 2 . In this view it may also be seen that the opening 62 includes an elongated slot 66 at a lower end thereof. Preferably, the plate 60 includes a downwardly extending tab 68 (see FIG. 3 ) which engages the slot 66 and thereby prevents rotation of the engagement device 44 relative to the window 28 .
The engagement device 44 is larger in size than the window 28 , and so the engagement device prevents the tubular string 42 from being conveyed too far into the branch wellbore 40 . The engagement device 44 thus secures the upper end of the tubular string 42 relative to the tubular structure 14 . Of course, other types of engagement devices may be used in place of the illustrated flange and backing plate, for example, an orienting profile could be formed on the tubular structure and keys, dogs or lugs could be carried on the tubular string 42 for engagement therewith to orient and secure the tubular string relative to the tubular structure.
As depicted in FIG. 3 , the engagement device 44 carries a seal 70 thereon which circumscribes the opening 62 and sealingly engages the guide structure 64 . The guide structure 64 carries seals 72 , 74 thereon which sealingly engage above and below the window 28 . Thus, the tubular string 42 is sealed to the tubular structure 14 so that leakage therebetween is prevented. The seals 70 , 72 , 74 , or any of them, may be elastomer seals, non-elastomer seals, metal to metal seals, expanding seals, and/or seals created by adhesive bonding, such as by using epoxy or another adhesive.
Referring additionally now to FIG. 4 , an enlarged view is representatively illustrated of the method 10 after the tubular string 42 is installed in the branch wellbore 40 and the whipstock 30 is retrieved from the well. Note that an alternatively constructed engagement device 44 is illustrated in FIG. 4 which does not include the plate 60 . Instead, the flange portion of the engagement device 44 is received in the opening 62 and the engagement device is sealed to the tubular structure 14 about the window 28 using one or more seals 76 , 78 , 80 circumscribing the window. The seal 76 is an adhesive, the seal 78 is an o-ring and the seal 80 is a metal to metal seal.
To further secure the tubular string 42 to the tubular structure 14 , a member 82 is expanded within the tubular structure using an expansion device 84 . As depicted in FIG. 4 , the member 82 is a tubular sleeve having an opening 86 formed through a sidewall thereof. Of course, other expandable member shapes and configurations could be used in keeping with the principles of the invention.
The opening 86 is rotationally aligned with an internal flow passage 88 of the tubular string 42 , for example, by engaging the expansion device 84 with the upper profile 18 . Then, the expansion device 84 is actuated to displace a wedge or cone go upwardly through the member 82 , thereby expanding the member outwardly. Such outward expansion also outwardly displaces seals 92 , 94 , 96 , 98 , 100 carried on the member.
The seals 94 , 96 sealingly engage the guide structure 64 above and below the opening 62 . The seals 92 , 98 are metal to metal seals and sealingly engage the tubular structure 14 above and below the guide structure 64 . The seal 100 is an adhesive seal which circumscribes the passage 88 and sealingly engages the flange portion of the engagement device 44 . Of course, the seals 92 , 94 , 96 , 98 , 100 , or any of them, may be any type of seal, for example, elastomer, non-elastomer, metal to metal, adhesive, etc.
After the member 82 is expanded, the expansion device 84 is retrieved from the well and the tubular string 42 is cemented within the branch wellbore 40 . For example, a foamed composition may be injected into the annulus radially between the tubular string 42 and the branch wellbore 40 . The foamed composition could expand in the annulus to fill any voids therein, and could expand to fill any voids about the structure 14 in the wellbore 12 .
Note that the engagement device 44 is retained between the member 82 and the tubular structure 14 , thereby preventing upward and downward displacement of the tubular string 42 . In addition, where metal to metal seals are used, the expansion of the member 82 maintains a biasing force on these seals to maintain sealing engagement.
Referring additionally now to FIG. 5 , a partial cross-sectional view, taken along line 5 — 5 of FIG. 4 is representatively illustrated. In this view, only the tubular string 42 , tubular structure 14 , guide structure 64 and expandable member 82 cross-sections are shown for clarity of illustration. From FIG. 5 , it may be more clearly appreciated how the engagement device 44 is received in the guide structure 64 , and how expansion of the member 82 secures the engagement device in the tubular structure 14 .
In addition, note that no separate seals are visible in FIG. 5 for sealing between the engagement device 44 and the tubular structure 14 or expansion member 82 . This is due to the fact that FIG. 5 illustrates an alternate sealing method wherein sealing between the engagement device 44 and each of the tubular structure 14 and expansion member 82 is accomplished by metal to metal contact between these elements.
Specifically, expansion of the member 82 causes it to press against an interior surface the engagement device 44 circumscribing the passage 88 , which in turn causes an exterior surface of the engagement device to press against an interior surface of the tubular structure 14 circumscribing the window 28 . This pressing of one element surface against another when the member 82 is expanded results in metal to metal seals being formed between the surfaces. However, as mentioned above, any type of seal may be used in keeping with the principles of the invention.
Referring additionally now to FIGS. 6 and 7 , the expansion member 82 is representatively illustrated in its radially compressed and radially expanded configurations, respectively. In FIG. 6 , it may be seen that the expansion member 82 in its radially compressed configuration has a circumferentially corrugated shape, that is, the member has a convoluted shape about its circumference. In FIG. 7 , the member 82 is radially expanded so that it attains a substantially cylindrical tubular shape, that is, it has a substantially circular cross-sectional shape.
Referring additionally now to FIGS. 8–13 , another method 110 embodying principles of the invention is representatively illustrated. In the method 110 , a tubular structure 112 is interconnected in a casing string 114 and conveyed into a parent wellbore 116 . The tubular structure 112 preferably includes a tubular outer shield 118 outwardly overlying a window 120 formed through a sidewall of the tubular structure. The shield 118 is preferably made of a relatively easily drilled or milled material, such as aluminum.
The shield 118 prevents cement from flowing outwardly through the window 120 when the casing string 114 is cemented in the wellbore 116 . The shield 118 also transmits torque through the tubular structure 112 from above to below the window 120 , due to the fact that the shield is rotationally secured to the tubular structure above and below the window, for example, by castellated engagement between upper and lower ends of the shield and the tubular structure above and below the window, respectively.
The tubular structure 112 is rotationally aligned with a branch wellbore-to-be-drilled 122 , so that the window 120 faces in the radial direction of the desired branch wellbore. This rotational alignment may be accomplished, for example, by use of a conventional wireline-conveyed direction sensing tool (not shown) engaged with a key or keyway 124 having a known orientation relative to the window 120 . Other rotational alignment means may be used in keeping with the principles of the invention.
In FIG. 9 it may be seen that a work string 126 is used to convey a mill, drill or other cutting tool 128 , a whipstock or other deflection device 130 and an orienting latch or anchor 132 into the casing string 114 . The drill 128 is releasably attached to the whipstock 130 , for example, by a shear bolt 134 , thereby enabling the drill and whipstock to be conveyed into the casing string 114 in a single trip into the well.
The anchor 132 is engaged with an anchoring and orienting profile 136 in the casing string 114 below the tubular structure 112 . Such engagement secures the whipstock 130 relative to the tubular structure 112 and rotationally orients the whipstock relative to the tubular structure, so that an upper inclined deflection surface 138 of the whipstock faces toward the window 120 and the desired branch wellbore 122 .
Thereafter, the shear bolt 134 is sheared (for example, by slacking off on the work string 126 , thereby applying a downwardly directed force to the bolt), permitting the drill 128 to be laterally deflected off of the surface 138 and through the window 120 . The drill 128 is used to drill or mill outwardly through the shield 118 , and to drill the branch wellbore 122 . Of course, multiple cutting tools and different types of cutting tools may be used for the drill 128 during this drilling process.
As depicted in FIG. 9 , the casing string 114 has been cemented within the wellbore 116 prior to the drilling process. However, it is to be clearly understood that it is not necessary for the tubular structure 112 to be cemented in the wellbore 116 at this time. It may be desirable to delay cementing of the casing string 114 , or to forego cementing of the tubular structure 112 , as set forth in further detail below.
In FIG. 10 it may be seen that the branch wellbore 122 has been drilled extending outwardly from the window 120 of the tubular structure 112 by laterally deflecting one or more cutting tools from the parent wellbore 116 off of the deflection surface 138 of the whipstock 130 .
In FIG. 11 it may be seen that a liner string 140 is conveyed through the casing string 114 , and a lower end of the liner string is laterally deflected off of the surface 138 , through the window 120 , and into the branch wellbore 122 . An engagement device 142 attached at an upper end of the liner string 140 engages a tubular guide structure 144 of the tubular structure 112 , thereby securing the upper end of the liner string to the tubular structure. This engagement between the device 142 and the structure 112 forms a load-bearing connection between the casing string 114 and the liner string 140 , so that further displacement of the liner string into the branch wellbore 122 is prevented.
Engagement between the device 142 and the structure 144 may also rotationally secure the device relative to the tubular structure 112 . For example, the slot 66 and tab 68 described above may be used on the device 142 and structure 144 , respectively, to prevent rotation of the device in the tubular structure 112 . Other types of complementary engagement, and other means of rotationally securing the device 142 relative to the tubular structure 112 may be used in keeping with the principles of the invention.
Note that the device 142 is depicted in FIG. 11 as a radially outwardly extending flange-shaped member which inwardly overlaps the perimeter of the window 120 . The device 142 inwardly circumscribes the window 120 and overlaps its perimeter, so if one or both mating surfaces of the device and tubular structure 112 are provided with a suitable layer of sealing material (such as an elastomer, adhesive, relatively soft metal, etc.), a seal 146 may be formed between the device and the tubular structure due to the contact therebetween. The device 142 may be otherwise shaped, and may be otherwise sealed to the tubular structure 112 in keeping with the principles of the invention.
In FIG. 12 it may be seen that the whipstock 130 and anchor 132 are retrieved from the well and a generally tubular expandable member 148 is conveyed into the tubular structure 112 and expanded therein. For example, the expandable member 148 may be expanded radially outward using the expansion device 84 , from a radially compressed configuration (such as that depicted in FIG. 6 ) to a radially extended configuration (such as that depicted in FIG. 7 ).
The member 148 preferably has an opening 150 formed through a sidewall thereof when it is conveyed into the structure 112 . In that case, the opening 150 is preferably rotationally aligned with the window 120 (and thus rotationally aligned with an internal flow passage 152 of the liner string 140 ) prior to the member 148 being radially expanded. Alternatively, the member 148 could be conveyed into the structure 112 without the opening 150 having previously been formed, then expanded, and then a whipstock or other deflection device could be used to direct a cutting tool to form the opening through the sidewall of the member.
Note that the method 110 is illustrated in FIG. 12 as though the casing string 114 is cemented in the wellbore 116 at the time the member 148 is expanded in the structure 112 . However, the structure 112 could be cemented in the wellbore 116 after the member 148 is expanded therein.
After being expanded radially outward, the member 148 preferably has an internal diameter D 1 which is substantially equal to, or at least as great as, an internal diameter D 2 of the casing string 114 above the structure 112 . Thus, the member 148 does not obstruct flow or access through the structure 112 .
Note that a separate seal is not depicted in FIG. 12 between the member 148 and the device 142 or the structure 112 . Instead, seals 154 , 156 between the member 148 and the structure 112 above and below the guide structure 144 are formed by contact between the member 148 and the structure 112 when the member is expanded radially outward. For example, one or both mating surfaces of the member 148 and tubular structure 112 may be provided with a suitable layer of sealing material (such as an elastomer, adhesive, relatively soft metal, etc.), so that the seals 154 , 156 are formed between the member and the tubular structure due to the contact therebetween. The member 148 may be otherwise sealed to the tubular structure 112 in keeping with the principles of the invention.
To enhance sealing contact between the member 148 and the structure 112 and/or to ensure sufficient forming of the internal diameter D 1 , the structure may be expanded radially outward somewhat at the time the member is expanded radially outward, for example, by the expansion device 84 . This technique may produce some outward elastic deformation in the structure 112 , so that after the expansion process the structure will be biased radially inward to increase the surface contact pressure between the structure and the member 148 . Such an expansion technique may be particularly useful where it is desired for the seals 154 , 156 to be metal to metal seals. If this expansion technique is used, it may be desirable to delay cementing the structure 112 in the wellbore 116 until after the expansion process is completed.
Similarly, a seal 158 between the member 148 and the device 142 outwardly circumscribing the opening 150 is formed by contact between the member 148 and the device when the member is expanded radially outward. For example, one or both mating surfaces of the member 148 and device 142 may be provided with a suitable layer of sealing material (such as an elastomer, adhesive, relatively soft metal, etc.), so that the seal 158 is formed between the member and the device due to the contact therebetween. The member 148 may be otherwise sealed to the device 142 in keeping with the principles of the invention. Radially outward deformation of the structure 112 at the time the member 148 is expanded radially outward (as described above) may also enhance sealing contact between the member and the device 142 , particularly where the seal 158 is a metal to metal seal.
The expandable member 148 secures the device 142 in its engagement with the guide structure 144 . It will be readily appreciated that inward displacement of the device 142 is not permitted after the member 148 has been expanded. Furthermore, in the event that the device 142 has not yet fully engaged the guide structure 144 at the time the member 148 is expanded (for example, the device could be somewhat inwardly disposed relative to the guide structure), expansion of the member will ensure that the device is fully engaged with the guide structure (for example, by outwardly displacing the device somewhat).
Referring additionally now to FIG. 13 , an alternate procedure for use in the method 110 is representatively illustrated. This alternate procedure may be compared to the illustration provided in FIG. 8 . Instead of the outer shield 118 , the procedure illustrated in FIG. 13 uses an inner generally tubular shield 160 having an inclined upper surface or muleshoe 162 . Although no separate seals are shown in FIG. 13 , the inner shield 160 is preferably sealed to the tubular structure 112 above and below the guide structure 144 , so that cement or debris in the casing string 114 is not permitted to flow into the window 120 from the interior of the structure 112 . Preferably, the inner shield 160 is made of metal and is retrievable from within the structure 112 after the cementing process.
To prevent cement or debris from flowing into the structure 112 through the window 120 , a generally tubular outer shield 164 outwardly overlies the window. Preferably, the outer shield 164 is made of a relatively easily drillable material, such as a composite material (e.g., fiberglass, etc.). A fluid 166 having a relatively high viscosity is contained between the inner and outer shields 162 , 164 to provide support for the outer shield against external pressure, and to aid in preventing leakage of external fluids into the area between the shields. A suitable fluid for use as the fluid 166 is known by the trade name GLCOGEL, a relatively high viscosity fluid.
The muleshoe 162 provides a convenient surface for engagement by a conventional wireline-conveyed orienting tool (not shown). Such a tool may be engaged with the muleshoe 162 and used to rotationally orient the structure 112 relative to the branch wellbore-to-be-drilled 122 , since the muleshoe has a known radial orientation relative to the window 120 .
After the structure 112 has been appropriately rotationally oriented, the casing string 114 may be cemented in the wellbore 116 , and the inner shield 160 may then be retrieved from the well. After retrieval of the inner shield 160 , the method 110 may proceed as described above, i.e., the whipstock 130 and anchor 132 may be installed, etc. Alternatively, the inner shield 160 may be retrieved prior to cementing the structure 112 in the wellbore 116 .
Referring additionally now to FIGS. 14–17 , another method 170 embodying principles of the invention is representatively illustrated. The method 170 differs from the other methods described above in substantial part in that a specially constructed tubular structure is not necessarily used in a casing string 172 to provide a window through a sidewall of the string. Instead, a window 176 is formed through a sidewall of the casing string 172 using conventional means, such as by use of a conventional whipstock (not shown) anchored and oriented in the casing string according to conventional practice.
One of the many benefits of the method 170 is that it may be used in existing wells wherein casing has already been installed. Furthermore, the method 170 may even be performed in wells in which the window 176 has already been formed in the casing string 172 . However, it is to be clearly understood that it is not necessary for the method 170 to be performed in a well wherein existing casing has already been cemented in place. The method 170 may be performed in newly drilled or previously uncased wells, and in wells in which the casing has not yet been cemented in place.
In FIG. 15 it may be seen that a liner string 178 is conveyed into a branch wellbore 180 which has been drilled extending outwardly from the window 176 . At its upper end, the liner string 178 includes an engagement device 182 which engages the interior of the casing string 172 and prevents further displacement of the liner string 178 into the branch wellbore 180 . Engagement of the device 182 with the casing string 172 may also rotationally align the device with respect to the casing string.
As depicted in FIG. 15 , the device 182 is a flange extending outwardly from the remainder of the liner string 178 . The device 182 inwardly overlies the perimeter of the window 176 and circumscribes the window. Contact between an outer surface of the device 182 and an inner surface of the casing string 172 may be used to provide a seal 184 therebetween, for example, if one or both of the inner and outer surfaces is provided with a layer of a suitable sealing material, such as an elastomer, adhesive or a relatively soft metal, etc. Thus, the seal 184 may be a metal to metal seal. Other types of seals may be used in keeping with the principles of the invention.
In an optional procedure of the method 170 , the liner string 178 (or at least the device 182 ) may be in a radially compressed configuration (such as that depicted in FIG. 6 ) when it is initially installed in the branch wellbore 180 , and then extended to a radially expanded configuration (such as that depicted in FIG. 7 ) thereafter. This expansion of the liner string 178 , or at least expansion of the device 182 , may be used to bring the device into sealing contact with the casing string 172 .
In FIG. 16 it may be seen that a generally tubular expandable member 186 is conveyed into the casing string 172 and aligned longitudinally with the device 182 . The member 186 has an opening 188 formed through a sidewall thereof. The opening 188 is rotationally aligned with the window 176 (and thus aligned with a flow passage 190 of the liner string 178 ).
However, it is not necessary for the opening 188 to be formed in the member 186 prior to conveying the member into the well, or for the opening to be aligned with the window 176 at the time it is positioned opposite the device 182 . For example, the opening 188 could be formed after the member 186 is installed in the casing string 172 , such as by using a whipstock or other deflection device to direct a cutting tool to cut the opening laterally through the sidewall of the member.
As depicted in FIG. 16 , the member 186 has an outer layer of a suitable sealing material 192 thereon. The sealing material 192 may be any type of material which may be used to form a seal between surfaces brought into contact with each other. For example, the sealing material 192 may be an elastomer, adhesive or relatively soft metal, etc. Other types of seals may be used in keeping with the principles of the invention.
In FIG. 17 it may be seen that the member 186 is expanded radially outward, so that it now contacts the interior of the casing string 172 and the device 182 . Preferably, such contact results in sealing engagement between the member 186 and the interior surface of the casing string 172 , and between the member and the device 182 .
Specifically, the sealing material 192 seals between the member 186 and the casing string 172 above, below and circumscribing the device 182 . The sealing material 192 also seals between the member 186 and the device 182 around the outer periphery of the opening 188 , that is, sealing engagement between the device 182 and the member 186 circumscribes the opening 188 . Thus, the interiors of the casing and liner strings 172 , 178 are completely isolated from the wellbores 174 , 180 external to the strings. This substantial benefit of the method 170 is also provided by the other methods described herein.
As depicted in FIG. 17 , the casing string 172 is outwardly deformed when the member 186 is radially outwardly expanded therein. At least some elastic deformation, and possibly some plastic deformation, of the casing string 172 outwardly overlying the member 186 is experienced, thereby recessing the member into the interior wall of the casing string.
As a result, the inner diameter D 3 of the member 186 is substantially equal to, or at least as great as, the inner diameter D 4 of the casing string 172 above the window 176 . Preferably, during the expansion process, the inner diameter D 3 of the member 186 is enlarged until it is greater than the inner diameter D 4 of the casing string 172 , so that after the expansion force is removed, the diameter D 3 will relax to a dimension no less than the diameter D 4 .
Thus, the method 170 does not result in substantial restriction of flow or access through the casing string 172 . This substantial benefit of the method 170 is also provided by other methods described herein.
Outward elastic deformation of the casing string 172 in the portions thereof overlying the member 186 is desirable in that it inwardly biases the casing string, increasing the contact pressure between the mating surfaces of the member and the casing string, thereby enhancing the seal therebetween, after the member has been expanded. However, it is to be clearly understood that it is not necessary, in keeping with the principles of the invention, for the casing string 172 to be outwardly deformed, since the member 186 may be expanded radially outward into sealing contact with the interior surface of the casing string without deforming the casing string at all.
When the member 186 is expanded, it also outwardly displaces the device 182 . This outward displacement of the device 182 further outwardly deforms the casing string 172 where it overlies the device. Elastic deformation of the casing string 172 overlying the device 182 is desirable in that it results in inward biasing of the casing string when the expansion force is removed. This enhances the seal 184 between the device 182 and the casing string 172 , and further increases the contact pressure on the sealing material between the device 182 and the member 186 .
The method 170 is depicted in FIG. 17 as though the casing string 172 is not yet cemented in the parent wellbore 174 at the time the member 186 is expanded therein. This alternate order of steps in the method 170 may be desirable in that it may facilitate outward deformation of the casing string 172 above and below the window 176 . The casing and/or liner strings 172 , 178 may be cemented in the respective wellbores 174 , 180 after the member 186 is expanded.
Referring additionally now to FIGS. 18–20 , another method 200 embodying principles of the invention is representatively illustrated. In FIG. 18 it may be seen that a tubular structure 202 is cemented in a parent wellbore 204 at an intersection with a branch wellbore 206 . However, it is not necessary for the tubular structure 202 to be cemented in the wellbore 204 until later in the method 200 , if at all.
The structure 202 is interconnected in a casing string 208 . The casing string 208 is rotationally oriented in the wellbore 204 so that a window 210 formed through a sidewall of the structure 202 is aligned with the branch wellbore 206 . Note that the window may be formed through the sidewall of the structure 202 , and that the branch wellbore 206 may be drilled, either before or after the structure is conveyed into the wellbore 204 .
A liner string 212 is conveyed into the branch wellbore 206 in a radially compressed configuration. Even though it is radially compressed, a flange-shaped engagement device 214 at an upper end of the liner string 212 is larger than the window 210 , and so the device prevents further displacement of the liner string into the wellbore 206 . Preferably, this engagement between the device 214 and the structure 202 is sufficiently load-bearing so that it may support the liner string 212 in the wellbore 206 .
An annular space 216 is provided radially between the device 214 and an opening 218 formed through the sidewall of a guide structure 220 . When the liner string 212 is expanded, the device 214 deforms radially outwardly into the annular space 216 . The liner string 212 is shown in its expanded configuration in FIG. 19 .
As depicted in FIG. 20 , a generally tubular expandable member 222 is radially outwardly expanded within the structure 202 . An opening 224 formed through a sidewall of the member 222 is rotationally aligned with a flow passage of the liner string 212 . The opening 224 may be formed before or after the member 222 is expanded.
Preferably, this expansion of the member 222 seals between the outer surface of the member and the inner surface of the structure 202 above and below the guide structure 220 , and seals between the member and the device 214 . Thus, the interiors of the casing and liner strings 208 , 212 are isolated from the wellbores 204 , 206 external to the strings. Alternatively, or in addition, a seal may be formed between the device 214 and the structure 202 circumscribing the window 210 where the structure outwardly overlies the device.
Preferably the seals obtained by expansion of the member 222 are due to surface contact between elements, at least one of which is displaced in the expansion process. For example, one of both of the member 222 and structure 202 may have a layer of sealing material (e.g., a layer of elastomer, adhesive, or soft metal, etc.) thereon which is brought into contact with the other element when the member is expanded. Metal to metal seals are preferred, although other types of seals may be used in keeping with the principles of the invention.
As depicted in FIG. 20 , the tubular structure 202 , and the casing string 208 somewhat above and below the structure, are radially outwardly expanded when the member 222 is expanded. This optional step in the method 200 may be desirable to enhance access and/or flow through the structure 202 , enhance sealing contact between any of the member 222 , device 214 , structure 202 , etc. If the casing string 208 is outwardly deformed in the method 200 , it may be desirable to cement the casing string in the wellbore 204 after the expansion process is completed.
Referring additionally now to FIGS. 21–25 another method 230 embodying principles of the invention is representatively illustrated. As depicted in FIG. 21 , an expandable liner string 232 is conveyed through a casing string 234 positioned in a parent wellbore 236 . A lower end of the liner string 232 is deflected laterally through a window 237 formed through a sidewall of a tubular structure 238 interconnected in the casing string 234 , and into a branch wellbore 240 extending outwardly from the window.
An expandable liner hanger 242 is connected at an upper end of the liner string 232 . The liner hanger 242 is positioned within the casing string 234 above the window 237 .
The liner string 232 is then expanded radially outward as depicted in FIG. 22 . As a result of this expansion process, the liner hanger 242 sealingly engages between the liner string 232 and the casing string 234 , and anchors the liner string relative to the casing string. Another result of the expansion process is that a seal is formed between the liner string and the window 237 of the structure 238 . Thus, the interiors of the casing and liner strings 232 , 234 are isolated from the wellbores 236 , 240 external to the strings. The seal formed between the liner string 232 and the window 237 is preferably a metal to metal seal, although other types of seals may be used in keeping with the principles of the invention.
A portion 244 of the liner string 232 extends laterally across the interior of the casing string 234 above a deflection device 246 positioned below the window 237 . As depicted in FIG. 23 , a milling or drilling guide 248 is used to guide a drill, mill or other cutting tool 250 to cut through the sidewall of the liner string 232 at the portion 244 above the deflection device 246 . In this manner, access and flow between the casing string 234 above and below the liner portion 244 through an internal flow passage 252 of the deflection device 246 is provided.
Alternatively, the liner portion 244 may have an opening 254 formed therethrough. The opening 254 may be formed, for example, by waterjet cutting through the sidewall of the liner string 232 . The opening 254 may be formed before or after the liner string 232 is conveyed into the well.
Preferably, the opening 254 is formed with a configuration such that it has multiple flaps or inward projections 256 which may be folded to increase the inner dimension of the opening, e.g., to enlarge the opening for enhanced access and flow therethrough. As depicted in FIG. 25 , the projections 256 are folded over by use of a drift or punch 258 , thereby enlarging the opening 254 through the liner portion 244 .
The projections 256 are thus displaced into the passage 252 of the deflection device 246 below the liner string 232 . A seal may be formed between the liner portion 244 and the deflection device 246 circumscribing the opening 254 in this process of deforming the projections 256 downward into the passage 252 . Preferably, the seal is due to metal to metal contact between the liner portion 244 and the deflection device 246 , but other types of seals may be used in keeping with the principles of the invention.
Referring additionally now to FIGS. 26 & 27 , another method 260 of sealing and securing a liner string 262 in a branch wellbore to a tubular structure 264 interconnected in a casing string in a parent wellbore is representatively illustrated. Only the structure 264 and liner string 262 are shown in FIG. 26 for illustrative clarity.
In FIG. 26 it may be seen that the liner string 262 is positioned so that it extends outwardly through a window 266 formed through a sidewall of the structure 264 . The liner string 262 would, for example, extend into a branch wellbore intersecting the parent wellbore in which the structure 264 is positioned.
An upper end 268 of the liner string 262 remains within the tubular structure 264 . To secure the liner string 262 in this position, a packer or other anchoring device interconnected in the liner string may be set in the branch wellbore, or a lower end of the liner string may rest against a lower end of the branch wellbore, etc. Any method of securing the liner string 262 in this position may be used in keeping with the principles of the invention.
As depicted in FIG. 26 , the upper end 268 is formed so that it is parallel with a longitudinal axis of the structure 264 . The upper end 268 may be formed in this manner prior to conveying the liner string 262 into the well, or the upper end may be formed after the liner string is positioned as shown in FIG. 26 , for example, by milling an upper portion of the liner string after it is secured in position. If the upper end 268 is formed prior to conveying the liner string 262 into the well, then the upper end may be rotationally oriented relative to the structure 264 prior to securing the liner string 262 in the position shown in FIG. 26 .
In FIG. 27 it may be seen that the upper end 268 of the liner string 262 is deformed radially outward so that it is received in an opening 270 formed through the sidewall of a generally tubular guide structure 272 in the tubular structure 264 . The opening 270 is rotationally aligned with the window 266 .
The upper end 268 is deformed outward by means of a mandrel 274 which is conveyed into the structure 264 and deflected laterally toward the upper end of the liner string 262 by a deflection device 276 . The mandrel 274 shapes the upper end 268 so that it becomes an outwardly extending flange which overlaps the interior of the structure 264 circumscribing the window 266 , that is, the flange-shaped upper end 268 inwardly overlies the perimeter of the window.
Preferably, a seal is formed between the flange-shaped upper end 268 and the interior surface of the structure 264 circumscribing the window 266 . This seal may be a metal to metal seal, may be formed by a layer of sealing material on one or both of the upper end 268 and the structure 264 , etc. Any type of seal may be used in keeping with the principles of the invention.
The flange-shaped upper end 268 also secures the liner string 262 to the structure 264 in that it prevents further outward displacement of the liner string through the window 266 . After the deforming process is completed, the mandrel 274 and deflection device 276 may be retrieved from within the structure 264 and a generally tubular expandable member (not shown) may be positioned in the structure and expanded therein. For example, any of the expandable members 82 , 148 , 186 , 222 described above may be used.
After expansion of the member in the structure 264 , the member further secures the liner string 262 relative to the structure by preventing inward displacement of the liner string through the window 266 . Various seals may also be formed between the expanded member and the structure 264 , the flange-shaped upper end 268 , and/or the guide structure 272 , etc. as described above. Any types of seals may be used in keeping with the principles of the invention.
Referring additionally now to FIGS. 28 & 29 , another method 280 of sealing and securing a liner string 282 in a branch wellbore to a tubular structure 284 interconnected in a casing string in a parent wellbore is representatively illustrated. In FIG. 28 a generally tubular expandable member 286 used in the method 280 is shown. The member 286 has a specially configured opening 288 formed through a sidewall thereof. The opening 288 may be formed, for example, by waterjet cutting, either before or after it is conveyed into the well.
The configuration of the opening 288 provides multiple inwardly extending flaps or projections 290 which may be folded to enlarge the opening. As depicted in FIG. 29 , the opening 288 has been enlarged by folding the projections 290 outward into the interior of the upper end of the liner string 282 . The projections 290 are deformed outward, for example, by a mandrel and deflection device such as the mandrel 274 and deflection device 276 described above, but any means of deforming the projections into the liner string 282 may be used in keeping with the principles of the invention.
The projections 290 are deformed outward after the member 286 is positioned within the structure 284 , the opening 288 is rotationally aligned with a window 292 formed through a sidewall of the structure, and the member is expanded radially outward. Of course, if the opening 288 is formed after the member 286 is expanded in the structure 284 , then the rotational alignment step occurs when the opening is formed.
Expansion of the member 286 secures an upper flange-shaped engagement device 294 relative to the structure 284 . Seals may be formed between the member 286 , structure 284 , engagement device 294 and/or a guide structure 296 , etc. as described above. Any types of seals may be used in keeping with the principles of the invention.
Furthermore, deformation of the projections 290 into the liner string 282 may also form a seal between the member 286 and the liner string about the opening 288 . For example, a metal to metal seal may be formed by contact between an exterior surface of the member 286 and an interior surface of the liner string 282 when the projections 290 are deformed into the liner string. Other types of seals may be used in keeping with the principles of the invention.
Preferably, the projections 290 are deformed into an enlarged inner diameter D 5 of the liner string 282 . This prevents the projections 290 from unduly obstructing flow and access through an inner passage 298 of the liner string 282 .
Referring additionally now to FIG. 30 , another method 300 of sealing and securing a liner string 302 in a branch wellbore to a tubular structure 304 interconnected in a casing string in a parent wellbore is representatively illustrated. The method 300 is similar to the method 280 in that it uses an expandable tubular member, such as the member 286 having a specially configured opening 288 formed through its sidewall. However, in the method 300 , the member 286 is positioned and expanded radially outward within the structure 304 prior to installing the liner string 302 in the branch wellbore through a window 306 formed through a sidewall of the structure.
Expansion of the member 286 within the structure 304 preferably forms a seal between the outer surface of the member and the inner surface of the structure, at least circumscribing the window 306 , and above and below the window. The seal is preferably a metal to metal seal, but other types of seals may be used in keeping with the principles of the invention.
After the member 286 has been expanded within the structure 304 , the projections 290 are deformed outward through the window 306 . This outward deformation of the projections 290 may result in a seal being formed between the inner surface of the window 306 and the outer surface of the member 286 circumscribing the opening 288 . Preferably the seal is a metal to metal seal, but any type of seal may be used in keeping with the principles of the invention.
After the projections 290 are deformed outward through the window 306 , the liner string 302 is conveyed into the well and its lower end is deflected through the window 306 and the opening 288 , and into the branch wellbore. The vast majority of the liner string 302 has an outer diameter D 6 which is less than an inner diameter D 7 through the opening 288 and, therefore, passes through the opening with some clearance therebetween. However, an upper portion 308 of the liner string 302 has an outer diameter D 8 which is preferably at least as great as the inner diameter D 7 of the opening 288 . If the diameter D 8 is greater than the diameter D 7 , some additional downward force may be needed to push the upper portion 308 of the liner string 302 through the opening 288 . In this case, the liner upper portion 308 may further outwardly deform the projections 290 , thereby enlarging the opening 288 , as it is pushed through the opening.
Contact between the outer surface of the liner upper portion 308 and the inner surface of the opening 288 may cause a seal to be formed therebetween circumscribing the opening. Preferably, the seal is a metal to metal seal, but other seals may be used in keeping with the principles of the invention. An upper end 310 of the liner string 302 may be cut off as shown in FIG. 30 , so that it does not obstruct flow or access through the structure 304 . Alternatively, the upper end 310 may be formed prior to conveying the liner string 302 into the well.
Referring additionally now to FIGS. 31–35 , another method 320 embodying principles of the invention is representatively illustrated. In FIG. 31 it may be seen that a liner string 322 is conveyed through a casing string 324 in a parent wellbore 326 , and a lower end of the liner string is deflected laterally through a window 330 formed through a sidewall of the casing string, and into a branch wellbore 328 . The casing string 324 may or may not be cemented in the parent wellbore 326 at the time the liner string 322 is installed in the method 320 .
The liner string 322 includes a portion 332 which has an opening 334 formed through a sidewall thereof. In addition, an external layer of sealing material 336 is disposed on the liner portion 332 . The sealing material 336 may be, for example, an elastomer, an adhesive, a relatively soft metal, or any other type of sealing material. Preferably, the sealing material 336 outwardly circumscribes the opening 334 and extends circumferentially about the liner portion 332 above and below the opening.
The liner string 322 is positioned as depicted in FIG. 31 , with the liner portion 332 extending laterally across the interior of the casing string 324 and the opening 334 facing downward. However, it is to be clearly understood that it is not necessary for the opening 334 to exist in the liner portion 332 prior to the liner string 322 being conveyed into the well. Instead, the opening 334 could be formed downhole, for example, by using a cutting tool and guide, such as the cutting tool 250 and guide 248 described above. As another alternative, the opening 334 may be specially configured (such as the opening 254 depicted in FIG. 24 ), and then enlarged (as depicted for the opening 254 in FIG. 25 ).
In FIG. 32 it may be seen that the liner string 322 is expanded radially outward. Preferably, at least the liner portion 332 is expanded, but the remainder of the liner string 322 may also be expanded. Due to expansion of the liner portion 332 , the outer surface of the liner portion contacts and seals against the inner surface of the window 330 circumscribing the window. The seal between the liner portion 332 and the window 330 is facilitated by the sealing material 336 contacting the inner surface of the window. However, the seal could be formed by other means, such as metal to metal contact between the liner portion 332 and the window 330 , without use of the sealing material 336 , in keeping with the principles of the invention.
In FIG. 33 it may be seen that the opening 334 is expanded to provide enhanced flow and access between the interior of the casing string 324 below the window 330 and the interior of the liner string 322 above the window. Expansion of the opening 334 also results in a seal being formed between the exterior surface of the liner portion 332 circumscribing the opening 334 and the interior of the casing string 324 . At this point, it will be readily appreciated that the interiors of the casing and liner strings 324 , 322 are isolated from the wellbores 326 , 328 external to the strings.
Additional steps in the method 320 may be used to further seal and secure the connection between the liner and casing strings 322 , 324 . In FIG. 34 it may be seen that the liner string 322 within the casing string 324 is further outwardly expanded so that it contacts and radially outwardly deforms the casing string. The opening 334 is also further expanded, and a portion 338 of the liner string 322 may be deformed downwardly into the casing string 324 as the opening is expanded.
This further expansion of the liner string 322 , including the opening 334 , in the casing string 324 produces several desirable benefits. The liner string 322 is recessed into the inside wall of the casing string 324 , thereby providing an inner diameter D 9 in the liner string which is preferably substantially equal to, or at least as great as, an inner diameter D 10 of the casing string 324 above the window 330 . The seal between the outer surface of the liner string 322 circumscribing the opening 334 and the inner surface of the casing string 324 is enhanced by increased contact pressure therebetween. In addition, another seal may be formed between the outer surface of the liner string 322 and the inner surface of the casing string 324 above the window 330 . Furthermore, the downward deformation of the portion 338 into the casing string 324 below the window 330 enhances the securement of the liner string 322 to the casing string. As described above, outward elastic deformation of the casing string 324 may be desirable to induce an inwardly biasing force on the casing string when the expansion force is removed, thereby maintaining a relatively high level of contact pressure between the casing and liner strings 324 , 322 .
In FIG. 35 it may be seen that a generally tubular expandable member 340 having an opening 342 formed through a sidewall thereof is positioned within the casing string 324 with the opening 342 rotationally aligned with the window 330 and, thus, with a flow passage 344 of the liner string 322 . The member 340 extends above and below the liner string 322 in the casing string 324 and extends through the opening 334 . The member 340 is then expanded radially outward within the casing string 324 .
Expansion of the member 340 further secures the connection between the liner and casing strings 322 , 324 . Seals may be formed between the outer surface of the member 340 and the interior surface of the casing string 324 above and below the liner string 322 , and the inner surface of the liner string in the casing string. The seals are preferably formed due to contact between the member 340 outer surface and the casing and liner strings 324 , 322 inner surfaces. For example, the seals may be metal to metal seals. The seals may be formed due to a layer of sealing material on the member 340 outer surface and/or the casing and liner strings 324 , 322 inner surfaces. However, any types of seals may be used in keeping with the principles of the invention.
The member 340 may be further expanded to further outwardly deform the casing string 324 where it overlies the member, in a manner similar to that used to expand the member 186 in the method 170 as depicted in FIG. 17 . In that way, the member 340 may be recessed into the inner wall of the casing string 324 and the inner diameter D 11 of the member may be enlarged so that it is substantially equal to, or at least as great as, the inner diameter D 10 of the casing string. Due to outward deformation of the casing string 324 in the method 320 , whether or not the member 340 is recessed into the inner wall of the casing string, it may be desirable to delay cementing of the casing string in the parent wellbore 326 until after the expansion process is completed.
Thus have been described the methods 10 , 110 , 170 , 200 , 230 , 260 , 280 , 300 , 320 which provide improved connections between tubular strings in a well. It should be understood that openings and windows formed through sidewalls of tubular members and structures described herein may be formed before or after the tubular members and structures are conveyed into a well. Also, it should be understood that casing and/or liner strings may be cemented in parent or branch wellbores at any point in the methods described above.
Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are contemplated by the principles of the present invention. For example, although certain seals have been described above as being carried on one element for sealing engagement with another element, it will be readily appreciated that seals may be carried on either or neither element. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents. | A sealed multilateral junction system provides fluid isolation between intersecting wellbores in a subterranean well. In a described embodiment, a method of forming a wellbore junction includes the steps of sealing a tubular string in a branch wellbore to a tubular structure in a parent wellbore. The tubular string may be secured to the tubular structure utilizing a flange which is larger in size than a window formed in the tubular structure. The flange may be sealed to the tubular structure about the window by a metal to metal seal or by adhering the flange to the tubular structure. | 4 |
FIELD OF THE INVENTION
The present invention relates to tubular prostheses such as grafts and endoluminal prostheses including, for example, stent-grafts and aneurysm exclusion devices, and methods for placement of such grafts and endoluminal structures. More particularly, the present invention relates to a graft or a prosthetic device including a graft constructed of monofilament fibers for placement within or in place of a body lumen, including, for example, vascular grafts for replacing blood vessels, devices for opening or supporting blood vessels, and devices for the treatment of abdominal and other aneurysms.
BACKGROUND OF THE INVENTION
A wide range of medical treatments have been previously developed using “endoluminal prostheses,” which terms are herein intended to mean medical devices which are adapted for temporary or permanent implantation within a body lumen, including both naturally occurring or artificially made lumens. Examples of lumens in which endoluminal prostheses may be implanted include, without limitation: arteries such as those located within coronary, mesentery, peripheral, or cerebral vasculature; veins; gastrointestinal tract; biliary tract; urethra; trachea; hepatic shunts; and fallopian tubes. Various types of endoluminal prostheses have also been developed, each providing a uniquely beneficial structure to modify the mechanics of the targeted luminal wall.
Also a number of vascular grafts have been developed for either replacing, supplementing or excluding portions of blood vessels. These vascular grafts may include but are not limited to endoluminal vascular prostheses.
Graft materials have been used in a number of medical applications including in vascular graft and/or in endoluminal prostheses. Among other applications, materials have been used in tubular vascular prostheses for repairing or replacing blood vessels. They have also been used in aneurysm exclusion devices such as abdominal aortic aneurysm (“AAA”) devices that are used to exclude aneurysms and provide a prosthetic lumen for the flow of blood. Further uses have included stent-grafts such as covered stents that are used for providing artificial radial support to the wall tissue, which forms the various lumens in the body. Such covered stents have attempted among other things to address problems that are presented by a thrombogenic environment or to promote healing in the vessel wall tissue that is prone to scarring. These attempts include providing a lining or covering in conjunction with an implanted stent. Typically graft materials used in these include multifilament woven polymer materials and polytetrafluoroethylene (“PTFE”). The stent-grafts may have graft material on the inner diameter or outer diameter of a support structure.
One very significant of these uses for endoluminal or vascular grafts is in treating aneurysms.
Vascular aneurysms are the result of abnormal dilation of a blood vessel, usually resulting from disease or genetic predisposition which can weaken the arterial wall and allow it to expand. While aneurysms can occur in any blood vessel, most occur in the aorta and peripheral arteries, with the majority of aneurysms occurring in the abdominal aorta. Typically an abdominal aneurysm will begin below the renal arteries and may extend into one or both of the iliac arteries.
Aneurysms, especially abdominal aortic aneurysms, have been most commonly treated in open surgery procedures where the diseased vessel segment is bypassed and repaired with an artificial vascular graft. While considered to be an effective surgical technique in view of the alternative of a fatal ruptured abdominal aortic aneurysm, the open surgical technique suffers from a number of disadvantages. The surgical procedure is complex and requires long hospital stays due to serious complications and long recovery times and has high mortality rates.
In order to reduce the mortality rates, complications and duration of hospital stays, less invasive devices and techniques have been developed. The improved devices include tubular prostheses that provide a lumen or lumens for blood flow while excluding blood flow to the aneurysm site. The prostheses are typically made of a tubular multifilament woven graft material that is secured to a vessel wall above and below the aneurysm site with at least one attached expandable ring member that provides sufficient radial force so that the prosthesis engages the inner lumen wall of the body lumen. Other mechanisms have been used to engage the vessel walls such as, for example, forcibly expandable members or hook like members that puncture the vessel wall.
Although frequently referred to as stent-grafts, these devices differ from covered stents in that they are not used to mechanically prop open natural blood vessels. Rather, they are used to secure an artificial lumen to the vessel wall without further opening the natural blood vessel that is already abnormally dilated.
These aneurysm exclusion devices are preferably loaded into a catheter, which is used to deliver and place the prosthesis at an appropriate location. This has been done one of several ways. Most frequently, a surgical cut down is made to access a femoral iliac artery. The catheter is then inserted into the artery and guided to the aneurysm site using fluoroscopic imaging where the device is released from the catheter. Where expandable rings are used, the rings supporting the graft, biased in a radially outward direction, then expand to engage the prosthesis in the vessel against the vessel wall to provide an artificial lumen for the flow of blood. Another technique, though less frequently used, includes percutaneously accessing the blood vessel for catheter delivery, i.e., without a surgical cutdown.
Multifilament fibers have been used in AAA devices, primarily because it was believed that the fibers provide relative strength and durability required by the prostheses and monofilament fiber based grafts have been avoided because they had insufficient leak resistance. Typically the woven multifilament graft material is made of yarns which consist of about 25 to 100 fibers. The selection of yarn dictates the resultant mechanical properties such as percent elongation, fatigue strength, burst strength, and permeability to water or other fluids. One disadvantage to using these materials is that the multifilament fiber adds bulk, and relatively bulky grafts are more difficult to deliver using modem low-profile endovascular techniques. Another disadvantage is that they cannot be woven into fabric without a significant number of fissures or hooks (frays) and defects that occur during the weaving process. These fissures, hooks and defects tend to make the woven graft material even thicker and may cause increased tissue immune response. Lower profile multifilament woven materials have not provided sufficient strength to the grafts in which they have been used.
One disadvantage of the currently used devices is that when radially compressed, they are larger than would be ideal and thus require larger diameter catheters for delivery. This makes catheter access to the site and maneuverability through the tortuous or narrowed diseased vessels more difficult and may exclude some patients from eligibility for some procedures. In most current AAA devices, the total outer diameter of the introducer systems are relatively large, i.e., around 20-24 French. Providing a smaller introducer system would, among other things, allow for treatment of patients with smaller blood vessel diameters and provides for faster delivery.
Therefore, it is desirable to provide an endoluminal graft that is made of a material having sufficient strength, durability and low-permeability, while capable of being radially compressed into and delivered from smaller diameter delivery catheters.
SUMMARY OF THE INVENTION
The present invention provides an improved endoluminal prosthesis made of a graft material having a relatively smaller collapsed profile. In particular, the present invention provides an endoluminal graft device made of monofilament fibers instead of the fiber bundles of the multifilament fibers. Accordingly the present invention provides for a lower volume structure with comparable strength. More particularly, the graft material comprises a finely woven monofilament fiber with a small enough pore size and low enough percent open area to provide thin graft material with low permeability. The monofilament fibers may be woven in a number of ways as are generally known in the art to provide more densely packed material and smaller pore sizes. In one preferred embodiment, the material is woven polyester. The monofilament fibers may be shaped in a manner to provide a more compact and stronger material. For example, the fibers may be rounded or oval in shape.
The graft material is of a sufficiently low permeability so as to avoid excessive leakage, to prevent pressurization of the aneurysm and/or to form a seal. Although some leakage of blood or other body fluid may occur into the aneurysm site isolated by the prosthesis, the graft material is believed to prevent the pressurization of the aneurysm and thus aneurysm rupture. It is believed that by preventing excessive leakage into the aneurysm site the chance of pressurization of the aneurysm will be significantly decreased. In other words, by isolating the aneurysm from the flow of blood through the blood stream, aneurysm rupture is prevented. Permeability of the graft, in part, determines whether or not excessive or clinically undesirable leakage will occur through the graft material. Preferably the water permeability of the graft is at about 2300 ml/cm 2 /min or less and most preferably at about 600 ml/cm 2 /min or less.
Another important parameter in constructing a graft is the material thickness. The thickness of the material is sufficiently low to allow the endoluminal graft to collapse to a small enough profile to allow placement into the vasculature. The graft is thus thin-walled so that is may be compressed into a small diameter catheter, yet capable of acting as a strong, leak-resistant, fluid conduit when in tubular form. The present invention in the embodiment of an AAA device would enable smaller French size introducer systems, i.e., to sizes of 18 French or less. Preferably the wall thickness is in the range of 80 microns or less.
The strength of the material is sufficient to allow it to withstand the loads applied during deployment and the cyclical loading in the body for a reasonable duration. Where an annular support structure or stent is used, the endoluminal graft must provide sufficient strength to allow attachment of the annular support structure or the stent.
Preferably the graft material has a pore size of 11 microns or less, a percent open area of about 5% or less, and/or a tensile strength of about 44 pounds per inch, most preferably a pore size of about 5 micron or less, a percent open area of about 1% or less and a tensile strength of about 65 pounds per inch or less. A suitable material would be a polyester.
A preferred embodiment of the present invention relates to a tubular grafts constructed of monofilament fibers for endoluminal placement within a body lumens, including blood vessels, and for the treatment of abdominal and other aneurysms. This embodiment of the tubular graft includes radially compressible annular spring portions which when released, bias the proximal and distal portions of the graft into conforming fixed engagement with an interior surface of the vessel.
One embodiment provides an aneurysm repair system characterized by a graft apparatus which can be placed within a diseased vessel via deployment means at the location of an aneurysm. The graft device comprises a tubular graft formed of a woven monofilament fiber for conducting fluid. The graft device may be in the form of either a straight single-limb graft or a generally Y-shaped bifurcated graft having a trunk joining at a graft junction with a pair of lateral limbs, namely an ipsilateral limb and a contralateral limb. Preferably the ipsilateral limb is longer so that when deployed, it extends into the common iliac. A single limb extension graft is provided having a mating portion for coupling with a lateral limb of a bifurcated graft and an adjustable length portion extending coaxially from a distal end of the mating portion.
The graft apparatus includes radially compressible spring means having at least two coaxially spaced annular portions for biasing the proximal and distal portion of an associated graft limb or limb portion radially outward into conforming fixed engagement with the interior of the vessel. The annular portions are preferably constructed of nitinol. Examples of such spring means are described, for example, in U.S. Pat. Nos. 5,713,917 and 5,824,041 incorporated herein by reference.
In the extension graft, an annular spring portion is located at a distal end of the adjustable length portion for similar biasing purposes. The proximal portion of the extension graft includes a spring means for engaging the inner lumen of the contralateral limb portion of the graft.
The spring means may be attached to the graft by various means, such as, for example, by stitching the annular portions on either the inside or outside of the tubular graft.
Various means for deployment of the devices are well known in the art and may be found for example is U.S. Pat. Nos. 5,713,917 and 5,824,041 which are incorporated herein by reference. In general, the graft is radially compressed and loaded into a catheter. The aneurysm site is located using an imaging technique such as fluoroscopy and is guided through a femoral iliac artery with the use of a guide wire to the aneurysm site. Once appropriately located, the sheath on the catheter covering the tubular graft is retracted, thus allowing the annular springs to expand and attach or engage the tubular graft to the inner wall of the body lumen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view showing a single-limb graft of the present invention fully deployed within an aorta of a patient to repair an aneurysm;
FIG. 2 is an elevational view showing a bifurcated graft of the present invention fully deployed within an aorta and lateral iliac vessels joined therewith.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred embodiment, a monofilament graft material is made into vascular grafts by sewing the material into single tubular structures. Seams are sewn with a Locking stitch with 5-0 size suture material (Ethibond PN 8890H). Then, annular nitinol support structures are sewn into the graft material in a manner as described with respect to the embodiments referred to in FIGS. 1 and 2.
Specific graft materials are selected based on performance criteria such as pore size, percent open space, water permeability, wall thickness, tensile strength, and strength per stitch.
Two examples of suitable materials based on these selection criteria are as follows:
EXAMPLE 1
The Medifab™ 7-11/5 material manufactured by Tetko, Inc., now Sefar America, Inc. was selected based on these parameters. The specification of the material provides a pore size 11 microns and a 5% open area. One manner in which pore size and open area may be determined is by taking images of the graft materials on suitable equipment such as a Scanning Electron Microscope, SEM. Measurements are made of the width of the fibers. Open area of the mesh is then measured in each direction and used to determine pore size, and based on the total graft area, the percent open area. The specified product thickness of about 60 microns was confirmed to be approximately correct. A tensile strength of about 45 per inch, and a seam strength of over 13 lbs. per inch were also measured where the seam stitching was on average at a rate of 19 stitches per inch.
The water permeability of the material was measured at approximately between 2100-2300 ml/cm 2 /min. Permeability testing was determined by supplying filtered water at 120 mm Hg to a circular aperture (between 1 and 0.5 cm 2 ) containing the sample and collecting the flow. The permeability is calculated from the equation: water permeability=Q/A where Q is the flow rate through the sample in mL/min and A is the cross-sectional area of the aperture in cm 2 . The testing is based on ANSI/AAMI VP20-1994 section 8.2.2 “Method for determination of water permeability.” Some exceptions to the testing protocol were it did not meet the specification that “there are no bends or changes in diameter of flow pathway within a distance from the test sample of six diameters of the test area.” Also, some testing was run for 30 seconds instead of 60 seconds.
The material was woven using a 2/2 Twill weave using fibers having a diameter of about 38 microns. The grafts were implanted in animals in studies and were found to have no excessive leakage.
The material was also found to have a strength of at least 48 lbs. per inch and at least comparable or lower permeability when the material was treated by a calendaring process where the material is heated below the melting point and pressed. The calendaring process reduced the thickness of the material from about 60 microns to about 40 microns, i.e., about a 30% reduction in material thickness. This process may also be used to make the material less permeable.
EXAMPLE 2
The Medifab™ 7-5/1 material manufactured by Tetko, Inc., now Sefar America Inc. were selected based on parameters described above. The material specifications provide a pore size of 5 micron and a 1% open area. The specified product thickness is about 80 microns. A tensile strength of about 68 lbs. per inch, and a seam strength of over 35 lbs. per inch were also measured where the seam stitching was on average at a rate of 19 stitches per inch. The water permeability of the material has been measured at approximately between 400 ml/cml/min and 600. The material is woven using a 4/4 Twill weave with fibers having a diameter of about 34 microns. The grafts were implanted in animals in studies and were found to have no excessive leakage.
Referring now to FIG. 1, there is illustrated the monofilament graft of the present invention in use with an aneurysm exclusion device.
The device is shown in place in an abdominal aorta. An aorta 10 is joined by renal arteries 12 and 14 at the aorto-renal junction 16 . Just below the aorta-renal junction is an aneurysm 18 , a diseased region where the vessel wall is weakened and expanded. An elongated single-limb tubular prosthesis 20 is deployed at the region of aneurysm 18 for the purpose of relieving blood flow pressure against the weakened vessel wall by acting as a fluid conduit through the region of the aneurysm. In its deployed condition, prosthesis 20 defines a central longitudinal axis 22 extending in a direction of blood flow through aorta 10 .
Prosthesis 20 comprises a graft material 24 enclosing radially compressible spring means 26 for biasing a proximal end 28 and a distal end 30 of the prosthesis into conforming fixed engagement with an interior surface of aorta 10 .
Graft material 24 is a biocompatible, low-porosity fabric, woven from a monofilament fiber such as polyester. The graft 24 is thin-walled so that is may be compressed into a small diameter catheter, yet capable of acting as a strong, leak-resistant, fluid conduit when in tubular form. Monofilament fibers are interwoven to form the graft material 24 . The graft material 24 is formed into a tube as illustrated.
A middle portion 29 of prosthesis 20 between proximal end 28 and distal end 30 is tapered to provide a decreased fluid-conducting cross-sectional area relative to ends 28 and 30 , such as by excising at least one longitudinal strip of graft material 24 and sewing the resulting gap or gaps closed, as a way of reducing the occurrence of folding and wrinkling and adapting the graft to fit within a wider range of differently sized vessels.
Enclosed within graft material 24 is a nitinol wire spring having a proximal spring portion 34 and a distal spring portion 36 . Alternatively, the proximal spring portion 34 may have uncovered portions or open areas proximal of the graft material so that in the event the spring portion 34 is deployed over the renal arteries 12 , 14 , the blood flow through arteries 12 , 14 will not be blocked. Spring portions 34 and 36 are designed to exert radially outward force sufficient to bias graft material 24 at graft ends 28 and 30 into conforming fixed engagement with the interior surface of aorta 10 above and below aneurysm 18 . The nitinol wire used to form the spring is in a superelastic, straight annealed condition and may be coated with titanium oxide to improve biocompatibility, reduce the incidence of allergic reaction to nickel, and improve radiopacity. Other coatings as are generally known in the art may also be used to lower the risks of blood clotting and wire corrosion. Spring portions 34 and 36 are each formed by revolving a sinusoidal wire pattern of straight spokes 38 connected by rounded alternating crests 40 and troughs 42 about central axis 22 to provide a continuous annular spring portion. A preferred spring portion includes five equispaced crests 40 and five equispaced troughs 42 formed to a predetermined radius to produce better spring properties and avoid sharp transitions in the wire, in that sharp transitions are more prone to failure. The coaxially spaced spring portions 34 and 36 are connected by at least one straight connecting bar 44 which preferably extends generally parallel to central axis 22 for minimal disruption of blood flow. Connecting bar 44 provides torsional stability for graft 20 , and may be welded to spring portions 34 and 36 , or fastened thereto by a small, tightened sleeve (not shown).
The wire spring is sewn within graft material 24 using a polyester suture. A preferred stitch pattern includes two generally parallel stitches extending along opposite sides of the wire, and a cross-over stitch around the wire for pulling the parallel stitches together to achieve tight attachment of graft material 24 to the wire spring. This method of attachment substantially prevents contact between wire spring and the interior surface of the vessel, and is reliable over time. In accordance with the present invention, graft material 24 may be cut out between crests 40 of proximal spring portion 34 and distal spring portion 36 to define a plurality of radially distensible finger portions 46 at graft ends 28 and 30 . Importantly, finger portions 46 allow graft 20 to be situated with proximal end 28 relatively close to aorto-renal junction since gaps between the finger portions may be aligned with renal arteries 12 and 14 so as not to block blood flow. Finger portions 46 may be radially compressed to approximate a conical tip to facilitate loading insertion of prosthesis 20 within a sheath.
The prosthesis 20 may be loaded into a catheter and delivered via catheter through a surgically accessed femoral artery, to the desired deployment site. These and suitable delivery methods and apparatus are generally known in the art and may be used to deliver the prosthesis. An example of such technique is set forth in U.S. Pat. No. 5,713,917, incorporated herein by reference.
A bifurcated prosthesis 60 as shown in FIG. 4 is also within the scope of the present invention for use in cases where involvement of one or both iliac vessels 11 and 13 is indicated. Prosthesis 60 is Y-shaped and includes a primary limb 62 for location within aorta 10 , and is joined by an ipsilateral limb 64 for location within ipsilateral iliac vessel 11 , and by a contralateral limb 66 for location within contralateral iliac vessel 13 , at a graft junction 63 . Each limb of bifurcated prosthesis 60 is generally similar in construction to single-limb prosthesis 20 . They are made of monofilament fiber graft material 24 . Proximal and distal ends of each limb are biased into conforming fixed engagement with the interior surface of a corresponding vessel by annular spring portions associated therewith, and middle portions of each limb are preferably tapered. A first nitinol wire spring is enclosed by, and attachably sewn within, graft material 24 and includes a proximal spring portion 68 A associated with a proximal end of primary limb 62 , a distal spring portion 68 B associated with a distal end of primary limb 62 , and an axially extending connecting bar 68 C coupling the proximal and distal spring portions together. Similarly, a second nitinol wire spring having a proximal spring portion 70 A, a distal spring portion 70 B, and an axially extending connecting bar 70 C, is sewn within ipsilateral limb 64 ; and a third nitinol wire spring having a proximal spring portion 72 A, a distal spring portion 72 B, and an axially extending connecting bar 72 C, is sewn within contralateral limb 66 . Terminal ends of bifurcated graft 60 , namely the proximal end of primary limb 62 and the distal ends of lateral limbs 64 and 66 , are provided with radially distensible finger portions 46 as described above. Where entry is to be made through an ipsilateral femoral artery to deploy prosthesis 60 , distal spring portion 72 B is held in a radially compressed condition by an expandable retainer ring 79 , which may simply be a length of suture material tied end to end using a purse-string type knot to form a loop, to prevent premature deployment of distal spring portion 72 B prior to proper positioning thereof within contralateral iliac vessel 13 . Likewise, where entry is to be made through a contralateral femoral artery, distal spring portion 70 B may be provided with a retainer ring 79 to prevent premature deployment of distal spring portion 70 B prior to proper positioning thereof within ipsilateral iliac vessel 11 .
Although this detailed description sets forth a particular and preferred embodiment, it is to be understood that the claimed invention is not limited to this particular embodiment. The present invention contemplates various other vascular grafts or endoluminal prostheses in which a monofilament material is used, such as, for example, forcibly expanded coronary and peripheral stents or stent-grafts, covered grafts, vascular grafts, and other aneurysm exclusion devices. The expandable support structures on various embodiments of the devices may be, for example, self-expanding, balloon expandable, or otherwise forcibly expanded. Other biologically compatible materials formed into monofilament fibers are contemplated, including other polymers that may be woven into graft materials. | A thin-walled prosthesis is provided that includes a tubular graft formed of a monofilament fiber. The graft has sufficient strength and durability to withstand loads applied during deployment and while implanted and sufficiently low permeability to prevent excessive leakage of body fluids through the material or to provide a sufficient seal, for example, so as to prevent aneurysm pressurization. A preferred embodiment of the present invention relates to a tubular grafts constructed of monofilament fibers for endoluminal placement within a body lumens, including blood vessels, and for the treatment of abdominal and other aneurysms. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a high power, high frequency resonant load inverter system for providing increased output power.
DESCRIPTION OF THE RELATED ART
The use of MOSFETs is not straightforward in such applications, due to the voltage level required (approximately 700 V at the DC link). Its internal diode can not be used as a free wheeling diode because a current through this diode sets up the conditions for possible turn-on of the parasitic BJT. The steep voltage rise across the reverse conducting MOSFET, caused by the complementary MOSFET turn-on, leads to destructive failure in this case. Unwanted MOSFET turn-on can be avoided by carefully monitoring the converter, but the only completely reliable solution is a diode in series with the MOSFET drain and an external free wheeling diode. This latter approach is expensive.
IGBT's do not have an internal diode. This is because the junction providing for conductivity modulation of the collector drift region functions Was a series diode. As a result a good external free wheeling diode can be chosen without the need of any series diode. The IGBT is a widely used device, and is produced in large numbers. It is a cheap component compared to the MOSFET said voltage level and power range of 10 kW-5 MW. This difference in cost between MOSFET's and IGBT's becomes even larger if the series diode is needed for the MOSFET application. The IGBT-solution could be more attractive than a MOSFET-solution even if severe derating is necessary for the IGBTs due to the high switching frequency in the range 75 kHz-500 kHz. It was basically cost arguments that was the motivation to develop an IGBT based solution.
It is also a fact that parameter spreading between MOSFET chips is much larger than among e.g. NPT IGBT chips, which make the IGBT chips easier to connect in parallel. Current sharing during turn-off is a problem in large MOSFET inverter with massive parallel connection.
The classic problem with IGBTs at these high frequency is the severe derating which has to be performed. The present invention therefore aims at providing a new control principle to cause such derating to be substantially less severe, which turns the IGBT solution highly competitive concerning both cost and size.
SUMMARY OF THE INVENTION
Thus, according to the invention there has been developed a new control strategy for IGBTs when used in high frequency (75 kHz-500 kHz) high power (10 kW-5 MW) inverters with series resonant load, a topology commonly used for induction heating. The strategy changes the IGBT strain elements into a total stress picture that fits the IGBT's behaviour and internal nature better. This makes the IGBT operate much more efficient, thus increasing the maximum output power from the inverter significantly compared to a standard control scheme. This makes the IGBT based inverter a much cheaper alternative than a MOSFET inverter, which has been state of the art for this application. Also, the invention provides for a more effective way of destressing IGBTs to make them capable of handling the losses at this high frequency.
Acoording to the invention, the system comprises an inverter device which is subdivided into sections, each section comprising two sets of current switches, each set having two IGBT (Insulated Gate Bipolar Transistor) switch means connected in series, each set having an output at a midpoint between said means for feeding a respective input terminal on a power load having an LC resonant compensation, and a main driver circuit for controlling each IGBT switch means of each set.
According to a feature of the system a power transformer is connected between said outputs and said input terminals.
Suitably, the inverter device operates with a reduced switching frequency which is lower than an LC resonant frequency by providing driver signals from said main driver unit to one section at a time, thus causing the switching frequency to become 1/n of said resonant frequency, n being the number of sections.
Said LC resonant compensation is suitably an LC series resonant compensation, and said sections have in such a case a DC voltage power supply. Alternatively, said LC resonant compensation is an LC parallel resonant compensation, said sections in such a case having a DC current power supply.
In a further embodiment, the inverter device operates with a reduced switching frequency which is lower than an LC resonant frequency by providing driver signals from said main driver unit to all sections simultaneously to cause all sections to deliver current output during only one cycle of the switching frequency, thus causing all sections to deliver current output at a rate 1/n of said resonant frequency, n being the number of sections. In such a case, the current output from all sections are added to cause oscillations in said LC series resonant compensated output load and thereby a continuous sinusoid output current, power being supplied to said LC series resonant compensated load at said rate and thereby providing a pulse-shaped output voltage at a rate of 1/n.
Suitably, the inverter device provides an operation frequency in the range of 75 kHz-500 kHz, and an output power in the range of 10 kW-5 MW.
The system as defined and to be further described in the description below and defined in the claims is suitable e.g. for operating an inductive load in an induction heating or a contact welding operation device.
It should be noted that by the term “switch means” in the context of the IGBT's, it is contemplated that said switch means could be a single IGBT as shown as a non-limiting example on the drawings or at least two IGBT's in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now to be described further with reference to the attached drawings, showing non-limiting examples of the inventive system.
FIG. 1 a illustrates a test circuit topology of an inverter and FIG. 1 b illustrates a waveform related thereto.
FIG. 2 a illustrates turn-off, turn-on and conduction loss measurements for an IGBT of type Eupec FF200R12KS4 (referred to as FF200) and FIG. 2 b shows the specific losses [mJ/A]. Current is peak current during on state. Conduction loss is conduction energy loss pr cycle at 300 kHz.
FIGS. 3 a and 3 b illustrate the electrical connections in a series compensated inverter shared into sections where the derating is performed by lowering the effective switching frequency rather than lowering the current density.
FIG. 4 illustrates current and voltage waveforms in a series compensated inverter shared into sections where derating is performed by lowering the effective switching frequency rather than lowering the current density.
FIGS. 5 a , 5 b and 5 c illustrate data for IGBT of type Eupec FF200; i.e. IGBT current level, output power per H bridge and power loss per IGBT for different number of current sections, respectively.
FIGS. 6 a and 6 b are examples of a parallel compensated inverter shared into sections where the derating is performed by lowering the effective switching frequency rather than lowering the current density.
FIG. 7 shows the current and voltage waveforms using four sections.
FIG. 8 relates to a further embodiment of a series compensated inverter shared into sections where the derating is performed by lowering the effective switching frequency rather than lowering the current density.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To understand the new control strategy, the loss picture in the IGBT for this application has to be investigated. At this high frequency, the turnoff losses are totally dominant, and very large. At normal current levels, the device will be destroyed through overheating very rapidly, so a destressing has to be performed. A simple current level reduction will make the inverter reliable, but the current level becomes very low. As such, the device does not seem to be well suited.
Thus, it is necessary to pay regard to the IGBT's nature. Turn-off loss measurements show that the losses do not vary linearly with the current, as shown in FIG. 2 . At low current levels, the turn off loss to current ratio is larger compared to at higher current levels. This indicates that simply lowering the IGBT current level is a poor way of performing a destressing. The turn-off efficiency will be very poor compared to what is achievable at higher current levels. The new control strategy secures an effective high current turn-off, but still gives the desired IGBT loss level. This is done by letting the output current rotate between different sections A-D in the inverter, see FIGS. 3 a , 3 b and 4 .
The sequence control method shown on FIGS. 3 and 4 is related to a series compensated inverter. FIG. 3 shows the electrical connections. It should be observed that FIG. 3 a shows an embodiment having a transformer between section outputs and the series compensated load. However, it is possible to dispense with the transformer, as indicated by FIG. 3 b. FIG. 4 shows the current and voltage waveforms. The electrical connections themselves introduce necessarily nothing new, a traditional inverter can very well have the same wiring. The difference occurs in the main driver circuit, where the inverter is shared into sections which are not switched simultaneously, but follow the pattern shown on FIG. 4 .
Through this switching pattern, a destressing by reduced switching frequency rather than by current reduction is achieved. FIG. 4 shows how the switching frequency of the IGBTs is lower than the resonant frequency. One section conducts the entire output current, but is relieved with currentless periods. The number of currentless periods equals the number of sections minus 1. With four sections as shown on FIG. 3 and represented on FIG. 4 , the sections A-D have three currentless periods. The reduced switching stress allows the IGBTs to operate at much higher current levels than if the IGBTs were switched each period, like in a standard parallel operation with equal current sharing in every cycle. The high current operation of the IGBT secures the most effective turn off, or more precisely, the minimum turn off loss to current ratio. This increases the effectiveness of the transistors, and the output power for a given IGBT loss level increases. FIG. 5 shows the enhanced maximum power output for different section numbers. This graph is based on the measurements shown in FIG. 2 .
The device suitably makes use of a new generation of NPT (Non-Punch-Through) IGBT devices from Infinion Technologies, which is designed for higher switching speed. However, an inverter utilizing PT (Punch-Through) IGBT's will exhibit a comparable output power increase by introducing the novel control strategy.
A traditional inverter would be an inverter with one section only, and with all the IGBTs parallelled in this section. When using more than one section, parallel connection of several IGBTs within each section is a way to achieve the desired output power. Another possibility is a modular system where each module is a complete system as shown on FIG. 3 .
An effect that is not yet discussed is that the passive IGBTs will act as a capacitive snubber and relieve the IGBTs turning off, and will therefore be a further advantage during inductive switching. This effect is not included in FIG. 5 . However, during capacitive switching, when IGBT turn on determines the voltage rise, a capacitive snubber enhances the losses, and is a disadvantage. However, capacitive switching only occurs during very steep load transients, like in the beginning of a load short circuit transient.
All the figures up till now describe a series compensated inverter. However, this control strategy can also be used on a parallel compensated inverter, which is current fed. This is shown on FIG. 6 . As shown on FIG. 7 , the current blocks will be rectangular and the output voltage sinusoidal, but the principle is equal, and the benefit comparable. It should be observed that FIG. 6 a shows an embodiment having a transformer between section outputs and the parallel compensated load. However, it is possible to dispense with the transformer, as indicated by FIG. 6 b.
An interesting side-effect of this principle is the possibility to achieve a very effective load impedance matching by using different timing between the sections, as shown in FIG. 8 . This is possible for a series compensated inverter. Load impedance matching is a crucial point in induction heating.
In FIG. 4 , each section carries current every fourth period. The inverter switches each period, and the inverter output current rotates between the four sections. FIG. 8 presents another way of arranging the switching pattern. Here, all four sections conducts current in the same period, and the inverter output only switches every fourth period. Between the switchings, the load current will oscillate, and power to the load is supplied by the stored energy in the oscillating LC circuit. (The load is symbolized by the variable resistor in FIG. 4. ) During this time interval, the load current will decrease, as indicated in FIG. 8 . When the inverter output switches, the DC link delivers power to the load and in addition enhances the stored energy in the oscillating LC circuit. The LC circuit thereby effectively acts as an energy storage means.
In FIG. 4 , the output voltage is defined being equal to 1 and the output current equal to 1. Hence, a power equal to 1 is delivered to a load impedance equal to 1. In FIG. 8 , where all four sections carry current in the same period, the output voltage then equals ¼ and the output current equals 4. Hence, a power equal to 1 is delivered to a load impedance which then is {fraction (1/16)}. Dependent on the number of sections used, different switching patterns are possible. With four sections, three patterns are possible, two of them being described here. The third possibility is letting two sections carry current at a time, serving an impedance equal to ¼.
What is worth to notice, is that the switching loss according FIGS. 4 and 8 will be the same, since the sections carry the same current. The difference occurs during the passive periods. In the case of FIG. 4 , the output will switch, but the IGBT will carry no current. In FIG. 8 , the output will not switch, and the IGBT will be constantly on or off. The current will circulate in either the lower or the upper IGBTs. This will cause extra conduction losses in the control scheme of FIG. 8 , leading to somewhat larger overall losses in this case compared to the case of FIG. 4 . To bring the losses down to the desired level while using the switching pattern in FIG. 8 , the current, and hence the maximum output power, has to be somewhat lower.
The conclusion is that in the cases of FIGS. 4 and 8 with four sections A-D, the same inverter is able to deliver (nearly) the same power into load impedances which differ by a factor of 16. In a section shared inverter, a wide range of load impedances can be served, while the inverter delivers close to rated output power. This is a great advantage compared to other control principles or strategies, where the current in semiconductor devices has to increase proportional to the load impedance fall in order to deliver constant output power. The consequence of this effect is severe in a MOSFET inverter, where losses caused by R DS,on are dominating.
With reference to FIG. 8 , it will be noted that the timing between sections is different compared to that shown in FIG. 4 , which makes the inverter deliver the same power, with only slightly higher losses, to a much smaller load impedance of {fraction (1/16)}.
When the IGBTs switch more seldom, the driving power decreases. Driving power is surprisingly large with heavy parallel connection at these frequencies, and a decrease to ¼ using four sections A-D is a convenient property. Another positive property is that current sharing between parallelled modules and chips cause less problems in a section shared inverter. The main reason for this is that the current level and thereby conduction voltage drop will increase, which will stabilize the current sharing. In addition, fewer chips will share the current, and they will be closer located. This comes in addition to the use of IGBT chips (NPT-type), which are not so exposed to parameter spreading as MOSFET chips.
Thus, the present invention provides a new control strategy for IGBTs used in high frequency applications where a destressing of the IGBTs has to be performed in order to handle the switching losses. The strategy results inter alia in the following benefits: reduced IGBT losses; fewer IGBT chips sharing the load current; effective impedance matching property; replacing expensive custom designed MOSFET modules by standard IGBT modules; an possibilty of utilizing similar technology for both high and low frequency applications.
The inventive implementation of the present new control strategy will lead to a significant improvement of products in the high power high frequency product range. The invention also greatly outweighs the following drawbacks: increased drive circuit complexity; slightly lower efficiency compared to MOSFET inverters; using standard IGBT modules implies more free wheeling diodes than necessary for the present applications, the extra free wheeling diodes being a drawback during capacitive switching. | A new control strategy for IGBTs when used in high frequency (75 kHz-500 kHz) high power (10 kW-5 MW) inverters with series resonant load, a topology commonly used for induction heating. The strategy changes the IGBT strain elements into a total stress picture that fits the IGBP's behaviour and internal nature better. This makes the IGBT operate much more efficient, thus increasing the maximum output power from the inverter significantly compared to a standard control scheme. This makes the IGBT based inverter a much cheaper alternative than a MOSFET inverter, which has been state of the art for this application. | 8 |
FIELD OF THE INVENTION
The present invention relates to an electrical plug and socket arrangement such as the ones used to join conventional extension cords or the like and more particularly to a plug and socket arrangement having a retractable connector for retaining both the plug and the socket together.
The retractable connector allows either elements of the novel combination to be used with a conventional corresponding plug or socket when needed.
BACKGROUND OF THE INVENTION
Conventional extension cords are provided at one of their end portions with a male plug having prongs and at the other end portion with a socket having bores adapted to receive prongs from another male plug.
In certain instances, a plurality of extension cords must be joined end to end to form a chain which will allow the user to obtain a desirable extension cord length. In these situations, any type of pulling action or other movement imparted on a section of the chain is susceptible of retracting the male prongs of a given extension cord from the corresponding bores into which they were initially inserted.
Once, one or more prongs are partially retracted from the corresponding bores into which they were initially inserted, not only is the flow of electrical current to the appropriate location interrupted but the situation also creates a potential serious hazard since the prongs become exposed to the environment and there is a possibility of short-circuiting, sparks, etc. . . .
A number of structures have been proposed to minimize such risks. U.S. Pat. No. 2,753,534 and 2,945,203 both disclose connectors that employ a threaded sleeve to connect two elements together in order to prevent the plug and socket members from separating. Such structures, however, present a major drawback. Even if the prongs and bores of these connectors were compatible with the corresponding prongs and bores of conventional plugs and sockets, the described socket elements could not be independently connected to any conventional plug and the described plug member could not be connected to any conventional socket. In both patents, the described structure comprise a rotatable, internally threaded sleeve on the plug side of the connector and a corresponding annular externally threaded ring on the socket side of the connector.
Both the sleeves and the rings form a physical obstacle which prevent insertion into conventional plugs and sockets. The threaded sleeve is laterally fixed to the plug side to physically and electrically protect the prongs.
Accordingly, the present invention provides a plug and socket arrangement which has an integral connector for retaining both the plug and the socket together.
The connector is slidingly mounted on one of the elements of the combination thus allowing either the novel plug or socket to be used independently with commercially available components. This advantage could prove to be particularly useful when one of the two parts of the novel combination fails to operate properly and one must rely on available conventional plug or sockets.
SUMMARY OF THE INVENTION
The present invention relates to electrical plug and socket adapted to be releasably secured together, in a longitudinal axial direction. The plug has a cylindrical body, a substantially flat abutting face and a plurality of prongs orthogonally projecting outside the abutting face. The cylindrical body has a peripheral threaded portion adjacent the abutting face. The socket has a cylindrical body, a substantially flat abutting face defining a plane and a plurality of bores adapted to receive the prongs to allow the abutting faces of the plug and the socket to substantially contact each other. The cylindrical body of the socket has successively a ring-like peripheral wall and recess adjacent the abutting face of the socket. The socket also has a ferrule with an internal cylindrical surface comprising a threaded portion adapted to threadally engage the threaded portion of the plug and an inwardly beaded ring adapted to rotate and sideways slide into the recess. The wall as an outer diameter sufficiently large to maintain the beaded ring inside the recess. The recess has a width sufficient to allow the ferrule to slidingly recede over the cylindrical body of the socket to completely clear the plane of the abutting face of the latter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a plug and socket arrangement according to the invention,
FIG. 2 is a perspective view illustrating the plug of the novel arrangement and a conventional wall socket adapted to be suitably connected together,
FIG. 3 is a perspective view of the socket of the novel arrangement and a conventional electrical cord plug adapted to be suitably connected together,
FIG. 4 is a longitudinal cross-sectional view taken along line 4--4 of FIG. 1, and
FIG. 5 is an elevation view of the novel plug and socket arrangement with the plug about to be inserted in the socket and the ferrule in an intermediate slidden position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, there is shown a plug 10 having a cylindrical body 12, a substantially flat abutting face 14 and a plurality of prongs 16 orthogonally projecting outside the abutting face 14.
The prongs 16 are electrically linked to a set of wires (not shown) protected by a cable sheating 18. The cylindrical body 12 has peripheral external threads 20 adjacent the abutting face 14.
Referring now more specifically to FIG. 4, there is shown a socket having a cylindrical socket body 24. The body 24 is divided into a first ring-like section 26 adjacent the abutting face 14 and separated by a second ring-like section 28 by a cylindrical recess 30.
The body 24 has a substantially flat abutting face 32 provided with bores 34. The bores 34 are sheathed with a conductive sleeve 36 adapted to receive the prongs 16. The sleeves 36 are electrically connected to a series of electrical wires 38 by a connecting component 40.
A ferrule 42 is slidably and rotatably mounted on the socket body 24 and forms part of the socket in the present embodiment. The ferrule 42 has an inner cylindrical surface 44 provided with internal threads 46. The internal threads 46 are adapted to threadedly engage the external threads 20 of the plug thus preventing separation of the plug from the socket. The ferrule 42 is also provided with an inwardly beaded ring 48. The ring 48 is adapted to slide parallel to a longitudinal axis 50 inside the recess 30 and to abut at both extremities of axial displacement against abutting walls 52 and 52', thus limiting the axial movement of the ferrule 42.
The length characterized by the distance 54 of recess 30 corresponds to the distance the ferrule 42 can slide. The ferrule 42 is adapted to recede over the cylindrical body 24 of the socket to completely clear the abutting face 32.
As illustrated in FIG. 3, the socket with the ferrule 42 in a fully retracted position can be used with any corresponding conventional plug such as conventional plug 56 having prongs 16'. As can be seen in FIG. 2, the novel plug can also be used with conventional equipment such as wall socket 58 wherein the prongs 16 fit in the bores 34' until the face 14 abuts against the socket 58.
Referring to FIG. 5, the dotted line 42a illustrates the back of the ferrule 42a in a fully retracted position while line 42b illustrates the front of the ferrule 42 in a forwardly projected position.
The ferrule 42 is provided on its outer periphery with a set of prehension ribs 43 adapted to provide abutting means for the fingers of a user when the ferrule is rotated.
In the preferred embodiment, the socket body is manufactured in two separate parts. Referring back to FIG. 4, the second ring-like section 28 and the cylindrical recess 30 are made from a single piece of material attached to the first ring-like section 26 with a set of screws 60.
The preferred embodiment also includes a double pair of jaw-like components 62 adapted to secure the electric cables 18 to the socket and to the plug. The socket and the plug 10 have a pair of fixing prongs 64' and 64 respectively which extend integrally from their back surfaces 66' and 66. Each pair of jaw-like components 62 and 62' has a pair of screws 68 and 68' which extends through the respective fixing prongs 64 and 64' and which are adapted to squeeze the components 62 and 62' together. The components 62 and 62' are thus adapted to squeeze the cables sheating 18 and 18' respectfully and releasably attach them to either the plug or the socket.
An alternative embodiment of the invention also provides means for securing the novel plug and socket together while allowing compatibility with conventional components. In this alternative embodiment, the ferrule and the associated structural components are located on the plug while the external threads are located on the socket. This alternative embodiment also allows the prongs 16 to clear the abutting face 14 and to be used on a wall socket as in FIG. 2. | An electric plug and socket arrangement includes a connecting sleeve threadedly engaging the plug to the socket. The sleeve is slidingly mounted on the plug or on the socket and can slide to completely clear their abutting face so that the plug or the socket may be used with conventional plugs and sockets. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical disc comprising a pair of discs bonded together and a method for manufacturing the same.
2. Description of the Related Art
In conventional optical discs such as a video disc and the like, a double sided recording disc is known which is composed of a pair of discs bonded together by an adhesive layer. Each disc comprises a circular substrate made of a light-transmissible resin on which pit rows or grooves are formed concentrically or spirally to hold information to be recorded as a data region. The disc further comprises a reflective layer and protective layer which are formed in turn on the data region. The double sided recording disc is assembled in such a manner that protective layers face each other via adhesive layer. Moreover, the double sided recording disc is operated so that the disc is clamped about a central hole and rotated and then irradiated with a reading laser beam to the data region in order to optically regenerate information.
In such a double sided optical disc of bonding-together type, a hot melt type adhesive has been generally used as its adhesive layer. However, such a hot melt type adhesive is relatively inferior in heat-resistance because of thermoplastic. Therefore, there is a problem that the double sided optical disc of bonding-together type is easily deformed and peeled off into halves by applied heat.
To overcome this problem, there is an idea that an ultraviolet ray setting is used as an alternative adhesive for bonding the two discs together. The ultraviolet ray setting in fluid hardens with application of an ultraviolet ray and has a high heat resistance. In this case, ultraviolet rays should be irradiated into the fluid ultraviolet ray setting resin through the substrate, reflective layer and protective layer in order to solidify the resin in the assembling process. Most of the ultraviolet rays are apt to be reflected and absorbed therein, and thus sufficient amounts of the ultraviolet rays are unable to reach the ultraviolet ray setting resin. As a result, much time is required for the resin to be hardened. Moreover, in the case that the ultraviolet ray setting resin contains a radical polymerization resin as a main component, Oxygen prevents the resin from hardening. If such an ultraviolet ray setting resin involves air bubbles during the bonding process, its hardening becomes difficult resulting in an insufficient adhesive strength of the resin.
SUMMARY OF THE INVENTION
Thus, the present invention has been made to solve such a problem in view of the forgoing status. An object of the invention is to provide an optical disc of improved reliability and a method for manufacturing the same.
An optical disc according to the present invention comprises;
a pair of light-transmissible circular substrates each comprising an inner non-data region disposed around a center hole thereof, a data region disposed around the inter non-data region for bearing signals corresponding to information to be recorded and an outer non-data region disposed around the data region which are formed on a major surface of the substrate,
a reflective layer formed on said data region, and
a protective layer made of an ultraviolet ray setting resin containing metal ions formed on said reflective layer; and
an adhesive layer made of an adhesive composition containing an ultraviolet ray setting component and an anaerobic hardening component disposed between said protective layers of the circular substrates for adhering said circular substrates.
A method of manufacturing an optical disc according to the present invention comprises the steps of;
forming a pair of light-transmissible circular substrates each comprising an inner non-data region disposed around a center hole thereof, a data region disposed around the inter non-data region for bearing signals corresponding to information to be recorded and an outer non-data region disposed around the data region which are formed on a major surface of the substrate;
forming a reflective layer formed on said data region, and
coating with a fluid ultraviolet ray setting resin containing metal ions on said reflective layer and said inner and outer non-data regions;
irradiating an ultraviolet ray to said ultraviolet ray setting resin to harden to form a protective layer of the ultraviolet ray setting resin;
coating on at least of the protective layers of the pair of light-transmissible circular substrates with a fluid adhesive composition containing an ultraviolet ray setting component and an anaerobic hardening component;
superimposing the pair of light-transmissible circular substrates each other in such a manner that the fluid adhesive composition is sandwiched between said protective layers of the circular substrates; and
irradiating an ultraviolet ray to said adhesive composition to harden to form an adhesive layer of the adhesive composition in such a manner that at least adhesive compositions existing in the outer and inner non-data regions harden first and, subsequently, a stop of contact with air and a reaction with metal ions contained in the protective layers allow the adhesive composition existing in the data region to harden.
According to the invention, an adhesive composition having both ultraviolet ray setting and anaerobic hardening properties is used for the adhesive layer disposed between the pair of light-transmitting substrates and, at the same time, an ultraviolet ray setting resin containing metal ions is used as a protective layer. It is therefore possible that the adhesive composition is efficiently solidified by a reaction of metal ions even if air exists in the adhesive layer. As a result, the invention provides a bonding-together type optical disc of improved reliability.
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 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 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 schematic sectional view partially broken showing a reflection type optical disc of an embodiment according to the present invention;
FIG. 2 is a graph showing results of measuring a warp angle of an optical disc in an embodiment according to the present invention; and
FIG. 3 is a graph showing results of measuring a warp angle of an conventional optical disc.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described hereinafter with reference to the accompanying drawing. FIG. 1 shows a double sided optical disc of the present invention. As shown in FIG. 1, the optical disc comprises a pair of light-transmitting circular substrates 1, 1 each having a data region in which pits or grooves are formed to represent information by fine unevenness, except outer (non-recording) and inner (non-recording) non-data regions. The disc halves comprises a reflective layers 2, 2 which are formed in the data regions on a pair of the light-transmitting substrates 1, 1 respectively. The disc halves further comprises protective layers 3, 3 which are so formed to cover the outer and inner non-data regions and reflective layers 2, 2 on the light-transmitting substrates 1, 1 respectively. In the disc structure, an adhesive layer 4 which is used to bond a pair of disc halves having the protective layers 3, 3 in such a manner that the protective layers 3, 3 sandwich the adhesive layer and facing each other.
Any material for forming light-transmitting substrates is acceptable, so far as it allows light beams of recording and regenerating to pass through per se. For example, synthetic resins such as polycarbonate (PC) and polymethyl methacrylate (PMMA) resins and glass or the like are usable. Among them, polycarbonate (PC) resin is most preferably used because it is superior in heat-resistance and dimensional stability. When the synthetic resin is used as a material for the light-transmitting substrate, it can be produced by an injection molding method. Moreover, the size and shape of the light-transmitting substrate can be appropriately selected depending on applications of the optical disc. For example, a circular substrate with an approximately 120 mm diameter and a thickness of from 0.2 to 1.2 mm, more preferably, 0.6 mm is usable.
The reflective layers 2, 2 are made of metal films of aluminum or an aluminum alloy with a thickness of from 300 to 1000 angstroms. The reflective layer can be formed by a sputtering method, a vacuum deposition method or the like.
The protective layers 3, 3 are made of ultraviolet ray setting resins containing metal ions derived from copper oxide, iron oxide, etc., with a thickness of from 5 to 20 micrometers. The protective layer can be formed by a spin coating method, a screen printing method or the like.
The adhesive layer 4 is made of an adhesive composition comprising an ultraviolet ray setting component and an anaerobic hardening component. The ultraviolet ray setting component is an unsaturated double-bonded compound in the form of ultraviolet ray setting type monomer and oligomer) comprising acrylates. The anaerobic hardening component is a reagent for imparting anaerobic hardening property to the adhesive composition such as hydroperoxide, etc. This adhesive composition is able to harden in an atmosphere of anaerobic and/or ultraviolet ray conditions.
The method of manufacturing of the optical disc of the present invention will be described hereinafter in detail.
A pair of light-transmitting substrates are prepared each of which has a data region in which pits or grooves with fine protrusions and recesses are formed in the main face except in outer and inner non-data regions. This light-transmitting substrate is available, using a stamper, by injection molding of synthetic resins including polycarbonate (PC) or the like. The size of the substrate has a diameter 120 mm and a thickness of from 0.2 to 1.2 mm, for example, 0.6 mm.
In the next process, the outer and inner non-data regions of the substrate are covered with a mask. Then aluminum or an aluminum alloy is evaporated or sputtered to form a metal reflective layer at a thickness of from 300 to 1000 angstroms on the data region except the outer and inner non-data regions.
Subsequently, a fluid ultraviolet ray setting resin containing metal ions derived from copper oxide, iron oxide, etc., is provided at a thickness of from 5 to 20 micrometers to the reflective layer by using a spin coating method or screen printing method. The fluid resin covers the outer and inner non-data regions and the reflective layer. The ultraviolet rays is then irradiated to the ultraviolet ray setting resin to harden to form a protective layer. An ultraviolet ray setting resin "UV-PA-5" made by CEMEDINE Co., Ltd., is usable as one of examples of the ultraviolet ray setting resin containing metal ions. Such an ultraviolet ray setting resin UV-PA-5 is a transparent liquid with light indigo color and has a viscosity of 80 cps at a temperature of 20 centigrade degree. In the case of using such an ultraviolet ray setting resin, a specified resin layer of, for example, 10 micrometers in thickness, can be obtained by a spin coating method under the conditions of 3000 rpm and rotation duration of from 3 to 5 seconds, which is then irradiated with ultraviolet rays of 100 to 200 mJ/cm 2 to be hardened. In this way, a protective layer is formed.
Next, a fluid adhesive composition is applied onto the protective layer of the light-transmitting substrate by using a screen printing or spin coating method to form an adhesive layer at a thickness of from 10 to 20 micrometers. The fluid adhesive composition comprises a component for imparting an ultraviolet ray setting property and a component for imparting an anaerobic property (i.e., ultraviolet ray setting and anaerobic hardening type adhesive). For example, an ultraviolet ray setting and anaerobic hardening type adhesive "UV-PA-6" made by CEMEDINE Co., Ltd., can be used as the adhesive composition. Such an adhesive composition UV-PA-6 is a transparent liquid with light yellow color and has a viscosity of 4500 cps at a temperature of 20 centigrade degree. The fluid adhesive composition is applied onto at least one of the protective layers preferably by using a screen printing method.
After that, half of the pair of light-transmitting substrates is aligned with the center hole and overlaid on the other on which the adhesive layer is provided onto at least and the substrates are the layer, so that the pair of the substrates sandwich the adhesive composition layer. Then an ultraviolet ray is irradiated at a given amount e.g., 300 mL/cm 2 onto the adhesive composition layer through the light-transmitting substrate, so that the outer and inner non-data regions without any reflective layer harden first. Immediately after that, the hardened outer and inner non-data regions prohibit the adhesive layer from coming contact with air, so that the adhesive layer portion existing between the reflective layers hardens under an anaerobic condition. At this time, a reaction with metal ions contained in the protective layer facilitates to promote the anaerobic hardening. Therefore, the adhesive layer existing between the reflective layers anaerobically harden rapidly, even if it involves air or air bubbles or the air-tightness of the layer is low between the adjacent protective layers. By this, there is reduced time for hardening required after the disc halves are overlaid each other.
Moreover, when the amount of ultraviolet rays irradiated onto ultraviolet ray setting resins for the protective layer is applied less than that for the adhesive layer, then the surface of the protective layer is somewhat tacky. This sticky condition of the protective layer facilitates the anaerobic hardening in the overlying step above mentioned.
Furthermore, advantageous actions and effects in an embodiment of the present invention will be described hereinafter by comparison with a comparative example. There are provided a pair of disc substrates each made of polycarbonate with a 120 mm diameter and a 0.6 mm thickness in which a reflective layer and a protective layer are stacked thereon. The two disc substrates are bonded together using an adhesive layer. In the embodiment, an ultraviolet ray setting resin "UV-PA-5" made by SEMEDINE Co., Ltd. is used as the protective layer and then an anaerobic hardening adhesive "UV-PA-6" made by SEMEDINE Co., Ltd. is used as the adhesive layer. In the comparative example, "DAICURECLEAR SD-211" made by Dainippon Ink & Chemicals, Inc., and then a hot-melt adhesive "NM-4085" made by SEMEDINE Co., Ltd. is used as the adhesive layer. Moreover, both the embodiment and the comparative example have the protective layers of a thickness of from 5 to 20 micrometers and the adhesive layers of a thickness of from 20 to 40 micrometers respectively.
A constant temperature and humidity test was performed on the optical discs having above configurations shown in the embodiment and comparative example under the conditions of 60 centigrade degree, 90% R.H. 96 hrs; 25 centigrade degree, 50% R.H. 24 hrs. and then the warp angles of the samples were measured before and after the test. The measurement results are shown in FIG. 2 (for the embodiment) and in FIG. 3 (for the comparative example). In FIG. 2, circle-marks show results obtained before the test while delta-marks show those after the test. In FIG. 3, circle-marks show results obtained before the test while black-circle-marks show those after the test.
The embodiments have the mean of warp angles of -0.187 degrees before the test and the mean of warp angles of -0.146 degrees after the test. In contrast, the comparative example has the mean of warp angles of 0.220 degrees before the test and the mean of warp angles of 0.418 degrees after the test. In this measurement, the warp angle is defined as a half (alpha/2) of the angle (alpha) formed by the reflecting beam with respect to the incident beam normal to the surface of the disc.
As seen from the above measurement results, it is found that the optical disc in the embodiment provides a great improvement in the warp angle in that both its warp angle and its changes in the angle are relatively small. It is thought that this improvement has been achieved by the reason that, owing to fluidity of the adhesive layer, the adhesive layer conforms uniformly between a pair of discs and is not subjected to undue stress when applied and bonded together.
In the above-mentioned embodiment, the adhesive layer can be formed on not only one side but also both internal sides of the pair of discs. In addition to the above embodiments illustrated as the bonding-together type optical disc to be exclusively used for regeneration of information, it is needless to say that the optical disc of the present invention is usable as a writable disc in which a recording layer is formed between a data region and a reflective layer on a substrate. Moreover, the disc of the invention is also usable as a bonding-together type disc including a dummy disc having no data region but the other side of the pair of discs is used for recording data.
According to the present invention, ultraviolet ray setting and anaerobic hardening adhesives is used for bonding a pair of discs together in which the protective layers each made of ultraviolet ray setting resin containing metal ions can facilitate the anaerobic hardening. As a result, it achieves a sufficient adhesive strength. Furthermore, since the adhesive layer has a fluidity property and less warp angles, flatness of the optical disc of a pair of discs bonded together are improved.
It should thus be apparent that the scope of the teaching of this invention is not intended to be limited by only the embodiments that have been expressly disclosed and illustrated, but that instead the scope of the teaching of this invention should be read as being commensurate with the scope of the claims that follow. | An optical disc has a pair of light-transmissible circular substrates each having an inner non-data region disposed around a center hole thereof, a data region disposed around the inter non-data region for bearing signals corresponding to information to be recorded and an outer non-data region disposed around the data region which are formed on a major surface of the substrate. The optical disc has a reflective layer formed on the data region and a protective layer made of an ultraviolet ray setting resin containing metal ions formed on the reflective layer. The optical disc has an adhesive layer made of an adhesive composition containing an ultraviolet ray setting component and an anaerobic hardening component disposed between the protective layers of the circular substrates for adhering the circular substrates. | 8 |
This invention was made with government support under Contract No. DE-FC26-97FT343656 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
This invention relates to oil and gas drilling, and more particularly to apparatus and methods for reliably transmitting information between downhole drilling components.
2. The Relevant Art
The need for signal repeaters to counteract signal loss encountered when transmitting data from downhole components to the earth's surface is known or has been suggested. Nevertheless, in downhole telemetry systems transmitting data on wires or cables integrated directly into the drill string, few if any useable implementations are known for repeating and amplifying data signals. The following references teach repeaters that are used in wireless electromagnetic or acoustic wave transmission systems, and are not applicable to wired solutions. Furthermore, none of the references address all of the challenges, such as cable routing from the repeater up and down the drill string, that are inherent in wired solutions.
U.S. Pat. No. 6,218,959 issued Apr. 17, 2001 to Smith describes a system and method of fail-safe communication of information transmitted in the form of electromagnetic wave fronts that propagate through the earth between surface equipment and downhole components. The system comprises two or more repeaters disposed within a well bore such that the two repeaters receive each signal carrying the telemetered information. The repeater that is farther from the source includes a memory device that stores information carried in the signal. A timer device, in the repeater that is farther from the source, triggers the retransmission of the information after a predetermined time period, unless the repeater that is farther from the source has detected a signal carrying the information, generated by the repeater, that is closer to the source.
U.S. Pat. No. 6,177,882 issued Jan. 23, 2001 to Ringgenberg et. al teaches downhole repeaters that utilize electromagnetic and acoustic waves to retransmit signals carrying information and methods for use of the same. The repeaters and methods provide for real-time communication between downhole equipment and the surface, and for the telemetering of information and commands from the surface to downhole tools disposed in a well using both electromagnetic and acoustic waves to carry information. The repeaters and methods detect and amplify signals carrying information at various depths in the well bore, thereby alleviating signal attenuation.
U.S. Pat. No. 6,160,492 issued Dec. 12, 2000 to Herman teaches an electromagnetic telemetry system for changing the operational state of a downhole device. The system comprises an electromagnetic transmitter disposed in a first well bore that transmits a command signal. An electromagnetic repeater disposed in a second well bore receives the command signal and retransmits the command signal to an electromagnetic receiver disposed in a third well bore that is remote from the first well bore. The electromagnetic receiver is operably connected to the downhole device such that the command signal received from the electromagnetic repeater is used to prompt the downhole device to change operational states.
U.S. Pat. No. 6,144,316 issued Nov. 7, 2000 to Skinner teaches an electromagnetic and acoustic signal repeater for communicating information between surface equipment and downhole equipment. The repeater comprises an electromagnetic receiver and an acoustic receiver for respectively receiving and transforming electromagnetic input signals and acoustic input signals into electrical signals that are processed and amplified by an electronics package. The electronics package generates an electrical output signal that is forwarded to an electromagnetic transmitter and an acoustic transmitter for generating an electromagnetic output signal that is radiated into the earth and an acoustic output signal that is acoustically transmitted.
U.S. Pat. No. 6,075,461 issued Jun. 13, 2000 to Smith teaches an apparatus, method and system for communicating information between downhole equipment and surface equipment. An electromagnetic signal repeater apparatus comprises a housing that is securably mountable to the exterior of a pipe string disposed in a well bore. The housing includes first and second housing subassemblies. The first housing subassembly is electrically isolated from the second housing subassembly by a gap subassembly having a length that is at least two times the diameter of the housing. The first housing subassembly is electrically isolated from the pipe string and is secured thereto with a nonconductive strap. The second housing subassembly is electrically coupled with the pipe string and is secured thereto with a conductive strap. An electronics package and a battery are disposed within the housing. The electronics package receives, processes, and retransmits the information being communicated between the downhole equipment and the surface equipment via electromagnetic waves.
In view of the foregoing, what are needed are apparatus and methods providing signal amplification in high-speed downhole telemetry systems that transmit data using cables or wires directly integrated into the drill string.
What are further needed are apparatus and methods to seal electronics of the repeater from the surrounding environment, while providing routing of cables to and from the repeater traveling uphole and downhole.
It would be a further advance to provide apparatus and methods that not only repeat or amplify a signal, but could also gather data from various sensors such as inclinometers, pressure transducers, thermocouplers, accelerometers, imaging devices, seismic devices, and the like, as well as provide control signals to various of these device to control them remotely.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to provide a robust repeater for amplifying signals in high-speed downhole telemetry systems that transmit data using cables or wires directly integrated into the drill string. It is a further object to provide adequate isolation of electronics of the repeater from the surrounding environment, while providing means of routing cables to and from the repeater traveling uphole and downhole. It is a further object to not only boost or amplify a signal, but to also gather data from various sensors such as inclinometers, pressure transducers, thermocouplers, accelerometers, imaging devices, seismic devices, and the like, as well as provide control signals to various of these device to control them remotely.
Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, a repeater is disclosed in one embodiment of the present invention as including a cylindrical housing, characterized by a proximal end and a distal end, and having a substantially cylindrical wall, the cylindrical wall defining a central bore passing therethrough. The cylindrical housing is formed to define at least one recess in the cylindrical wall, into which a repeater is inserted. The cylindrical housing also includes an annular recess formed into at least one of the proximal end and the distal end. An annular transmission element, operably connected to the repeater, is located in the annular recess.
One or several channels may be formed within the cylindrical housing that extend from the recess to the proximal end, the distal end, or both. In selected embodiments, the annular transmission element inductively converts electrical energy to magnetic energy. In other embodiments, the annular transmission element includes an electrical contact to transmit electrical energy directly to another contact. In certain embodiments, at least one battery is located in another recess provided in the cylindrical housing.
In selected embodiments, the cylindrical housing is inserted into the bore of a host downhole tool. The host downhole tool may include a pin end and a box end, the pin end having an external threaded portion and the box end having an internal threaded portion. In certain embodiments, the box end lacks an integrated secondary shoulder. In this case, a secondary shoulder insert, independent from the box end, may be inserted into the box end, and may be capable of absorbing stresses normally incident on an integrated secondary shoulder.
In selected embodiments, stresses normally incident on a secondary shoulder are not imposed on the cylindrical housing. Surface characteristics of the secondary shoulder insert may engage corresponding surface characteristics of the inside diameter of the host tool to transfer a load, incident on the secondary shoulder insert, to the host tool.
In selected embodiments, the repeater circuit further comprises a data acquisition circuit to acquire data from at least one sensor. The sensor may be a pressure transducer, an inclinometer, a thermocoupler, an accelerometer, an imaging device, a seismic device, or the like. The repeater circuit may also include added functionality including signal filtering circuitry, signal error checking circuitry, device control circuitry, a modem, a digital signal processor, a microcontroller, and the like.
In another aspect of the invention, a downhole link module includes a cylindrical housing, characterized by a proximal end and a distal end, having a substantially cylindrical wall, the cylindrical wall defining a central bore passing therethrough. The cylindrical housing is formed to define at least one recess in the cylindrical wall to accommodate a repeater circuit. A data acquisition circuit, located within the recess, is connected to the repeater circuit to acquire data from at least one sensor.
In yet another aspect of the invention, a downhole repeater may include a cylindrical housing, characterized by a proximal end and a distal end, having a substantially cylindrical wall, the cylindrical wall defining a central bore passing therethrough. The cylindrical housing has at least one recess formed into the outer rounded surface of the cylindrical wall, accommodating a signal repeater.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will become more fully apparent from the following description, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments in accordance with the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is a profile view of a drill rig illustrating a context in which an apparatus and method in accordance with the invention may be used;
FIG. 2 is a perspective view illustrating one embodiment of a link module configured for insertion into a host downhole tool;
FIG. 3 is a perspective cross-sectional view illustrating one embodiment of the internal makeup of a link module in accordance with the present invention;
FIG. 4 is an inverted perspective view illustrating one embodiment of various electronic components that may be included within a link module in accordance with the present invention;
FIG. 5 is a schematic block diagram illustrating one embodiment of various components that may be included within a link module circuit in accordance with the invention;
FIG. 6 is a perspective cross-sectional view illustrating one embodiment of a host downhole tool that may be used to house or enclose a link module in accordance with the present invention;
FIG. 7 is an exploded, perspective, cross-sectional view illustrating certain selected embodiments of components used in conjunction with a link module and a host downhole tool in accordance with the present invention; and
FIG. 8 is an enlarged cross-sectional view illustrating more detail of various component components illustrated in FIGS. 6 and 7 .
DETAILED DESCRIPTION OF THE INVENTION
It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of embodiments of apparatus and methods of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected embodiments of the invention.
The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the apparatus and methods described herein may easily be made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected embodiments consistent with the invention as claimed herein.
Referring to FIG. 1 , a drill rig 10 may include a derrick 12 used to operate a drill string 14 . The drill string 14 may be comprised of multiple sections of drill pipe 16 and other downhole tools 16 . A drill bit 20 may be connected to the end of the drill string 14 . In certain instances, a drill string 14 may extend into the ground 20,000 feet or more. Thus, when information is transmitted up or down the drill string 14 , ample opportunity exists for signal loss.
Signal loss may occur as a data signal is transmitted from one downhole tool to another. In certain instances, an electrical signal may be converted to a magnetic field or vice versa when encountering tool joints, losing energy each time it is converted. Signal loss may occur because of signal attenuation in cables or wires due to the sheer length of the drill string. Thus, apparatus and methods are needed to ensure that data received from a drill bit 20 or other downhole tool 16 is safely transmitted to the surface. In selected embodiments, one or several repeaters 18 or signal boosters 18 may be inserted at desired intervals along the drill string 14 , such as every 1000 to 5000 feet. In selected embodiments, a repeater 18 may be integrated into an existing drill pipe 16 or downhole tool 16 , or the repeater 18 may be a downhole tool 18 dedicated exclusively to that function.
Referring to FIG. 2 , a link module 30 , or a repeater 30 , may include a cylindrical housing 34 defining a central bore 32 . The cylindrical housing 34 may be substantially circular, or in other embodiments, may be polygonal. The central bore 32 may have a diameter that is slightly smaller than the inner bore diameter of a typical section of drill pipe 16 to accommodate and provide space to components of the link module 30 , or repeater 30 .
Nevertheless, in selected embodiments, as batteries and electronic components become more compact, it is feasible that the central bore 32 of the link module 30 could be substantially equal to that normally encountered in sections of drill pipe 16 or other downhole tools 16 . The link module 30 may be configured for insertion into a host downhole tool. Thus, the link module 30 may be removed or inserted as needed to access or service components located therein.
In selected embodiments, the link module 30 may include one or several grooves 36 or seal contact surfaces 36 to seal the link module 30 within a host downhole tool. The host downhole tool will be described in more detail in the description of FIG. 6 . Seals inserted into the seal contact surfaces 36 or grooves 36 may prevent fluids such as drilling mud, lubricants, oil, water, and the like from contaminating circuitry or components inside the link module 30 . Moreover, the entry of other substances such as dirt, rocks, gasses, and the like, may also be prevented.
In selected embodiments, the link module 30 may include one or several recesses 38 a - c to house various components contained by the link module 30 , or repeater 30 . Selected recesses 38 may contain circuitry while others 38 may be used for batteries or other components. One or several channels 41 may be milled or formed into the cylindrical housing 34 to provide for the routing of wires between recesses 38 . In selected embodiments, a connector 40 may be used to connect link module circuity to a cable, wire, or other link, traveling up or down the drill string 14 . An aperture 42 may likewise be provided for routing cable, wire, or other transmission means up or down the drill string 14 .
Referring to FIG. 3 , an inverted cross-sectional view of the drawing of FIG. 2 is illustrated. As illustrated, the link module 30 may be characterized by a general wall thickness 48 . Likewise, in regions proximate recesses 38 or other channels 41 , a thinner wall thickness 50 may be present. Nevertheless, a critical wall thickness 48 should be maintained to provide structural reliability to the link module 30 to support stresses encountered in a downhole environment. The cylindrical housing 34 may be constructed of any suitable material including steel, aluminum, plastics, and the like, capable of withstanding the pressures, stresses, temperatures, and abrasive nature of a downhole environment.
As illustrated, one or several transmission paths 42 a , 42 b may be milled or formed into the wall of the link module 30 to provide an outlet for cables, wires, or other transmission media exiting the recess 38 . In selected embodiments, connector 40 may be provided to simply link up with or connect to repeater circuitry, or in other embodiments, a channel 42 a may enable the routing of cables, wires, and the like from a repeater circuit, within the recess 38 , to a transmission element (not shown). For example, a transmission element may be provided in an annular recess 44 milled or otherwise formed into the end of the cylindrical housing 34 .
Referring to FIG. 4 , a link module 30 , or repeater 30 , is illustrated equipped with components or circuitry needed to provide functionality to the link module 30 . For example, batteries 54 connected in series or parallel may be inserted into selected recesses 38 of the link module 30 . Wires 56 may be routed through channels 41 interconnecting the recesses 38 to connect the batteries 54 together, or to connect the batteries to the link module circuit 58 .
Likewise, the link module circuit 58 , or components 58 , may be located within other recesses 38 . As was previously stated, a conductor 60 , cable 60 , or other transmission media 60 , may travel from the link module circuit 58 to a transmission element 52 . The transmission element 52 may transmit energy to another transmission element 52 in contact therewith. The transmission element 52 may have an annular shape and may transmit energy by direct electrical contact, or may convert an electrical current to a magnetic field. The magnetic field may then be detected by another transmission element 52 in close proximity thereto located on a subsequent downhole tool 16 .
Referring to FIG. 5 , in selected embodiments, a link module circuit 58 within the link module 30 may include various components to provide desired functionality. For example switches 64 , multiplexers 64 , or a combination thereof may be used to receive, switch, and multiplex signals, received from uphole 66 b and downhole 66 a sources, into and out of the link module circuit 58 . The switches/multiplexers 64 may direct traffic such as data packets or other signals into and out of the link module circuit 58 , and may ensure that the packets or signals are transmitted at proper time intervals, frequencies, or a combination thereof.
In certain embodiments, the multiplexer 64 may transmit several signals simultaneously on different carrier frequencies. In other embodiments, the multiplexer 64 may coordinate the time-division multiplexing of several signals. Signals or packets or received by the switch/multiplexer 64 may be amplified 68 and filtered 70 , such as to remove noise. In certain embodiments received signals may simply be amplified. In other embodiments, the signals may be received, data may be demodulated therefrom and stored, and the data may be remodulated and retransmitted on a selected carrier frequency having greater signal strength. A modem 74 may be used to demodulate analog signals received from the switch/multiplexer into digital data 64 and modulate digital data into analog signals for transfer to the switches/multiplexer where they may be transmitted uphole or downhole
The modem 74 may also perform various tasks such as error-checking 76 . This is typically performed when the data is digital. The modem 74 may also communicate with a microcontroller 78 . The microcontroller 78 may execute any of numerous applications 86 . For example, the microcontroller 78 may run applications 86 whose primary function is acquire data from one or a plurality of sensors 82 a - c . For example, the microcontroller 78 may interface to sensors 82 such as inclinometers, thermocouplers, accelerometers, imaging devices, seismic data gathering devices, or other sensors. Thus, the link module circuit 58 may include circuitry functioning as a data acquisition tool.
In other embodiments, the microcontroller 78 may run applications 86 that may control various devices 84 located downhole. That is, not only may the link module circuit 58 be used as a repeater, and as a data gathering device, but may also be used to provide control signals to selected devices as needed. The link module circuit 58 may include a memory device 80 such as a FIFO 80 that may be used to store data needed by or transferred between the modem 74 and the microcontroller 78 .
Other components of the link module circuit 58 may include non-volatile memory 90 , which may be used to store data, such as configuration settings, node addresses, system settings, and the like. One or several clocks 88 may be provided to provide clock signals to the modem 74 , the microcontroller 78 , or any other device. A power supply 72 may receive power from an external power source such as the batteries 54 illustrated in FIG. 4 . The power supply 72 may provide power to any or all of the components located within the link module circuit 58 . Likewise, an RS 232 port 92 maybe used to provide a serial connection to the link module circuit.
Thus, the link module circuit 58 described in FIG. 5 may have many more functions than those supplied by a simple signal repeater. The link module circuit 58 may be though of as a node 30 connected to a downhole network, and may provide many of the advantages of an addressable node on a network. The addressable node may amplify signals received from uphole 66 b or downhole 66 a sources, be used as a point of data acquisition, and be used to provide control signals to desired devices 84 . These represent only a few examples of the versatility of the link module 30 . Thus, the link module circuit 58 , although useful and functional as a repeater 30 , may have a greatly expanded capability.
Referring to FIG. 6 , a host downhole tool 94 may be used to house the link module 30 . For example, a host downhole tool 94 may include a first portion 96 b threadable into a second portion 96 a . The first portion 96 a may include a pin end 95 connectable to another downhole tool 16 . Likewise, a second portion 96 b may include a box end (not shown) connectable to the pin end of another downhole tool 16 .
The first and second portions 96 a , 96 b may have a standard bore size 98 typical of various downhole tools 16 . An oversize bore 100 may be provided to accommodate the link module 30 , which may have a narrowed bore 102 smaller than the standard bore 98 , but sufficient to accommodate the flow of mud or other drilling fluids flowing therethrough. Nevertheless, as was previously stated, as electronic circuitry, batteries, and the like become smaller and more compact, the diameter of the narrow bore 102 will more closely approximate the diameter of the standard bore 98 .
Drill pipe 16 suitable for use with the present invention typically includes a pin end that threads into a corresponding box end of another downhole tool. Normally, a primary shoulder on a pin end mates to a corresponding primary shoulder on the box end. Likewise, a secondary shoulder on the pin end mates to a corresponding secondary shoulder on the box end.
Although a primary shoulder may absorb the majority of the joint stress between two interconnected downhole tools, stress absorbed by the secondary shoulder is significant to the strength of the joint. Thus, when threading a first portion 96 b of a host downhole tool 94 into a second portion 96 a , the structure 96 a , 96 b should provide at least as much strength as is provided by a normal pin end and box end connection.
As is illustrated, the portion 96 a lacks a secondary shoulder to enable insertion of link module 30 into the oversize bore 100 . Thus, in selected embodiments a secondary shoulder insert 104 may be inserted into the portion 96 a to absorb stress normally incident on a secondary shoulder. In addition, since the insert 104 absorbs stress normally incident on a secondary shoulder, pressure may be relieved from the link module 30 . More details with respect to the secondary shoulder insert 104 are provided in the description of FIG. 8 .
In addition, a transmission interface 106 may be provided that couples to the link module 30 to permit routing of a transmission path from the link module 30 into the portion 96 b of the host downhole tool 94 . More details with respect to the transmission interface 106 are provided in the description of FIG. 8 .
Referring to FIG. 7 , an exploded perspective view of the host downhole tool 94 , containing the link module 30 , is illustrated. As illustrated, a first portion 96 a may include a threaded pin end 95 . An annular transmission element 52 , which may operate by inductive coupling or direct electrical contact, may reside within an annular recess formed or milled into the pin end 95 . A conductor 60 or other cable 60 may be connected to the transmission element 52 and be transmitted along the section 96 a.
As was previously mentioned, an oversized bore 100 , larger than the standard bore 98 , may be provided to accommodate the link module 30 . Likewise, within the inside diameter of the pipe section 96 a , insert grooves 112 or other surface characteristics 112 may be provided to engage corresponding grooves or surface characteristics of the secondary shoulder insert 104 . The pipe section 96 a may also include internal threads 110 that may couple to external threads 108 of the other section 96 b.
Also illustrated are the secondary shoulder insert 104 , insert grooves 105 or surface characteristics 105 that may engage corresponding grooves 112 in the pipe section 96 a , a transmission interface 106 that may slide into the secondary shoulder insert 104 to couple to the link module 30 . Also illustrated are several springs that may be used to keep the transmission interface 106 pressed firmly against the link module 30 to ensure that signal coupling successfully occurs between each component 30 , 106 .
The springs 114 may include a separator 115 used to isolate the springs 114 and improve the range of bias. Lastly, an annular buttress 116 may sit within the pipe section 96 b and provide a fixed surface for the springs 114 to press against. Added details with respect to the annular buttress 116 , springs 114 , spacer 115 , transmission interface 106 , and the secondary shoulder insert 104 are provided in an enlarged cross-sectional view in FIG. 8 .
Referring to FIG. 8 , an enlarged cross-sectional view of the joint between pipe sections 96 a , 96 b shown in FIG. 6 is illustrated. For example, external threads of the pipe section 96 b may thread into internal threads 110 of the other pipe section 96 a . As was previously explained, due to the lack of a natural secondary shoulder, a secondary shoulder insert 104 may include grooves 105 or threads 105 that may engage corresponding grooves 112 formed in the internal diameter of the section 96 a . Thus, the secondary shoulder insert 104 may provide a quasi-secondary shoulder, but also be removed to allow insertion and removal of the link module 30 from the pipe section 96 a.
As was also previously described, a transmission interface 106 may fit within the inside diameter of the secondary shoulder insert 104 and be pressed firmly against the link module 30 to provide effective signal coupling therefrom. For example, the link module 30 may include an annular transmission element 52 . The transmission interface 106 may also include an annular transmission element 52 b in close proximity to the transmission element 52 a to provide efficient signal coupling therebetween.
The transmission interface 106 may include a link transition area 120 where the cable may transition from the transmission interface 106 into a bore within the pipe section 96 b . In order to keep the transmission interface 106 pressed firmly against the link module 30 , several annular springs 114 may be provided to provide a biasing force.
In selected embodiments, the annular springs 114 may be separated by a separator ring 115 to provide addition range of motion to the bias. Likewise, an annular buttress 116 may sit against a shoulder 122 formed in the pipe section 96 b to provide a firm push-point for the springs 114 . As was previously mentioned in the description of FIG. 2 , various seals 118 in grooves or recesses of the link module 30 may seal against the inside diameter of the pipe section 96 a thereby keeping out unwanted contaminants.
The present invention may be embodied in other specific forms without departing from its essence or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. | A repeater is disclosed in one embodiment of the present invention as including a cylindrical housing, characterized by a proximal end and a distal end, and having a substantially cylindrical wall, the cylindrical wall defining a central bore passing therethrough. The cylindrical housing is formed to define at least one recess in the cylindrical wall, into which a repeater is inserted. The cylindrical housing also includes an annular recess formed into at least one of the proximal end and the distal end. An annular transmission element, operably connected to the repeater, is located in the annular recess. In selected embodiments, the annular transmission element inductively converts electrical energy to magnetic energy. In other embodiments, the annular transmission element includes an electrical contact to transmit electrical energy directly to another contact. | 4 |
This is a division of application Ser. No. 08/661,858, filed Jun. 11, 1996, now U.S. Pat. No. 5,711,394 which is a continuation of application Ser. No. 08/398,715, filed Mar. 6, 1995, abandoned which is a continuation of application Ser. No. 08/112,922, filed Aug. 30, 1993, now abandoned, the disclosures of all of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Nonwoven fabrics were developed in an attempt to produce an inexpensive fabric by eliminating many of the various steps required to produce woven or knitted fabrics. Initially, nonwoven fabrics were produced from card or air-laid webs of fibers which were bonded with a chemical binder. Such fabrics have relatively limited usage because their strength characteristics were poor compared to woven or knitted fabrics and their absorbency and softness characteristics left something to be desired because of the use of chemical binders. Major advances were made in eliminating or considerably reducing the amount of binder used in a nonwoven fabric by rearranging or entangling the fibers in a fibrous web to produce what are termed "yarn like" fiber segments and entangled fiber areas. Methods and apparatus for producing fabrics of this nature are more fully disclosed in U.S. Pat. Nos. 2,862,251, 3,033,721, and 3,486,168. While these techniques improve the strength characteristics of nonwoven fabrics, they still did not have the strength characteristics of the woven or knitted fabrics. These entangled or rearranged fiber fabrics did require less binder and, hence, had good absorbent characteristics and excellent softness. As a result of this, nonwoven fabrics found primary uses in many products such as sanitary napkins, disposable diapers, replacement gauze, medical bandages, and the like. While such products were accepted for uses where absorbency and softness was desired, the various different fiber areas would absorb differently. For example, yarn-like structures would absorb different than non-yarn-like structures. Furthermore, many of these fabrics included apertures or holes and while suitable for facing materials, were not suitable for some absorbent products unless used in multi-layer configurations. While nonwoven fabrics have gained wide acceptance, it is still desired to improve the absorbent characteristics of such fabrics and make them more efficient in use.
It is an object of the present invention to produce a nonwoven fabric having improved absorbent characteristics. It is a further object of the present invention to produce a nonwoven fabric having relatively uniform absorbent characteristics. It is still a further object of the present invention to produce a nonwoven fabric that has improved absorbent characteristics without any deleterious effects on the other desired properties of nonwoven fabrics.
SUMMARY OF THE PRESENT INVENTION
Nonwoven fabrics of the present invention have substantially uniform absorbent characteristics in all directions within the plane of the fabric. The nonwoven fabric has a repeating pattern of three interconnected fiber arrays. The first fiber array of the fabric comprises a plurality of parallel fiber segments. The second fiber array comprises a plurality of twisted and turned fiber segments that form a band disposed substantially perpendicular to the parallel fiber segments of the first fiber array. The second fiber array is disposed adjacent the first fiber array. The nonwoven fabric of the present invention includes a third fiber array which interconnects the first and second fiber arrays. The third fiber array comprises a plurality of highly entangled fiber segments.
Nonwoven fabrics of the present invention have uniform absorbent characteristics such that the pattern of absorption of fluid by the fabric has a mean roundness factor of 0.6 or greater. Also, the pattern of absorption has a generally smooth perimeter such that it has a mean form factor of 0.7 or greater.
It is believed these combined absorbent properties of the fabrics of the present invention may result from the unique distribution and configuration of fiber in the fabric. Nonwoven fabrics of the present invention have a generally sinusoidal fiber distribution curve over their cross-sectional area. This generally sinusoidal fiber distribution curve of the fabrics of the present invention must meet certain criteria. We have found that one way of defining and measuring these criteria is by mathematically defining the fiber distribution curve. The curve may be defined by the average percentage of area covered by fibers, the cycles or periodicity of the curve and the average amplitude of the curve. We have found that the fabrics of the present invention have a fiber distribution index of at least 600 and preferably at least 800. This fiber distribution index is determined by multiplying the average percentage of area of fiber coverage in a specific measured cross-sectional area of the fabric by one-half the number of clearly identifiable points of minimum fiber coverage over said specific cross-sectional area and dividing this figure by the average amplitude of the fiber distribution curve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photomicrograph of a nonwoven fabric of the present invention enlarged about 20 times;
FIG. 2 is a schematic perspective view of the nonwoven fabric photomicrographed in FIG. 1;
FIG. 3 is a photomicrograph of a cross section of a portion of a fabric according to the present invention;
FIG. 3a is a computerized image of the fibers of the cross-section depicted in FIG. 3 from which a fiber distribution curve is produced;
FIG. 4 is a generally sinusoidal fiber distribution developed from the image depicted in FIG. 3a;
FIG. 5 is a photograph of an absorbency pattern produced by a nonwoven fabric of the present invention;
FIG. 6 is a schematic sectional view of one type of apparatus for producing nonwoven fabrics of the preset invention;
FIG. 7 is a diagrammatic view of another type of apparatus for producing the nonwoven fabrics of the present invention;
FIG. 8 is an enlarged perspective view of one type of topographic support member that may be used in the apparatus depicted in FIG. 7;
FIG. 9 is an enlarged perspective view of yet another type of topographical support member that may be used to produce the fabrics of the present invention; and
FIG. 10 is a photo micrograph of another nonwoven fabric in accordance with the present invention enlarged about 20 times.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 is a photomicrograph of a nonwoven fabric 20 of the present invention at an enlargement of about 20 times. The fabric has a repeating pattern of three interconnected fiber arrays. The first fiber array 21 is a plurality of parallel fiber segments. The second fiber array 22, which is adjacent to the first array, is a plurality of twisted and turned fiber segments that form a band. The band is disposed substantially perpendicular to the parallel fiber segments. The third fiber array 23 interconnects the first and second arrays and comprises a plurality of highly entangled fiber segments.
In FIG. 2, there is a schematic representation of a nonwoven fabric of the present invention. As may be seen, in this embodiment the bands 25 of twisted and turned fiber segments more or less form ribs extending longitudinally of the fabric 26. On each side of these bands and connected to the bands is a plurality of highly entangled fiber segments 27 which extend longitudinally of the fabric. Adjacent the plurality of highly entangled fiber segment areas and connecting the adjacent areas are a plurality of parallel fiber segments 28. These parallel fiber segments are disposed substantially perpendicular to the bands of twisted and turned fiber segments.
FIG. 3 is a cross-sectional view of the fabric depicted in FIG. 1. As may be seen in this view, the bands 30 of twisted and turned fiber segments are the thickest areas of the fabric, whereas, the plurality of parallel fiber segments 31 are the thinnest areas of the fabric. These two areas as described above are connected to each other by an area 32 comprising a plurality of highly entangled fiber segments.
The fabrics of the present invention are durable. That is, they have substantial strength even in the absence of binder. Furthermore, the fabrics of the present invention have a unique fiber distribution which provides the fabrics not only with their durability but also with uniform absorbent characteristics.
The fiber distribution of fabrics may be determined by image analysis of the fabric. Imaging analysis using image analyzers such as the Leica Quantimet Q520 have become relatively standard techniques for determining the fiber distribution in fabrics. An image analysis is carried out on a cross-sectional area of the fabric. A piece of fabric is cut to a size of about 1" in the machine direction of the fabric and 3" in the cross-direction of the fabric. The fabric is dried to remove moisture and then embedded in a transparent resin as is well known in the art. In the embedding process, the fabric is maintained in a relatively relaxed state. Once the fabric has been appropriately embedded in a resin, a low speed saw may be used to slice off sections in the cross direction of the fabric. The cut or sliced sections have a thickness of from about 6 to 8 mils. A number of these sections are then analyzed using a Leica Quantimet Q520 image analyzer. A typical image formed by such an image analyzer is shown in FIG. 3a. The image analyzer uses a computer to quantify images. The fabric cross section is imaged through a microscope such as an Olympus SZH model equipped with a stabilized transmitter light source. A video camera links the microscope to the image analyzer. This image is transformed to an electronic signal suitable for analysis. The stabilized light source on the microscope is used to produce an image of a suitable visual contrast such that the fiber in the cross section are various shades from gray to black and are readily distinguishable from the pale gray to white resin background as more clearly shown in FIG. 3a. This image is divided into sample points or pixels for measurement. The fiber distribution in the cross-section may be characterized by the variation across the section and can be expressed as the area in square millimeters of fibers in a specified rectangular measuring frame. In this instance, the specific measuring frame is 17 pixels wide by 130 pixels high or approximately 95 square millimeters. To determine fiber distribution, the fiber cover or the area of fiber within the measured frame is detected and measured. The measuring frame is then advanced two pixels across the cross-sectional area and the measurement repeated for that adjacent area. This is accomplished anywhere from 200 to 300 times depending on the size of the cross-section. The fiber area in each specific measured area is then plotted on a graft such as that shown in FIG. 4. The amount of fiber coverage is plotted along the ordinate or Y axis and the position of the specific measured area from the starting point is plotted along the abscissa or X axis. As may be seen in FIG. 4, approximately 232 specific sized areas are measured along the cross-section of the fabric. The amount of fiber in each specific measured area is plotted and as may be seen in FIG. 4 varies from about 0.10 or 10% of the measured area being covered by fiber to about 0.30 or 30% of the measured area being covered by fiber. In selecting the size of the measured area, the height of the area should be such that it is greater than any fabric thickness. The width of the area should be selected to give good resolution of fiber areas. Fiber distribution index of the fabric may then be determined from this graph. As seen in FIG. 4, the curve is a generally sinusoidal curve and the fiber distribution index is determined by multiplying the average fiber area covered by the number of clearly identifiable points of minimum fiber coverage over the cross-sectional area and dividing this figure by the average amplitude of the fiber distribution curve.
Referring to FIG. 4, the average fiber area covered is depicted by the dotted line A. In this example, that area of coverage is about 0.23 or 23% of the area of the specific measured area. The cycles or repeats are indicated by the numerals I, II, III, IV. In the repeats I through III, there are a total of 12 maximum and minimum points so there are an average of 4 maximum and minimums in each repeat. On dividing this figure by two, you then have a cycle or a periodicity of two. The average amplitude is determined by measuring the amount of fiber difference between the maximum fiber coverage points and the average fiber coverage and the amount of fiber difference between the minimum fiber coverage point and the average fiber coverage. A maximum fiber coverage point is where the slope of the curve changes from a positive slope to a negative slope. A minimum fiber coverage point is where the slope of the curve changes from a negative slope to a positive slope. The change in slope to be considered a maximum or minimum should occur over at least six measuring frames or a twelve pixel distance. The average amplitude of the curve in FIG. 4 is 0.04.The fiber distribution index of this fabric may then be determined by multiplying the average fiber area coverage of 0.23% times the cycles or periodicity which is 2, divided by the average amplitude of the curve, which is 0.04, to give a fiber distribution index of 1150. The fiber distribution index of fabrics of the present invention are greater than 600 and preferably are in the range from about 800 to 3300. The fiber distribution index of the fabrics of the prior art are usually considerably lower than 400. In fact, some of the art will have a fiber distribution index of 100 or even lower.
Generally, the fabrics of the present invention will have an average fiber area coverage of from 13% to 24%, a periodicity of from 1.3 to 4, and an average amplitude of from 0.02 to 0.06.
While the fabrics of the present invention have excellent durability, they also surprisingly and unexpectedly have very desirable absorbent characteristics. surprisingly, the fabrics of the present invention have relatively uniform absorbent characteristics in that their pattern of absorption has substantially a round shape. Also the perimeter of absorption pattern is relatively smooth. An absorbent pattern of a fabric of the present invention is depicted in FIG. 5.
The absorbent pattern is produced using a test solution of 0.05% Sandolan Rhodamine Red Dye in water. An eye dropper is filled with the test solution. One drop of solution is applied to the fabric being tested. The eye dropper delivers a drop which results in an absorbent pattern of about one inch diameter. The fabric is supported in such a way that there is no contact between fabric and any substrate which could influence the absorbent pattern. A series of drops (at least ten on each side of the fabric) are applied and spaced far enough apart that one drop does not interfere with any adjacent drop. In application, the dropper is positioned approximately one centimeter above the fabric surface and a single drop is expelled from the dropper onto the fabric surface. The supported fabric is allowed to air dry prior to image analysis.
To determine the roundness and the perimeter smoothness of the absorption pattern, the pattern is placed under a microscope and using appropriate computer software is measured for roundness and for form. The roundness is determined by measuring the area of the absorption pattern and also measuring the length that is the longest diameter of the pattern. The roundness factor is determined by multiplying the area of the pattern times 4 and dividing this figure by "pi" times the length of the longest diameter squared. The roundness for a perfect circle is 1. The roundness of the absorption patterns of fabrics of the present invention have a mean roundness factor of at least 0.6 and preferably from about 0.65 to 1.0.
The form factor of the absorbent pattern; that is, the smoothness of the perimeter, is determined by measuring the area of the absorption pattern and the perimeter of the absorption pattern. The form factor is equal to 4 times "pi" times the area of the absorption pattern divided by the perimeter squared of the absorption pattern. For a perfectly smooth circle, the form factor is 1. The absorption pattern of the fabrics of the present invention have a mean form factor of at least 0.7 and preferably from about 0.75 to 1.0.
By "mean" roundness factor and "mean" form factor it is meant the arithmetical average of at least 15 measurements.
FIG. 6 is a schematic cross-sectional view of apparatus which may be used to produce fabrics of the present invention. The apparatus includes a movable conveyer belt 55. Placed on top of this belt to move with the belt is a topographically novel configured support member 56. The support member has a plurality of longitudinally extending raised triangular areas. Holes, or openings extending through the support member, are disposed between triangular areas as will be more fully discussed in conjunction with FIG. 8. The fiber web 57 to be treated is disposed or supported by the apex of these triangular areas. openings in the support member are disposed between the triangular areas. Specific forming members will be more fully described hereinafter. As previously mentioned, placed on top of this support member is a web of fibers. The web may be a nonwoven web of carded fibers, air-laid fibers, melt blown fibers, or the like. Above the fiber web is a manifold 58 for applying fluid 59, preferably water, through the fibrous web as the fibrous web is supported on the support member and moved on the conveyer belt beneath the manifold. The water may be applied at varying pressures. Disposed beneath the conveyer belt is a vacuum manifold 60 for removing water from the area as the web and support member are passed under the fluid manifold. In operation, the fiber web is placed on the support member and the fiber web and support member passed under the fluid manifold. Water is applied to the fibers to wet out the fiber web to be certain the web is not removed or disrupted from its position on the support member on further treatment. Thereafter, the support member and web are passed beneath the manifold a series of times. During these passes, the pressure of the water of the manifold is increased from a starting pressure of about 100 PSI to pressures of 1000 PSI or more. The manifold consists of a plurality of orifices of from about 4 to 100 or more holes per inch. Preferably, the number of holes in the manifold is from 13 to 70 per inch.
In this embodiment, there are about 12 longitudinal ribs per inch of web. These triangular longitudinal ribs have a height of about 0.085 inches. The width at the base of the triangular areas is about 0.030 inches. The distance between triangular areas is approximately 0.053 inches. The holes in the support member have a diameter of about 0.044 inches and are spaced on 0.0762 inch centers. After the web and support member are passed under the manifold a series of times, the water is stopped and the vacuum continued to assist in dewatering the web. The web is then removed from the support member and dried to produce a fabric as described in conjunction with FIGS. 1 through 3.
In FIG. 7, there is depicted an apparatus for continuously producing fabrics in accordance with the present invention. The schematic representation includes a conveyer belt 80 which serves as the support member in accordance with the present invention. The belt is continuously moved in a counterclockwise direction about spaced apart members as is well known in the art. Disposed above this belt is a fluid feeding manifold connecting a plurality of lines or groups 81 of orifices. Each group has one or more rows of fine diameter holes with 30 or more holes per inch. The manifold is equipped with pressure gauges 87 and control valves 88 for regulating fluid pressure in each line or group of orifices. Disposed beneath each orifice line or group is a suction member 82 for removing excess water and to keep the water from causing undue flooding. The fiber web 83 to be treated and formed into a fabric of the present invention is fed to the support member conveyer belt. Water is sprayed through an appropriate nozzle 84 onto the fibrous web to pre-soak or pre-water the web and aid in controlling the fibers as they pass under the pressure manifolds. A suction box 85 is placed beneath the water nozzle to remove excess water. The fibrous web passes under the fluid feeding manifold with the manifold preferably having progressively increased pressures. For example, the first line of holes or orifices may supply fluid forces at 100 PSI while the next line of orifices may supply fluid forces at a pressure of 300 PSI and the last line of orifices may supply fluid forces at a pressure of 700 PSI. Though six lines of orifices are shown, the number of lines or rows of orifices is not critical but will depend on the width of the web, the speed, the pressures used, the number of rows of holes in each line, etc. After passing between the fluid feeding and suction manifolds, the formed fabric is passed over an additional suction box 86 to remove excess water from the web. The support member may be made from relatively rigid material and may comprise a plurality of slats. Each slat extends across the width of the conveyer and has a lip on one side and a shoulder on the opposite side so that the shoulder of one slot engages with the lip of an adjacent slot to allow for movement between adjacent slots and allow for these relatively rigid members to be used in the conveyer configuration shown in FIG. 7. Each orifice strip comprises one or more rows of very fine diameter holes of approximately 1/5000 of an inch to 10/1000 of an inch in diameter. There are approximately 50 holes per inch across the orifice.
FIG. 8 is a perspective view of one type of support member that may be used to produce the fabrics of the present invention. The member comprises a plate 90 having longitudinally spaced apart raised rib areas 91. The plate has 12 of these raised rib areas per inch of width. The raised areas have a triangular cross-sectional shape with the width at the bottom of the triangular being approximately 0.03 inches. These ribs are 0.085 inches in height and come to a point having an occluded angle of about 20 degrees. The base of the rib is spaced from the base of the adjacent rib about 0.053 inches. In this area between ribs there are openings 92 or holes in the plate. These openings also extend the length or longitudinally of the plate between each adjacent ribs. The openings have a diameter of about 0.044 inches and are spaced on 0.0762 inch centers. The raised areas of the support members used to produce the fabrics of the present invention should have a height of at least 0.02 inches. Their bottom width should be from about 0.04 inches to 0.08 inches and their top width must be less than or equal to the bottom width. In the preferred embodiments of the support members used in the present invention, the cross sectional area is triangular so that the top width is in fact 0. The spacing between adjacent raised areas should be at least 0.04 inches. The openings in the spacing between adjacent areas should be from about 0.01 in. to 0.045 in. in diameter, with the distance between openings being from about 0.03 to 0.1 in.
Following is a specific example of a method for producing fabrics of the present invention.
EXAMPLE I
Apparatus as depicted and described in regard to FIG. 2 is used to produce the fabric. A 21/2 oz/per square yard fiber web of 100% cotton is prepared by taking a 11/2 ounce per square yard random web and laminating it on top of a one ounce per square yard carded web. This laminated web is placed on a support member as described in conjunction with FIG. 8. The support member and web are passed, at a speed of 92 feet per minute, under columnar jet streams produced from the orifices as depicted in FIG. 8. Three passes are made at a pressure of 100 PSI and 9 passes are made at pressure of 800 PSI. The orifices have a 0.007 inch diameter and there are approximately 30 orifices per inch so that the energy applied is approximately 0.8 horse power hours per pound. The web is spaced from the orifices approximately 0.75 inches. After accomplishing this first processing, the web is removed from the support member and turned over so that the opposite side of the web now faces the orifice jets. The support member with the reversed web is placed under the water jets at a speed of 4 yards per minute. The web and support member are passed once at 600 PSI and two additional passes at 1500 PSI. The web is dried and the fiber distribution of the web determined. The fiber distribution index of this web is approximately 820. Samples of the web are tested for absorbent characteristics utilizing the absorbency test previously described. The mean roundness factor of the absorbent pattern of this sample is approximately 0.6 and the mean form factor of the absorbent pattern of this sample is approximately 0.72.
While the support members used to produce the fabrics described previously all have had longitudinally extending ribs it is not necessary that the ribs be longitudinally extended. Support members having horizontal ribs or diagonal ribs or combinations of diagonal, horizontal, and/or longitudinal ribs may be used to produce fabrics in accordance with the present invention.
In FIG. 9 there is shown another type of forming plate that may be used to produce fabrics of the present invention. The member comprises a plate 94 having diagonally disposed raised rib areas 95. The rib areas are disposed in a herringbone pattern. The pattern is made of slanting parallel lines in rows with adjacent rows forming a V or inverted V. Each rib has a triangular shape cross-section with the apex 96 of the triangle forming the upper surface of the member. Between parallel rows of its areas at the base 97 of the triangle is a plurality of openings 98 or holes extending through the thickness of the plate.
Referring to FIG. 10 there is shown a photomicrograph of a fabric according to the present invention which was produced utilizing the support member depicted in FIG. 9.
EXAMPLE 2
The fabric depicted in FIG. 10 is prepared from a 21/3 oz. per sq. yd. fiber web of 100% cotton. The web is pretreated by placing it on a 100×92 mesh bronze belt and passing the web under columnar water jet streams at 92 feet/min. Three passes under the streams at 100 psig are made followed by 9 passes at 800 psig. The jet streams are produced from 0.007 in diameter orifices arranged in a line with 30 orifices per inch. The web to orifice spacing is 0.75 inch. The pretreated web is taken from the bronze belt and turned over and the surface of the pretreated web exposed to the water jet streams placed on a forming plate as depicted in FIG. 9. The web and forming plate are passed under the columnar jet streams as described above at a speed of 90 ft/minute. One pass is made at 600 psig and 7 passes at 1400 psig. The treated web is removed from the forming plate and directed to produce the fabric shown in FIG. 10.
As seen in the photomicrograph the fabric 1000 has a herring-bone pattern of three interconnected fiber arrays. The first fiber array 101 comprises a plurality of fiber segments. The second fiber array 102 is a band of twisted and turned fiber segments with the band disposed substantially perpendicular to the parallel fiber segments. The third fiber array 103 in interconnects the first and second fiber arrays and comprises a plurality of highly entangled fiber segments.
Having now described the invention in specific detail, and an exemplified manner in which it may be carried into practice, it will be readily apparent to those skilled in the art that many variations, applications, modifications, and extensions of the basic principals involved may be made without departing from its spirit or scope. | A non-woven fabric having improved absorbent characteristics. The fabric has three different fiber arrays which are interconnected to produce a unique fiber distribution in the fabric. | 3 |
FIELD OF THE INVENTION
The invention concerns a drilling system having a drilling head fixed to a drill string which comprises an outer pipe and a percussion string inserted therein, wherein the percussion string comprises a plurality of rods which bear against each other with their end faces.
DESCRIPTION OF THE RELATED ART
A drilling system of that kind is known from EP 0 387 218 B1. This involves a rock drilling arrangement for producing straight boreholes for receiving anchors for buildings or explosive charges for carrying out rock blasting operations. In that case the cylindrical shank of the drilling bit is mounted axially displaceably to the front end of the outer pipe by way of a cylindrical guide which is several centimetres long and which is in contact with a small clearance. The same applies in regard to the free end of the rear drill rod against which a hammer or percussion piston strikes to apply the percussion forces. Each individual rod is guided in the region of two bushes at two positions on its length. Provided in the region of the guides for the percussion rod are axially extending ducts for passing therethrough a flushing medium, which make it possible for a flushing medium to be conveyed towards the drilling head from the rear end of the drill string through the intermediate space between the outer pipe and the percussion string or through the axially extending ducts between the outer pipe and the percussion string. The end faces of the individual rods of the percussion string, which bear against each other, extend in the radial direction so as to afford a maximum effective surface area for transmission of the axially acting percussion forces.
The arrangement described in EP 0 387 218 B1 has some major advantages which are essentially that the inner percussion string comprises various individual rods which bear against each other without screwing. The individual short rod has a natural frequency which is very much higher than a long screwed percussion string. Thus, in terms of transmission of the percussion force, very much harder and undamped transmission of the percussion force is afforded by way of a plurality of short rods which bear against each other without a screw connection. Added to that is greater ease of handling during the drilling operation. After the drilling arrangement is advanced by the length of an outer pipe section or an inner rod, the rotary and percussion drive is separated from the drill string and a fresh inner rod and a fresh outer pipe is introduced into the drill string. That situation involves time savings by virtue of the fact that the inner rod to be inserted does not have to be screwed in place.
The arrangement known from the above-quoted document is however suitable by virtue of its structure only for making bores which extend precisely in the axial direction of the drill string.
The object of the present invention is to provide a drilling system which permits a greater variation in the drilling direction.
In accordance with the invention that object is attained in that the outer pipe is adapted to be deformable along its longitudinal axis and the end faces of two rods which bear against each other are such that they bear against each other substantially in surface contact upon inclined positioning of the axes of the two rods relative to each other.
Drilling systems with elastically bendable outer pipes—so-called directional drilling systems—are known from the state of the art, for example from DE 196 12 902 A1. That publication states that a drill string having a drilling head which produces a curved borehole configuration is used for directional drilling. In straight-line drilling the drilling head is rotated at a uniform, generally low angular speed so that the force deflecting the drilling head is uniformly distributed to the entire periphery of the drilling head and is thus cancelled out. For drilling a radius, the drilling head remains in a given angular position without drilling drive so that it follows the curved path which is predetermined by virtue of its structural features. In that case the drilling heads may be of very different configurations. The drill string is usually mounted on a rail-guided sliding carriage connected to a linear drive and has a rotary or rotary-percussion drive with which the string can be caused to rotate and possibly also driven into the ground. In the previously known directional drilling systems the outer string was in principle used for transmission of the percussion force. Besides the above-described problem that the long outer string has a low natural frequency and is of a high mass, that gave rise to an additional problem that the wall friction of the outer string which is guided in the curvedly extending borehole in the earth nullifies a considerable proportion of the percussion energy. Furthermore, in addition to the mass of the outer pipe, the mass of the flushing medium contained in the outer pipe also has to be accelerated by the percussion drive. Finally, a hammer blow on the rear end of a curved pipe produces not only axial acceleration but also a bending force. In practice it has been found that the percussion force acting on the rear end of the drill string scarcely arrives in the region of the drilling head.
The inner string which can be found for example in FIGS. 6 and 7 of DE 196 12 902 A1 could not be used for percussion force transmission purposes. Either it was proposed that the individual elements of the inner string are connected together by way of universal joints which are destroyed by ongoing percussion forces. Alternatively, it was proposed that the universal joints be omitted, if the inner string is sufficiently flexible. With a high degree of flexibility however, it is not possible to achieve a sufficiently great percussion force transmission effect.
SUMMARY OF THE INVENTION
The proposal in accordance with the present invention, to provide a drilling system with rods which bear against each other in unscrewed relationship as a directional drilling system with a flexible outer pipe permits the transmission of percussion force by way of the inner percussion string if the end faces of two rods, which bear against each other, are so designed that they bear against each other substantially in surface contact even upon inclined positioning of the axes of the two rods. In other words, based on the drilling system described in the opening part of this specification and disclosed in EP 0 387 218 B1, end faces which depart from the flat radial shape had to be proposed, so as to ensure effective transmission of percussion forces even in a situation involving bending of the outer pipe which results in inclined positioning of the longitudinal axes of two drill rods relative to each other.
In comparison with the previously known transmission of percussion forces in directional drilling systems by way of the outer pipe, percussion force transmission by way of an inner percussion string has the crucial advantage that the percussion force cannot be reduced by virtue of friction of the percussion string against the wall of the borehole. As a general rule a flushing medium is passed between the outer pipe and the inner string, the flushing medium comprising for example water with swellable clay (bentonite). The aqueous swellable clay is of a viscous to pasty consistency and produces relatively slight frictional resistances upon movement of the percussion string with respect to the outer pipe. In that respect the flushing medium itself is not accelerated by the hammer blows and cannot absorb any percussion energy.
The hammer blows are transmitted by short straight rod sections of the inner string, in which respect no bending forces can occur as the individual rods of the inner string are not curved.
An essential feature of the invention provides that, in the case of the inner percussion string of the directional drilling system according to the invention, no fixed connection exists between the ends of the individual rods of the percussion string. In particular, screwing of the rod ends was eliminated. A screwed percussion string is unsuitable precisely in relation to directional drilling in which—unlike the situation with straight drilling operations—often only a slow rotary drive for the drilling head is involved or the drilling head remains completely in a specific angular position for a relatively long period of time. If a permanent hydraulic percussion drive acts on a screwed string, the screw connections generally loosen due to the hammer blows. It is only if the string is constantly driven in the fastening direction of the screw means by a rotary drive that it is ensured that the screw connections do not come apart, in spite of the hammer blows on the string. In the case of a directional drilling arrangement in which the rotary drive often has to be stopped for a relatively long period of time, there is the risk that the screw connections of the individual rods of the percussion drive come loose because of the hammer blows, and that results in destruction of the percussion string upon further forward drive movement of the drilling system.
That risk does not occur in the drilling system according to the invention which eliminates fixed connections between the rod ends and in particular screw connections between the rod ends.
As the outer pipe is adapted to be deformable along its longitudinal axis, that is to say the longitudinal axis is bendable in a radius about a centre of a circle, care should be taken to ensure that each rod is supported against the inner wall of the outer pipe only in one or two short regions of the length of the rod. In that respect, the preferred structure is one in which each rod is supported against the outer pipe only in a single annular region of the rod periphery and in the other regions of its length it is of an outside diameter which is one or more centimetres smaller than the inside diameter of the outer pipe. In the region of a bend in the outer pipe the inner percussion string can extend from one support location to another in various straight sections.
Care should still be taken to ensure that flushing medium can pass unimpededly through the annular space between the outer pipe and the percussion string. For that reason, in the region in which each rod of the percussion string is guided against the inner wall of the outer pipe, there should be provided a recess which extends in the axial direction or a duct which extends in the axial direction, so that the flushing medium can still pass therethrough. For example, grooves which extend in the longitudinal direction and through which the flushing medium flows can be provided in the wide regions of the rod, which bear against the inner wall of the outer pipe. Alternatively, the outer pipe can be provided over its entire length with axial grooves for the flushing liquid to be passed therethrough. That means however that it is necessary to reckon on an increase in the manufacturing costs for the outer pipe.
In a particularly preferred embodiment of the invention the end faces, which bear against each other, of two rods of the percussion string are curved on the one hand convexly and on the other hand concavely. Preferably each rod of the percussion string has a first end with a ball head and a second end with a ball socket, wherein the radii of curvature of the ball surfaces of the ball head and the ball socket substantially correspond to each other. The percussion rod of the percussion drive, on which the percussion piston of the percussion drive acts, should then have a surface which is complementary to the end face of the rearmost rod of the percussion string. Likewise the shank of the drilling bit with the drilling head has an end face which is complementary to the foremost end face of the foremost rod of the percussion string.
When the end of the percussion rod is in the form of a ball head, the ball head preferably forms the region for radial support of the rod against the inner wall of the outer pipe. The section of the rod, which extends from the ball head and which is in the form of a cylindrical rod, is of a smaller diameter than the ball head. To form the axially extending flow ducts for the flushing medium, the ball head has axially extending recesses which are arranged in the region of its equator, with respect to the longitudinal axis of the rod.
As mentioned in the opening part of this specification, a rotary force is transmitted to the drilling head in order either to rotate it continuously or to move it into a given angular position when a radius is to be drilled. In the case of directional drilling systems in accordance with the state of the art, in which percussion forces which are possibly produced are transmitted by way of the outer pipe, the drilling head is simply rigidly connected to the outer pipe. In the present case in which percussion forces are transmitted to a drilling bit, the drilling bit can be held non-rotatably in the outer pipe, in which case it should be movable axially by a certain distance. The axially movable support for the drilling bit ensures that the percussion energy acting on the drilling bit is not applied to the outer pipe. The drilling bit is displaceable with respect to the outer pipe so that the percussion energy is transmitted directly on to the bottom of the borehole by way of the drilling head.
The non-rotatable fitment of the drilling bit in the outer pipe can be achieved for example by a positively locking connection between the shank of the drilling bit and the outer pipe. The shank of the drilling bit can be provided with an external spline or tooth configuration which engages into an internal spline or tooth configuration of the outer pipe. The rotary drive is then connected to the rear end of the outer pipe and is preferably hydraulically actuated to achieve the required torque levels.
Alternatively the torques can be transmitted to the drilling head by way of the percussion string if the ends of two rods which bear against each other have connecting elements which engage into each other in positively locking relationship. For example, one of the ends, in particular the end in the form of a ball socket, can be provided with a recess into which projects a projection at the other end, in particular the end in the form of the ball head. The ball socket, in the region of the outer periphery of the ball, may have a groove disposed on a great circle extending in the longitudinal direction of the rod. The ball head, at two mutually diametrally oppositely disposed positions, may have a respective cylindrical protrusion, each of the protrusions engaging into an end of the groove in the ball socket. The protrusions can be displaced in the direction of the groove and pivoted about their protrusion axis. Such a claw-like connection between the end of the first rod and the end which bears thereagainst of the second rod permits the transmission of sufficiently high rotary forces. In an embodiment of that kind, the drilling bit must also be non-rotatably connected to the foremost end face of the percussion string. The rear end of the percussion string in that case must be non-rotatably connected to the rotary drive so that rotary forces can be transmitted from the drive unit outside the borehole to the drilling head. The frictional loss can also be considerably reduced by virtue of transmission of the rotary forces by way of the inner percussion string. The rotary forces do not have to be transmitted against the friction within the entire borehole, but only against the frictional forces operative between the outer pipe and the percussion string.
The above-described claw-like connection between the rod ends only represents an example. Any other connections involving a positively locking relationship which permit pivotal movement of the individual rods of the percussion string relative to each other are possible. In that respect, it is to be noted that a motion play of a few degrees between the two end faces of the rods may be sufficient to permit the required inclined positioning between two rods. By virtue of the limited flexibility of the outer pipe, in general very large radii for the borehole axis are achieved, so that the individual rods are each inclined relative to each other only by a few degrees.
Preferably the ends of two rods which bear against each other have guide elements which guide the protrusion for the transmission of rotary force into the recess, when the rod ends bear and press axially against each other. That ensures that for example when fitting a new outer pipe and a new inner rod to the drill string, the non-rotatable connection between the individual rods of the drill string is achieved without involving special adjustment by the operators. Even if the rods of the inner string come loose from each other when inserting a new section of the drill string, the non-rotatable connection between the individual rods is restored automatically by virtue of the action of the guide elements, when the drill string is subsequently fixedly connected to the drive unit.
In this embodiment the rotary drive has to be connected to the percussion string. In order not to apply percussion forces to the rotary drive or the transmission assembly of the rotary drive, a percussion rod should be held axially movably but non-rotatably in the rotary drive. For that purpose a drive pinion may have an internal tooth configuration which co-operates with an axially extending external tooth configuration on the percussion rod and which ensures freedom of axial movement with a positively locking connection in the peripheral direction.
A seal is preferably arranged between the shank of the drilling bit and the outer pipe to prevent uncontrolled discharge of the flushing liquid. The shank of the drilling bit also has an axially extending duct through which the flushing liquid or the flushing medium is passed from the annular space between the percussion string and the outer pipe to the drilling head.
In order to fix the drilling bit within the end section of the outer pipe, the outer pipe, near the drilling head, has a radial reduction in inside diameter, while arranged on the shank of the drilling bit is an enlargement in diameter, which is greater than the reduction in the inside diameter of the outer pipe. In that way the drilling bit is secured by the radial diametral enlargement to prevent it from falling out of the end section of the outer pipe. In a practical embodiment the entrainment profile of the outer pipe in the form of an internal spline or tooth configuration is screwed fast to the end of the outer pipe. That screw connection preferably fixes a divided holding ring which can be fitted into the outer pipe and which forms the reduction in the inside diameter of the outer pipe. Also mounted on the shank of the drilling bit is an annular body which forms the enlargement in the diameter thereof. The element with the spline configuration, which is screwed to the end of the front section of the outer pipe, preferably also carries a sensor or signal generator, by means of which it is possible to ascertain the position of the drilling head by way of a measuring device outside the borehole so that the drilling drive can be controlled to achieve the desired drilling configuration.
Preferably all sections of the outer pipe are connected together by screw sleeves. The screw sleeves may be of a diameter which is enlarged with respect to the diameter of the sections of the outer pipe, for receiving the ball head.
The percussion drive for the percussion string strikes against the rod of the percussion string, which is rearmost in the direction of advance movement. It is generally flange-mounted behind the rotary drive, in which case it acts on a percussion rod which protrudes through the rotary drive and which is axially displaceable with respect to the rotary drive so that the percussion forces applied thereto are not transmitted to the rotary drive but to the percussion string.
The feed for the flushing liquid is preferably arranged near the front end of the percussion rod at a screw connection between the rotary drive and the rearmost section of the outer pipe and is formed by a radial duct which acts through the outer pipe into the annular space between the outer pipe and the percussion string. Preferably, arranged between the outer pipe and the front section of the percussion rod is a seal set which seals off the annular space between the outer pipe and the percussion rod. That ensures that the flushing medium is conveyed exclusively through the annular space between the outer pipe and the percussion string forwardly to the drilling head and not rearwardly in the direction of the drive for the drill string.
In a further preferred embodiment the percussion string can be arrested selectively in the axial direction with respect to the outer pipe. The arresting effect operates at least in the forward feed direction in which the percussion forces also act. The arresting means provide that the percussion forces are transmitted from the piston by way of the percussion string to the outer pipe. As long as the percussion forces are to be used to drive the drilling bit forwardly as rapidly as possible, the outer pipe is to be uncoupled from the percussion string so that the percussion forces act exclusively on the drilling bit and are transmitted thereby to the bottom of the borehole. If however there is a wish to apply hammer blows to the outer pipe by way of the percussion mechanism, for example in order to overcome high frictional forces in the borehole, the outer pipe can be coupled to the percussion string. The percussion forces can also be temporarily applied to the outer pipe which comprises a plurality of pipe sections screwed together, in order to release the screw connections between the pipe sections. The coupling, that is to say the connection which is fixed in the axial direction, must be ensured at least in the direction in which the percussion forces act.
Preferably, the coupling between the outer pipe and the percussion string is effected in the region of the drilling bit at the front end of the drill string. In that way, the drill string is subjected to a pressure loading by the percussion mechanism and transmits its pressure forces at the front end in the region of the drilling bit to the outer pipe. The latter is pulled by the percussion forces in the forward feed direction or the percussion direction. Preferably, the enlargement in diameter of the drilling bit, which fixes it in the outer pipe, is used to provide for axial coupling. For that purpose, the enlargement in diameter can be adapted to be arrested in the condition of bearing in the axial direction against the reduction in diameter of the outer pipe.
That can be achieved by the outer pipe being mounted to the forward drive machine displaceably in the axial direction and fixably in at least two different axial positions. For example, a part of the outer pipe may have radial pins or protrusions which are guided in a sliding sleeve which is fixed to the forward drive machine. For each radial protrusion the sliding sleeve has a guide groove with an axial portion and two holding portions extending in the peripheral direction at the two ends of the axial portion. The radial protrusions of the outer pipe can be accommodated in the guide groove either in the first holding portion or in the second holding portion. In the first holding portion the front end of the front pipe end section of the outer pipe bears against the rearward contact face of the drilling bit so that the drilling bit is freely held in the outer pipe in the forward direction, that is to say in the percussion and forward feed direction. In contrast, in the second holding portion, the reduction in diameter of the outer pipe bears against the enlargement in diameter of the drilling bit so that the axial percussion forces are transmitted to the outer pipe by way of the drilling bit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter by means of embodiments with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic view of an arrangement for carrying out directional drilling,
FIG. 2 shows a drill string according to the invention of a directional drilling system,
FIG. 3 shows an alternative embodiment of the drilling head of the directional drilling system of FIG. 2,
FIG. 4 is a view on an enlarged scale of the drive device of the drilling system according to the invention,
FIG. 5 is a view of a connecting region in which two sections of the drill string are fitted together,
FIG. 6 shows the end section of the drill string with the first embodiment of the drilling head of FIG. 2,
FIGS. 7-10 show an alternative embodiment of the directional drilling system according to the invention with a percussion string adapted for the transmission of rotary forces, and
FIGS. 11 and 12 show an embodiment corresponding to FIGS. 7-10 of the directional drilling system according to the invention with percussion force transmission from the percussion string to the outer pipe.
INCORPORATION BY REFERENCE
European Patent Application No. 01 201 167.2 filed on Mar. 12, 2001, whose inventor is Dr. Gunter W. Klemm, is hereby incorporated by reference in its entirety as though fully and completely set forth herein.
European Patent Application No. 00 126 781.4 filed on Dec. 6, 2000, whose inventor is Dr. Gunter W. Klemm, is hereby incorporated by reference in its entirety as though fully and completely set forth herein.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the mode of operation involved in directional drilling can be seen therein. Using a forward drive machine 1 , to produce a borehole a drilling head 2 is driven into the ground at an angle by means of a drill string 3 . The drill string 3 is carried on a rail-guided sliding carriage of the machine 1 and is driven into the ground by a linear drive. After a forward drive movement by a given distance, a fresh section of the drill string 3 is attached to the drill string 3 , the fresh section comprising an outer pipe section 15 and a rod 14 inserted therein of a percussion string 13 (see FIG. 2 ), and the sliding carriage is withdrawn in order further to advance the drill string 3 which has been increased in length.
Arranged in the proximity of the drilling head 2 is a usually magnetic probe 4 which makes it possible to ascertain the respective precise position of the drilling head 2 by way of a navigation system and a monitor unit. The machine 1 also has a rotary drive with which the drill string 3 can be rotated about its longitudinal axis and arrested in a given angular position. In that way, the plane of the radius of curvature of the borehole produced can be inclined in any directions. The borehole can thus be guided substantially parallel to the surface of the earth in any directions. In particular, as can be seen in FIG. 1 , the borehole can be guided with a large radius of curvature from an entry opening into the ground as far as an exit opening so that it is possible to overcome obstacles such as buildings, bodies of water or traffic areas, without an open timbering or lining. If straight borehole sections are to be produced the drilling head 2 is rotated uniformly about its axis.
A pump and mixing unit 5 for a flushing medium, also referred to as drilling mud, which comprises a mixture of bentonite and water, is connected to the drill string 3 . The drilling mud is passed into the drill string 3 under high pressure and issues from flushing nozzles in the drilling head 2 . That causes material to be removed in the region of the drill head 2 . The bentonite in the drilling mud then passes into the annular gap between the drill string and the borehole. That on the one hand supports the borehole which has been formed and on the other hand produces a really low-friction sliding film which reduces the resistance to the forward movement of the drill string 3 .
After the pilot bore has been finished, the drilling head 2 which has issued from the exit opening of the borehole is removed from the drill string 3 . An enlargement drilling head can then be fixed to the drill string 3 , which is again drawn through the pilot bore with the drill string 3 .
The substantial proportion of the material removed during the drilling operation is effected by the flushing medium issuing from the flushing nozzles of the drilling head 2 . Particularly in the case of relatively hard rock the amount of material removed is increased by hammer or percussion forces applied to the drilling head and possibly continuous rapid rotary movements.
FIG. 2 shows a drill string according to the invention, which permits the transmission of hammer or percussion forces and rotary movements from the forward feed machine 1 to the drilling head 2 . This embodiment includes a directional drilling head which is in the form of a guide shoe. The front end face 6 of the drilling head 2 is inclined with respect to the radial direction of the borehole to be produced. Shown by way of example are three outlet nozzles 7 , 8 , 9 for the drilling mud which is fed to the drilling head 2 through an axial duct 10 . The medium issuing from the outlet nozzle 8 flows along a groove 11 in the end face of the drilling head 2 and is then distributed in the borehole. A plurality of outlet nozzles 9 are distributed at the periphery of the drilling head 2 and one opens at the end face 6 thereof. The end face 6 of the drilling head 2 further has hardened drilling tips 47 . The drilling head 2 is deflected along a circular path, as shown in FIG. 1, by virtue of the inclined positioning of the end face 6 . When the drilling head 2 is rotated by rotation of the drill string 3 , the plane in which the drilling head 2 is deflected is turned.
As can be seen from FIG. 2, the drill string 3 comprises an outer pipe 12 and a percussion string 13 . In this case the percussion string 13 comprises individual rods 14 and the outer pipe 12 comprises individual pipe sections 15 . The pipe sections 15 are respectively screwed together by way of connecting sleeves 16 . The rods 14 of the drill string 13 bear against each other with their end faces without a connection therebetween in the axial direction.
A hammer or percussion rod 17 acts on the rearmost rod 14 . Axial hammer blows are applied to the percussion rod 17 by a hydraulically driven piston 18 (see FIG. 4 ).
As can be seen from FIG. 1, a slight curvature must be applied to the entire drill string 3 in order to follow the curved configuration of the borehole, which is typical of directional drilling. The outer pipe 12 or the pipe sections 15 thereof are of sufficient flexibility to be curved elastically within the borehole. The individual rods 14 of the percussion string 13 in contrast should be substantially rigid in order for the percussion energy to be transmitted to the drilling head 2 with as little delay and as few losses as possible. For that reason, the end faces of the rod ends, which bear against each other, are curved, so that the axes of the rods 14 can be at an angle relative to each other and nonetheless the rod ends bear against each other in surface contact for percussion force transmission purposes.
FIG. 5 shows in particular the features of the design configuration of the various rod ends. In this case the rod end 19 which is the rear end in the forward drive direction is of a ball-shaped configuration. The front rod end 20 is of a smaller diameter and is in the shape of a ball socket whose diameter corresponds to the diameter of the spherical rod end 19 . It will be readily apparent that, even upon inclined positioning of the longitudinal axes of the two rods 14 which can be seen in FIG. 2, the rod ends 19 , 20 are guaranteed to bear against each other in surface contact. That ensures effective transmission of percussion forces from the percussion drive to the drilling head 2 . As FIG. 2 shows the diameter of the rear spherical rod end 19 is larger than the diameter in the remaining region of the rod 14 . The region of the spherical rod end 19 is also larger than the inside diameter of a pipe section 15 . The spherical rod end 19 is inserted into the connecting sleeve 16 which is of a larger inside diameter than the pipe sections 15 connected thereto. In that way the rod end is held in the connecting sleeve 16 displaceably axially over a certain distance without being capable of falling out of the connecting sleeve. It will also be seen from FIG. 5 that the surface of the spherical rod end 19 has radially outwardly disposed recesses 21 which extend in the axial direction and which permit the flushing medium to pass therethrough. The inside diameter of a pipe section 15 is somewhat larger than the outside diameter of a rod 14 so that inclined positioning of the rod 14 through a few degrees is made possible, within the pipe section 15 .
As FIG. 1 shows, the curvature of the borehole is of a very large radius so that the drill string rods are inclined only by a few degrees relative to each other and the relatively small gap between the percussion rod 14 and the section 15 of the outer pipe 12 is sufficient to permit the bending of the drill string 3 .
FIG. 4 shows the rotary drive 22 and the hammer or percussion drive 23 which are fixed on the linear guide of the forward drive machine 1 (FIG. 1 ). The rotary drive 22 comprises a hydraulic motor 24 , on the motor shaft of which is fixed a pinion 25 meshing with a gear 26 which is connected non-rotatably to the outer pipe 12 by way of a connection sleeve 27 . The connection sleeve 27 is embraced by a sealed collar member 28 into which opens a feed line 29 for a flushing medium. The connection sleeve 27 has two radial feed ducts 30 through which the flushing medium can pass into the interior of the outer pipe 12 .
The gear 26 is hollow along its axis and has a percussion rod 17 extending therethrough. The front end face of the percussion rod 17 is in the form of a ball socket and bears against the end face, which is at the rear in the direction of forward feed, of the rearmost rod 14 of the percussion string 13 . The percussion rod 17 is sealed with respect to the connection sleeve 27 by means of a plurality of seals 33 in order to prevent flushing liquid from escaping rearwardly. The above-mentioned hydraulically driven piston 18 of the percussion drive 23 acts on the rearward end of the percussion rod 17 . FIG. 4 only shows the front end section of each of the piston 18 and the percussion drive 23 . Percussion drives of that kind for applying percussion forces to drill strings have long been known to the men skilled in the art.
When the drilling head 2 is driven forward the drill string 3 is moved forwardly by a respective given longitudinal distance by the forward drive machine 1 (see FIG. 1 ). Then, a unit of the drill string 3 comprising a rod 14 and an outer pipe section 15 is attached, with the sliding carriage of the forward drive machine 1 having been retracted beforehand. In a fresh forward drive step, the sliding carriage of the forward drive machine 1 is displaced forwardly.
Therefore, following the rotary/percussion drive which can be seen in FIG. 4, the drill string 3 shown in FIG. 2 comprises a plurality of drill string sections, in which respect the section of the drill string 3 which is the foremost section in the forward feed direction is connected to an end section 31 of the outer pipe and a drilling bit 32 . The end section 31 of the outer pipe 12 and the drilling bit 32 can be particularly clearly seen in FIG. 6 . FIG. 6 is a view on an enlarged scale in relation to FIG. 2 showing the drilling head 2 with the inclined end face 6 , and the outlet nozzles 7 - 9 for the flushing medium, which are fed from the axial duct 10 . The drilling head 2 which is at the front in the forward drive direction and a shank 31 in the form of a cylindrical rod form the two main components of the drilling bit 32 .
The drilling bit 32 is held non-rotatably in the front end section 31 of the outer pipe 12 . The shank 34 of the drilling bit 32 has an external tooth configuration 35 meshing with an internal tooth profile 36 . In that way the drill shank 34 is held axially displaceably and fixedly in the direction of rotation, in the pipe end section 31 . The pipe end section 31 is formed by a sleeve member which bears a male screwthread at the end which is the rear end in the forward drive direction, and is fixedly screwed to a connecting sleeve 37 at the front end of the foremost pipe section 15 of the outer pipe 12 . Fixed by way of that screwthread connection is a holding ring 38 which forms a reduction in the diameter of the outer pipe 12 near its end section 31 . That holding ring 38 co-operates with an annular shoulder 39 which is carried on the rear end of he shank 34 of the drilling bit 32 and forms and enlargement in the diameter of the shank 34 . In that way the drilling bit 32 is prevented from falling out when the drill string 3 is retracted in the opposite direction to the forward drive direction.
Also arranged in the holding ring 38 is a seal 40 which seals off the internal space in the outer pipe 12 with respect to the shank 34 of the drilling bit 32 . Arranged at the rear end of the shank 34 of the drilling bit 32 are two inclinedly extending duct portions 41 which open into the annular space between the shank 34 and the outer pipe 12 and which permit flushing medium to pass into the axial duct 10 of the drilling it 2 .
FIG. 7 and the detailed views on an enlarged scale in FIGS. 8 a - 8 c , 9 a - 9 c and 10 show an alternative embodiment of the drilling system in which rotary forces are also applied to the drilling head 2 by way of the percussion string 13 ′.
The views on an enlarged scale showing individual parts in FIGS. 8 a - 8 c show the two ends 19 ′ and 20 ′ of the rods 14 ′. In this respect, FIG. 8 a is a view in longitudinal section showing the rod end 20 ′ which is in the form of a ball socket and into which the rod end 19 ′ which is in the form of a ball head is inserted. FIG. 8 b shows only the rod end 19 ′ in the form of the ball socket, as a plan view and two side views. FIG. 8 c shows the rod end 20 ′ in the form of a ball socket, as a plan view, in longitudinal section and as a side view. Each rod 14 ′ of the percussion string 13 ′ includes a rear rod end 19 ′ which is curved in the form of a ball head and on which are arranged projections 42 in the form of a star. The front rod end 20 ′ which is curved in the form of a ball socket has star-shaped grooves 43 for receiving the projections 42 of the rear rod end 19 ′ of the adjoining rod 14 ′. The oppositely disposed rod ends 19 ′, 20 ′ are fixedly connected together in the direction of rotation by the projections 42 engaging into the grooves 43 . Preferably the front rod end 20 ′ is provided with guide surfaces which guide the projections 42 at the rear rod end 19 ′ into the grooves 43 at the front end 20 ′ of the adjoining rod 14 ′ when the ends are pressed against each other. In that way the rod ends 19 ′, 20 ′ do not have to be oriented relative to each other in respect of direction of rotation, in the assembly procedure.
No trouble is caused if the projections 42 and the grooves 43 limit the free pivotability of the ball joint which is formed by the rod ends 19 ′, 20 ′. As already mentioned, the angle involved in the inclined positioning of two mutually adjoining rods relative to each other is very slight. Thus, a certain clearance between the projections 42 and the grooves 43 is sufficient to permit adequate pivotability of mutually adjoining rods 14 ′ about the parallel position.
In an alternative representation of the individual parts shown on an enlarged scale in FIGS. 9 a - 9 c in respect of the rod ends 19 ′ and 20 ′ for transmission of the rotary force, FIG. 9 a shows the interengaged rod ends 19 ′ and 20 ′, FIG. 9 b shows a side view of the rod end 19 ′ in the form of a ball head and FIG. 9 c shows a view in longitudinal section of the rod end 20 ′ in the form of a ball socket. Here, the projections 42 ′ are in the form of radially extending, mutually diametrally opposite pins or protrusions. The grooves 43 ′ in the rod end 20 ′ in the form of the ball socket are also disposed in diametrally opposite relationship and receive the protrusions 42 ′. The embodiment illustrated here for the non-rotatable. connection permits a greater angle of pivotal movement of the ball head 19 ′ with respect to the ball socket 20 ′.
By virtue of the rotary movement being transmitted by means of the percussion string 13 ′, the drive force of the rotary drive 22 is no longer reduced by friction of the outer pipe 22 against the wall of the borehole.
It will be appreciated that other structural systems of the drilling system are also altered because of the transmission of rotary force by means of the percussion string 13 ′. Thus, the drilling bit 34 ′ which has the drilling head 2 is held freely rotatably in the front end of the outer pipe 12 ′. To apply the rotary force to the percussion string 13 ′, the hollow gear 26 ′ is mounted rotatably in the housing 44 of the rotary drive 22 and is not connected to the outer pipe 12 ′ in the direction of rotation. The hollow gear 26 ′ has an inner tooth or spline profile 45 which co-operates with an external tooth or spline configuration 46 on the percussion rod 17 ′. Thus, the rotary force of the rotary drive 22 is transmitted to the percussion rod 17 ′ by way of the inner tooth or spline profile 45 and the external tooth or spline configuration 46 , in which case the percussion rod 17 ′ is axially displaceable with respect to the gear 26 ′ so that the percussion or hammer forces transmitted by the piston 18 of the percussion drive 23 on to the rear end of the percussion rod 17 ′ are not transmitted to the gear 26 ′ but only to the percussion rod 13 ′. All end faces which bear against each other, in the form of a ball and a ball socket, have the projections 42 , 42 ′ and grooves 43 , 43 ′ for making the connection which is fixed in the direction of rotation, so that the rotary drive 22 is non-rotatably connected to the drilling head.
If the inner percussion string 13 ′ is non-rotatably connected to the gear 26 ′ of the rotary drive, it will be appreciated that the non-rotatable coupling of the outer string 12 ′ to that gear 26 ′ can be omitted. The detail view in FIG. 10 shows that the outer pipe 12 ′ is uncoupled in the direction of rotation with respect to the gear 26 ′ by a rolling bearing 48 . In this case positively locking connecting bodies 49 can be releasably arranged in the region of the connection between the outer pipe 12 ′ and the gear 26 ′. When those connecting bodies 49 are inserted the rotary drive acts both on the percussion string 13 ′ and also on the outer pipe 12 ′. If the positively locking connecting bodies 49 ′ are removed, then only the inner percussion string 13 ′ is rotated.
FIG. 11 with the detail views in FIGS. 11 a and 11 b and FIG. 12 with the detail views of FIGS. 12 a and 12 b show an embodiment in which the percussion energy can be transmitted on the one hand to the drilling bit 32 ′ alone and on the other hand to the drilling bit 32 ′ and the outer pipe 12 ′. For that purpose the outer pipe 12 ′ is connected to the forward drive machine by way of a sliding sleeve member 50 . The sleeve member 50 is arranged in front of the connecting sleeve member 27 in the direction of advance movement and co-operates with a coupling portion 51 which is screwed to a reduced-length rear pipe section 52 of the outer pipe 12 ′.
The coupling portion 51 has at uniform spacings at three peripheral positions respective protrusions 53 which are accommodated in a guide groove in the thrust member 50 . Each of the three guide grooves includes an axial portion 54 which goes into two holding portions 55 , 56 which extend in the peripheral direction. The protrusion-groove connection between the coupling portion 51 and the sleeve member 50 acts like a bayonet fastening. In the first rotational position of the coupling portion 51 , which is shown at the left in FIGS. 11 b and 12 b , the protrusions 53 can be displaced in the axial portion 54 of the guide groove. In the second rotational position of the coupling portion 51 , which is shown at the right in FIGS. 11 b and 12 b , the protrusions 53 can be received in the peripherally extending holding portions 55 , 56 of the guide grooves. The two rotational positions are illustrated in FIGS. 11 a and 12 a on the one hand above the centre line (protrusion 53 received in the holding portion 55 or 56 ) and on the other hand below the centre line (protrusion displaceable in the axial portion 54 of the guide groove).
When the protrusions 53 are disposed in the front holding portion 56 , as shown in FIGS. 11 and 11 a , the outer pipe 21 ′ is pushed relative to the percussion string 13 ′ and the drilling bit 32 ′ into the front position. The drilling bit 32 ′ is pushed substantially into the outer pipe 12 ′ and can be driven axially out of the outer pipe 12 ′ by the percussion string 13 ′. It is to be noted that the annular collar member 39 which forms the enlargement in the diameter of the drilling bit 32 ′ has adequate motion clearance as far as the holding ring 38 in the connecting sleeve 37 in the advance or percussion direction.
When in contrast the protrusions 53 are disposed in the rear holding portion 55 , as shown in FIGS. 12 and 12 a , the outer pipe 12 ′ is pushed into the rear position relative to the percussion string 13 ′ and the drilling bit 32 ′. The drilling bit 32 ′ is pushed substantially out of the outer pipe 12 ′. In this case, the annular collar member 39 which forms the enlargement in the diameter of the drilling bit 32 ′ bears axially against the holding ring 38 in the connecting sleeve 37 so that the hammer blows which are transmitted by the percussion string 13 ′ to the drilling bit 32 ′ are passed by the drilling bit 32 ′ to the outer pipe 12 ′. In that way, in the drilling operation, starting from the bottom of the drill hole, percussion forces can be applied to the outer pipe 12 ′, which forces for example pull the string further into the borehole with a high level of friction at the outside of the string. Before dismantling of the arrangement the hammer blows which are transmitted to the outer pipe 12 ′ can loosen the connecting screwthreads between the individual pipe sections 15 of the outer pipe 12 ′.
List of References
1 forward drive machine
2 , 2 ′ drilling head
3 drill string
4 magnetic probe
5 pump and mixing device/conveyor device
6 end face
9 outlet nozzle
8 outlet nozzle
9 outlet nozzle
10 duct
11 groove
12 , 12 ′ outer pipe
13 , 13 ′ percussion string
14 , 14 ′ rod
15 pipe section
16 connecting sleeve
17 , 17 ′ percussion rod
18 piston
19 , 19 ′ rear rod end, rear end face, ball head
20 , 20 ′ front rod end, front end face, ball socket
21 recess
22 rotary drive
23 percussion drive
24 hydraulic motor
25 pinion
26 , 26 ′ gear
27 connecting sleeve member
28 collar member
29 feed line
30 feed duct,
31 pipe end section
32 , 32 ′ drilling bit
33 seal
34 , 34 ′ shank
35 external tooth configuration
36 internal tooth profile
37 connecting sleeve member
38 holding ring, reduction in diameter
39 annular collar member, enlargement in diameter
40 seal
41 inclined duct portions
42 , 42 ′ projection
43 , 43 ′ groove
44 housing
45 tooth profile
46 external tooth configuration
47 drilling tip
48 rolling bearing
49 connecting element
50 sliding sleeve member
51 coupling portion
52 reduced-length pipe section
53 protrusion
54 axial portion of the guide groove
55 front holding portion of the guide groove
56 rear holding portion of the guide groove | The invention concerns a drilling system having a drilling head ( 2, 2 ′) fixed to a drill string ( 3 ) which comprises an outer pipe ( 12, 12 ′) and a percussion string ( 13, 13 ′) inserted therein, wherein the percussion string ( 13, 13 ′) comprises a plurality of rods ( 14, 14 ′) which bear against each other with their end faces ( 19, 20; 19′, 20 ′). One object of the present invention is to provide a drilling system with an inner percussion string, which permits a greater variation in the drilling direction and which can be used as a directional drilling system. To attain that object the outer pipe ( 12 ) is adapted to be deformable along its longitudinal axis and the end faces ( 19, 20 ) which bear against each other of two rods ( 14 ) are so designed that they bear against each other substantially in surface contact upon inclined positioning of the axes of the two rods ( 14 ) relative to each other. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 61/763,004 filed on Feb. 11, 2013 the content of which is relied upon and incorporated herein by reference in its entirety.
TECHNICAL FIELD
The disclosure relates generally to a system and apparatus for facilitating an automated manufacturing process, more particularly it relates to a system and apparatus for providing a steady and uninterrupted stream of prepositioned articles in a manufacture process for robot pickup.
BACKGROUND
Human operators have been tending, loading and unloading manufacturing machines for many years. While human operators allow for flexibility in the manufacturing process, they also introduce errors due to the repetitive nature of automated mass assembly lines, they add to cost, and require frequent downtime. Modern day manufacturing practices dictate continual process improvement including: increased part quality, increased throughput, increased reliability, decreased part cost, reduced scrap, and continuous operation sometimes 24/7. One method for meeting these goals is the use robotics. Industrial robots are good at repetitive motions and are very good at material handling such as pick and place applications. Robots minimize the variables an operator introduces when handling parts such as, improper part placement into the manufacturing machine, dropped or damaged parts or even the inconsistency in loading or unloading a waiting manufacturing machine in a timely manner. Many times the use of robotics enables a human operator to control operation of multiple manufacturing machines as opposed to being tied to tending just one machine.
One critical aspect for the successful implementation of robotic manufacturing and material handling applications is that parts must be presented to the manufacturing robot in a consistent, reliable and repeatable method. The second aspect is that the human operator understands supports and is able to provide a continuous uninterrupted supply of parts to the manufacturing robot during the production process. Accordingly, there is a need in the industry for a method and apparatus for providing an intuitive consistent parts supply for robot assisted manufacturing.
SUMMARY
Thus, robotic tending machines that provide an uninterrupted flow of parts to a robotic manufacturing machine during the manufacturing process are important parts of the robotic manufacturing process. By providing a steady flow of parts to the robotic manufacturing system they ensure an uninterrupted operation of the system that maximizes its value.
In one variation the present invention provides a system that can provide an uninterrupted flow of parts to a robotic manufacturing machine. It includes a carousel with eight adjustable part caddies placed on arms on the periphery of the carousel. Each parts caddie holds a stack of pans needed in a robotic manufacturing process, such as gears or similar parts. The carousel rotates successively into a dispensing position each caddy full of parts needed in the specific manufacturing process. At the parts dispensing position, a mechanical lift arm raises the stack of parts which sit on a movable lift plate to a position where a robotic manufacturing arm takes each part in the raised stack and uses it in the manufacturing process that the robotic manufacturing system has been programmed to do. As the robotic arm takes a part from the stack the mechanical lift arm in response to a signal sent to the systems control computer by an appropriately placed sensor then incrementally moves the stack of parts up so that the next part in the stack is in the predetermined position to be grasped by the robotic arm. When the caddy is emptied of all parts, the system lowers the empty lift plate and then positions itself below the carousel. The carousel then rotates the next full parts caddy into the dispensing position and the process starts over. On the side of the carousel opposite the dispensing position, clam shell type doors can be rotated open and shut by operator at the tending station who refills the empty caddies with parts to assure the uninterrupted flow of manufacturing process. The rotating doors are designed to limit the amount of space needed for the system.
In another variation of the invention the parts supply caddy includes: a) a base plate with at least three posts movably mounted at a first end of the posts to a top surface of the base plate; b) a lever plate with at least three slot shaped apertures which allow the lever plate to be placed over the movably mounted posts and allow the posts to protrude up through the lever plate which lever plate rests on top of the base plate and wherein when the lever plate is moved with respect to the base plate it changes the position of the movably mounted posts to thereby provide a variable holding space between the posts to hold a stack of items of varying size depending on the space between the posts as determined by movement of the lever plate; c) the at least three movably mounted posts are movably mounted by offset extended base portions from a pivot point such that they are movable in an arch about the pivot point, which pivot points are located on a circumference of a circle about a center of the base plate; d) the lever plate is detachably and rotatably attached at the center of the base plate and the slot shaped apertures in the lever plate through which the posts project are formed in the shape of an arch such that when the lever plate is rotated about its center on the base plates the posts move in unison either in towards or out away from the center of the lever plate to thereby describe a variable space that can hold a stack of items of varying size depending the extent the lever plate is rotated; e) a lift plate with three slotted apertures through which the three pivotally mounted posts can project, the lift plate being position able over the lever plate and the slots of the lift plate configured to accommodate movement of the posts by the lever plate such that a stack of items can be placed on the lift plate within the space between the posts and wherein the lift plate extends beyond an edge of the base plate and the lever plate to thereby allow an elevating mechanism to lift the lift plate off of the lever plate and thereby lift a stack of items on the lift plate for prepositioning items at the top of the stack of items for access by a manufacturing robot; and f) a scale positioned at a periphery of the lift plate such that a flange projecting from the lever plate, when the lift plate is positioned on the lever plate aligns with the scale and when calibrated can accurately define the space provided between the posts when the lever plate is moved to adjust a position of the posts.
In another aspect of the invention it provides a parts supply apparatus for providing a continuous supply of parts for a manufacturing process that includes: a) a carousel rotatable about a center; b) a plurality of adjustable parts caddies positioned on the carousel, the parts caddies being adjustable to hold stacks of parts of varying size and each caddy having a lift plate to allow the moving up of a stack of parts placed on the caddies; c) a power source to rotate the carousel about its center; d) a production side stop position wherein each parts caddy can be successively positioned by rotation of the carousel to position each of the parts caddies with parts for access by a manufacturing robot; e) an operator side stop position wherein each of the parts caddies can be successively positioned by rotation of the carousel to position each of the parts caddies for placing a stack of parts in the caddy; and f) a lift arm at the production side stop position for engaging the lift plate of each of the parts caddies as they are successively positioned at the production side stop position for lifting the lift plate with a stack of items to a predetermined placement position at which a manufacturing robot can grasp an item at the top of a stack of items on the lift plate.
In yet another variation of the invention it provides a method for providing a continuous flow of work pieces for a manufacturing robot during a manufacturing operation which method includes the steps of: a) providing a carousel rotatable about a center, b) providing a plurality of adjustable parts caddies; c) positioning said plurality of adjustable parts caddies on said carousel, said plurality of parts caddies being adjustable to hold stacks of work pieces of varying size and each caddy having a lift plate to allow the lifting up of a stack of work pieces placed on said plurality of caddies; d) providing a power source to rotate said carousel about its center; e) rotating in incremental steps said carousel so that each of said plurality of caddies can be successively positioned at a production side stop position where worked pieces positioned in each said caddies can be accessed by a manufacturing robot; f) successively positioning each of said caddies after it has been emptied of work pieces at an operations position wherein each of said caddies can be successively filled with a new set of work pieces; and g) providing a lift arm at said production side stop position for engaging said lift plate on each of said plurality of parts caddies positioned at said production side stop position for progressively lifting said lilt plate with a stack of work pieces to a predetermined placement position at which a manufacturing robot can grasp a work piece at the top of a stack of work pieces on said lilt plate.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims.
The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the base plate with moveable posts:
FIG. 2 is a perspective view of lever plate placed over the base plate with the post projecting through the lever plates;
FIG. 3 is a perspective view of the base plate and lever plate with the lift plate sitting on top of the lever plate;
FIG. 4 is perspective view of a carousal with adjustable parts caddies around its periphery;
FIG. 5 is a perspective view of the system from the operator side:
FIG. 6 is a perspective view of the system from the production side;
FIG. 7 is a top plane view of the system including the elevation mechanism for lifting the lift plate on each caddy;
FIG. 8 is a side view of the lift arm and lift fork; and
FIG. 9 is a perspective view of the system from the production side adjacent to the robotic arm.
DETAILED DESCRIPTION
FIG. 1 provides a perspective view of the primary structure of the caddy. Base plate 101 has three adjustable posts 103 a , 103 b and 103 c . Each post at its base is attached to one end of a moveable arm 105 a , 105 b and 105 c . The opposite end of each movable arm 105 a , 105 b and 105 c are rotate-ably attached to base plate 101 at pivot points 107 a , 107 b and 107 c respectively. The base plate 101 also has at its center retention post 109 .
Referring to FIG. 2 , placed over posts 103 a , 103 b and 103 c is an adjustable lever plate 211 above base plate 101 . Adjusting lever plate 211 has adjusting knob 215 which allows for the rotational motion of the plate around a center retention post 109 to which the center of adjusting lever plate is rotate-ably attached. Each of the posts 103 a , 103 b and 103 c project up through curved adjusting slots 217 a , 217 b and 217 c on adjusting lever plate 211 . Adjusting slots 217 a , 217 b and 217 c have a curvature so that when knob 215 is either moved clockwise or counterclockwise around center retention post 109 , the three posts 103 a , 103 b and 103 c move in unison either inward or outward. This movement allows for precisely positioning each one of the posts at the same distance from the center point, namely center retention post 109 .
FIG. 3 provides a perspective view of a fully assembled adjustable parts caddy 301 . Lift plate 309 is positioned over the three posts 103 a , 103 b and 103 c of base plate 101 with adjusting lever plate 211 positioned between them. Each post 103 a , 103 b and 103 c projects up through lift plate slide slots 323 a , 323 b and 323 c respectively in lift plate 309 . Lift plate 309 is not physically attached to the base plate 101 . Lift plate 309 rests on and the adjusting lever plate 211 and is not attached to it. Additionally, lift plate 309 has post position or parts size measuring scale 311 along its outside periphery. When adjusting lever plate 211 is moved by moving adjusting knob in either clockwise or counterclockwise direction, posts 103 a , 103 b and 103 c move back and forth in unison in slots 323 a , 323 b and 323 c . This is caused by their moving along the curved slots of adjusting lever plate 211 . An indexing slot 221 in knob 215 indicates on scale 311 the outside radius of parts that can be placed in the caddy. Lift plate 309 also has retention notch 313 . Given the configuration of the slots 323 a, b & c in plate 309 the orientation of scale 311 remains in the same and correct orientation even as adjustable lever plate 211 is rotated to change the position of posts 103 a, b & c.
Referring to FIG. 4 , in the embodiment of the invention shown therein adjustable parts caddy carousel 421 has eight adjustable caddies 301 located around its periphery on arms 425 . Each arm has a notch holding pin 427 that holds the top plate of each adjustable caddy in place by fitting into retention notch 313 of each of the caddies. Carousel 421 is connected at its center by four bolts 429 to a motive and control apparatus 431 located thereunder. Naturally depending on the circumference of carousel 421 and the size of parts caddies 301 the number of parts caddies that can be positioned on a carousel made according to the present invention can vary. Thus, given these variables the carousel and parts caddies can vary in size and the number of parts caddies on the carousel can vary from less than eight to twelve or more. As can be seen in FIG. 4 parts caddy 409 is filled with a stack of gears.
FIG. 5 provides a perspective view of the overall parts supply system from the operator tending side 501 . Outer rotary door 503 a and inner rotary door 503 b are in a partially open position. Both doors attach at pivot point 509 and have bearings or some other means at their base to allow them to freely slide in a clockwise or counter clockwise direction to provide access to the caddies or enclose the tending side as needed. Thus doors 503 a and 503 b can be opened or closed by simply sliding the interior door 503 b under the outer door 503 a or vice versa, sliding outer door 503 a over interior door 503 b . This provides ready access for an operator without the need for excessive floor space that would be necessitated by a standard hinged door. Thus, the operator can access and easily fill the cadies 301 on carousel 421 as each empty caddy rotates around to the operator side after robot arm 505 has emptied each full caddy at the dispensing or production stop position. Robotic arm 505 picks up each part from the pre-positioned caddies. Additionally, the system control station 507 is positioned adjacent to the system and provides computer and electronic control of the operation of the system. It contains a standard programmable computer which can be programmed to operate the system in the desired manner. Fork lift fork sheaths 515 allow for the insertion of the forks of a fork lift into the base of the system so the system can be easily moved around and positioned in the manufacturing facility.
FIG. 6 is a perspective view of the manufacturing production side 601 of the current system. Dispensing position 603 is visible adjacent to lift arm 607 . Additionally, lift fork 605 which curves around the posts of the caddy located at the dispensing position is at its fully top extended position without a lift plate on it for illustrative purposes. Laser sensor 609 is positioned to determine if a part is located at the appropriate position for robotic arm 505 to take the next part. The information provided by laser sensor 609 tells the control system 507 to advance lift fork 605 by means of lift arm 607 up to the next position to properly position parts that would be on a lift plate. Once the last part in the stack of parts placed on the caddy has been removed lift fork 605 will have reached its highest position and the sensor signals that there are no longer any parts left with this caddy. Accordingly, it signals lift arm 607 to drop lift fork 605 down to a position below carousel 421 to thereby allow carousel 421 to advance the next full caddy to dispensing or production stop position 603 . The process is then repeated where the lift plate 309 of the caddy 301 full of parts that is now positioned at dispensing position 603 is emptied of pans in the same fashion. As can be seen in FIG. 6 lift fork 605 is in the shape of fork or horseshoe in the embodiment depicted.
FIG. 7 provides a top view of the system where the tender/operator side 501 appears and the production/manufacturing side 601 is positioned opposite it. Doors 503 a and 503 b are in the closed position. Lift fork 605 , which attaches by connector 703 to lift arm 607 can be seen. Additionally, sprocket 707 and drive chain 705 of lift arm 607 can be seen.
Referring to FIG. 8 , a side view of lift arm 607 is presented with lift fork 605 , chain 705 and the lower sprocket 807 of the lift arm. Lift arm drive motor 801 is operatively connected to sprocket 807 which in turn drives chain 705 to control movement of lift fork 605 . Motor 801 is controlled by computerized control system 507 .
FIG. 9 is a perspective view of the system from the production side adjacent to robotic arm 505 and shows the system in operation. Lift fork 605 holds lift plate 309 of parts caddy 301 a , which has four work pieces 905 left on it. After manufacturing robot arm 505 removes all of the work pieces 905 from lift plate 309 a lift arm 607 will lower lift fork 605 to a point below parts caddy 301 a and the bottom of carousel 421 . Once lift fork 605 is at its fully retracted position 611 carousel 421 will then advanced in a clockwise direction to the left in FIG. 9 to bring the next full parts caddy 301 e to the production stop position 603 where lift arm 607 will lift the lift plate 309 of caddy 301 e with work pieces 905 on it in to the predetermined position where robot arm 505 will pick each work piece in sequence and use the work piece in the particular manufacturing process it is engaged in. Empty parts caddy 301 b is visible in FIG. 9 it having been emptied of work pieces. Also, parts caddies 301 c and 301 d are visible on the operator side of the system where they have been refilled with more work pieces. Laser sensor 609 positioned on top of lift arm 607 and as noted is operatively connected to the computer control system and is used to determine if the work pieces are in the predetermined position for pick up by robot arm 505 and when the caddy has been completely emptied so the next full caddy can be moved into the production stop position to continue the manufacturing process.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the invention. Since modifications combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and their equivalents. | An apparatus that provides a continuous flow of parts to a manufacturing robot during a manufacturing process has a plurality of adjustable parts caddies on rotating carousel where the parts used in manufacturing process are placed in each adjustable caddy on an operator side of the apparatus and then taken out of the caddy on a production side as the carousel turns. A lift mechanism on the production side works in conjunction with the adjustable caddies and a manufacturing robot to position parts in each caddy in a predefined position for pick up by the manufacturing robot. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is divisional application of and claims priority to U.S. patent application Ser. No. 14/361,394, filed on May 29, 2014, which is a national phase application of PCT Application No. PCT/EP2012/004697, filed Nov. 12, 2012, which claims priority to German Patent Application No. 10 2011 119 895.8 filed Nov. 29, 2011, all of these are incorporated by reference.
BACKGROUND AND SUMMARY
[0002] The invention relates to a weight compensation device for a drive of a lifting door for the position-dependent compensation of the weight force of a door leaf of the lifting door, with a force transmission unit which can be coupled to the drive in order to carry out an opening movement which raises the door leaf and a closing movement which lowers the door leaf.
[0003] A generic weight compensation device is known from GB 570,469.
[0004] From prior art, lifting doors with integrated weight compensation devices are moreover known. For example, DE 40 15 214 A1 discloses a lifting door with a slatted armor with bending slats. The lifting door disclosed therein comprises two guide tracks disposed at the two opposite sides of the door aperture, and a slatted armor with slats placed on hinge straps at such a distance to each other that the hinge pins engage within a space between the adjoining slats. It is furthermore disclosed that this lifting door is configured as an industrial lifting door in the sense of a high-speed lifting door. Such lifting doors are configured as rolling doors which close or open walk-through or drive-through door apertures.
[0005] It is known from DE 40 15 214 A1 that tension springs are employed for compensating the weight of the individual slats forming the door leaf. However, a disadvantage of tension springs consists in that they only have a service life of about 200,000 lifts.
[0006] Torsion springs employed as an alternative have an even shorter service life of about 30,000 to 40,000 lifts.
[0007] The often employed tension springs even have yet another disadvantage, i. e. they require a lot of installation space for heavy doors which must be available in particular at the sides of the door aperture. If a frame of the door is not wide enough to receive adjoining tension springs which provide the required supporting spring force, it is also possible to dispose them one behind the other, but both types affect efficient space utilization in the region of a lifting door.
[0008] From prior art, alternative weight compensation devices which are employed, for example, in sectional doors, are also known. For example, DE 102 32 577 A1 discloses a weight compensation device for a sectional door with a rotatably mounted shaft, a rope drum at least at one end of the shaft on which a traction rope connected to the door leaf of the sectional door is connected, and at least one torsion spring configured as a coil spring. The coil spring is retained at one spring end at a stationary receiving part and at the other spring end at a receiving body fixed to the shaft and acts as torsion spring having a particularly short service life.
[0009] Even the employment of hydraulic accumulators in industrial lifting doors does not represent an optimal embodiment because constructions employing such hydraulic accumulators are expensive and complex.
[0010] It is therefore the object of the present invention to avoid the disadvantages of prior art and to provide an inexpensive, long-life weight compensation device which may be employed in doors where foil-like door leaves or several hinged, preferably rigid segments are lifted, such as spiral doors or doors that employ the drum principle.
[0011] This object is achieved according to the invention by a weight compensation device having the features disclosed herein. Such compression springs may bear higher loads over years as compared to tension and especially torsion springs, without any failure occurring already after a relatively short time of use or maintenance works having to be performed at an early stage. In tests performed at certain compression springs, no essential spring deformations showed after one million lifts. The compression spring is arranged in a hollow-cylindrical guide element, the hollow-cylindrical guide element being attached to a mount so as to rotate or, alternatively, in a torque-proof manner, for supporting a rotary motion of the force transmission unit. This permits efficient spring force utilization with a compact design.
[0012] A solution according to the invention is therefore not only inexpensive and long living, but also permits the advantage of a particularly simple and efficient construction.
[0013] Advantageous embodiments are claimed in the subclaims and will be illustrated more in detail below.
[0014] For example, it is advantageous for the compression spring to be coupled to a motion conversion device which employs the force acting in the longitudinal direction to the compression spring for supporting a rotary motion of the force transmission unit that raises or lowers the door leaf. The motion conversion device therefore utilizes the force that can be stored in a compression spring to transfer a supporting torque to the force transmission unit.
[0015] It is furthermore advantageous for the compression spring to be arranged essentially horizontally, preferably transversely to the lifting or lowering direction of the door leaf. Thereby, the installation space may be well utilized.
[0016] The weight compensation device may be particularly compactly realized when the door leaf surrounds a hollow space in its lifted, wound-up state where the compression spring and/or the motion conversion device are arranged.
[0017] To be able to realize spiral doors and drum doors in a particularly easy way, it is advantageous for the guide element to embody a torque-proof hollow cylinder, or for the guide element to embody the drive shaft configured as hollow shaft.
[0018] The force of the compression spring may be particularly efficiently used as supporting torque for compensating the weight of the door leaf if the compression spring supports itself at a base part fixed with respect to the guide element and an adjusting element translationally movable relative to the guide element with force transmission.
[0019] An advantageous embodiment is characterized in that the drive shaft is in active relation with the adjusting element which is movable in a longitudinal direction of the drive shaft by the compression spring.
[0020] A transmission-like embodiment may be achieved if the adjusting element is coupled to the drive shaft so as to transmit torques, preferably in such a way that a movement of the adjusting element along the longitudinal direction enforces torque transmission from the adjusting element to the drive shaft.
[0021] In order to avoid any rotation of the adjusting element, for example when the drive shaft is rotating, it is advantageous for the adjusting element to be guided within the hollow shaft so as to be movable in the longitudinal direction, preferably in a groove on the inner side of the hollow shaft which preferably extends essentially in the longitudinal direction. However, it is also possible for the groove to be present at the adjusting element and corresponding diametrically opposed projections to be present on the inner side of the hollow shaft.
[0022] If the adjusting element is configured as a spindle nut, one may use a tried and tested conversion element. By this, high forces may be transmitted and components be used that are loadable over a long time.
[0023] It is particularly suitable for the spindle nut to be coupled to the drive shaft by threaded engagement. The spring force of the compression spring may be then particularly easily supportively impressed on the drive shaft.
[0024] A further advantageous embodiment is characterized in that at least one flexible clutch is embodied in the drive shaft which splits up the latter. Such a flexible clutch, in particular of a claw clutch type, is advantageous for compensating a mechanical overdetermination between lateral bearings which are employed for mounting the drive shaft. It is possible to only use plain bearings on the one side of the claw clutch, whereas on the other side of the claw clutch, a thrust bearing and a plain bearing are combined. It is also possible to use several flexible clutches, such as claw clutches, axially one behind the other and to arrange the corresponding bearings outside these flexible clutches.
[0025] The invention also relates to a lifting door, in particular an industrial lifting door, which comprises a door leaf, with a drive, such as a motor, and an inventive weight compensation device as illustrated above. Such a motor may be, for example, an electric motor or a hydraulic or pneumatic motor. Even internal combustion engines are possible power units.
[0026] It is then furthermore advantageous for a control window to be provided in the hollow shaft which permits a view to the spindle nut. In this manner, the adjustment of the individual elements with respect to each other becomes controllable.
[0027] It is advantageous for the control window to extend along the longitudinal direction and to be preferably oriented horizontally, so that a readjustment or an initial adjustment of the individual elements may be particularly easily controlled. Such a horizontal orientation offers itself especially due to the fact that the hollow shaft, i. e. the drive shaft, is normally arranged such that it extends above the door aperture in the horizontal direction.
[0028] If the spindle nut comprises an end plate for which an assembly position is marked in the control window, even untrained personnel may easily perform adjustment and assembly.
[0029] It is furthermore advantageous if during the assembly of the lifting door, the coupling between the motor and the spindle nut may be cancelled to bring the spindle nut into a desired assembly position preferably manually and/or using a crank, where coupling may be restored in this position. In this context, a method which uses the control window to bring the end plate, after a decoupling of the corresponding elements, back into the planned position and then restore the coupling is also advantageous.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention will be illustrated more in detail with reference to the drawing in which different embodiments are represented in different views. In the drawings:
[0031] FIG. 1 shows a first weight compensation device according to the invention for a spiral door,
[0032] FIG. 2 shows a slightly modified weight compensation device of FIG. 1 in a side view,
[0033] FIG. 3 shows a weight compensation device of FIG. 1 in a longitudinal sectional view as in FIG. 1 , however in a position in which, different from FIG. 1 , the door aperture is closed,
[0034] FIG. 4 shows a front view of a spiral lifting door with the weight compensation device of FIGS. 1 to 3 in a partial longitudinal sectional representation where the weight compensation device has assumed a position which is present when the door leaf is raised, while in FIG. 4 , the door leaf is shown in a lowered position,
[0035] FIG. 5 shows a view of the lifting door of FIG. 4 from above,
[0036] FIG. 6 shows a side view of the spiral lifting door of FIGS. 4 and 5 with a plug-in drive,
[0037] FIG. 7 shows the variant of a lifting door of FIGS. 4, 5 and 6 , however with a straight bevel gear drive and a sprocket belt,
[0038] FIG. 8 shows an enlarged sectional representation of the straight bevel gear drive of FIG. 7 ,
[0039] FIG. 9 shows a weight compensation device for a lifting door which realizes a drum winding in a partial longitudinal sectional representation, the weight compensation device being shown in a position where the door aperture is unclosed, i. e. the door is held open,
[0040] FIG. 10 shows a view from the side onto the slightly modified weight compensation device of FIG. 9 ,
[0041] FIG. 11 shows a partial longitudinal sectional view of the weight compensation device of FIG. 9 , but in a closed position, i. e. in a position where the door aperture is closed by the door,
[0042] FIG. 12 shows a view of a lifting door in which the weight compensation device of FIG. 9 is employed which is shown in a position assumed when the door leaf is in a lifted, opened position, the door leaf itself, however, being shown in a closed position in FIG. 12 ,
[0043] FIG. 13 shows a view onto the door of FIG. 12 from above,
[0044] FIG. 14 shows a side view of the door of FIGS. 12 and 13 with a plug-in drive,
[0045] FIG. 15 shows a side view of the door of FIGS. 12 to 14 , but in the variant of a cylindrical drive with a sprocket belt instead of a plug-in drive,
[0046] FIG. 16 shows an enlarged schematic diagram of the cylindrical drive with a sprocket belt of FIG. 15 in a front view,
[0047] FIG. 17 shows a schematic diagram of the different spring positions of the compression spring, and
[0048] FIG. 18 shows a torque diagram for the compression spring with a fixed motor torque.
DETAILED DESCRIPTION
[0049] The figures are only schematic drawings and only serve the understanding of the invention. Identical elements are provided with identical reference numerals.
[0050] FIG. 1 shows a first embodiment of a weight compensation device 1 . The weight compensation device 1 is provided for being employed at a drive 2 . The drive 2 comprises a motor 3 , such as an electric motor. The weight compensation device is provided for compensating the weight of a door leaf 4 depending on the position of the door leaf shown, for example, in FIG. 4 , the door leaf being the so-called curtain, assembled from several segments 5 as required.
[0051] The weight compensation device comprises a force transmission unit 6 . The force transmission unit is designed for activating a raising motion, i.e. an opening motion, and a lowering motion, i. e. a closing motion, of the door leaf 4 . The force transmission unit 6 is thus directly or indirectly connected to the door leaf 4 , i. e. at least one segment 5 of the door leaf 4 .
[0052] In the variant for embodying a spiral door represented in FIG. 1 , the individual segments 5 are guided at their sides within a spiral or a spiral guide 40 without the segments 5 coming into contact with each other during the winding process. A continuous traction member 7 , such as a belt or a chain, functions as drive member for driving the force transmission unit 6 .
[0053] The force transmission unit 6 is embodied as drive shaft 8 . The drive shaft Bis mounted via four bearings 9 , in particular bearings 9 configured as rolling bearings. FIG. 1 shows a position in which the door is opened. On the right side of the weight compensation device 1 , a thrust bearing is provided on the inner side of a right-hand continuous traction member 7 , whereas a plain bearing is provided on the outer side. On either side of the continuous traction member 7 located on the left side of the weight compensation device 1 , several bearings 9 configured as plain bearings are provided.
[0054] By means of the drive 2 of the force transmission units 6 , i. e. the drive shaft 8 , the door leaf 4 is held so that it may be raised and lowered.
[0055] A spindle nut 10 is provided on the drive shaft 8 so as to grip around the latter, the spindle nut comprising an end plate 11 . The end plate 11 is located in a stationary hollow shaft 12 . At least one projection 13 of the end plate 11 is positively locked with a groove 14 on the inner side 15 of the hollow shaft 12 . The groove 14 is a longitudinal groove, i. e. a groove extending in parallel to the longitudinal axis 16 of the drive shaft 8 .
[0056] A preferably metallic compression spring 17 is provided concentrically to the longitudinal axis 16 . The compression spring 17 is configured as flat spiral spring extending along the longitudinal axis of the hollow shaft 12 . The compression spring 17 is a component which is in a solid aggregation state under normal pressure and temperature conditions that normally prevail in the surrounding area. It is a metallic component which acts in an elastically restituting manner. Being relieved, it returns to its original shape. Here, it is embodied as a wound spring.
[0057] The compression spring 17 is prestressed by the value Δ v between the end plate 11 and a base part 18 . The base part 18 is in this embodiment connected to the hollow shaft 12 in a torque-proof and axially fixed manner. For the compression of the compression spring 17 , it is relevant that it is disposed between the base part 18 and the adjusting element 37 , such that it may be translationally compressed.
[0058] It is also possible for the base part 18 to be replaced by an embodiment similar to an adjusting element such that this component similar to an adjusting element is present on the same spindle as the spindle nut 10 . The two parts are then arranged on threads running in opposite directions.
[0059] Projecting from the end plate 11 in the direction of the base part 18 , a bushing 19 is embodied which may be integrally formed with the end plate 11 or may be connected to it with a form-fit, a frictional connection and/or by a material bond. On the inner side of the bushing 19 , a thread is formed which is in threaded engagement with a threaded section 20 of the drive shaft 8 .
[0060] The drive shaft 8 is split into three parts, where in the transitional region between the individual parts of the drive shaft 8 , one flexible clutch 21 , in particular of a flexible claw clutch type, is provided each.
[0061] In operation of the spiral door, the hollow shaft 12 is standing still, whereas the drive shaft 8 is rotatable. Depending on the compression state of the spring 17 , more or less torque is applied to the drive shaft 8 by means of the spindle nut 10 by the longitudinal displacement of the end plate 11 via the threaded engagement of the bushing 19 .
[0062] In FIG. 2 , two diametrically opposed projections 13 of the spindle nut 10 can be seen which are engaged in two longitudinal grooves, i. e. grooves 14 which extend in the longitudinal direction, i. e. in parallel to the longitudinal axis 16 . It is also possible for the groove 14 to be provided in the hollow shaft 12 of an external tube-type or the spindle nut 10 .
[0063] FIG. 3 shows a detail of the weight compensation device 1 in the position where the door is closed. The interior of the hollow shaft 12 is represented in a dot-dash line, where now the end plate 11 is spaced apart from a left end of the hollow shaft or an extension of the hollow shaft by a distance Δ v +s. Δ v designates the path caused by the spring tension, and s designates the spring trajectory caused by the adjustment.
[0064] A control window 22 , i. e. an opening in the wall of the hollow shaft 12 , is formed which permits a view to the end plate 11 . In the central region of the control window 22 , a widening 23 is present which represents a mark for an optimal assembly position.
[0065] FIGS. 4 to 7 show the complete lifting door in three views, where in FIG. 6 , a drive 2 configured as plug-in drive 24 is employed, and in the variant as it is shown in FIG. 7 , instead of the plug-in drive 24 , a straight bevel gear drive 25 with a sprocket belt 26 is employed.
[0066] A frame width is only determined by a door leaf guide 39 and possibly also by the continuous traction member 7 . In the variant shown in FIGS. 1 to 8 , the frame width is determined by both components, whereas in the embodiment of FIGS. 9 and 16 , the width is exclusively determined by the door leaf guide 39 , because no continuous traction member 7 is present, and the drive is realized via the hollow shaft 12 .
[0067] In FIG. 8 , a further cross-section of FIG. 7 is shown by which a so-called “longitudinal arrangement” may be realized. The motor may be arranged to be aligned with the frame, permitting a particularly efficient saving in space. In particular also by the arrangement of the compression spring 14 remote from the frame, the frames may be kept relatively narrow. These arrangements of the motor and the compression spring may be generally realized in all shown embodiments of the invention.
[0068] Different to prior art, the spring configured as compression spring is not arranged in the vertical direction but in the horizontal direction within the hollow shaft 12 so as to surround the drive shaft 8 .
[0069] The compression spring 17 is located in a hollow space 33 . The hollow space 33 is defined by the wound-up door leaf 4 . The door leaf 4 is guided in the spiral guide 40 and surrounds the hollow space 33 in its wound-up state.
[0070] A motion conversion device 32 is coupled to the compression spring 17 and comprises at least the base part 18 , the pressure element 34 which is configured as hollow cylinder 36 and has in particular assumed the shape of the hollow shaft 12 and comprises the groove 14 extending in the longitudinal direction on its inner side, and an adjusting element 37 which is configured as spindle nut 10 with a bushing 19 and an end plate 11 .
[0071] The motion conversion device 32 converts the rotary drive energy into a translational kinetic energy.
[0072] The compression spring 17 is arranged horizontally between two vertical frames 50 of a mount 35 .
[0073] FIG. 9 shows a second embodiment of a weight compensation device 1 which is also represented in an opened door position. The drive shaft 8 is connected to the hollow shaft 12 in a torque-proof manner, so that the hollow shaft 12 may be rotated in the sense of a drum, and when the door is being opened, the individual segments 5 of the door leaf 4 are wound onto the hollow shaft 12 like on a drum. The door leaf 4 may also have a foil-like character and then be just as easily wound up. The spindle nut 10 also comprises an end plate 11 and a bushing 19 , as in the first embodiment. The bushing 19 has a threaded engagement section which is provided with reference numeral 27 . This threaded engagement section 27 engages a threaded section 20 of a stationary shaft 28 . The shaft 28 is firmly connected to the base part 18 .
[0074] The end plate 11 comprises projections 13 which are guided in a groove 14 formed on the inner side 15 of the hollow shaft 12 in the longitudinal direction. One projection 13 each is guided in one groove 14 each. The base part 18 also comprises such projections 13 which are also guided in one groove 14 each. However, it is also possible for the compression spring 17 configured as base part 18 to be connected to the hollow shaft 12 in a torque-proof and/or translationally fixed manner by a form-fit, a frictional connection, and/or a material bond.
[0075] In the illustrated second embodiment, the drive shaft 8 is connected to the hollow shaft 12 in a torque-proof manner. In this embodiment, as can be seen in FIG. 10 , one does not rely on only two opposed projections 13 at the end plate 11 , but four projections 13 which have the same angular distance with respect to each other.
[0076] As can also be seen in FIG. 10 , the projections or grooves may be either located at the one component or at the other component as long as a longitudinal guidance is ensured. It is principally also conceivable to interchange the positions of the longitudinal guiding elements and screw elements.
[0077] In all embodiments, the compression spring may optionally support itself radially in the hollow-cylindrical guide element 34 , preventing a buckling of the spring.
[0078] The base part of FIG. 9 also comprises an extension section 38 which permits to shorten the stationary shaft 28 with the threaded section 20 .
[0079] As was already stated with respect to the embodiment according to FIGS. 1 to 8 , the second embodiment of FIGS. 9 to 16 , too, comprises a control window 22 , where here, however, a plate-like section of the base part 18 can be seen. The base part 18 may be interchanged with the spindle nut 10 , if desired.
[0080] In FIGS. 13 and 15 , the door leaf 4 is, for illustration reasons, shown with a control window 41 and a termination shield (not shown) in a position closing the passage, although the compression spring 17 is in a relieved position.
[0081] Views corresponding to the views shown in FIGS. 4 to 8 with respect to the second embodiment of the weight compensation device 1 are shown in FIGS. 12 to 16 .
[0082] In FIG. 17 , three positions of the compression spring 17 are shown, which are a non-stressed compression spring 17 leftmost, a prestressed spring in the middle, and a completely stressed compression spring 17 rightmost. In operation, the compression spring 17 is in its maximal positions in a state in accordance with the central and right positions.
[0083] FIG. 18 shows a spring tension relative to a present motor torque M, where the continuous first line 29 represents the torque T t caused by the weight of the door leaf 4 in response to its position, and the dashed second line 30 represents the torque T f caused by the spring. The torque moment is designated with M and is the distance between lines 29 and 30 . From the maximum opening position, a compensation point 31 is achieved by the intersection of both lines 29 and 30 , so that a deceleration of the door leaf is achieved just before the maximum opening position.
[0084] In the embodiment visualized in FIGS. 9 to 16 , too, the compression spring 17 is located in a hollow space within the wound-up door leaf 4 .
[0085] Embodiments which are designed corresponding to the following computations proved to be particularly advantageous:
[0086] 1. Door Leaf-Related Torque:
[0087] Door leaf weight: G t =115 kg
[0088] Crown gear diameter: d o =75 mm
[0089] g: Gravitational acceleration 9.81 m/s 2
[0000]
T
t
=
F
t
·
a
=
G
t
·
g
·
d
o
2
=
115
·
9
,
81
·
75
2
=
42
,
3
Nm
[0090] 2. Spring-Related Torque:
[0091] Spring force F f =9000 N
[0092] Spindle diameter 40 mm, pitch P h =40 mm
[0093] Efficiency with linear rotation η 2 =0.98
[0000]
T
f
=
F
f
·
Ph
·
η
2
2
π
=
9000
·
40
·
0
,
98
2
π
=
56
,
2
Nm
[0094] 3. Required Motor/Driving Torque
[0000] T m =T f −t l =56.2−42.3=13.9 Nm | The invention relates to a weight compensation device for a drive of a lifting door, for the position-dependent compensation of the weight force of a door leaf of the lifting door, with a force transmission unit which can be coupled to the drive in order to carry out an opening movement which raises the door leaf and a closing movement which lowers the door leaf, wherein at least one compression spring is provided which is arranged in such a way that it supports the opening movement. The invention also relates to a lifting door, in particular an industrial lifting door, which has a door leaf, with a drive, such as a motor, and with a weight compensation device according to the invention. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a filmless, self-contained, portable device for capturing X-ray images. More particularly, the invention relates to a handle for holding and positioning the portable device.
2. Description of the Related Art
Digital radiography (DR) systems have grown in popularity over the past number of years. Some DR systems include a portable flat panel image detector connected to a power supply or other power source as well as well as to an image processor or control computer. DR systems facilitate the production of direct, digital x-ray image information by transferring the x-ray image information captured by the flat panel to the image processor or control computer. In most instances, the image processor or control computer is connected to a picture archiving and communications system (PACS) network.
Because of its portable design, the flat panel image detector can be freely positioned in relation to the patient's anatomy, just like traditional screen-film cassettes. This portability makes it especially useful for trauma imaging as well as neonatal, pediatric, and orthopedic applications. Patients who have limited mobility can also be readily x-rayed. The compact feature of the portable flat panel allows for easy capture of images at angles that are difficult to set with fixed devices. Lateral and axial imaging of limbs, shoulders, the skull, the neck, and extremities are supported. Quick positioning is another benefit, as the portable flat panel is light enough for a radiologic technologist or patient to hold in place. Current flat panels include a single fixed handle for carrying and positioning the panel. The handle is either integrated into the structure of the panel itself, or affixed to one side of the panel.
Existing portable flat panel image detectors are approximately 13″×13″, with image capture area of 9″×11″, and weigh approximately 6.2 lbs (2.8 kg). The image capture area includes among other things a sensor panel and an analog/digital conversion board. The image capture area also includes lead, which makes up most of the panels weight. Lead is necessary to reduce the intensity of the X-ray as it passes through the sensor panel. For example, as shown in FIG. 10, when the X-ray 35 enters the image capture area of the flat panel image detector 36 , the sensor plate 37 absorbs a certain amount of the X-ray, forming an image. The lead 38 prevents the X-ray not absorbed by sensor plate from hitting anything or anyone located behind the flat panel image detector. Because of the small image capture area, there is not a need for a large amount of lead 38 . Thus, one handle is sufficient to hold and position flat panel image detectors with this dimension and weight.
There is a need for portable flat panel image detectors that are larger than the current image detectors. As the flat panel image detectors become larger, the amount of lead they contain increases accordingly. The additional lead makes these panels heavier and more difficult to manage. A single handle is not sufficient to use to hold and position these larger flat panel image detectors. What is needed is a mechanism for making it easier to hold and position larger flat panel image detectors.
SUMMARY OF THE INVENTION
It is an object of the foregoing invention to address the foregoing difficulty by providing a handle structure for holding and positioning large DR portable flat panel image detectors.
In one aspect, at least one handle is secured in hinged relation to a portable DR flat panel image detector. The handle is hingedly moveable from a position parallel to the plane of the panel, hereinafter referred to as zero-degree position to a position perpendicular to the plane of the panel, hereinafter referred to as 90-degree position. Hinged movement of the handle is preferably obtained by a user (i.e., radiologic technologist) moving the handle from the zero-degree position to the 90-degree position and from the 90-degree position back to the zero-degree position. By virtue of the hinged movement of the handle, a user can easily move and place a DR flat panel image detector in relation to a patient's anatomy to take an X-ray.
In yet another aspect, at least two handles are secured in hinged relation to a portable DR flat panel image detector. At least a first handle is secured to a horizontal side of the DR flat panel image detector and the at least second handle is secured to a vertical side of the DR flat panel image detector. Providing at least two handles provides the user with even better control when positioning the DR flat panel image detector in relation to a patient's anatomy to take an X-ray.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment(s) thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective of the preferred embodiment of the portable device of the present invention.
FIG. 2 is a top-down perspective of the preferred embodiment of the portable device of the present invention.
FIG. 3 is a side perspective of the preferred embodiment of the portable device of the present invention.
FIG. 4 is a cross-sectional view of the preferred embodiment of the means for moveably connecting handle(s) to the portable device of the present invention.
FIG. 5 is a cutaway view of the preferred embodiment of the means for moveably connecting handle(s) to the portable device of the present invention.
FIG. 6 depicts use of the portable device of the present invention in a first orientation.
FIG. 7 depicts use of the portable device of the present invention in a second orientation.
FIG. 8 depicts use of the portable device of the present invention in a third orientation.
FIG. 9 depicts use of the portable device of the present invention in a fourth orientation.
FIG. 10 is a cross-sectional view of a flat panel image detector.
FIG. 11 depicts the front view of a first accessory to the portable device of the present invention in use with the portable device.
FIG. 12 depicts the back view of the first accessory to the portable device of the present invention in use with the portable device.
FIG. 13 is a top-down perspective of a second accessory to the portable device of the present invention in use with the portable device.
FIG. 14 is a stand-alone top-down perspective of the second accessory to the portable device of the present invention.
FIG. 15 is a side perspective of the second accessory to the portable device of the present invention.
FIG. 16 is a top-down perspective depicting the movement of the latching mechanism of the second accessory to the portable device of the present invention.
FIG. 17 is side view of the latching mechanism of the present invention in the latched position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a front perspective of the preferred embodiment of the portable device of the present invention. Portable device 9 consists of an outer housing 10 connected to and surrounding an inner plate 11 . Outer housing 10 is composed of plastic, aluminum, lead, and carbon. However, the composition of outer housing 10 is not limited to these materials. Inner plate 11 is a high-resolution flat panel detector composed of a high-precision amorphous silicon (a-Si) and a thin film transistor (TTF) array. Interface cable port 14 is secured to one side of outer housing 10 and connected to interface cable 15 . Interface cable 15 connects portable device 9 to a control station (not shown), which is typically an image processor. The control station allows a radiologic technologist to view images captured by portable device 9 and transmitted via interface cable 15 , and can be connected to a picture archiving and communication system (PACS) network. Handles 12 , 13 are secured to separate sides of outer housing 10 , different from the side that interface cable port 14 is secured to. In the preferred embodiment, handle 12 is located on the side opposite the side interface cable port 14 is secured to, and handle 13 is located on one of the two remaining sides. In addition, handles 12 , 13 are preferably located in the center of their respective sides. Centering handles 12 , 13 provides for even balancing of portable device 9 when in use, as well as ease of use by the user. For example, as shown in FIG. 6, centering of handle 12 allows a radiologic technologist to easily position portable device 9 with respect to a patient. FIG. 7 is another example of how the centered position of handles 12 , 13 allows a user to easily position portable device 9 with respect to a patient. The preferred material of handles 12 , 13 is plastic, but is not limited to plastic and any material that would allow practice of the present invention would be applicable. Handle 8 is connected to interface cable port 14 . The method of securing handles 12 , 13 to outer housing 10 is discussed below with respect to FIGS. 4 and 5.
FIG. 2 is a top-down perspective of the preferred embodiment of portable device 9 . FIG. 3 is a side perspective of portable device 9 . More specifically, FIG. 4 depicts movement of handle 12 with respect to portable device 9 . A more detailed description of this movement is provided below with respect to FIGS. 4 and 5.
FIG. 4 is a cross-sectional view of the preferred embodiment of the means for moveably connecting handles 12 , 13 to portable device 9 of the present invention. Briefly, handles 12 , 13 are moveably connected to portable device 9 in order for a user to more easily hold and/or position portable device 9 with respect to a patient's anatomy when taking an X-ray of the patient. The following description of the means for moveably connecting handles 12 , 13 to portable device 9 references handle 12 . The same means apply to handle 13 .
In more detail, handle 12 includes two shafts 20 , 21 connected perpendicularly to each of the legs of handle 12 . Shafts 20 , 21 are enclosed by stoppers 18 , 19 respectively, and affixed to outer housing 10 of portable device 9 . Stoppers 18 , 19 are secured to outer housing 10 of portable device 9 by screws 16 , 17 respectively.
FIG. 5 is a cutaway view of the preferred embodiment of the means for moveably connecting handle(s) 12 , 13 to portable device 9 of the present invention.
In more detail, shaft 21 contains two openings 24 , 29 that are located 90 degrees from one another. Contained in each opening are springs 26 , 27 and ball bearings 25 , 28 respectively. Both springs 26 , 27 and ball bearing 25 , 28 have the same diameter has openings 24 , 29 . Handle 12 includes opening 30 , which has the same diameter as openings 24 , 29 and its depth is equivalent to radius of ball bearings 25 , 28 .
When handle 12 is in the zero-degree position (parallel to the plane of portable device 9 ), opening 30 is aligned with opening 24 . When opening 30 is aligned with opening 24 , ball bearing 25 is moved out of opening 24 by spring 26 and into opening 30 . Since the depth of opening 30 is equivalent to the radius of ball bearing 25 , one half of ball bearing 25 is positioned in opening 30 and the other half remains positioned in opening 24 . The location of ball bearing 25 locks handle 12 in the zero-degree position.
When pressure is applied to handle 12 and handle 12 is rotated in direction D 1 , ball bearing 25 moves away from opening 24 and completely back into opening 30 . When handle 12 reaches 90-degree position (perpendicular to the plane of portable device 9 ), opening 30 aligns with opening 29 . Alignment of opening 29 and 30 results in spring 27 moving ball bearing 28 out of opening 29 and into opening 30 . Since the depth of opening 30 is equivalent to the radius of ball bearing 28 , one half of ball bearing 28 is positioned in opening 30 and the other half remains positioned in opening 29 . The location of ball bearing 28 locks handle 12 in the 90-degree position.
Handle 12 can be returned from the 90-degree position to the zero-degree position by applying pressure to handle 12 and rotating in the direction opposite direction D 1 . Stopper 21 works in conjunction with ball bearings 25 , 29 to prevent handle 12 from moving past the zero-degree or 90-degree positions.
FIG. 8 illustrates using portable device 9 where handle 12 is in the 90-degree position. Portable device 9 is placed behind a patient 32 sitting upright on X-ray table 34 and directly across from X-ray machine 33 . In order to easily position portable device 9 given patient's 32 positions with respect to X-ray machine 33 and X-ray table 34 , handle 12 is placed in the 90-degree position. The image captured by portable device 9 is transmitted via interface cable 15 to control computer 31 . As described above, control computer 31 allows for among other things, a radiologic technologist to view the captured image transmitted via interface cable 15 . In addition, control computer 31 can be connected to a picture archiving and communication system (PACS).
FIG. 9 provides another use of portable device 9 where handles 12 , 13 (not shown) are in zero-degree position. In this configuration, portable device 9 is placed flat under patient 32 while patient is lying on X-ray table 34 . As previously described, interface cable 15 is used to transmit the image captured by portable device 9 to control computer 31 .
The above embodiment of the present invention includes handle 8 connected to interface cable port 14 . In another embodiment, handle 8 is not present. In another embodiment, in addition to handles 12 , 13 , an additional handle is moveably connected to the side of outer housing 10 opposite the side handle 13 is connected to. In still yet another embodiment, only a single handle is moveably connected to outer housing 10 .
FIG. 11 depicts the front view of a first accessory to the portable device of the present invention in use with the portable device. More specifically, FIG. 11 depicts a protective cover 40 that fits over portable device 9 to protect inner plate 11 . Protective cover 40 contains three openings (not shown) that allow access to handles 8 , 12 , 13 and interface cable port 14 . When not in use, the openings are covered by flaps (not shown), with the flaps secured by velcro fasteners (not shown). The preferred material of protective cover 40 is nylon, which allows a user to easily slide portable device 9 underneath a patient as depicted in FIG. 9 . In addition, nylon does not affect interfere with the X-ray entering the portable device. The material of protective device 40 is not limited to nylon, and any material that would allow practice of the present invention would be applicable.
FIG. 12 depicts the back view of the protective cover 40 . In more detail, FIG. 12 depicts carrying belt 41 and pocket 42 . Carrying belt 41 and pocket 42 are used to carry portable device 9 from location to location. To carry portable device 9 , a user would position an arm underneath carrying belt 41 and place a hand inside pocket 42 . Pocket 42 provides a place for a user to hold portable device 9 , while carrying belt 41 secures the user's arm to portable device 9 . In addition, the combination of carrying belt 41 and pocket 42 can be used to help position portable device 9 in a situation where the use of handles 12 , 13 may not be difficult.
FIG. 13 is a top-down perspective of a second accessory to the portable device of the present invention in use with the portable device. More particularly, FIG. 13 depicts portable device 9 as described with respect to FIGS. 1 and 2. However, unlike portable device 9 depicted in FIGS. 1 and 2, portable device 48 of FIG. 13 does not include handles 12 , 13 . Rather, handles 44 , 45 are secured to a separate frame 43 which can be secured to outer housing 10 of portable device 48 . Frame 43 is secured to outer housing 10 via latching mechanism(s) 46 . Handles 44 , 45 are moveably connected to frame 43 in the same manner that handles 12 , 13 are moveably connected to portable device 9 . The preferred material of frame 43 handles 44 , 45 and latching mechanism 45 is plastic, but is not limited to plastic and any material that would allow practice of the present invention would be applicable.
FIG. 14 is a stand-alone top-down perspective of frame 43 depicted in FIG. 13 . Arrow 49 illustrates the motion of latching mechanism 46 used to secure frame 43 to outer housing 10 of portable device 9 . A more detailed description of this motion is provided below with respect to FIG. 16 .
FIG. 15 is a side perspective of frame 43 . More specifically, FIG. 15 depicts movement of handle 45 with respect to frame 43 . Movement of handle 45 with 5 respect to frame 43 is the same as the movement of handle 12 with respect to portable device 9 as described above.
FIG. 16 is a top-down perspective depicting movement of latching mechanism 46 with respect to frame 43 . In more detail, when latching mechanism 46 is parallel to the plane of frame 43 , frame 43 is not secured to outer housing 10 of portable 10 device 48 . In order to secure or latch frame 43 to outer housing 10 of portable device 48 , latching mechanism 46 is rotated to a position perpendicular to the plane of frame 43 . To disengage or unlatch frame 43 from outer housing 10 of portable device 48 , latching mechanism 46 is rotated back to a position parallel to the plane of frame 43 .
FIG. 17 is side view of the latching mechanism of the present invention in the latched position. As shown in FIG. 17, the underside of latching mechanism 46 contains element 47 . Element 47 is used to help maintain latching mechanism 46 in the secured or latched position. The preferred material of element 47 is rubber, as rubber will prevent damage to outer housing 10 of portable device 48 when latching mechanism is in the secured or latched position. However, any material which will maintain latching mechanism 46 in the secured or latched position and protect outer housing 10 of portable device 48 would be applicable.
The above embodiments describe the portable flat panel image detector of the present invention with respect to a digital radiography system. The application of the present invention is not limited to a digital radiography system and the invention may be used with other systems employing portable flat panel image detectors.
While the invention is described above with respect to what is currently its preferred embodiment, it is to be understood that the invention is not limited to that described above. To the contrary, the invention is intended to cover various modifications and equivalent arrangements within the spirit and scope of the appended claims. | A portable device for recording X-ray images. The device comprising an X-ray image capture panel, a housing member connected to and surrounding the X-ray capture panel, at least a first handle secured to the housing member, means moveably connected to the at least first handle for moving the handle from a position parallel to the plane of the portable device to a position perpendicular to the plane of the portable device and from a position perpendicular to the plane of the portable device to a position parallel to the plane of the portable device. An accessory for carrying or holding the portable device, wherein the accessory is in the form of a frame secured to the portable device or a cover that portable device is placed within. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to valves for regulating the flow of a fluid medium and particularly to improvements in diaphragm valves.
2. Discussion of Prior Art and the Invention
More specifically, the invention relates to a diaphragm regulating valve for regulation of the flow of a fluid medium, with a number of flat diaphragm elements in mutual contact and insertible into the flow channel mounted between two housing halves and actuatable by at least one catch ring also mounted in the housing.
Diaphragm regulating valves afford substantial advantages over traditional shutoff devices such as slide valves, cocks, lifting valves, throttle valves, and so forth. The continuously variable aperture cross-section of the diaphragm regulating valve is always positioned coaxial with the axis of the pipe, so that the flow in the valve is not deflected and experiences only slight losses of pressure. The medium need not change direction repeatedly, as is the case with lifting valves.
The rate of flow can be determined with precision in every closing position, the flow characteristic in theory exhibiting the shape of a parabola. The accuracy of the characteristic is affected chiefly by the rate of leakage between the segments of the diaphragm and by the nature of the medium which is to be regulated. The actual shape of the characteristic approaches the theoretical parabolic form in the case of semifluid media where the rate of leakage is correspondingly lower.
A diaphragm regulating slide valve is known from Swiss Pat. No. 369,943, one whose diaphragm elements can be introduced into a flow channel perpendicular to the wall of this channel. There are between the individual elements relatively large gaps which cannot be sealed off even in the closed position. The state-of-the-art slide valve thus exhibits a high leakage rate, so that it is not suited for precise flow regulation and thus cannot be employed in place of a conventional regulating valve.
The state-of-the-art regulating slide valve has a movable regulating ring sealed off toward the exterior and on the two plane surfaces. Lateral sealing is effected against the housing or against the movable diaphragm elements. When the pressure inside the system rises, the pressure per unit area on the seals also increases, thus resulting in an increase in the displacement force. Consequently, structural limits are imposed on the state-of-the-art slide valves from the viewpoint of rated pressure.
As a result, the slide valve is massive and material-intensive in point of design, thus rendering manufacture a costly process. Installation of the slide valve is also complicated and expensive. Because of the high rate of leakage, it is suited only for semifluid media such as sludge, paste, concrete, etc. It cannot be employed for highly fluid media, let alone gaseous ones, and thus affords no decisive advantages over the conventional regulating valves.
The object of the invention is to create a diaphragm regulating valve in which the disadvantages of the state-of-the-art regulating slide valve are avoided. It is claimed for the invention that this is achieved in such a way that at least one of the housing halves is provided with supporting ribs forming a star for the diaphragm elements, said ribs projecting into the flow channel, and so that the ribs fully cover the contact edges of the diaphragm elements when the valve is closed. It is expedient for the contact edges of adjacent diaphragm elements to be graduated to a reciprocally equal extent.
SUMMARY OF THE INVENTION
The diaphragm regulating valve is designed for regulation of the flow of a fluid medium. It has a number of flat diaphragm elements in mutual contact and insertible into a flow channel, which diaphragm elements are mounted in two housing halves. The diaphragm elements are set in movement by a catch ring also mounted in the housing. The contact edges of the diaphragm elements are recessed to a reciprocally equal extent. When the valve is in the closed state, the contact edges are completely covered by the ribs of a star mounted in the flow channel. This diaphragm regulating valve is characterized by a substanially lower leakage rate than the state-of-the-art diaphragm regulating valves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-section through the valve in an exploded view;
FIG. 2 shows a plan view of the valve with the top removed;
FIG. 3 shows a plan view of the bottom housing plate;
FIG. 4 shows a plan view of a diaphragm element;
FIG. 5 shows a front view of the diaphragm element illustrated in FIG. 4;
FIG. 6 shows a guide pin with guide sleeve;
FIG. 7 shows a second guide pin with guide sleeve;
FIG. 8 shows a plan view of the catch ring;
FIG. 9 shows a longitudinal section IX--IX through the diaphragm regulating valve as illustrated in FIG. 2;
FIG. 10 shows a plan view of another form of embodiment of a diaphragm regulating valve; and
FIG. 11 shows cross-section through the valve illustrated in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The diaphragm regulating valve shown in the figures has two housing plates 1, 2, which are pressed tightly against each other by means of screws 3. The downward projecting edge 4 of the upper (first) housing plate 1 extends into a corresponding annular groove 5 of the lower (second) housing plate 2 and compresses an O-ring 6 which is present in this groove 5. The upper housing plate 1 is provided with a cylindrical recess 7 in which six diaphragm elements 8 and a catch ring 9 are embedded.
As is to be seen from FIGS. 4 and 5, the diaphragm elements in essence have the shape of an equilateral triangle, one corner 10 of which, adjacent to edge 4, is beveled out of considerations of space. Every two adjacent diaphragm elements 8 are in contact along the arm edges 11 common to them, these arm edges 11 being complementarily recessed and assuming the function both of a guide and of a seal between the adjacent elements 8.
Each diaphragm element 8 has two guide pins 12, 13, onto the ends of each of which a downward projecting guide sleeve 14 is screwed.
One guide pin 13 is positioned on the angle bisector of the two stepped arms 11 and has an upper, camlike extension 15 which is mounted eccentrically relative to the axis of the pin 13. As will be explained in greater detail later, the precise position of the diaphragm elements relative to each other can be adjusted by means of the eccentric cam 15.
Six straight guide slots 17 forming an equilateral hexagon have been fashioned in the lower housing plate 2 to receive the diaphragm element 8. All guide slots 17 have the same radial spacing relative to the axis 30 of the discharge opening 18. An end of each of slots 17 is extended beyond of the pertinent corner of opening 18.
Each diaphragm element 8 is guided tangentially to the discharge opening 18 by the guide slots 17. In the closed position the tips 19 of the diaphragm elements 8 extend into the discharge opening 18, and the stepped arm edges 11 are covered by the ribs 20 of a star 21 which is a component of the lower housing plate 2 and also extends into the discharge opening 18.
The edges of the star facing the diaphragm elements 8 are flat and are situated in the same plane as the interior surface 22 of the plate. Together with the interior surface 22 of the plate the star forms a guide surface for the slide element 28. These elements are forced against this guide surface 22 by the pressure of the flow.
For the purpose of opening the valve the slide elements 8 are moved in concert in their slots 17, whereby a central, hexagonal flow cross-section is formed which is enlarged progressively until the diaphragm elements have reached their final position.
The diaphragm elements 8 are displaced by the catch ring 9 accommodated in the recess 7 in the upper housing plate 1.
The catch ring 9 has fashioned in it six oblique, bent guide slots 23 into which the cams 15 of the diaphragm element guide pins 13 extend. To rotate the catch ring 9 use is made of a pinion 24 whose shaft 25 penetrates the lower housing plate 2. The pinion 24 meshes with a gear-ring segment 26 on the external circumference of the catch ring 9.
The mutual position of the diaphragm elements 8 can be set and adjusted with the precision by rotating the eccentric cams 15. When the valve is in the open position, the cams 15 are in section 23a of the guide slot 23. If the catch ring 9 is now rotated to close the valve, the diaphragm elements 8 are displaced into the discharge opening of the flowing medium until the opening is more or less closed off.
With the diaphragm elements 8 in this position, the cams 15 are in the area of the bend in the guide slot 23 and the guide sleeves 14 in the area of radial extensions 27 of the guide slots 17 of housing plate 2. If the catch ring 9 is now rotated further, the cams 15 reach the sections of guide slot 23 designated as 23a, whereby the diaphragm elements are subjected to an increased radial force component.
The guide sleeves 14 enter the radial extensions 27 of the slot 17, so that the diaphragm elements radially lock relative to each other, in order that a high sealing effect can be achieved. It is expedient for the tips 19 of the diaphragm elements to be blunt ended, as is shown in FIG. 4 below number 28. The closing edges 11 and the blunt ended tips 28 are completely covered by the guide star 21, 29.
The upper housing plate 1 as well may be provided with a guide star 29, so that the diaphragm elements 8 are guided between the two starts inside the discharge opening 18. In order to achieve a heightened clamping effect in the closed position, the diaphragm elements could be sloped at the top in the form of a wedge.
Means other than the wedge-shaped or tapering surfaces could also be employed to produce locking, ones such as oblique ribs on the diaphragm elements which are engaged with the ribs of the star shortly prior to complete closing of the valve.
In other embodiments grooves 50 could be recessed into the ribs 20 of the stars, into which grooves sealing strips 52 are introduced which are pressed against the contact edges 11 of the diaphragm elements 8 when the valve is closed, as shown in FIG. 1.
The diaphragm elements can assume various shapes, for example, four rectangular elements or a multiplicity of crescent-shaped elements. In this case the ribs of the stars as well would have to assume the corresponding shapes.
It is essential for the segments always to be guided through 90° relative to the angle bisector of the segment tip with the valve in the closed position.
The diaphragm regulating valve described in the foregoing affords the following advantages:
By means of apporiate arrangement of the pin guide in the adjusting ring, the movement of the segments with the valve in the closed position is modified in such a way that the segments undergo a central movement to the center. This results in pressure on the sides which improves the reciprocal sealing of the elements.
As a result of inclination of the segments and corresponding surfaces of the guide star in the upper portion, pressure is generated between the two guide stars in the last phase of closing, when the segments are in radial movement; that is, the segments are pressed against the projecting surfaces and are sealed.
In every position except the closed position the diaphragm elements fit together loosely and are guided loosely by the graduated arm edges. Frictional forces are very slight.
Guiding of the adjusting ring is provided by means of the recess in the upper part of the housing. The adjusting ring is actuated in a very simple manner by way of the gear-ring and the pinion. The shaft of the pinion extending to the exterior can be sealed by means of a retaining ring. This shaft can be connected to a drive of any nature, such as a motor or manual drive.
The diaphragm regulating valve which has been described causes no noise, since its design is decidedly such as to facilitate flow. In comparison to conventional valves, higher flow rates can be accommodated at the same noise level.
As was stated at the outset, in the case of conventional valves the displacement force works entirely against the pressure of the system. The displacement force must consequently always be higher than the pressure of the system. Depending on the application, resort is had to pressure equalization devices in the case of conventional valves, but this entails a higher production expense and higher costs. With the diaphragm regulating valve here proposed the displacement force no longer works against the pressure of the system; it rather utilizes this pressure to improve the sealing effect. The displacement force represents a mere fraction of the pressure of the system. High flow rates can thus be regulated accurately with a minimal displacement force.
The adjusting drives can be designed so as to be smaller and largely independent of the flow rate. As a result, any drive system can be employed and a higher degree of accuracy can be achieved in regulation.
The Kv R value indicates the smallest flow rate which can be regulated and is measured as a percentage of the maximum flow rate. The Kv R value ranges from 5 to 10% for conventional valves. With the valve claimed for the invention the Kv R value is much lower, coming very near 0%.
The diaphragm regulating valve is very simple in design and is characterized by very small dimensions, so that it may also be installed in pipelines at a later period with the prospect of it not generating future problems. The sealing is comparable to that achieved with conventional lifting valves, so that the latter may readily be replaced by the valve claimed for the invention. Owing to its very slight thickness, it is very simple, for example to insert it between two flanges of a pipeline, in which case the drive between the flanges must be extended to the exterior. This structural embodiment should be clear to the specialist and requires no further explanation.
In the case of the embodiment of the diaphragm regulating valve shown in FIGS. 10 and 11, the diaphragm segments 31 are mounted between two catch rings 32, 33, which are mounted rotatably inside a twin-shell housing 1, 2. The straight guide slots 17 are in this case not provided in the lower housing plate 2, as in the embodiment example discussed above, but in the lower catch ring 33, while guide slots 23 are in the upper catch ring 32. Each diaphragm segment 31 has at the top upper catch ring connecting means in the form of a guide pin 34 which extends into one of the guide slots 23 of the upper catch ring 32. At the bottom, the diaphragm segment 31 is provided with lower catch ring connecting means in the form of an elongated, beam-shaped projection 35 which extends into one of the guide slots 17 of the lower catch ring 33.
For the purpose of actuation of the valve a Y-shaped control lever 36 is provided, the two arms 38 or fork of which is acommodated inside the housing 1, 2. The ends 37 of the arms have small milled recesses 39 into each of which an acutating pin 40, 41 extends. One pin 40 is anchored in the upper catch ring, while the other 41 is fastened in the lower catch ring 33 and extends through an arcuate recess 42 in the upper catch ring 32.
The handle 43 of the control lever 36 extends to the exterior through a connecting sleeve 44, the connecting sleeve being mounted perpendicular to the axis of the housing. The valve is closed and opened by moving this handle 43 back and forth. The two arm ends 37, which are positioned diametrically opposite each other, effect simultaneous rotation of the two catch rings 32, 33 by way of pins 40, 41, one catch ring being rotated clockwise and the other counterclockwise, an equal distance in opposite directions. This in turn effects displacement of the diaphragm segments, in a manner similar to that already described in the first embodiment example.
The drive can be very simple in design with this embodiment of the diaphragm valve. The motive power is directed toward the center and the control movement path traveled by the lever 43 is short, since motion is transmitted to both catch rings simultaneously. A short, simple closing movement is thereby ensured, and manufacture of the valve entails a relatively small design effort.
The surfaces of the star and the corresponding surfaces of the blades can be ground in order to achieve a good sealing. The sealing effect is intensified by the differential pressure present when the valve is closed. | A diaphragm regulating valve for the flow regulation of a fluid medium. The valve includes a housing having two halves defining a flow channel. A plurality of diaphragm elements in contact with one another are arranged for insertion into the flow channel to control fluid flow therethrough. An actuating mechanism is provided to move these diaphragm elements as desired. One or both of the housings have radial ribs forming a star in the flow channel and covering the contact edges of the diaphragm elements when the valve is closed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to U.S. patent application Ser. No. 12/948,841, filed on Nov. 18, 2010.
FIELD OF THE INVENTION
The invention is directed to a method and system for synchronizing a clock employing time transfer with a time reverse mirror, and more particularly, to computing a delay between a return signal and an imaginary time-reversed signal and applying the computed delay to a clock input calibration for a desired signal such as a multistatic radar signal.
BACKGROUND OF THE INVENTION
A bistatic radar is a radar with transmit and receive antennas separated by a considerable distance with respect to target range. In recent years, these bistatic and multistatic radars are gaining more and more attention because they can provide low-cost, ECCM capabilities against stealth targets.
Due to the geometry of bistatic or multistatic radars, e.g. such as described in U.S. Patent Application No. 20060202885, “Operational Bistatic Radar System Synchronization,” P. Chen. Sep. 14, 2006, incorporated herein by reference, which describes a direct line-of-sight (LOS) connection employing QPSK bit synchronization, the synchronization of time and frequency at the transmitters and receivers is a crucial problem for coherent signal processing and range measurement. The coherent integration of signals from remote nodes for cohere-on-transmit and cohere-on-receive require very stringent and hard phase locking and synchronization. Typically, the remote nodes must be synchronized to less than a few percent of a carrier frequency. Also, the clock at each node must be phase locked not to cause drift of the summed signals during the coherent integration time. These become even more difficult when the nodes are on a moving platform as in the case of synthetic aperture radar (SAR).
When the nodes are separated by a line-of-sight distance, direct measurements using hard-wired cables (fiber-optic or RF) or free-space (free-space optics or free-space RF wave) communications are used to achieve synchronization on the order of ns.
When the nodes are separated beyond the line-of-sight, satellites are required. Rubidium or quartz clocks using four or more GPS space vehicles, e.g. such as described in U.S. Pat. No. 6,995,705, “System And Method For Doppler Track Correlation For Debris Tracking”, Bradford et al., 2006, incorporated herein by reference, are most commonly used to achieve synchronization of remote nodes to tens of ns. However, in adverse environments with multipath interference or moving platforms, performances become significantly degraded. Furthermore, timing depends on propagation delays which depend on sensor locations. To extract the desired timing portion from the measurements, precise location is also necessary. Other representative bistatic or multistatic radar systems that employ direct LOS include: U.S. Patent Application No. 20050128135, “Remote Phase Synchronization Using A Low-Bandwidth Timing Referencer”, Hester et al., Jun. 16, 2005; U.S. Pat. No. 4,021,804, “Synchronized, Coherent Timing System For Coherent-On-Receive Radar System”, Eric A. Dounce, May 3, 1977; U.S. Pat. No. 5,361,277, “Method And Apparatus For Clock Distribution And For Distribuuted Clock Synchronization”, Wayne D. Grover, Nov. 1, 1994; U.S. Pat. No. 6,297,765, “Bistatic Passive Radar System With Improved Ranging”, Lawrence M. Frazier, Oct. 2, 2001; U.S. Pat. No. 7,589,665, “Multistatic Method And Device For Radar Measuring A Close Distance”, P. Heide et al., Sep. 15, 2009; and U.S. Pat. No. 5,818,371, “Coherent Synchronization And Processing Of Pulse Groups”, C. Lu et al., Oct. 6, 1998, all of which are incorporated herein by reference.
Time transfer is a method for transferring a reference clock from one point to another over a long distance. Due to the recent advances in global positioning system, navigation, etc., time transfer has become an important element. Various methods of time transfer have been developed over many years including one-way transfer, two-way transfer, and common view transfer. However, these methods lack precision mainly due to the incomplete cancellation of propagation delays.
BRIEF SUMMARY OF THE INVENTION
According to the invention, a Time Transfer Time Reverse Mirror (TT TRM) method and system includes a radio transceiver for transmitting a series of short pulses repeatedly at a period T and for receiving from a remote node a return signal that is a retransmission of the original signal at the same period T; a clock circuit for inputting a clock signal to the transceiver; and a computer for (i) computing and generating an imaginary time-reversed signal version of the original signal, (ii) comparing the return signal with the imaginary version, (iii) computing a delay between the return signal and the imaginary version that is substantially equal to twice the time difference between the two nodes, and (iv) applying the computed delay to a clock input calibration for a desired signal.
The invention is directed to a time-transfer method and system using time reversal. By operating time reversal repeatedly at a pre-defined period, one can transfer time with high precision, without being affected by the delays caused by propagation, multipath and instruments, permitting time transfer anywhere within the reach of radio signals.
Compared with other existing time transfer methods, TT-TRM has the following advantages: simple and low cost; high precision due to better cancellation of propagation delays; and, no satellite required; no communications between CO and each node is required.
Also, multiple nodes can be supported by a single TRM at CO, whereas with single frequency—TWSTF uses two different frequencies that can propagate along different paths, making cancelation of propagation delay difficult.
The invention has application in bistatic and multistatic passive radars. These radars are coherently combined to produce optimized performance at both transmitter (cohere on transmit) and receiver sides (cohere on receive). Also, time delay of arrival and angle of arrival measurements require precise synchronization among nodes.
The invention differs from conventional approaches in that it utilizes time reversal to extract the purely timing portion by substantially nulling out other effects such as propagation delays, distortion or dispersion. Therefore, it can be used for any environments such as multipath, moving platform, or even ionospheric propagation that consists of multiple layers (D, E, F 1 and F 2 , etc.), multiple heights (low and high), multiple hopping, and two different polarization modes. The invention also includes time transfer using the ionospheric reflection (refraction), producing precise synchronization among remote nodes beyond the line-of-sight and thus without necessitating satellites (GPS or communication satellites).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating the operational principle of time transfer using a time reversal mirror (TT TRM) according to the invention;
FIG. 2 is a schematic diagram illustrating the time difference determination between two nodes being independent of various propagation delays according to the invention;
FIG. 3 is a schematic diagram illustrating the compensation for signal distortion according to the invention;
FIG. 4 is a schematic diagram illustrating the processing of continuous wave signals such as linear chirp or pseudo random noise signals commonly used in code-division multiple access (CDMA) according to the invention;
FIG. 5 is a schematic diagram illustrating the application of time transfer for multiple nodes (>2) according to the invention;
FIG. 6 is a schematic diagram of a TT TRM system according to the invention;
FIGS. 7A-D are screen displays showing the experimental results using the apparatus of FIG. 6 according to the invention; and
FIG. 8 is a schematic overview of the experimental setup according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The operational principle of time transfer using a time reversal mirror (TT-TRM) is simple, as shown in FIG. 1 . At first, Node A sends out a series of short pulses repeatedly at a period T. Node B receives, time reverses, and retransmits the incoming signals at the same period. At Node A, the returned signal is compared with the imaginary time-reversed version of the original signal (shown with a dotted red vertical line). The delay between the two pulses measured at Node A is twice the time difference between the two nodes. This amount of time is independent of various propagation delays due to the unique feature of time reversal, as explained below in detail.
FIG. 2 explains how the amount of time delay between the transmitted and returned pulses measured at User node is solely dependent on the time difference between the two nodes—User and Reference nodes—and is independent of various propagation delays and multipath effects.
In the example shown in the Figure, the following values are assumed: period T=30 sec, the time skew of the User node with respect to Reference node s=5 sec. and propagation delay between the two nodes p=15 sec. These numbers are exaggerated only for illustration. The time measured in User frame is shown on the top of the figure with vertical dotted lines.
A pulse signal (represented with a thick solid line) is transmitted from User node to Reference node at t=0 in User time. After p sec (at t=p=15 sec in User and t=p-s=10 sec in Reference time), the pulse arrives at Reference node. The signal is then time-reversed with respect to the axis at t=T=30 to t=2T−(p−s)=2*(30)−(15−5)=50 sec both in Reference time and is transmitted to User node. The retransmitted pulse after time-reversal arrives at User node at t=2T−(p−s)+p in Reference time or at t=2T−(p−s)+p+s=2T+2s in User time. Since each node updates its frame at a pre-defined period T, the User will measure the returned pulse at modulo(2T+2s, T)=2s (2*5=10 sec), which is twice the amount of skew s.
Here one should note that this temporal shift of 2*s is independent of the propagation delay p, even through a distorting medium or multipaths, since the propagation delay is canceled out by time reversal after the round trip.
The invention compensates for signal distortion due to intermediate media such as ionosphere, troposphere and multipaths. As shown in FIG. 3 , the initial short pulse (impulse) is distorted to h(t) (i.e. the impulse response of the propagating media and instruments). However, after time-reversal and re-transmission though the same medium, the waveform is refocused to a sharp peak. This autocorrelation has a maximum peak at the center and a symmetrical shape with respect to the center, allowing a precise location of the peak position. Unlike other time-transfer methods, an increase in distortion often contributes to a sharper peak in the present time-reversal system.
In order to avoid the need for high power pulse transmission, one can consider lower power continuous wave signals such as linear chirp or pseudo random noise signals commonly used in code-division multiple access (CDMA), as shown in FIG. 4 . In this case, the received signal at Node A must be convolved (rather than correlated) with the original transmitted reference signal for pulse compression.
As shown in FIG. 5 , time transfer can also be implemented in a large number of nodes, because the TRM at central office (CO) can operate independently without the need for communication or coordination with each node (like a satellite in GPS which supports multiple users), as long as the TRM is operated at the pre-defined period. In this case, to avoid the propagation of time-reversed signals from the CO to unwanted nodes (e.g. Node 1 →TRM→Node 2 ), different frequencies can be used for different nodes. Also, when the CO has several TRM's, the selective beam focusing can be achieved on the transmitter, permitting the use of the same frequency among different nodes.
FIG. 6 shows a schematic diagram of a TRM system 10 . A Rubidium (Rb) clock 12 , a high precision clock generator 14 , a delay generator 16 , and a computer 18 , including a machine-readable storage media 19 having programmed instructions stored thereon for computing and generating the time-reversed signal, are added to a conventional radio transceiver 20 , which normally consists of an arbitrary waveform generator (AWG) 22 , an oscilloscope (OSC) 24 , a duplexer 26 , a high power amplifier (HPA) 28 , a low noise amplifier (LNA) 30 , and a bandpass filter (BPF) 32 , with signals transmitted and received via antenna 34 . A clock circuit 11 includes a rubidium clock 12 for generating a precision 10 MHz time-base signal to phase-lock all the instruments locally, a clock generator 14 to generate a square wave to trigger both the AWG 22 and OSC 24 after a suitable amount of delay generated by a delay generator 16 . The OSC 24 is used here as an alternative to an analog-to-digital converter (ADC) to digitize incoming signals. The signal is then time-reversed by the computer 18 , and the waveform is loaded on the AWG 22 . At each trigger signal at a given period, the AWG 22 emits the time-reversed waveform.
The configuration shown in FIG. 6 may be used for both Nodes and TRMs interchangeably. For example, the nodes receiving precision time from a CO as shown in FIGS. 3-5 may not need a time reversal process. On the other hand, a TRM at a CO may not need a delay generator.
The configuration of FIG. 6 was constructed using COTS components to demonstrate that the time reversal-based time transfer (TT TRM) invention cancels out propagation delays, and was used for both User and Reference Nodes, while noting, that the User Node does not perform time reversal and the Reference Node does not need a delay generator to adjust the time skew. In order to focus on the effects of propagation delays, the time skew between the User and the Reference Nodes was set to 0. FIG. 7A shows the received signal at the Reference Node. The signal was delayed by 1.4 μs (the propagation time through the RF cables and free space) and was distorted due to multipath and other distortion effects. A 20 times magnified view is shown in FIG. 7C . FIG. 7B shows the returned signal at the User after the round trip. As shown, the returned signal had a peak at 0 (center) and symmetric with respect to the peak, as can be seen more clearly in the magnified view in FIG. 7D . The position of the peak can be easily and precisely located without ambiguity, as explained previously.
FIG. 7D also shows the effects of the pathlength difference between the nodes. Another connection between the two nodes was made with a short (one ft long) cable. Although the pathlengths between the two different connections are different by 1.4 μs in time, both signals arrived at the User almost at the same time. The time difference of 3 ns is attributed to the drift of the Rubidium clock while the connection between the two nodes was manually switched. If fast electronic switching is used, the time difference is expected to be negligible. This result clearly demonstrates that the TT TRM system and method of the invention substantially cancel all or at least most of the propagation delays and detect only the desired time skew with great precision.
FIG. 8 shows an overview of the experimental setup to prove the p (propagation delay) independence of the signal received by the User after time reversal, as explained above. A series of short impulses are generated at a period of 100 μs (or 10 KHz repetition rate) and is transmitted from the User to the Reference Node through an RF cable (1000 ft long) and through free space (200 ft). The signal is delayed by the propagation time of about 1.4 μs before arriving at the Reference Node. The signal is also distorted by multipath effects and the antenna responses. The distorted signal waveform is represented by h(t), which is the impulse response of the transmission system connecting the two nodes. The signal received by the Reference Node is digitized, time reversed, and retransmitted to the User. The signal received by the User is given by autocorrelation h(t)★h(t), where ★ represents correlation.
It should be noted that the computer-generate time-reversed signal can be generated by executing one or more sequences of one or more computer-readable instructions read into a memory of the computer from volatile or non-volatile computer-readable media capable of storing and/or transferring computer programs or computer-readable instructions for execution by the computer. Volatile computer readable media that can be used can include a compact disk, hard disk, floppy disk, tape, magneto-optical disk, PROM (EPROM, EEPROM, flash EPROM), DRAM, SRAM, SDRAM, or any other magnetic medium; punch card, paper tape, or any other physical medium. Non-volatile media can include a memory such as a dynamic memory in a computer. In addition, computer readable media that can be used to store and/or transmit instructions for carrying out methods described herein can include non-physical media such as an electromagnetic carrier wave, acoustic wave, or light wave such as those generated during radio wave and infrared data communications.
Obviously many modifications and variations of the present invention are possible in the light of the above teachings. For example, to increase the precision further, conventional techniques such as closure phase, pseudo range, or time integration methods may be employed in this system. To support multiple nodes without crosstalk, an array of TRM's may be used to selectively focus the beam on the desired node. The TRM in FIG. 6 may be integrated into a compact box using FPGA and DSP chips. It is therefore to be understood that the scope of the invention should be determined by referring to the following appended claims. | A Time Transfer Time Reverse Mirror (TT TRM) method and system includes a radio transceiver for transmitting a series of short pulses repeatedly at a period T and for receiving from a remote node a return signal that is a retransmission of the original signal at the same period T: a clock circuit for inputting a clock signal to the transceiver: and a computer for (i) computing and generating an imaginary time-reversed signal version of the original signal, (ii) comparing the return signal with the imaginary version, (iii) computing a delay between the return signal and the imaginary version that is substantially equal to twice the time difference between the two nodes, and (iv) applying the computed delay to a clock input calibration for a desired signal. The system includes time transfer using the ionospheric reflection (refraction), producing precise synchronization among remote nodes beyond the line-of-sight and thus without necessitating GPS or communication satellites. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a clothes dryer, and particularly, to a structure for a roller capable of supporting a drum inside a clothes dryer.
2. Background of the Invention
Recently, a clothes dryer serves to dry an object to be dried by absorbing moisture inside the object by blowing blast generated by an electric heater or a gas heater into a drum. According to a method for processing humid air generated when drying the object, the clothes dryer is largely classified into an exhaustion-type clothes dryer and a condensation-type clothes dryer.
FIG. 1 is a view showing a clothes dryer in accordance with the conventional art.
Referring to FIG. 1 , the conventional clothes dryer comprises a body 10 that forms appearance, a drum 20 rotatably installed in the body 10 , a door 30 through which an object to be dried is introduced into the clothes dryer, etc. Although not shown, the conventional clothes dryer further comprises a circulation duct having both ends connected to the drum thus to form a flow path for air circulation; a heater disposed in the circulation duct for heating air; a blowing fan for forcibly circulating air; etc. The condensation-type clothes dryer comprises a heat exchanger for removing moisture included in air exhausted from the drum 20 .
The drum 20 is rotated by receiving a driving force, through a belt (not shown), from a motor (not shown) installed at an inner lower side of the body 10 . The clothes dryer requires a means configured to prevent the drum 20 to be downwardly deformed due to a load of laundry and a load of the drum 20 , and configured to support a lower side of the drum 20 for smooth rotation of the drum 20 . For this, a supporting roller 40 is generally installed below the drum 20 .
FIGS. 2 and 3 are perspective and sectional views of the supporting roller.
Referring to FIGS. 2 and 3 , the supporting roller 40 of the drum 20 includes a roller shaft 41 ; a roller frame 42 slidably installed at the roller shaft 41 and rotated; a roller outer circumferential portion 43 formed of rubber having an elastic force to support the drum 20 , and attached to an outer circumference of the roller frame 42 ; a bearing 44 disposed between the roller frame 42 and the roller shaft 41 , and configured to allow the roller frame 42 to be smoothly rotated; and a triangular pin 45 configured to support the roller frame 42 at both sides so as to prevent the roller frame 42 from being separated from the roller shaft 41 .
The supporting roller 40 of the conventional clothes dryer is mounted to the roller shaft 41 by using an oil-less bearing formed between the roller frame 42 and the roller shaft 41 . However, when a load supported by the bearing increases, oil included in the oil-less bearing may be discharged out. This may degrade a lubricating characteristic of the supporting roller 40 , and may cause noise occurrence and damage of the supporting roller 40 . Especially, in the case of 24-inch clothes dryer rather than 27-inch clothes dryer, the above problems may become more severe due to a narrow inner space and an overload.
Furthermore, in the conventional bearing, the roller outer circumferential portion 43 contacting the drum 20 has a convexed portion at a central part thereof. This may cause only parts of the entire region of the roller outer circumferential portion 43 to contact the bearing. As a result, a stress applied to the supporting roller 40 is concentrated on specific regions, thereby shortening the lifespan of the supporting roller 40 .
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a clothes dryer capable of providing a structure of a roller which supports a drum of the clothes dryer, the roller configured to endure even a large load applied thereto, capable of prolonging the lifespan of the roller by preventing stress concentration by increasing a contact area between the roller and the drum, and capable of enhancing the reliability.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a clothes dryer, comprising: a body; a drum rotatably installed in the body; and a roller disposed below the drum, and configured to support the drum, wherein the roller is mounted to a roller shaft by a ball bearing.
When coupling the roller to the roller shaft, may be used a ball bearing, not the conventional oil-less bearing. This may enable the bearing of the roller shaft to have stronger endurance against thermal deformation or abrasion due to heat.
A stopping portion for mounting the ball bearing may be formed at the roller shaft.
A screw thread for nut mounting may be further formed at one side of the roller shaft, and a screw thread for fixing the roller into the clothes dryer may be formed at another side of the roller shaft. As a nut is mounted to the screw thread after mounting the roller to the roller shaft, the roller may be more stably mounted to the roller shaft.
A contact portion of the roller contacting the drum may be formed to be flat.
The roller may comprise a roller frame configured to insert the roller shaft; and an outer wheel portion mounted to the roller frame, and configured to encompass an outer circumferential surface of the roller frame.
Since the contact portion of the roller may be formed to be flat, a stress applied to the roller may be distributed to prolong the lifespan of the roller.
A plurality of concave-convex portions may be formed on an outer circumferential surface of the roller frame, and a plurality of concave-convex portions engaged with the concave-convex portions may be formed on an inner circumferential surface of the outer wheel portion. As the concave-convex portions of the roller frame may be coupled to the concave-convex portions formed on the inner circumferential surface of the outer wheel portion, the roller frame may be stably coupled to the outer wheel portion. The outer wheel portion of the roller may be formed of rubber having an elastic force.
Under these configurations, even when a large load may be applied to the roller, the roller may endure the load. This may prolong the lifespan of the roller that supports the drum, and enhance the reliability of the clothes dryer.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a view showing a clothes dryer in accordance with the conventional art;
FIG. 2 is a perspective view of a roller of FIG. 1 ;
FIG. 3 is a sectional view of FIG. 2 ;
FIG. 4 is a sectional view of a roller which supports a drum of a clothes dryer according to the present invention; and
FIG. 5 is a perspective view of a roller shaft of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Description will now be given in detail of the present invention, with reference to the accompanying drawings.
Hereinafter, a clothes dryer according to the present invention will be explained in more detail with reference to the attached drawings.
FIGS. 4 and 5 are views respectively showing a roller for supporting a drum of a clothes dryer according to the present invention.
The roller for supporting a drum of a clothes dryer according to the present invention is mounted to a roller shaft 51 by a ball bearing 53 . That is, in the present invention, the roller is provided with a ball bearing, not the conventional oil-less bearing. This may enable the bearing of the roller shaft 51 to have a stronger endurance against thermal deformation or abrasion due to heat.
The roller shaft 51 for mounting the roller is provided with a bearing mounting surface 51 e for mounting the ball bearing 53 . For stable mounting of the ball bearing 53 , a stopping portion 51 c having a diameter a little larger than that of the bearing mounting surface 51 e is disposed on a side surface of the bearing mounting surface 51 e . On the basis of the bearing mounting surface 51 e of the roller shaft 51 , a screw portion 51 a for mounting a nut 52 is formed at an opposite side to the stopping portion 51 c . A stepped portion 51 d may be formed between the screw portion 51 a and the bearing mounting surface 51 e , thereby showing the position of the nut coupled to the screw portion 51 a . After inserting the ball bearing 53 into the bearing mounting surface 51 e of the roller shaft 51 , the nut 52 is coupled to the screw portion 51 a . As the ball bearing 53 is disposed between the stopping portion 51 c and the nut 52 , the ball bearing 53 is prevented from being separated from the roller shaft 51 . That is, owing to the stopping portion 51 c and the nut 52 mounted to the screw portion 51 a , the ball bearing 53 can be easily and precisely mounted on the roller shaft 51 , and the ball bearing 53 can be prevented from being separated from the roller shaft 51 .
At one side of the roller shaft 51 , the ball bearing 53 is mounted. And, another side of the roller shaft 51 is mounted to a fixing member 61 inside the clothes dryer. For this, a screw thread 51 b is formed at another side of the roller shaft 51 . The roller shaft 51 is inserted into the fixing member 61 inside the clothes dryer, and a nut 60 are coupled to the screw thread 51 b , thereby fixing the roller shaft 51 to a predetermined position inside the clothes dryer.
An outer circumferential surface of the roller, i.e., a contact portion contacting the drum is formed to be flat. This may enable a contact surface of the roller contacting the drum to have a wider area. Therefore, a stress applied to the outer circumferential surface of the roller decreases to prolong the lifespan of the roller.
Preferably, the roller includes a roller frame 54 configured to insert the roller shaft 51 therein by using the ball bearing 53 ; and an outer wheel portion 55 mounted to the roller frame 54 , and configured to encompass an outer circumferential surface of the roller frame 54 . In this case, an outer circumferential surface 55 a of the outer wheel portion 55 directly contacting the drum is formed to be flat thus to have a wider contact area. As the contact portion of the outer circumferential surface 55 a contacting the drum is formed to be flat, the stress applied to the roller is distributed to prolong the lifespan of the roller.
A plurality of concave-convex portions are formed on an outer circumferential surface of the roller frame 54 , and a plurality of concave-convex portions engaged with the concave-convex portions are formed on an inner circumferential surface of the outer wheel portion 55 . As the concave-convex portions of the roller frame 54 are coupled to the concave-convex portions formed on the inner circumferential surface of the outer wheel portion 55 , the roller frame 54 can be stably coupled to the outer wheel portion 55 . The outer wheel portion 55 of the roller is preferably formed of rubber having an elastic force.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
As the present features may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims. | Disclosed is a clothes dryer comprising a drum rotatably disposed in a body; and a roller disposed below the drum, and configured to support the drum. The roller is mounted to a roller shaft by a ball bearing, and a contact portion of an outer circumferential surface of the roller contacting the drum is formed to be flat. | 3 |
BACKGROUND OF THE INVENTION
Material handling carts mounted upon wheels must be anchored when transported within the cargo compartment of a truck, van, boxcar, or the like. For instance, shelved carts are widely used in the transportation and distribution of bread and bakery products, wherein the carts are loaded and then wheeled upon a truck for retail bread distribution. A variety of systems have been used to anchor the carts within the cargo compartment, including strap and buckle systems, and present cargo cart anchors are difficult to maintain, expensive, and do not have the desired versatility of installation and operation.
It is an object of the invention to provide a cargo cart anchor which may be readily used with a conventional cargo control track wherein the anchor may be readily attached to, or removed from, the track, but cannot be accidentally removed therefrom.
Another object of the invention is to provide a cargo cart anchor which is simple to operate, and wherein a single anchor is capable of being associated with two adjacent carts.
Yet another object of the invention is to provide a cargo cart anchor of economical and rugged construction, utilizing stamped and readily fabricated components.
A further object of the invention is to provide a cargo cart anchor employing a screw operation to produce the anchoring force, and wherein vibration will not release the anchor.
An additional object of the invention is to provide a cargo cart anchor of a relatively rigid construction wherein the anchor pivots to a non-use storage condition adjacent the cargo compartment wall when not in use.
The cart anchor in accord with the invention includes a pair of telescoping tubular members interconnected by a screw operated through a hand crank. A hook is mounted upon the movable telescoping component for engaging cart structure. The fixed telescoping conduit supports a fitting whereby the anchor may be readily attached to a cargo control track mounted upon the wall of the cargo compartment.
The fitting includes a slotted U-shaped element adapted to be inserted into the cargo control track, and the fitting is locked to the track by means of a sliding retainer which prevents vertical fitting displacement to a position which would permit the fitting to be removed from the track.
The retainer is operated by the telescoping components of the cart anchor wherein raising of these components to an unusual predetermined position permits the retainer to be displaced to a position wherein the fitting may be removed from the cargo control track. This operation of the retainer is accomplished through a cam surface formed on the telescoping section pivotally affixed to the fitting.
The pivotal interconnection between the fitting and the telescoping components permits the telescoping components to pivot downwardly to a stored location adjacent the cargo compartment wall when the anchor is not in use.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is a top, plan, partial, schematic view of a cargo compartment illustrating the orientation of the anchor to cargo carts,
FIG. 2 is an elevational view, partially in section, showing the anchor in accord with the invention, the stored position being shown in dotted lines,
FIG. 3 is a top, plan, detail view as taken along Section III--III of FIG. 2,
FIG. 4 is an elevational, detail view of the fitting and of the anchor along Section IV--IV of FIG. 2 illustrating the anchor in the storage position,
FIG. 5 is a top plan view of the fitting end of the anchor taken along Section V--V of FIG. 2, the track being shown in dotted lines,
FIG. 6 is an elevational sectional view taken through the fitting along Section VI--VI of FIG. 5 illustrating the retainer in the operative condition, and
FIG. 7 is a view similar to FIG. 6 illustrating the retainer in the release position for removing the anchor fitting from the cargo control track.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 a schematic representation of the use of the anchor in accord with the invention is shown. A cargo compartment is illustrated at 10, and represents a plan view of a truck or boxcar compartment wherein the floor is shown at 12, and a vertical side wall at 14. The carts to be anchored are of a rectangular plan configuration as shown at 16, and these carts may be of the shelf type commonly used in the distribution of bread and bakery products. The carts are each mounted upon their own wheels, usually caster wheels, and are easily movable. The carts include vertical corner columns 18 upon which the shelves are supported.
A cargo control track 20 of known construction, such as apparent in FIGS. 2 and 4, is mounted upon the vertical wall 14 in the usual manner. The track 20 will be parallel to the floor 12, and may be three or four feet above the floor. The anchor 22 in accord with the invention is affixed at one end to the track 20, and the other end of the anchor includes a hook which hooks around the corner columns 18 of the carts 16, and upon tensioning of the anchor the associated carts are forced against the wall 14 and track 20 holding the carts at the desired location in the cargo compartment. As apparent from FIG. 1, the anchors 22 are located at the ends of the carts wherein only a single cart corner column is engaged by the anchor, but when the anchors are located between adjacent carts 16 a single anchor is used to engage two carts. Thus, the number of anchors required is one greater than the number of carts being anchored.
The overall construction of the cart anchor in accord with the invention is best appreciated from FIG. 2. The anchor 22 includes an inner tubular section 24 over which telescopes the movable outer tubular section 26. The inner end of the section 24 is flattened at 28 and is pivotally connected to a fitting, generally indicated at 30, by pivot pin 55, and the other end of the tubular section 24 is inwardly swaged to define a reduced diametrical section 32 which is internally threaded for cooperation with the threaded shaft 34 having a head 36 at its outer end upon which the crank handle 38 is mounted.
The outer telescoping tubular section 26, at its inner end, closely slides over the section 24, and the outer end of the section 26 supports a sheet metal hook 40 which is welded to the end of the section. The hook 40 is of an elongated form extending at right angles to the length of the section 26 and includes body portion 42 reinforced by ribs 44, and flanges 46 extend from the end of the body portion in a direction parallel to the section 26 for hooking around the corner columns of the carts 16. The screw shaft head 36 extends toward and bears against the outer surface of the hook body 42, FIG. 2, wherein rotation of the screw shaft and head by the handle 38 in a clockwise direction will force the hook 40 and section 26 to the right, FIG. 2, toward the fitting 30 to "tension" the anchor against the cart associated therewith. The handle 38 includes portion 48 which is slidably received within a transverse hole 50 defined within head 36, and the portion 48 is enlarged at 52 to retain the handle within the head. Under gravitational forces the handle 38 will assume the position shown in FIG. 2 wherein the major weight of the handle is disposed below the axis of the threaded shaft 34.
The fitting 30 includes a U-shaped body 54 pivotally connected to section 24 by a pivot pin 55 having legs 56 interconnected by base portion 58, FIG. 5. The legs each include an aligned lower notch 60 adjacent the "short" base extension 62, and each of the legs includes an upper aligned notch 64 adjacent the long base extension 66. The depth of the notches 64 is greater than the depth of the notches 60, for cooperation with the opening within the cargo control track, as later described.
A sliding retainer plate 68 is located intermediate the fitting legs 56, as best illustrated in FIGS. 6 and 7. The retainer includes a head 70 having an upper edge 72, and a lower extension 74 is disposed adjacent the base 58. The head 70 is provided with an elongated vertical slot 76 in which the roll pin 78 is received, and the fitting legs 56 also include holes 80 which support the roll pin. In this manner the roll pin retains the retainer 68 between the legs. Also, the head 70 is provided with a hole 82 which will align with holes 84 defined in each of the fitting legs for a purpose later described.
The configuration of the flattened end of tube section 24 is shown in FIG. 6, wherein the fitting end includes a cylindrical cam surface 86 concentric with the axis of the pivot pin 55. A notch 88 is defined in the upper edge of the flattened section 28 whereby upon pivoting of the tubes 24 and 26 to approximately 45° from the vertical, as shown in FIG. 7, the corner 90 of the retainer head 70 may be received within the notch permitting the retainer to lower to the position shown in FIG. 7 wherein the retainer edge 72 will be in substantial alignment with the lowermost edge of the upper notches 64.
The cargo control track 20 is of conventional construction, and may be of the type sold by the assignee, Aeroquip Corporation, Series A or E. The track includes flanges 92 in which holes are defined for attaching the track to the cargo compartment wall 14. The offset track portion 94 extends from the wall and has a plurality of generally rectangular openings 96 defined therein at equally spaced intervals along the portion 94. The rectangular openings 96 include an upper edge 98, a lower edge 100, and lateral sides defined by inwardly formed flanges, not shown.
To mount the cargo control anchor 22 to the track 20 the sections 24 and 26 are pivoted with respect to the fitting 30 to the position shown in FIG. 7 wherein the retainer corner 90 is received within the notch 88. This orientation permits the retainer, under gravity, to fall to its lowest position providing access to the maximum "depth" of the upper notches 64. Thereupon, the fitting extension 66 may be inserted into the track opening 96 behind the edge 98, and the track edge 98 is then received within the notches 64. As the retainer 68 is in its lowermost position the fitting 30 may be raised its maximum extent within the track opening 96, which permits the lower fitting extension 62 to pass over the lower track opening edge 100 and align the notches 60 with the edge 100. Thereupon, the fitting 30 is lowered to the position shown in FIG. 2, and the sections 24 and 26 are pivoted to a horizontal position, or lower, which causes the cam surface 86 to engage the retainer corner 90 raising the retainer 68 to the position shown in FIGS. 2 and 6. When the retainer is in the "locked" condition of FIGS. 2 and 6 the fitting 30 cannot be raised within the track opening 96 a sufficient distance to remove the lower notches 60 from the track opening due to the engagement of retainer edge 72 with the opening edge 98, and the anchor 22 is firmly locked to the cargo control track.
After the cart anchor has been affixed to the cargo control track at the desired location the operator unscrews the threaded shaft 34 sufficiently to position the hook 40 around the corner column, or columns, or a cart, or carts, to be anchored. Thereupon, the shaft is tightened by means of the handle 38 and the hook 40 and section 26 will be forced toward the fitting 30 and the cargo wall 14. Tightening of the screw continues until the cart 16 is snugly forced against the wall. This process is repeated at each cargo anchor location.
As the handle portion 48 of the crank handle is slidably located within the screw shaft head 36 the majority of the weight of the crank handle is located below the axis of the shaft, and vibration will not rotate the screw shaft due to the weight of the handle as the handle acts as a counterweight.
When it is desired to remove the anchor 22 from a cart 16, the threaded shaft is rotated by the crank handle sufficiently to permit the hook 40 to be released from the cart corner column. Thereupon, the hook 40 and section 26 may be rotated 90° to permit the sections 24 and 26 to pivot to the stored dotted line position of FIG. 2 between the carts, and the carts may be readily wheeled from the cargo compartment 10. The cart anchors 22 will normally be mounted at the desired location upon the track 20, and upon reloading the carts the anchors are pivoted to the substantially horizontal operative position, and the anchoring process repeated, as described above. If it is desired to remove or relocate an anchor relative to the track 20, the sections 24 and 26 are pivoted upwardly about the pivot pin 55 to the position of FIG. 7 wherein the notch 88 will align with the corner 90 of the retainer 68, and this orientation will permit the retainer to drop to the position of FIG. 7, permitting the fitting 30 to be raised within the track opening 96 removing the notches 60 from the track opening, and permitting the fitting extension 62 to pass through the opening over lower edge 100, and thereupon, the fitting is lowered, the notches 64 removed from the track edge 98, and the fitting is removed from the track opening 96.
If it is desired that retainer 68 be locked in its notch blocking position of FIG. 6 a wire or pin can be inserted into aligned holes 82 and 84, and such wire or pin will prevent the retainer from lowering into notch 88 even though the notch is aligned with corner 90.
From the above description it will be appreciated that the operation of the cart anchor is simple and easily accomplished. Locking to the cargo control track is positive and easily accomplished, and yet accidental removal of the anchor from the cargo control track is highly unlikely as the telescoping sections must be raised to an unusual position. Unloosening of the threaded shaft due to vibration is prevented by the counterweight effect achieved by the crank handle, and the use of stamped and conventional tube components reduces costs. For instance, the swaging of the section 24 at 32 eliminates the need for a separate nut or threaded element.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | The invention pertains to an anchor for cargo carts wherein transported carts are restrained against movement within a cargo compartment. The anchor consists of a jack type implement utilizing a screw interconnecting telescoping tubular sections wherein the anchor includes a fitting attachable to permanently installed cargo control track within the cargo compartment. The anchor is formed of economically producible components, and is readily attached to, or removed from, the track by orienting the telescoping sections in a predetermined manner to the track. | 1 |
TECHNICAL FIELD
This invention relates generally to low temperature or cryogenic refrigeration and, more particularly, to pulse tube refrigeration.
BACKGROUND ART
The cooling, liquefaction and/or subcooling or densification of certain gases such as neon, hydrogen or helium requires the generation of very low temperature refrigeration. For example, at atmospheric pressure neon liquefies at 27.1 K, hydrogen liquefies at 20.39 K, and helium liquefies at 4.21 K. The generation of such very low temperature refrigeration is very expensive. Inasmuch as the use of fluids such as neon, hydrogen and helium are becoming increasingly important in such fields as energy generation, energy transmission, and electronics, any improvement in systems for the liquefaction of such fluids would be very desirable.
A recent significant advancement in the field of generating low temperature refrigeration is the pulse tube system wherein pulse energy is converted to refrigeration using an oscillating gas. Such systems can generate refrigeration to very low levels sufficient, for example, to liquefy helium. However, such refrigeration generated by pulse tube systems is very costly if the starting point is a relatively high temperature such as ambient temperature.
Accordingly, it is an object of this invention to provide a system for providing cryogenic refrigeration using a pulse tube system which can more efficiently provide such refrigeration than can heretofore available systems using pulse tube technology.
SUMMARY OF THE INVENTION
The above and other objects, which will become apparent to those skilled in the art upon a reading of this disclosure, are attained by the present invention, one aspect of which is:
A method for providing refrigeration to a heat load comprising:
(A) compressing pulse tube gas to produce hot compressed pulse tube gas, cooling the compressed pulse tube gas, and expanding the cooled pulse tube gas to produce cold pulse tube gas;
(B) warming the cold pulse tube gas by indirect heat exchange with heat transfer medium to produce cooled heat transfer medium, and warming the cooled heat transfer medium by indirect heat exchange with refrigeration fluid to produce cooled refrigeration fluid at a first temperature within the range of from 10 to 280 K;
(C) providing refrigeration into the cooled refrigeration fluid to produce cold refrigeration fluid at a second temperature lower than said first temperature and within the range of from 3 to 150 K; and
(D) warming the cold refrigeration fluid by passing refrigeration from the cold refrigeration fluid into a heat load.
Another aspect of the invention is:
Apparatus for providing refrigeration to a heat load comprising:
(A) a pulse tube refrigerator comprising a regenerator body, a pulse tube body having a pulse tube heat exchanger, means for generating pressurized gas for oscillating flow within the regenerator body, and means for expanding gas within the pulse tube body through the pulse tube heat exchanger;
(B) a forecooling circuit comprising a forecooling heat exchanger, means for passing heat transfer medium from the pulse tube heat exchanger to the forecooling heat exchanger, and means for passing heat transfer medium from the forecooling heat exchanger to the pulse tube heat exchanger;
(C) means for passing refrigeration fluid to the forecooling heat exchanger, and means for providing refrigeration into the refrigeration fluid downstream of the forecooling heat exchanger; and
(D) a heat load and means for passing refrigeration from the refrigeration fluid into the heat load.
As used herein the term “indirect heat exchange” means the bringing of fluids into heat exchange relation without any physical contact or intermixing of the fluids with each other.
As used herein the term “direct heat exchange” means the transfer of refrigeration through contact of cooling and heating entities.
As used herein the term “magnetize” means to induce magnetic properties to a substance by use of an externally applied electrical field.
As used herein the term “heat load” means an entity at a higher temperature capable of receiving refrigeration and thus being cooled to a lower temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of one preferred embodiment of the invention wherein lower level refrigeration is provided to the cooled refrigeration fluid by operation of a multiple component refrigerant compression/expansion cycle.
FIG. 2 is a schematic representation of another preferred embodiment of the invention wherein lower level refrigeration is provided to the cooled refrigeration fluid by operation of a Brayton refrigerator.
FIG. 3 is a schematic representation of another preferred embodiment of the invention wherein lower level refrigeration is provided to the cooled refrigeration fluid by operation of a magnetic refrigerator.
DETAILED DESCRIPTION
The invention will be described in detail with reference to the Drawings. Referring now to FIG. 1, pulse tube refrigerator 40 comprises regenerator body 41 and pulse tube body 1 having pulse tube heat exchanger 42 . Regenerator 41 contains pulse tube gas which may be hydrogen, neon, nitrogen, a mixture of helium and neon, a mixture of neon and nitrogen, or a mixture of helium and hydrogen. Mixtures of helium and hydrogen are preferred.
A pulse, i.e. a compressive force, is applied to the hot end of regenerator body 41 by means of pulse generator 43 thereby initiating the first part of the pulse tube sequence. Preferably the pulse is provided by a piston which compresses a reservoir of pulse tube gas in flow communication with regenerator body 41 . Another preferred means of applying the pulse to the regenerator is by the use of a thermoacoustic driver which applies sound energy to the gas within the regenerator. Yet another way for applying the pulse is by means of a linear motor/compressor arrangement. Yet another means to apply pulse is by means of a loudspeaker. Another preferred means to apply pulse is by means of a travelling wave engine. The pulse serves to compress the pulse tube gas producing hot compressed pulse tube gas at the hot end of the regenerator body 41 . The hot pulse tube gas is cooled by indirect heat exchange with heat transfer fluid 33 in heat exchanger 44 to produce warmed heat transfer fluid in stream 34 and to produce cooled compressed pulse tube gas for passage through the remainder of the regenerator body. Examples of fluids useful as the heat transfer fluid in the practice of this invention include water, air, ethylene glycol and the like.
The regenerator body contains heat transfer media. Examples of suitable heat transfer media in the practice of this invention include steel balls, wire mesh, high density honeycomb structures, expanded metals, lead balls, copper and its alloys, complexes of rare earth element(s) and transition metals.
The heat transfer media is at a cold temperature, generally within the range of from 10 to 280 K at the cold end to 200 to 310 K at the warm end, having been brought to this cold temperature in the second part of the pulse tube sequence which will be described more fully below. As the cooled compressed pulse tube gas passes through the regenerator body, it is further cooled by direct contact with the cold heat transfer media to produce warmed heat transfer media and further cooled pulse tube gas, generally at a temperature within the range of from 9 to 279K at the cold end to 199 to 309 at the warm end.
The further cooled pulse tube gas is passed from the regenerator body 41 to pulse tube body 1 at the cold end and is expanded through pulse tube heat exchanger 42 . As the further cooled pulse tube gas passes into pulse tube body 1 at the cold end it generates a gas pressure wave which flows toward the warm end of pulse tube body 1 and compresses the gas within the pulse tube, termed the pulse tube working fluid, thereby heating the pulse tube working fluid.
Cooling fluid 35 is passed to heat exchanger 36 wherein it is warmed or vaporized by indirect heat exchange with the pulse tube working fluid, thus serving as a heat sink to cool the pulse tube working fluid. Resulting warmed or vaporized cooling fluid is withdrawn from heat exchanger 36 in stream 37 . Preferably cooling fluid 35 is water, air, ethylene glycol or the like.
Attached to the warm end of pulse tube body 1 is a line having orifice 38 leading to reservoir 39 . The compression wave of the pulse tube working fluid contacts the warm end wall of the pulse tube body and proceeds back in the second part of the pulse tube sequence. Orifice 38 and reservoir 39 are employed to maintain the pressure and flow waves in phase so that the pulse tube generates net refrigeration during the expansion and the compression cycles in the cold end of pulse tube body 1 . Other means for maintaining the pressure and flow waves in phase which may be used in the practice of this invention include inertance tube and orifice, expander, linear alternator, bellows arrangements, and a work recovery line with a mass flux suppressor. In the expansion sequence, the pulse tube gas expands through pulse tube heat exchanger 42 to produce cold pulse tube gas at the cold end of the pulse tube body 1 . The expanded gas reverses its direction such that it flows from the pulse tube body toward regenerator body 42 .
The pulse tube gas emerging from pulse tube heat exchanger 42 is passed to regenerator body 41 wherein it directly contacts the heat transfer media within the regenerator body to produce the aforesaid cold heat transfer media, thereby completing the second part of the pulse tube refrigerant sequence and putting the regenerator into condition for the first part of a subsequent pulse tube refrigeration sequence.
In the practice of this invention the pulse tube body contains only gas for the transfer of the pressure energy from the expanding pulse tube gas at the cold end for the heating of the pulse tube working fluid at the warm end of the pulse tube. That is, pulse tube refrigerator 40 contain no moving parts such as are used with a piston arrangement. The operation of the pulse tube without moving parts is a significant advantage of this invention. The pulse tube may have a taper to aid adjustment of the proper phase angle between the pressure and flow waves. In addition, the pulse tube may have a passive displacer to help in separating the ends of the pulse tube. Furthermore, the pulse tube will have a connecting line between the pulse tube warm end and pressure wave line 45 , replacing the orifice and reservoir with a mass flux suppressor such as a bellows arrangement to recover lost work.
Heat transfer medium is passed in line 7 to pump 4 and from there is pumped through line 5 to pulse tube heat exchanger 42 wherein it is cooled by indirect heat exchange with the cold pulse tube gas which was expanded into pulse tube body 1 from regenerator body 41 . Examples of heat transfer medium suitable for use in the practice of this invention include helium, neon, hydrogen, atmospheric gases such as nitrogen, argon and air, hydrocarbons such as methane, ethane, ethylene, liquefied natural gas and liquefied petroleum gas, fluorocarbons and hydrofluorocarbons such as carbon tetrafluoride and fluoroform, selected fluoroethers and hydrofluoroethers, and mixtures comprising one or more of the above.
Resulting cooled heat transfer medium is passed from pulse tube heat exchanger 42 in line 6 to forecooling heat exchanger 30 wherein it is warmed serving to cool by indirect heat exchange refrigeration fluid passed to heat exchanger 30 in line 13 . The warmed heat transfer medium is withdrawn from forecooling heat exchanger 30 in line 7 and recirculated back to the pulse tube refrigerator as was previously described.
In the embodiment of the invention illustrated in FIG. 1 the system used to provide lower level refrigeration to the refrigeration fluid is a multiple component refrigeration system wherein a multiple component refrigeration fluid recirculating in a circuit undergoes compression and expansion steps and delivers refrigeration to a heat load. In this embodiment the multicomponent refrigeration fluid preferably comprises at least one atmospheric gas preferably nitrogen, argon and/or neon, and preferably at least one fluorine containing compound having up to six carbon atoms such as fluorocarbons, hydrofluorocarbons, hydrochlorofluorocarbons, fluoroethers and hydrofluoroethers, and/or at least one hydrocarbon having up to five carbon atoms.
Referring back now to FIG. 1, compressed refrigeration fluid 13 , which in this embodiment is a multicomponent refrigeration fluid, is cooled to a first temperature within the range of from 10 to 280 K by passage through forecooling heat exchanger 30 by indirect heat exchange with the aforediscussed warming heat transfer medium. Resulting cooled refrigeration fluid 14 is further cooled by passage through heat exchanger 31 and resulting refrigeration fluid stream 15 undergoes expansion through an expansion device, such as Joule-Thomson valve 16 , to generate refrigeration. The refrigeration provided to the refrigeration fluid by the expansion through valve 16 results in the establishment of cold refrigeration fluid 17 at a second temperature, which is lower than the first temperature, and is within the range of from 3 to 150 K. The cold refrigeration fluid 17 is passed to heat exchanger 32 wherein it is warmed thereby passing refrigeration from the cold refrigeration fluid to heat load 3 . Examples of the uses of the refrigeration passed into heat lead 3 include superconducting cable cooling, industrial gas liquefaction, reliquefaction, propellant densification, air separation, and cryogenic gas separation.
The resulting warmed refrigeration fluid 18 is further warmed by passage through heat exchanger 31 and then resulting stream 19 is still further warmed by passage through forecooling heat exchanger 30 wherein it assists in the cooling of the refrigeration fluid down to the first temperature. Resulting refrigeration fluid 20 from heat exchanger 30 is compressed to a pressure generally within the range of from 50 to 2000 pounds per square inch absolute (psia) in compressor 10 . Compressed refrigeration fluid 11 is cooled of the heat of compression by passage through cooler 12 and resulting compressed refrigeration fluid 13 is passed to forecooling heat exchanger 30 and the refrigeration cycle repeats.
FIGS. 2 and 3 illustrate other preferred embodiments of the invention. The numerals in FIGS. 2 and 3 are the same as those of FIG. 1 for the common elements and these common elements will not be discussed again in detail. FIG. 2 illustrates an embodiment wherein lower level refrigeration is provided to the refrigeration fluid using a Brayton refrigerator and FIG. 3 illustrates an embodiment wherein lower level refrigeration is provided to the refrigeration fluid using a magnetic refrigerator.
Referring now to FIG. 2, Brayton system working fluid is compressed in Brayton system compressor 70 and the heat of compression is removed (not shown). Resulting refrigeration fluid 13 is desuperheated in heat exchanger 30 by returning stream 19 and by stream 6 to the first temperature. Resulting stream 14 is further desuperheated in heat exchanger 31 and expanded isentropically by Brayton system expander 71 to generate refrigeration and cool the refrigeration fluid or Brayton system working fluid to the second temperature. Resulting working fluid 17 provides refrigeration to heat load 3 in heat exchanger 32 and is then returned to the suction of Brayton system compressor 70 .
Referring now to FIG. 3, magnetic refrigerator 100 comprises magnetizable material bed 101 , moveable strong electromagnet or superconducting magnet 102 , pistons 103 and 104 , a cold heat exchanger 105 and a hot heat exchanger 106 . Examples of magnetizable material which can be used in the practice of this invention include GdNi 2 , GdZn 2 , GdTiO 3 , Gd 2 Ni 17 , GdAl 2 , GdMg, GdCd, Gd 4 CO 3 , GdGa, Gd 5 Si 4 , and GdZn. The void space surrounding the magnetic bed particles in bed 101 and the volumes in piston cylinders 107 and 108 are filled with working fluid, examples of which include helium, neon, nitrogen, argon, methane, carbontetrafluoride fluorocarbons, hydrofluorocarbons, fluoroethers and hydrofluoroethers.
At the beginning of the cycle cold heat exchanger 105 is initially at a low temperature and hot heat exchanger 106 is at a warmer temperature. Magnet 102 is used to magnetize bed 101 . The magnetocaloric effect causes each magnetic particle in bed 101 to warm slightly. Pistons 103 and 104 are moved to their extreme right position causing the enclosed working fluid, e.g. helium gas, to flow from the left cylinder 107 , through cold heat exchanger 105 , magnetic refrigerator bed 101 and hot heat exchanger 106 to fill the volume in cylinder 108 . The particles in bed 101 are cooled by the flowing gas, and the gas in turn is warmed. Heat from the gas is transferred to cooling water as the gas flows through hot heat exchanger 106 . When the pistons have reached their extreme right position the gas flow is stopped and the magnetic field is removed, cooling bed 101 by the magnetocaloric effect. Pistons 103 and 104 are moved back to their extreme left positions causing the helium gas to flow from cylinder 108 , through hot heat exchanger 106 , magnetic refrigerator bed 101 and cold heat exchanger 105 into cylinder volume 107 . The helium gas is cooled by direct heat exchange as it passes through bed 101 , and is warmed in cold heat exchanger 105 as it provides refrigeration into cooled refrigeration fluid to produce the cold refrigeration fluid at the second temperature which is further processed as was previously described. In this embodiment the refrigeration fluid is passed through the refrigeration fluid circuit by operation of pump 72 .
In Table 1 there is tabulated the calculated energy requirements, in kilojoules per kilogram, to cool helium to 4.3 K using each of the three illustrated embodiments of the invention wherein the pulse tube refrigerator generates refrigeration from 300 K to 50 K and each of the multicomponent refrigerant cycle (A), Brayton refrigerator (B) and magnetic refrigerator (C) generate the refrigeration from 50 K to 4.3 K. For comparative purposes there is also shown, as comparative example D, the energy requirements for going from 300 K to 4.3 K using only a pulse tube system. As can be seen, the hybrid refrigeration system of this invention with the upstream pulse tube refrigerator enables a significant reduction in the energy requirements for the provision of comparable refrigeration over systems which employ only pulse tube refrigeration.
TABLE 1
Refrigeration
Energy
System
Required
A
58,100
B
45,200
C
40,800
D
707,100
Although the invention has been described in detail with reference to certain preferred embodiments, those skilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims. | A system for providing refrigeration to a heat load, especially over a larger temperature range and at a cryogenic temperature, wherein pulse tube refrigeration cools a heat transfer medium to provide higher level refrigeration to a refrigeration fluid, and lower level refrigeration is provided to the refrigeration fluid using a non-pulse tube system. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The instant patent application claims priority to and the benefit of pending U.S. Provisional Patent Application Ser. No. 61/142,693, filed on Jan. 6, 2009, titled “Field Installed Lug Landing Accessory,” the entire disclosure of which provisional application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a lug landing accessory. More particularly, the invention encompasses a field installed lug landing accessory. The present invention is also directed to a novel lug landing kit that can be installed by an installer in the field. The invention further comprises a lug coupler comprising a set of bus bars, each of the set of the bus bars are secured to an electrically non-conductive housing of the lug coupler. The bus bar has at least one opening for the passage of at least one electrically conductive protrusion, and the bus bars are electrically connected to at least one corresponding breaker strap.
BACKGROUND INFORMATION
[0003] During the installation process of many modular panel boards, it becomes necessary for some applications to be electrically connected to the modular panel boards with specific connectors and/or lugs. In the case of existing units, a kit or means to easily or affordably provide such an electrical connection does not exist. For some applications the installers usually purchase a separate panel board accessory that mounts next to a standard unit so these specific connectors can be installed. This additional separate panel board unit or accessory takes up precious wall space. In some cases the installers prefer not to give up that extra wall space or in other situations there many not be extra wall space available in the vicinity of the modular panel board. Other manufacturers have their own solution to solve this problem. Some manufacturers have overcome the wall space issue, but they have put a burden on the supply chain in order to build these special units, while at the same time supporting a standard line of product.
[0004] Therefore there is a need for improvement in a lug landing accessory and in particular a field installed lug landing accessory.
[0005] U.S. Pat. No. 5,989,073 (Scott D. Kahoun), the entire disclosure of which is incorporated herein by reference, discloses a power block including an insulative block which is mounted to a panel and a plurality of connection mounts which are coupled to the insulative block. The insulative block includes a plurality of molded dividers and the connection mounts are located therebetween. Each connection mount includes at least one stud extending upward from the block and a conductor having first and second portions. The first portion of each conductor is conductively coupled to the one or more studs and the second portion extends through the block in a direction opposite the one or more studs. The second portion includes a free end provided with a connector directly couplable to a destination point. A preferred aspect of the invention is that the conductor is a copper braid partially covered in a tin plated copper sleeve. According to a first embodiment, the connector at the free end of the conductor is a sleeve extending over the free end and having a hole for directly receiving a lead from a power filter. According to a second embodiment, the second portion of the conductor is formed of solid copper and the connector is a tapered free end of the second portion of the conductor which is “pluggable” into resilient clips. According to a third embodiment, the second portion of the conductors are substantially elongate and flexible, and the connector at the free end is a sleeve having a coupling slot or hole.
[0006] U.S. Pat. No. 6,379,196 (Randy Greenberg, et al.), the entire disclosure of which is incorporated herein by reference, discloses a termination connector for a circuit breaker. The termination connector preferably includes a plurality of single pole screw receiving members integrally attached by a molded housing for unitary attachment to a line or load end of a circuit breaker to assist in holding a nut or nut plate adjacent each screw hole in the circuit breaker's terminal straps. The molded housing preferably includes a line of perforations between each single pole screw receiving member so that the correct number of single pole screw receiving members can be retained and the others can be knocked off along the line of perforations. Provisions are disclosed for adaptation of the connector to metric or English standard nut hardware. In addition, the termination connector and circuit breaker are provided with mating attachment devices for providing a simple yet secure connection.
[0007] U.S. Pat. No. 7,578,711 (Kristopher Scott Robinson), the entire disclosure of which is incorporated herein by reference, discloses certain exemplary embodiments that can provide a system, which can comprise a lug coupler that comprises a set of bus bars. Each of the set of bus bars can be adapted to be releasably attached to a corresponding terminal of a set of terminals of a circuit breaker. The system can comprise a set of studs adapted to engage a corresponding set of apertures defined by an end connector of one of a set of electrical leads adapted to be electrically coupled to the lug coupler.
[0008] However, this invention overcomes the problems and deficiencies of the known art and provides an inventive field installed lug landing accessory, which can be easily field installed on a standard line of panel board accessories. This invention also resolves any supply chain burden and provides the installer with a product that they can electrically connect to with their specific connector and/or lugs. This inventive accessory also complies with all agency requirements, i.e., UL, for use in the product in which this inventive accessory can be field installed.
PURPOSES AND SUMMARY OF THE INVENTION
[0009] The invention is a novel field installed lug landing accessory.
[0010] Therefore, one purpose of this invention is to provide a field installed lug landing accessory.
[0011] Another purpose of this invention is to provide a reliable solution for field installing lugs.
[0012] Yet another purpose of this invention is to provide a robust lug landing kit that can be field installed.
[0013] Therefore, in one aspect this invention comprises a lug landing pad apparatus, comprising:
[0014] a lug coupler comprising a set of bus bars, each of said set of bus bars secured to an electrically non-conductive housing of said lug coupler, said bus bar having at least one opening for the passage of at least one electrically conductive protrusion, said bus bar electrically connected to at least one corresponding breaker strap, and thereby forming said lug landing pad apparatus.
[0015] In another aspect this invention comprises a lug landing pad apparatus, comprising:
[0016] a lug coupler comprising a set of bus bars, each of said set of bus bars snapably connected, via an engagement of at least one bus bar snap, to an electrically non-conductive housing of said lug coupler, said bus bar having at least one opening for the passage of at least one electrically conductive protrusion, said bus bar electrically connected to at least one corresponding breaker strap, and thereby forming said lug landing pad apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Although the scope of the present invention is much broader than any particular embodiment, a detailed description of the preferred embodiment follows together with drawings. These drawings are for illustration purposes only and are not drawn to scale. Like numbers represent like features and components in the drawings. The invention may best be understood by reference to the ensuing detailed description in conjunction with the drawings in which:
[0018] FIG. 1 illustrates a front isometric view of the completed lug landing pad assembly of a first embodiment of this invention.
[0019] FIG. 2 illustrates a side view of the completed lug landing pad assembly of the embodiment of this invention as illustrated in FIG. 1 .
[0020] FIG. 3 illustrates a rear isometric view of the completed lug landing pad assembly of the first embodiment of this invention as illustrated in FIG. 1 .
[0021] FIG. 4 is a detailed view showing the detail 4 , from FIG. 3 , which is an enlarged view showing the bus bar snap of this invention engaged with an edge of the bus bar.
[0022] FIG. 5 is a detailed view showing the detail 4 , from FIG. 3 , which is an enlarged view showing the bus bar snap of this invention but without the bus bar.
[0023] FIG. 6 illustrates a detailed cut-away view of a second embodiment of this invention illustrating in detail the profile of the A, B, and C phase cavities along with the corresponding bus bars and bus bar snaps.
DETAILED DESCRIPTION
[0024] The inventive field installed lug landing pad accessory of this invention provides an alternative wiring option for contractors, electricians, or anyone who might install a circuit breaker in a standard panel board accessory. This inventive lug landing pad accessory can be field installed during the installation process, and it provides the convenience of installing compression or mechanical/pressure connectors and/or lugs on a standard line of panel board accessories.
[0025] It should also be appreciated the way in which this lug landing pad accessory is assembled. The conservation of wall space, especially the width of the unit, during the installation process which is rather important in this industry is also achieved with this invention. This inventive lug landing pad accessory has been designed to minimize width, as required for multiple studs per phase arrangements. In addition to this, this inventive lug landing pad accessory design reduces the metal scrap associated with connecting multiple studs per phase arrangement bussing to a circuit breaker. This is achieved by forming the circuit breaker connecting bus in a z shape and having a second set of connector/lug connecting bus (out of the same material or a different material) also formed in a z shape attached to one another. Mechanically fastening these two z shaped bus bars of this invention allows the current path to change from a direction that is parallel to the bussing of the circuit breaker to a direction that is perpendicular to the circuit breaker. All of this is achieved using standard width bussing and without creating any scrap material.
[0026] It should be understood that all of the phase bussing is coupled together by the use of a lug landing base or pad. This lug landing pad is made out of a non-electrically conductive material, such as, for example, plastic. The bus bars are fastened to the plastic base by the use of securing means, such as, snaps. Mechanical fasteners for attaching connectors and/or lugs to the bus are also retained by the lug landing base. This inventive assembly preferably travels as a kit and preferably contains no loose parts. This inventive kit makes it very easy to convert a standard circuit breaker unit to one that will accept the specific connectors and/or lugs as required by some of the customers or applications.
[0027] FIG. 1 illustrates a front isometric view of a completed lug landing pad assembly or kit or apparatus 23 , of a first embodiment of this invention. This completed lug landing pad assembly or kit or apparatus 23 , has a support base or an electrically non-conductive housing 20 , at least one electrically conductive protrusion 14 , such as, a stud 14 , and at least one bus bar 18 . To assemble a bus bar 18 , to the support base 20 , one could simply slide the bus bar 18 , in the appropriate support base phase cavity until at least one bus bar snap 28 , engages with at least one bus bar edge 19 , of the bus bar 18 , as more clearly illustrated with reference to FIG. 4 . The electrically non-conductive housing 20 , has at least one mounting tab or feet 22 , which can be used to secure the lug landing apparatus 23 , to a modular panel board (not shown). It is preferred that the bus bar snap 28 , has an open area or bus bar snap cavity or opening 29 , so as to allow the bus bar snap 28 , to be able to move vertically when it either engages or disengages from the bus bar edge 19 . In order to further secure or strengthen the electrically non-conductive housing 20 , one could have at least one rib or strengthening feature 27 . For most applications it is preferred that the bus bar 18 , has at least one opening 13 , to allow for the passage of the stud 14 . It is preferred that the stud 14 , is a NEMA stud 14 . The electrically non-conductive housing 20 , is also preferably provided with at least one bus bar rail or track 24 , 34 , which allow for the sliding motion of the bus bar 18 , into and out of the electrically non-conductive housing 20 . The bus bar rail or track 24 , tracks or holds one edge of the bus bar 18 , while the bus bar rail or track 34 , tracks or holds the opposite edge of the bus bar 18 . In order to control or stop the movement of the bus bar 18 , along the bus bar rail or track 24 , 34 , the electrically non-conductive housing 20 , could also have at least one bus bar stop 26 . It is preferred that the bus bar stop 26 , works in conjunction with the bus bar snap 28 , this way when the bus bar 18 , is positioned into the electrically non-conductive housing 20 , the bus bar stop 26 , stops the movement of the bus bar 18 , at one end of the bus bar 18 , while the other end or the bus bar edge 19 , is engaged by the bus bar snap 28 . The electrically non-conductive housing 20 , can also have at least one insulation phase barrier or isolation tab 30 , to electrically insulate or isolate the various bus bar 18 , phases, such as, for example, A-Phase bus bar 11 , B-Phase bus bar 21 , C-Phase bus bar 31 . The lug landing apparatus 23 , is also provided with at least one breaker strap 10 . For some applications it is preferred that the breaker strap 10 , has at least one breaker strap laminate 15 . The breaker strap 10 , could also have at least one hole or opening 12 , for securing means (not shown), such as, a screw, a bolt, a rivet, to name a few. For some applications the breaker strap 10 , having the breaker strap laminate 15 , helps in heat sink purposes. For some applications the mounting feet or tab 22 , can also be used for fastening or securing the lug landing apparatus 23 , to at least one mounting bracket in the main breaker enclosure (not shown).
[0028] FIG. 2 illustrates a side view of the completed lug landing pad assembly 23 , of the embodiment of this invention as illustrated in FIG. 1 . As one can see that the bus bar 18 , is held in place at one end by the bus bar stop 26 , and by the bus bar snap 28 , at the opposite end. It is preferred that the stud 14 , has a head or a similar feature 16 , which is securely held inside the electrically non-conductive housing 20 . The stud 14 , could also be carriage bolt 14 , having a head 16 . The breaker strap 10 , along with the breaker strap laminate 15 , is electrically connected to the bus bar 18 , and is securely held inside the electrically non-conductive housing 20 , via at least one securing means 42 . The securing means 42 , could be a fastener, a hex bolt fastener, a rivet, a weld, to name a few. As illustrated in FIG. 2 , the securing means 42 , passes through an opening or hole 43 , in the bus bar 18 , and the breaker strap 10 , and is secured to another fastening means 44 . The fastening means 44 , could be a nut, a hex nut, a rivet, a weld, to name a few. It is preferred that the electrically non-conductive housing 20 , has at least one cavity 49 , to accommodate the securing means 42 , the fastening means 44 , and the related components that are secured via the securing means 42 , and the fastening means 44 .
[0029] FIG. 3 illustrates a rear isometric view of the completed lug landing pad assembly 23 , of the first embodiment of this invention as illustrated in FIG. 1 . As one can see that the bus bar 18 , is held on one side via the bus bar snap 28 , while the two adjacent sides of the bus bar 18 , are held within the bus bar rail or track 24 , 34 , and the forth edge of the bus bar 18 , is held in place via the bus bar stop 26 . The enlarged view of the bus bar snap area or detail 4 is more clearly shown with reference to FIG. 4 . The ribs 27 , can also be strengthening ribs 27 , which can be used to prevent the movement of the bus bar 18 , especially, during the application of tightening torque on the connector studs 14 . The electrically non-conductive housing 20 , can also be provided with at least one rib 37 , to further strengthen the electrically non-conductive housing 20 .
[0030] FIG. 4 is a detailed view showing the detail 4 , from FIG. 3 , which is an enlarged view showing the bus bar snap 28 , of this invention engaged with an edge 19 , of the bus bar 18 . As one can see that the electrically non-conductive housing 20 , has a bus bar snap cavity or opening 29 , to allow pivotal movement of the bus bar snap 28 , when it is used to either engage or disengage from the bus bar 18 . The ribs 37 , can also be strengthening ribs 37 , which can be used to prevent cracking of the base of the electrically non-conductive housing 20 , especially, during the application of tightening torque on the connector studs 14 . For some applications the rib 37 , can also be used as a spacer 37 .
[0031] FIG. 5 is a detailed view showing the detail 4 , from FIG. 3 , which is an enlarged view showing the bus bar snap 28 , of this invention but without the bus bar 18 . The bus bar snap 28 , preferably has a bus bar snap extension 39 , which is held in place via rib or bus bar snap rail 38 . The bus bar snap extension 39 , could also be secured or welded to the rib or bus bar snap rail 38 . The bus bar snap extension 39 , allows for the pivotal movement of the bus bar snap 28 . For some applications the rib or bus bar snap rail 38 , could also be used as a spacer 38 , or as a resting surface 38 , for resting or holding the surface of the bus bar 18 . For some applications the rib or bus bar snap rail 38 , could be strengthening ribs 38 , to further strengthen the electrically con-conductive housing 20 . The bus bar rail or track 24 , 34 , can be a channel like feature 24 , or a flat step like surface 34 , or just a flat wall surface 24 , 34 .
[0032] FIG. 6 illustrates a detailed cut-away view of a second embodiment 33 , of this invention illustrating in detail the profile of the A, B, and C phase cavities along with the corresponding bus bars 18 , and bus bar snaps 28 . Also shown in FIG. 6 is the phase stud arrangement and bus hardware used in this particular embodiment 33 . Bus hardware is optional and could be replaced with welds or other fastening methods. The construction of the embodiment 33 , shown in FIG. 6 consists of at least two sets of studs 14 , per phase. The number of sets of studs 14 , is dependent on the amperage required for the end use. To clarify, there are preferably two studs 14 , per set, and a set includes at least one stud 14 , assembled towards the front of the lug landing pad assembly, and one towards the back of the lug landing pad assembly. It should be appreciated that A-phase bus bar 11 , is electrically connected to an A-phase breaker strap 10 , while a B-phase bus bar 21 , is electrically connected to a B-phase breaker strap 10 , and the C-phase bus bar 31 , is electrically connected to a C-phase breaker strap 10 . For some applications the electrically non-conductive housing 20 , could have at least one rib 47 . The rib 47 , can be used as a spacer 47 . The rib 47 , can also be used to strengthen the electrically non-conductive housing 20 .
[0033] The electrically non-conductive housing 20 , is made from a material, such as, for example, nylon, polytetrafluoroethylene (PTFE), plastic, electrically non-conductive material, electrically non-conductive composite material, to name a few.
[0034] The breaker strap 10 , the stud 14 , the bus bar 18 , are made from an electrically conductive material, such as, for example, copper, aluminum, silver, electrically conductive metallic material, electrically conductive composite material, to name a few.
[0035] It should be appreciated that the embodiments are shown in a three-phase electrical configuration, however, a person skilled in the art can easily modify the lug landing apparatus 23 , 33 , into a single-phase configuration, such as, by not installing center bus lugs.
[0036] While the present invention has been particularly described in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention. | The present invention relates generally to a lug landing accessory. More particularly, the invention encompasses a field installed lug landing accessory. The present invention is also directed to a novel lug landing kit that can be installed by an installer in the field. The invention further comprises a lug coupler comprising a set of bus bars, each of the set of the bus bars are secured to an electrically non-conductive housing of the lug coupler. The bus bar has at least one opening for the passage of at least one electrically conductive protrusion, and the bus bars are electrically connected to at least one corresponding breaker strap. | 7 |
FIELD OF THE INVENTION
The present invention relates to pole line hardware and further relates to the class of devices which will, upon insertion of a cable, wire or conductor, initiate and maintain a continuous gripping action to prevent premature release of the cable. More particularly the present invention relates to such devices which are also range taking in the sense that cables of various diameters may be accommodated by the device.
BACKGROUND OF THE INVENTION
Devices are known in the art which purport to grip a cable inserted therein and they are to some extent useful. The devices known to the inventor are, however, non-range taking and provide no means for insuring that the cable remains within the holder when subjected to impact or severe vibration or loss of tension in the cable, such as may occur when a pole is hit by a vehicle, when lines are crossed by fallen trees, or when violent gusty winds occur. The known devices employ a housing having a frusto-conical cavity therein within which a set of conical segments are free to move axially. The conical segments have a combined outer diameter which causes them to wedge against the housing at a predetermined minimum diameter, and when so wedged, the sides of the segment abut to form a cone with an axial bore therethrough. As will be appreciated, this structure imposes a strict limit on the cable size which can be properly gripped for a given device. Accordingly, prior practice has been to build a plurality of devices of varying size to handle a variety of cable sizes.
Yet another problem with the prior art are two opposite extremes which may occur in operation. One extreme occurs when the gripper elements become so tightly wedged in the housing that they cannot be removed, thus the device is not reusable. The other extreme occurs when the tension in the cable is lost and the grippers move into a larger volume inside the housing such that the gripping action is lost and the cable escapes the gripper or moves axially in the device. When tension is restored to the cable, obviously untoward results may occur.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a cable gripping device which is automatic in the sense that it grips and retains the cable upon insertion thereof into the device.
Another object of the invention is to provide a device which is range taking such that a number of different cable diameters may be accommodated by a single device.
Yet another object of the invention is to provide such a device which will not loosen its grip on the cable due to adverse conditions or loss of tension in the cable.
Still another object of the invention is to provide such a device wherein the grippers may be retracted to release the cable such that the apparatus is reusable.
An object of the invention and of each of the above objects is to make it easier for the lineman to secure the cable, thereby promoting efficiency in installation, maintenance and cost management.
The present invention accomplished these objects as well as other novel advantages through the unique utilization of a plurality of component parts, one of the most significant of which is the gripper element itself. In contrast to the prior art, the gripper element is not conical but rather is planar and moves in a planar longitudinally extending guideway. The gripper elements are wedge-shaped members which do not encircle the cable and are attached to a gripper guide and retractor which can retract the grippers from their cable-engaging position. Numerous other features of the novel construction will become apparent from a study of the appended drawings and the description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
Apparatus embodying features of my invention are disclosed in the accompanying figures which form a portion of this disclosure and wherein:
FIG. 1 is an exploded perspective of the apparatus with the component parts separated for purposes of illustration;
FIG. 2 is a sectional view taken perpendicular to the longitudinal centerline of the apparatus showing the locking cover removed;
FIG. 3 is a section view taken as in FIG. 2 with the locking cover secured to the housing;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a sectional view of a second embodiment of the apparatus taken perpendicular to the longitudinal centerline of the apparatus;
FIG. 6 is a sectional view as in FIG. 5 showing the locking sleeve holding the grippers against a cable;
FIG. 7 is a sectional view as in FIG. 5 showing the apparatus in the operative position;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 5;
FIG. 9 is a perspective view of the apparatus of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings for a clearer understanding of the invention it may be seen in FIG. 1 that the apparatus includes a housing 11 which defines a substantially conical cavity extending from a minor opening 12 to a major opening 13, that is a smaller end to a larger end and being open at both ends. A cable 14 is received through the minor opening 12 for retention within the housing 11. As used herein, the term cable means any cable, wire, conductor or like element which would be placed under tension in an electrical distribution system or the like. The housing 11 has an inner surface 16 which is generally frusto-conical extending from its apex near the minor opening 12 to its base at the major opening 13. Formed in the inner surface 16 are a pair of opposed rectangular guide recesses 17 which have a planar surface 18 inclined substantially parallel to the inner surface 16 and aligned longitudinally to the housing 11. Cooperatively positioned for sliding movement within and along the recesses 17 are a pair of gripper elements 19, each of which have a planar outer surface 21 aligned with surface 18 and a cable engaging surface 22 substantially parallel to the longitudinal axis of the housing 11. To facilitate the sliding of the gripper elements 19, to reduce wear, and to reduce the need to machine planar surface 18, a pair of smooth metallic pressure bearing slides 23 may be fitted into the recesses 17 intermediate the planar surface 18 and the gripper elements 19.
As may be seen in the figures, the gripper elements 19 are not conic sections but rather are wedge shaped, tapering toward the minor opening 12 of the housing. A flat bearing surface 24 perpendicular to the longitudinal axis of the housing is formed in the larger end of the gripper elements 19 and abuts an annular bearing member 26 or spring bearing washer. Proximal the larger end of the gripper elements 19 and opening toward the center of the housing is a groove or recess 27 which extends transversely across the width of the gripper element 19, forming a tab 28 between the flat bearing surface 24 and the groove 27.
A tubular retractor guide 29 extends concentrically through the annular bearing member 26. The retractor guide has an inner end which forms an annulus 31 and stirrup 32 combination such that the stirrup 32 connects the annulus 31 to the remainder of the retractor 29 and defines a spaced region 33 between the annulus 31 and the retractor 29. As may be seen in FIGS. 2, 3, 5, 6 and 8, the annulus 31 is sized to fit into the groove 27 and the tab 28 fits into the spaced region 33 such that the gripper elements 19 and retractor are connected for concomitant annular and axial movement, however the gripper elements 19 may move radially relative to the retractor 29 without disengaging therefrom. The outer surface of the retractor 29 is threaded as at 37. Mounted concentrically about the retractor 29 and abutting the annular bearing member 26 is a compression spring 34 which, as shown in FIGS. 2 and 4, is a somewhat conical spring with the end thereof distal the annular bearing member 26 resting in an axially opening internal groove 36 formed internally of the housing 11 at the base of the cavity. As may be seen this spring 34 biases the gripper elements towards the apex of the cavity.
A second tubular element or retractor 38, having an internal threaded surface 39, cooperatively engages the retractor guide 29 such that rotation of the retractor 38 causes the retractor guide 29 to move axially within the retractor 38, thus moving the gripper elements 19 axially within the housing 11. The retractor 38 has an outer end on which a radially extending flange 40 or head is formed for cooperative engagement thereof by a turning tool such as a wrench. Note in FIG. 2 and 3 that the flange 40 has an outside diameter greater than the inside diameter of the housing 11 at the major opening 13 and that the housing is threaded as at 41 on its outer surface proximal the major opening 13. An annular cap 42 having an internal threaded surface 43 and a sufficient axial depth to enclose the flange 40 is provided and can be threadedly engaged on the threads 41 of housing 11 such that the retractor 38 is confined within the housing 11 and cap 42 with the inner surface 44 of the cap 42 holding flange 40 against the housing.
An alternative embodiment is shown in FIGS. 5 and 6. Note that in this embodiment a lock down sleeve 46 is threadedly engaged within the major opening 13 of housing 11 and has a spring seat formed therein to receive compression spring 34 within. The sleeve is concentric about the spring 34, the retractor guide 29, and the retractor 38, and is of sufficient length that the inner end thereof 47 may be urged against annular bearing member 26 while the cable is held by the gripper elements 19. The outer end of the sleeve 46 has an annular flange 48 formed thereon and adapted for engagement by a turning tool. Also note that the retractor 38 extends completely through the sleeve 46 with flange 40 in abutting relationship with the outer end of sleeve 46.
Regardless of which embodiment is utilized, the gripping action and range taking action is the same. As may be seen in FIGS. 3 and 4, the gripper elements 19 are restrained from rotational movement by the sidewalls of recess 17 and have gripping faces 22 which are independent of the diameter of the cable inserted. Thus the limiting factor on the size of the cable which can be secured by the apparatus is the size of the opening available along the axis of the housing.
Note that the embodiments shown in FIGS. 1-3, 5 and 6 also include a pulling eye 51 formed on the housing to facilitate tensioning the cable 14 after insertion. FIG. 9 illustrates an optional bail 52 which is a U-shaped metallic rod having a knob 53 formed on each end thereof and having a flattened region 54 spaced from each knob 53. A pair of bail receptacles 56 are formed on opposite sides of the housing and have formed therein a seat 57, a laterally opening slot 58, and a circular passageway 59 bisected by the slot 58. The slot 58 is smaller than the diameter of the bail 52, yet wide enough to allow the flattened region 54 pass therethrough, thus the bail 52 is attached by aligning the flattened regions 54 with the slot 58 and inserting the region into the slot. Once inserted, the bail may be drawn axially along the passageway 59 to seat the knob 53. The flattened region is thus out of alignment with the slot and therefore the bail cannot move laterally through the slot.
In operation, a cable 14 is inserted through the minor aperture 12 and encounters the gripping elements 19. The formed inner edge 61 of the elements 19 is beveled such that axial pressure applied by urging the cable thereagainst urges the gripper elements 19 against the spring 34 and outwardly such that the cable passes between the faces 22 thereof and through the retraction guide 29. As shown in FIGS. 3, 6 and 8, the cable 14 may extend completely through the apparatus. As is well known in the art, attempted retraction of the cable 14 wedges the gripper elements between the cable 14 and the housing 11 thus firmly securing the cable 14 in the apparatus. To lock the apparatus shown in FIG. 2 to the cable, the retractor 38 is turned to bring the flange 40 into contact with the housing 11 and the annular cap 42 is threaded onto the housing 11 to capture the flange 40 and hold it in place. Thus, even if the tension in the cable 14 is released the gripping elements 19 are held in place by the retractor guide 29 which is engaged by the retractor 38 which cannot move, therefore the cable 14 remains securely held within the apparatus. When it is desired to remove the apparatus from the cable 14, the end cap 42 is removed using a conventional turning tool such as an adjustable wrench and the retractor 38 is rotated, while bearing against the housing 11 such that the threaded connection therewith of the retractor guide 29 causes the retractor guide to be urged toward the major aperture 13, thus pulling the guide elements 19 along therewith into a region of larger diameter such that the gripper elements are not urged against the cable. Note that the compressive force of the spring 34 is overcome by the movement of the retractor 38. In the alternate embodiment locking of the gripper 19 to the cable -4 is accomplished by rotating locking sleeve 46 until the inner end thereof abuts the annular bearing element 26 and thus urges the gripper elements against the cable 14. To release the cable 14, the locking sleeve 46 is rotated to move toward the major aperture 13 and then the retractor 38, with flange 40 bearing against the sleeve 46 is rotated as previously described.
To those familiar with the art, the foregoing embodiments present a marked improvement over the cable ends currently in use and provide consistent lockable gripping action which can be selectively released without damage to either the cable or device. It should also be understood that the present invention may be configured as a splice by connecting a pair of the disclosed embodiments with the major opening 13 in abutting relationship.
While I have shown my invention in various forms, it will be obvious to those skilled in the art that it is not so limited but is susceptible of various changes and modifications without departing from the spirit thereof. | An automatic, lockable, and releasable range-taking cable connection for use in pole line application utilizes a pair of spring loaded gripper elements movable on inclined planar surfaces within a housing, with the gripper elements connected to a retractor mechanism that translates rotational motion of a retractor into axial movement of the grippers to release the same from the cable. A rotatable locking sleeve or cap is used to secure the gripper elements in locked position when in normal use. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to materials for storage of coded information and methods of fabricating such materials, and more particularly to such materials which are designed specifically for optical information storage and their production.
BACKGROUND INFORMATION
Optically retrievable information storage systems have been commercially available for some time in the form of video discs and audio discs (more commonly referred to as compact discs, i.e., CDs). More recently, systems in other formats such as optical tape (Gelbart U.S. Pat. No. 4,567,585) and data information cards like those developed by Drexler Technology Corporation, Mountain View, Calif. (Drexler U.S. Pat. No. 4,544,835) are beginning to attract commercial attention.
Information carriers or storage media such as video discs and audio discs are often referred to as read-only memories (ROM). The information is typically stored as extremely small structural relief features which are permanently molded into the substrate during the manufacturing process. Optical retrieval of such data is typically accomplished through differential reflection techniques using a laser light source.
In addition to ROM media, both write-once media and write-read-erase systems have been recently introduced into the marketplace in disc, card, and tape formats. Typically, these systems utilize a diode laser to both "read" and "write" coded information from and to the medium. Data can be of several forms: that which includes some permanent prerecorded data (similar to ROM) in addition to that which can be permanently formed by the laser through direct or indirect interaction by the user (write-once); that in which all the information is recorded by the laser; or that which can be interactively formed and removed by the laser (write-read-erase).
Write-once applications for optical information storage are often referred to as "direct-read-after-write" (DRAW) or more recently, "write-once-read-many" (WORM) media. In this application, the optical storage medium (disc, card or tape) may be already preformatted with the appropriate tracking and associated access information. Some of the media incorporate suitably reflective and active layers into a multilayered structure.
Functionally, the basic performance criteria associated with these different media formats are very similar, the most important of which are data input sensitivity and archival stability. Information is stored in the write-once systems as micron-sized optically readable "spots". These spots can be created in a thin absorbing layer above the reflective metal layer or can be formed directly in the metal layer within the medium using a focused laser beam as the writing source (pulsed, high power). The data is "read" by scanning the laser (CW, low power) back over the spots and monitoring the intensity of the reflected laser light
Information can be placed on these optical memories in extremely high densities, the theoretical limit being determined by the absolute resolving power of a laser beam focused down to its diffraction-limited size (λ/2NA, wherein λ is the wavelength of the laser and NA is the numerical aperture of the focusing beam optics). Presently, most write and read lasers being employed operate within a wavelength range of 780 to an 830 nm. However, in order to increase memory density, shorter wavelength (down to 300 nm or less wavelengths) are being tested throughout the industry. The information stored in these write-once media is, in principle, capable of being optically accessed an infinite number of times.
Mechanically, there are differences between the tape, disc and card formats which make it difficult for one thin-film system to work as a universal write-once active layer. For example, discs which are based on alloys of tellurium, selenium and/or their oxides have been developed as ablative write-once media using conventional sputtering technology. These discs are typically put together in a rigid, air-sandwiched construction to enhance environmental stability while maintaining compatibility with the ablative writing mechanism (i.e., the writing laser beam directly melts away the metal layer to form the information spot).
Tape, on the other hand, is a nonrigid medium and must be flexible enough to accommodate motion around the small hubs and rollers associated with tape handling. Additionally, because tape is in constant frictional contact with itself and the roller mechanisms, optical tape must be abrasion resistant. This protection is best afforded by some type of thin film hard overcoat However, this hard overcoat in direct contact with the active layer renders the active layer less sensitive to laser writing.
Cards, which traditionally have been considered low-end media, require many of the criteria associated with both tape and disc formats. Like discs, cards are functionally rigid media. When they are in the optical drive the media do not experience any of the same frictional or bending forces associated with tape media. However, outside the drive, the media must be able to withstand the forces associated with external handling and storage by the consumer. Surface abrasion and bending are commonplace for media used in credit card applications.
There are other differences and similarities which exist between the three media formats, but due to the variety of potential thin-film layers being developed as write-once media and the large number of diverse drive designs, many of the precise requirements for these three types of media are still in the process of being standardized. For example, media performance standards such as write sensitivity, carrier-to-noise ratio (CNR), data bit size, and reflectivity level will be dependent on the end-use for the specific system. No one thin-film system has been able to meet all the criteria which are required to make the media compatible with the various media drives.
As noted above, tellurium and selenium alloys are among materials that have been used heretofore. The reflective layer can be deposited by sputtering, vacuum evaporation, chemical plating or the like. In some cases, this reflective layer (film) is overcoated with one or more semitransparent or transparent polymer layers.
In 1991, U.S. Pat. No. 5,016,240 described the use of a highly reflective soft metal alloy reflective metal layer for information storage. The soft metal alloy is flexible and can be manufactured into any of the three formats, tapes, cards or discs. Representative techniques for depositing layers of this alloy include vacuum evaporation and sputtering.
SUMMARY OF THE INVENTION
The present invention provides an improvement in the use of soft metal alloys in optical recording media and in the manufacturing of layers of this alloy in such media.
The present invention offers improved optical memory storage media based on soft metal alloys and an improved vacuum deposition method of fabricating the same. The present invention utilizes an oxidant-containing atmosphere in a vacuum deposition process to produce an optical memory storage medium with enhanced properties, i.e., less surface inhomogeneities, less phase segregation of the alloy, improved laser write sensitivity, improved environmental stability (oxidation and moisture resistance), lower noise characteristics, improved signal, improved carrier-to-noise level and improved modulation depths. The oxidant present in the sputtering gas atmosphere is an oxygen-containing gaseous species, such as oxygen gas, water vapor, carbon dioxide, nitrogen oxide, or the like.
The medium which results is characterized by having the soft metal alloy present as a partial oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be further described with reference being made to the accompanying drawings, in which
FIG. 1 is a schematic cross-section of a magnetron sputtering machine capable of producing the products of this invention.
FIG. 2 is a cut-away perspective view of a sputtering cathode minichamber useful in a sputtering machine as depicted in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present optical recording media include a substrate having a thin film of a flexible metal alloy adhered to one or both sides wherein the alloy is present in a uniform, partially oxide form. By partial oxide is meant that not all of the metal atoms have been converted to their oxide form.
Any material normally used for substrates for making optical media known in the art can be used. For example, the substrates can be selected from solid materials such as rigid or reinforced plastic or glass or can be a flexible plastic or additionally any of the above classes of substrate with a subbing layer adhered to the surface(s) to be coated.
Examples of representative plastic media include polyester films, especially polyethylene terephthalate (PET), polycarbonate, polyacrylate, polymethylmethacrylate, polystyrene, polyurethane, polyvinylchloride, polyimide and the like.
Polyester, and especially polyethylene terephthalate, and polycarbonate are preferred plastics because of their hardness, clarity and scratch-resistance.
Examples of representative subbing layers include UV-cured acrylics, siloxanes, Teflon®, SiO 2 and the like. UV-cured acrylics are preferred subbing layers because they cause no decrease in performance of the media and improve the adhesion of the metal layer to the substrate.
The substrates can be in a form suitable for forming discs, cards or tapes. This is generally in film or sheet form ranging in thickness from about 0.5 mil to about 60 mil.
The metal layer is a highly reflective soft metal alloy which is partially oxidized. The highly reflective soft metal alloy comprises at least 5% by weight of each of at least two metals selected from the group consisting of cadmium, indium, tin, antimony, lead, bismuth, magnesium, copper, aluminum, zinc and silver.
As examples (all are percent by weight), the metal alloy can comprise of about 5 to about 95% tin, about 5 to about 95% bismuth, and 0 to about 40% copper, about 5 to about 95% tin, about 5 to about 95% bismuth and 0 to about 49.9% silver; about 5 to about 95% cadmium, about 5 to about 95% zinc and 0 to about 49.9% silver; about 5 to about 95% zinc, about 5 to about 95% cadmium and 0 to about 10% magnesium; about 5 to about 95% bismuth, about 5 to 95% cadmium and 0 to about 49.5% silver; about 0.1 to about 95% tin and about 5 to about 99.9% of indium; about 5 to about 95% tin, about 5 to about 95% lead, and 0 to about 40% copper; about 5 to about 95% tin, 5 to 95% lead and 0 to 49.9% silver; about 40 to about 94% tin, about 3 to about 30% antimony, about 3 to about 37% bismuth and 0 to about 40% copper; at least about 8% tin, at least about 8% bismuth and at least one of Mg, Au, Fe, Cr, Mn, Cu, Ag and Ni(at least about 1%) wherein Bi is present in an amount greater than any of Mg, Au, Fe, Cr, Mn, Au, Ag and Ni. Layering materials having these compositions are defined herein as "soft metal layers," "soft metal alloy layers," and "flexible metal alloy layers." A preferable alloy is made up of about 25 to about 90% tin, about 8 to about 60% bismuth and about 1 to 25% copper.
Soft metal alloys which comprise predominantly tin, i.e., 55-80%; a major amount of bismuth, i.e., 20-35%; and an amount of copper, i.e., about 1 to about 10% can be used. The partial oxide of an alloy composed of about 70 to about 75% tin, about 20 to about 25% bismuth and from about 1 to about 5% by weight copper is preferred.
The soft metal alloy layer is present in a uniform partially oxidized form. By "uniform" is meant that the degree of oxidation is substantially constant at any selected depth below the surface and that the degree of oxidation generally decreases as a function of this depth. This is because the surface oxygen content of the film can go up when the product is removed from the vacuum chamber and exposed to atmospheric oxygen.
Oxidation levels in the film are difficult to arrive at by mass balancing the added oxygen during oxidation deposition because the vacuum system is constantly removing gas (including the gaseous oxidants employed herein) to some extent from the sputtering zone.
When a metal alloy layer is laid down without added oxidant, removed and equilibrated in air, it appears there is about 0.5 to about 0.6 atoms of oxygen present for each atom of tin (when tin is one of the components). Conversely, when too great a level of oxidant is present, there is about 0.7 to about 0.8 atoms of oxygen per atom of tin. These ranges would appear to suggest a very narrow band of acceptable oxygen levels. It is believed that useful levels of partial oxidation are broader than this range would suggest. In light of the extreme difficulties posed in determining and comparing these numbers accurately, it is considered that one way to define oxidation levels is not by chemical constituency but rather by the optical and performance properties of the metal alloy films.
One indirect measure of oxidation level in these thin films of the present invention is reflectivity measured in situ in the vacuum chamber before exposure of the film to atmospheric oxidation. At high oxidation levels, the metal layer appears brown and reflectance at 830 nm drops below useful levels. Suitable oxidation levels diminish the 830 nm reflectance of the film, as compared to film prepared under the same conditions without oxidant. Suitable levels of oxidation are achieve when the ratio of ##EQU1## ranges between about 0.50 and about 0.95, and especially between about 0.60 and about 0.85.
Another observable characteristic of the partially oxidized soft metal layer (when at a suitable level of oxidation) is a film surface free of dendrites particularly bismuth-rich dendrites (when bismuth is one of the metals in the alloy), and nodules which are generally observed when no oxidation takes place during deposition. This can be observed by comparing micrographs of the film surface without oxidation with the micrographs of the film when in the partially oxidized form.
Yet another observable characteristic of the partially oxidized soft metal layer (when at a suitable level of oxidation) is a film surface made up of uniform grain size particles with a mean diameter of less than about 250 Å. More specifically, typically at least 80% of the particles are sized within ±25% of the mean diameter with that mean being below about 250 Å, especially from about 100 Å to about 200 Å.
The partially oxidized soft metal alloy layer is from about 75 Å in thickness to about 5,000 Å in thickness, preferably from about 100 Å to about 1,500 Å, and often from about 350 Å to about 1000 Å.
The soft metal alloy is laid down in a thin layer on the substrate by vacuum deposition, e.g., sputter-depositing, in an atmosphere containing an oxidizing species. This oxidizing species is preferably water or oxygen. The oxidizing species is added to the inert sputtering gas atmosphere (e.g., argon) to a level such that the deposited alloy film shows the above defined favorable characteristics, e.g., no dendrites and a reflectivity at the desired level.
Sputter depositing is a commercial process for depositing inorganic materials, metals, oxides and the like, on surfaces. Representative descriptions of sputter depositing processes and equipment may be found in U.S. Pat. Nos. 4,204,942 and 4,948,087 which are incorporated by reference. A schematic view of a representative sputtering system is provided in FIG. 1 and will be described in and prior to Example I.
In sputtering, a voltage is applied to a sputtering cathode in the presence of a reactive and/or nonreactive gas to create a plasma. The action of the sputtering gas plasma on the cathode causes atoms of the cathode (source) to be dislodged and to travel to and deposit upon a substrate positioned adjacent to the sputtering source.
Typically, the non-reactive sputtering gas is a noble gas such as krypton or argon or the like. Argon is the most common sputtering gas because of its attractive cost.
It is also known in the art to employ a reactive gas as a component of a sputtering gas mixture but not for the purpose of the subjects invention. When a reactive gas is present it can cause a metal to be deposited as an oxide (when an oxygen source is present), a nitride (when a nitrogen source is present) and the like. This reactive sputtering process is well known and used commercially.
As applied to the present invention, the soft metal alloy is deposited using a sputtering gas which includes an oxygen source, i.e., an oxidative sputtering gas.
The gaseous oxygen source can be oxygen gas (O 2 ), water vapor, carbon dioxide, a nitrogen oxide such as NO 2 or a mixture of these materials. Water and oxygen gas have worked well.
The relative proportion of oxygen source to noble sputtering gas ranges from about 0.1 to about 2.0 parts by volume oxygen source to each part of noble gas and especially 0.3 to about 1.0 parts of oxygen source per part of noble sputtering gas.
This invention will be further described with reference to the accompanying examples and comparative experiments. These are provided to illustrate the invention but are not to be construed as limiting its scope.
These experiments were all carried out in a continuous sputtering machine. The sputtering equipment used was a research-sized coater for 13.5-inch-wide web. A simplified schematic of the web coating system is shown as System 10 in FIG. 1. System 10 includes vacuum chamber 12 which is evacuated via line 14. Contained within chamber 12 is a drive mechanism for moving a sheet of flexible plastic substrate 16 past a series of magnetron sputtering stations 50, 48, and 46. The drive mechanism includes feed roll 18, idlers 20, 22, 24, 26, 28, 30 and 32 and take-up roll 34.
The film passes around chilled idler drum 36 as well. The film passes a pair of monitors for determining its transmittance, 38, and reflectance, 40, before coating and a similar pair of monitors 42 and 44 after coating. This coater is configured to sputter coat simultaneously up to three layers on a 13.5-inch-wide web using three separate DC magnetron cathodes 46, 48 and 50. Also located in the system is a pre-glow station 52 for ionized gas cleaning or surface modifying of the substrate before coating. Each of these four stations is isolated from each other in space as a mini-chamber; thereby producing a local environment for the containment of the plasma gasses. This allows separate processes to be carried out simultaneously at each station without cross-contamination between the four sources (see FIG. 2). Mini-chamber 46 is equipped with a manifold for distributing oxidant gas such as water vapor or oxygen, supplied from vessel 53 via valve 54 and line 56.
As shown in FIG. 2, a mini-chamber such as 46 includes a housing 61 with a curved side 62 which conforms to the contour of idler drum 36 (FIG. 1). This side 62 contains a slit 64 through which the sputter deposited alloy is conveyed onto the substrate that moves past it. The mini-chamber 46 has a cathode 66 made of the soft metal alloy and a manifold 68 which mixes sputtering gas (Ar) from line 70 and water vapor or oxygen from line 56 and distributes this mixture in its sputtering zone via line 72-74, etc.
The control and monitoring of the sputtering system are normally accomplished using equipment and sensors which are standard in this coating machine. These are shown in FIG. 1 and include: 75, mass flow controllers (MKS) for regulation of gas flow into the cathode mini-chambers; 76, 5-10 kilowatt DC power supplies (Advanced Energy) for all three sputtering cathodes; 77, an optical monitoring system (Hexatron/Southwall Technologies) which measures both reflectance and transmission of the film over the spectral region from 300 to 2000 nm; and 78, a film motion control system (Drivex) which regulates the tension, speed, and distance of the film as it moves through the system.
In addition to this equipment, the chamber 46 was fitted with an optical emission spectrometer (OES) 60 and a residual gas analyzer (RGA) 58 for in situ monitoring of the composition of the gas species in the plasma (see FIGS. 1 and 2).
The process parameters are equipment sensitive and may vary from equipment to equipment and even on the same equipment from day to day. Thus, before making the media of the present invention, the equipment should be calibrated before use.
The experiments were carried out using the following protocol for experimental sample preparation:
1) the chamber was setup:
a) a plastic (usually PET) substrate film was loaded into the chamber,
b) the chamber was evacuated to 1-2×10 -5 Torr,
c) the argon gas flow rate was set,
d) the oxidant gas valve was opened to give a desired ratio of argon to oxidant source, with oxygen being the common oxidant source,
e) the film reels were set in motion,
f) the pre-glow station was turned on,
g the cathode power was set and turned on,
2) the system was allowed to equilibrate for a period of time,
3) 10 to 20 feet of film was coated with the soft metal alloy,
4) the power to the cathode was turned off for a short period of time to leave a "blank" region on the film as a marker to identify the end of "sample",
5) new system parameters were set (1c-g),
6) the plasma was then reignited and the cycle repeated (2-6) until the film was used up or the experiments were complete, and then
7) the film was removed from the vacuum chamber and cut into sections for analysis.
Using the protocol outlined above, a set of preparations were carried out to demonstrate the effect of oxidant source and amount on the soft metal alloy sputtering process and products. Films of varying reflectivities were made at different oxidant levels.
COMPARATIVE EXPERIMENTS
The tables set forth herein reflect the equipment and process parameters (Table 1a and 2a) and the properties of the media (Tables 1b and 2b).
The first series of films was made at varying film reel speeds with no oxidant added to the system. These experiments were used as a base-line in which to compare materials prepared in accordance with the invention. Six samples at varying reflectivity levels were made in this series from a high of ˜82% down to 50%. This corresponds to reel speeds of 5 mm/sec and 30 mm/sec, respectively (see Tables 1a and 1b Samples 1-6).
In these experiments the sputtering target (5"×15.5"×0.25") comprised an alloy, in percentage by weight, of Sn (about 65 to about 80), Bi (about 13 to about 30), and Cu (about 1 to about 7). The alloy composition may have varied within these limits from test to test. The substrate was 3 mil PET (ICI 393) film. In the six samples, the chamber was evacuated to about a pressure of 2×10 -5 Torr, then back-filled with argon gas to a pressure of about 1.07×10 -3 Torr. A DC power of 1000 watts at 593 volts and 1.64 amps was applied to the magnetron sputtering source. The substrate was translated in front of the sputtering source at different rates to coat the soft metal alloy onto the substrate at different thicknesses.
The reflectance light write threshold, modulation depth and carrier-to-noise level are set forth in the Table 1b.
Bismuth-rich dendrites were present on all of the medium surfaces. These features resulted in inhomogeneities in reflectivity, laser write sensitivity, modulation depth, and carrier-to-noise level.
EXAMPLES OF THE INVENTION (H 2 O VAPOR)
A 13.5-inch wide web coating machine was used to sputter deposit the soft metal alloy onto polymeric substrate materials. The sputtering target (5"×15.5"×0.25") consisted of the same alloy composition as described above. The substrate was 3 mil PET film. The chamber was evacuated to about a pressure of 1×10 -5 Torr, then back-filled with argon gas to a pressure of about 1.07×10 -3 Torr, and then with water vapor to a total pressure as shown in the Table 1a. A DC power was applied to the magnetron sputtering source. The substrate was translated in front of the sputtering source at a rate shown in the Table 1a so as to allow for a coating of the alloy to be deposited onto the substrate.
The resulting medium had a reflectance, a modulation depth and a carrier-to-noise level as shown in Table 1b. The media surfaces were homogeneous.
EXAMPLES OF THE INVENTION (OXYGEN AS OXIDIZING GAS)
Another series of Examples were run as described above except O 2 was used instead of H 2 O. These Examples are set forth in Tables 2a and 2b. The surfaces of these media were also homogeneous.
TABLE 1a__________________________________________________________________________Process Parameters Reel Mini-Chamber Water Flow In Situ In SituSample Power Speed Pressure Micrometer Reflectivity Transmission# (Watts) (mm/sec) (mTorr) Setting (% at 830 nm) (% at 830 nm)__________________________________________________________________________ 1 1000 5 1.03 0 82.8 0.0 2 1000 10 1.02 0 78.1 2.2 3 1000 15 1.02 0 70.1 6.0 4 1000 20 1.06 0 62.5 10.3 5 1000 25 1.03 0 55.3 15.0 6 1000 30 1.02 0 48.0 19.7 7 1000 5 1.03 10 81.5 0.0 8 1000 10 1.03 10 78.5 1.9 9 1000 15 1.03 10 71.3 5.510 1000 20 1.05 10 63.4 9.611 1000 25 1.07 10 56.0 14.412 1000 30 1.09 10 49.4 18.913 1000 5 1.05 20 80.8 0.014 1000 10 1.06 20 78.5 2.115 1000 15 1.09 20 70.6 6.016 1000 20 1.11 20 61.5 10.817 1000 25 1.11 20 53.4 15.518 1000 30 1.13 20 46.2 20.519 1000 5 1.13 30 78.3 0.020 1000 10 1.14 30 76.3 2.121 1000 15 1.16 30 68.4 6.422 1000 20 1.17 30 59.5 11.823 1000 25 1.18 30 50.5 17.024 1000 30 1.21 30 44.1 22.425 1000 5 1.23 40 65.2 0.326 1000 2.5 1.21 40 48.3 0.027 1000 5 1.21 40 61.9 0.428 1000 10 1.23 40 72.1 2.929 1000 15 1.24 40 66.5 6.730 1000 20 1.25 40 57.7 11.731 1000 25 1.28 40 49.3 16.832 1000 30 1.26 40 43.5 21.633 1000 2.5 1.27 50 42.1 0.034 1000 5 1.27 50 59.2 0.435 1000 10 1.28 50 68.9 3.236 1000 15 1.32 50 63.1 7.437 1000 20 1.32 50 55.6 11.838 1000 25 1.34 50 48.5 16.739 1000 2.5 1.54 75 44.5 0.040 1000 5 1.54 75 55.9 1.141 1000 10 1.54 75 60.9 5.942 1000 15 1.55 75 55.8 9.743 1000 20 1.57 75 49.7 14.144 1000 2.5 1.72 100 52.7 0.145 1000 5 1.72 100 55.7 2.546 1000 10 1.73 100 58.1 8.947 1000 15 1.77 100 50.7 14.548 1000 20 1.77 100 43.6 20.049 200 2.2 1.54 60 52.0 15.950 200 2 1.64 70 50.3 18.351 200 1.5 1.76 80 48.7 20.152 500 8 1.43 60 51.9 13.153 500 7 1.52 70 51.5 13.754 500 6 1.60 80 52.6 14.155 500 5 1.68 90 53.9 14.356 1000 19 1.42 60 53.5 11.657 1000 17 1.47 70 54.6 10.558 1000 17 1.55 80 53.1 11.559 1000 15 1.50 90 53.6 11.360 1500 32.5 1.35 60 53.6 13.661 1500 30 1.47 70 53.3 12.862 1500 28 1.57 80 52.0 12.563 1500 25 1.64 90 53.6 11.2__________________________________________________________________________
TABLE 1b__________________________________________________________________________Optical Measurements at 830 nmStatic Trans- Laser Write DynamicSample Reflectivity mission Absorption Sensitivity Modulation Carrier-to-# (%) (%) (%) (nanoseconds) Depth (%) Noise (dBs)__________________________________________________________________________ 1 80.59 0.02 19.22 160000 0.0 -- 2 75.61 2.41 21.98 8000 0.0 -- 3 67.57 6.28 26.15 1600 0.0 -- 4 58.28 11.39 30.33 540 0.0 -- 5 49.15 18.01 32.84 340 52.3 37 6 40.60 24.65 34.76 240 64.7 43 7 80.34 0.02 19.49 110000 0.0 -- 8 75.64 1.96 22.40 9000 0.0 -- 9 68.54 5.72 25.74 3000 0.0 310 59.85 10.65 29.50 7000 0.0 611 49.91 17.10 32.99 340 26.4 2812 41.59 23.10 34.83 270 57.1 4113 77.57 0.18 22.24 32000 0.0 --14 75.53 2.20 22.27 4000 0.0 --15 66.49 6.43 27.08 1000 0.0 516 56.91 11.82 31.26 550 0.0 --17 46.90 18.54 34.55 380 37.5 3218 38.31 25.64 36.05 300 58.6 4319 77.1 0.02 22.69 13000 0.0 --20 74.81 2.25 22.94 3000 0.0 --21 64.39 6.79 28.82 870 0.0 322 53.32 12.37 34.31 470 0.0 923 44.06 19.92 36.01 300 47.4 3724 36.58 26.68 36.74 240 71.4 4425 64.12 0.47 35.41 1800 0.0 --26 45.13 0.07 54.80 5000 0.0 --27 61.04 0.52 38.44 1800 0.0 --28 70.78 2.86 26.35 1500 0.0 --29 64.02 6.74 29.24 750 0.0 --30 53.55 11.96 34.49 390 58.3 2631 43.51 19.65 36.84 540 59.5 3832 36.50 25.39 38.11 230 78.6 4733 41.35 0.07 58.59 990 0.0 --34 56.67 0.59 42.75 930 0.0 --35 66.35 3.31 30.34 930 0.0 1036 61.13 7.15 31.72 490 44.4 3437 52.86 12.13 35.01 350 57.1 4438 45.20 17.40 37.40 260 6.4 2339 42.38 0.09 57.54 350 0.0 2240 54.03 1.34 44.63 390 19.4 3541 59.64 5.69 34.67 260 61.7 4542 54.11 9.69 36.20 210 80.0 4643 47.52 14.64 37.85 180 8.3 2744 51.20 0.20 48.60 290 0.0 2645 54.15 2.70 43.16 360 46.4 3446 56.78 8.87 34.35 270 65.9 4447 48.63 14.91 36.46 200 82.4 4448 41.41 20.87 37.72 180 40.4 39.549 49.94 16.36 33.70 220 28.3 3050 48.94 18.60 44.63 290 13.3 2751 48.17 19.75 34.67 320 64.4 4252 49.87 13.86 36.27 180 65.2 41.553 49.92 14.25 35.82 190 58.3 40.554 50.63 14.69 34.67 200 44.0 36.555 52.85 14.19 32.96 230 54.2 4356 50.38 12.48 37.13 210 51.0 43.557 51.50 11.32 37.18 200 66.0 4458 50.52 12.54 36.93 190 67.3 4459 51.29 11.93 36.78 200 47.7 3260 49.22 14.99 35.79 290 50.0 3961 48.91 14.04 37.04 230 53.5 4462 47.97 14.31 37.72 190 58.7 42.563 49.18 13.09 37.74 180 0.0 0.0__________________________________________________________________________
TABLE 2a__________________________________________________________________________Process Parameters Mini-Chamber Oxygen Flow In SituSamplePower Reel Speed Pressure Rate Reflectivity# (Watts) (mm/sec) (mTorr) SCCM (% at 830 nm)__________________________________________________________________________64 1000 33.0 1.11 0.0 50.465 1000 29.9 1.15 2.0 49.066 1000 24.5 1.17 4.0 50.267 1000 20.0 1.20 6.0 51.368 1000 16.0 1.23 8.0 49.869 1000 12.5 1.24 10.0 50.5__________________________________________________________________________
TABLE 2b__________________________________________________________________________Optical Measurements at 830 nmStatic Laser Write DynamicSample Reflectivity Transmission Absorption Sensitivity Modulation Carrier-to-# (%) (%) (%) (nanoseconds) Depth (%) Noise (dBs)__________________________________________________________________________64 45.32 19.14 35.54 290 55 4365 48.07 13.93 38.00 200 63 4566 50.25 13.55 36.20 200 71 4567 48.26 16.47 35.28 230 71 4468 48.85 16.69 34.19 260 56 4369 38.66 27.46 33.88 360 44 33__________________________________________________________________________
EXAMPLE (POLYCARBONATE SUBSTRATE)
A 13.5-inch wide web coating machine was used to sputter deposit a soft metal alloy onto polymeric substrate materials. The sputtering target (5"×15.5"×0.25") consisted of an alloy, in percentage by weight, of Sn (70), Bi (25), and Cu (5). The substrate was 130 mm wide, 5 mil thick polycarbonate cast film. This film was embossed with 1300 A" high features. A 5" square uniformity shield was installed in the mini-chamber to limit the metallization to the embossed regions of the film.
The chamber was evacuated to about a pressure of 1×10 -5 Torr, then back-filled with argon gas to a pressure of about 2.04×10 -5 Torr, and then with oxygen gas to a total pressure of about 2.57×10 31 3 Torr. A DC power of 390 watts at 429 volts and 0.88 amps was applied to the magnetron sputtering source. The substrate was translated in front of the sputtering source at a rate of 8 mm/sec so as to allow for a coating of the alloy to be deposited onto the substrate.
EXAMPLE (SUBBING LAYER)
A 13.5-inch wide web coating machine was used to sputter deposit the soft metal alloy onto polymeric substrate materials. The sputtering target (5"×15.5"×0.25") consisted of an alloy, in percentage by weight, of Sn (70), Bi (25), and Cu (5). The substrate was a 10 mil PET film with a cured, UV acrylic subbing hardcoat on the surface. The plastic sheet was formed in a clean environment to give optically clean materials.
The chamber was evacuated to about a pressure of 1×10 -5 Torr, then back filled with argon gas a pressure of about 2.06×10 -3 Torr, and then with oxygen gas to a total pressure of about 2.57×10 -3 Torr. A DC power of 920 watts at 489 volts and 1.85 amps was applied to the magnetron sputtering source. The substrate was translated in front of the sputtering source at a rate of 16 mm/sec so as to allow for a coating of the alloy to be deposited onto the substrate. | An optical memory storage medium based on a partially oxidized deposited layer of soft metal alloy is described. A method of preparing the medium by vacuum depositing the soft metal alloy layer in the presence of controlled amounts of gaseous oxidant to thereby form the layer in a uniform partially oxidized form. | 8 |
CROSS REFERENCE
[0001] The Applicant claims the benefit and incorporates by reference U.S. Provisional Patent No. 60/403,982, filed Aug. 16, 2002, titled “Collapsible Loop Antenna for In Vivo Magnetic Resonance”.
FIELD OF THE INVENTION
[0002] The present invention relates generally to magnetic resonance (MR) imaging and MR spectroscopy of living tissue and more particularly to an antenna for minimally invasive surgical use.
BACKGROUND OF THE INVENTION
[0003] Advances in magnetic resonance imaging have placed this non-invasive imaging technology at the forefront of medical imaging technologies. Although MRI imaging is widely used in a variety of diagnostic settings, it is rarely used to image small regions of the body. Although the use of MRI devices for spectroscopy and thermal measurements these applications are not widely practiced.
[0004] Some examples of small region imaging technologies are taught by U.S. Pat. No. 5,964,705 to Truwit which shows a solenoid antenna coil mounted on the distal tip of a intravascular catheter. This approach allows one to image the vessel walls as a mechanism for ascertaining the underlying disease-state. This intravascular use is minimally invasive but suffers from a number of limitations.
[0005] There is a continuing need to improve in vivo MRI devices and techniques for in vivo use.
SUMMARY OF THE INVENTION
[0006] In contrast to the prior art the present invention provides a collapsible loop MRI antenna which can be introduced into the pericardial space surrounding the patient's heart. The diameter of the loop can be adjusted while in situ and it can be used to image relatively large areas and relatively small areas. This advantage permits the device to be used to locate vessels or other regions of interest than to navigate to those regions and adjust the antenna size so that the resolution of the image is sufficient for the diagnostic purpose.
[0007] The ability to restrict or expand the field of view for imaging also permits the device to be used quantitatively and qualitatively for spectrographic analysis of suspected lesions and the like.
[0008] The ability to monitor the composition of lesions within the heart as well as image them allows a differential diagnosis of a lesion between vulnerable plaque and other disease states. The device can also be used to measure the temperature of tissue as an aid to distinguishing lesions from each other and may especially useful to determine the degree of inflammation of vulnerable plaque.
[0009] The MRI antenna may also be used to follow the course of RF ablation applied to the heart wall from either the pericardial space or from the blood pool within the heart. The present invention relates to the use of a small collapsible loop antenna having a nominal diameter between one and five centimeters. The coil is deployed in the pericardial space using a PerDUCER access approach.
[0010] Once inside the pericardial space the loop antenna is navigated to the coronary arteries where it may be positioned over sections of the coronary artery. Since the loop antenna and the heart are moving it is likely that there will be minimal artifacts associated with the motion of the antenna and this will allow higher resolution imaging and spectroscopy of the coronary artery sites. In addition to spectrographic analysis or imaging analysis to characterize the nature of the plaque deposits, it is also possible to measure the temperature of the plaque departments using the MR antenna. This technique relies on the detection of the brownie in motion of the molecules based upon their temperature. It is expected that temperature differences as small as a few tenths of a degree can be detected, imaged and presented to the physician to help characterize the nature of the plaque.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Throughout the several figures identical refers to identical structure wherein:
[0012] [0012]FIG. 1 is a schematic over view of the device;
[0013] [0013]FIG. 2 is a partial view depicting the distal tip of the device;
[0014] [0014]FIG. 3 is a cross section of a portion of the device;
[0015] [0015]FIG. 4 is a first embodiment of the antenna;
[0016] [0016]FIG. 5 is a second embodiment of the antenna;
[0017] [0017]FIG. 6 is a second embodiment of the antenna;
[0018] [0018]FIG. 7 is a second embodiment of the antenna;
[0019] [0019]FIG. 8 is a third embodiment of the antenna;
[0020] [0020]FIG. 9 is a third embodiment of the antenna;
[0021] [0021]FIG. 10 is a panel depicting a step in a method;
[0022] [0022]FIG. 11 is a panel depicting a step in a method;
[0023] [0023]FIG. 12 is a panel depicting a step in a method;
[0024] [0024]FIG. 13 is a panel depicting a step in a method;
[0025] [0025]FIG. 14 is a panel depicting a step in a method;
[0026] [0026]FIG. 15 is a panel depicting a step in a method;
[0027] [0027]FIG. 16 is a panel depicting a step in a method; and,
[0028] [0028]FIG. 17 is a panel depicting a step in a method.
DETAILED DESCRIPTION
[0029] [0029]FIG. 1 shows the antenna device 10 positioned within an intrapericardial access sheath 12 . The distal tip of the device 10 is formed as a loop 14 . The proximal end of the device 10 terminates in a proximal connector 16 , which is coupled to a matching network 18 . The matching network in turn is connected to the MRI machine through a cable 20 . The function of the matching network is to match the impedance of the loop 14 with the required impedance of the MRI machine. This may be done automatically or through manual adjustments shown in the figure as adjustment screw 22 and 24 . In general the nature of matching networks is well known in this art and an LRC network will be provided to tune the antenna to the MRI machine.
[0030] [0030]FIG. 2 and FIG. 3 show the distal tip loop 14 in more detail. FIG. 2 depicts the unconstrained shape of the device forming a circular loop antenna as opposed to other shapes. A biocompatible surface coating 30 is applied to the underlying substrate 28 . FIG. 3 shows a cross section of the loop 14 . It is preferred to form the underlying substrate material from nitinol with a preferred conductivity coating 26 of gold. A biocompatible insulated sheath is formed over the individual wire elements as indicated by insulation 30 . As shown in the figure, the loop antenna terminates in a twin line transmission line 32 . Each leg of this line may be individually manipulated and the spacing between the legs is retained at a constant distance to prevent impedance mismatching.
[0031] As an alternative to the twin line transmission line depicted in FIG. 2 and FIG. 6, a twisted pair transmission line 34 may be used to couple the loop 14 to the matching network as seen in FIG. 4. In FIG. 5 an external insulating sheath 36 is supplied over the transmission line and the interior cross-section of the transmission line may be an insulated twin line construction shown in FIG. 6 with a nitinol core 38 surrounded by a gold sputtered coating 40 , which is held together at a fixed distance from the other conductor.
[0032] As an alternative a coaxial construction may be adopted as seen in FIG. 7 where the exterior insulating layer 46 is coaxial with the nitinol substrate, once again coated with a conductivity enhancing coating such as gold 42 . A braid 48 may be provided to provide electrical connection for the ground reference of the loop antenna 14 .
[0033] [0033]FIG. 8 and FIG. 9 should be considered together. FIG. 8 shows an alternative form of construction where a nitinol loop 14 is delivered out of the side port of a catheter 50 through an aperture 52 . As the loop emerges as seen in FIG. 9 the shape memory property of the nitinol core forms a circular loop. Each leg is connected to the MRI matching network through connections not shown in FIG. 9.
[0034] [0034]FIG. 10 shows a step in the method of introducing the pericardial MRI antenna into the pericardial space through the use of a PerDUCER device as manufactured by Comedicus of Minneapolis, Minn. In FIG. 10 the PerDUCER device has been inserted through the chest wall 62 and advanced to the pericardial “sac”. A procedure sheath 64 allows the PerDUCER 66 to approach the pericardial space of the heart while leaving the pericardium 68 intact. The distal tip of the PerDUCER 66 includes a bleeb forming suction device 70 which draws the pericardium 68 into the device permitting it to be pierced as seen in FIG. 11.
[0035] [0035]FIG. 12 shows a guidewire 80 being deployed through the hole in the pericardial sac permitting the entry of other devices into the pericardial space such as the MRI antenna introduced through sheath 60 and sheath 64 . As seen in FIG. 14 the loop 14 may be manipulated to multiple positions indicated with reference numeral a, b and c in the figure. With the loop deployed into its maximum diameter configuration imaging can be performed helping the physician locate anatomic features of interest such as the coronary arteries. FIG. 14 shows the loop being adjusted to multiple diameters seen in the figure as diameter a, b and c. The imaging field of view depends directly upon the diameter of the device. When operated in a spectrographic mode where the underlying physiology is measured by spectroscopy the smaller the loop the smaller volume is interrogated. In FIG. 15 for example, the physician may be reducing the size of the loop antenna from position c to position a to interrogate whether or not a particular underlying piece of cardiac tissue is ischemic. In FIG. 16 a coronary artery is approached as seen in FIG. 17 and the loop of the antenna is reduced to provide both imaging and spectrographic analysis of the nature of the lesion present there. It is believed that this technique of imaging along with spectroscopy can allow the identification of vulnerable plaque. When the loop is small it is possible to monitor the temperature of tissue using the MRI system and it is a portion of the method of this invention to provide both imaging, spectrographic and temperature measurement capabilities in a single antenna device placed over a single location of the heart with the data taken at the same time, or sequentially without moving the loop.
[0036] With regard to FIG. 14 it should be clear that the physician may be performing an RF ablation procedure on the interior of the heart. In this instance the pericardial loop antenna can be used to “track” the therapeutic lesion by imaging, thermal sensing or spectrographically. Although not illustrated in the FIG. 1 f the ablation procedure is performed in the pericardial space then the MRI antenna can be deployed inside the heat to rack the procedure. | A catheter based loop antenna is delivered to the pericardial space through an opening in the chest. The size of the antenna may be modified to selectively view tissue for imaging or spectrographic analysis purposes. | 6 |
RELATED APPLICATIONS
[0001] This application claims priority to Taiwan Application Serial Number 100143531, filed Nov. 28, 2011, which is herein incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a lottery method, and more particularly to a method combining a taxi service with a lottery game.
BACKGROUND
[0003] A lottery game is frequently used as a promotional activity for a company. This is especially the case when the company is introducing a new product into the market or is having an annual promotional sale, at which time the company may hold a lottery so that customers spend time on the new product or participate in the promotional sale.
[0004] However, in a typical lottery game, lottery tickets are handed out to people on the street. In this case, those receiving the lottery tickets are chosen at random. Therefore, the company is not able to ascertain which persons buy the new product or participate in the promotional sale. Such a method of distributing lottery tickets is ineffective. In another case, the lottery tickets are given to a customer when he or she has spent a certain amount of money. Although there is certainty with respect to the persons receiving the tickets in this case, such a method makes it necessary for customers to write their personal information on the lottery tickets by hand. This is not convenient for the customers. Moreover, it is also possible for the information to be disclosed in an undesirable manner. Therefore, some customers refuse to participate in such a lottery game.
SUMMARY
[0005] According to one aspect of the present disclosure, a method combining a taxi service with a lottery game is provided. When a customer takes a taxi, an event message, such as a lottery game message, is sent to the customer. Such a method helps companies better target customers and thereby improve the effectiveness of distributing event tickets.
[0006] According to another aspect of the present disclosure, an identification method is provided. When a customer takes a taxi, an identification company performs an identification process to obtain information provided by the customer when he or she calls a taxi service. Such a method is convenient for both customers and companies. For example, such a method ensures that mistakes made by customers when writing information on event tickets by hand are avoided.
[0007] The present disclosure discloses a method for participating in an event when a customer takes a taxi. The customer has a portable communication apparatus. The taxi has a car communication apparatus. The method includes sending a message of customer having taken a taxi to an identification apparatus. Next, a determination step is performed to determine whether the customer wants to participate in the event. When the customer wants to participate in the event, a communication connection with the identification apparatus is built. Finally, a confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus.
[0008] In an embodiment, the step of building a communication connection comprises building a communication connection between the portable communication apparatus and the identification apparatus. The identification apparatus generates an identification code according to a customer information transferred by the car communication apparatus. A confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus based on the identification code.
[0009] In an embodiment, the step of building a communication connection comprises building a communication connection between the car communication apparatus and the identification apparatus. The identification apparatus generates an identification code according to a customer information transferred by the car communication apparatus. A confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus based on the identification code.
[0010] In an embodiment, the step of building a communication connection comprises building a communication connection between the portable communication apparatus and the identification apparatus. The portable communication apparatus has an application program to automatically build the communication connection with the identification apparatus. The identification apparatus generates an identification code according to customer information transferred by the application program. A confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus based on the identification code.
[0011] In an embodiment, the step of sending the confirmation message to the portable communication apparatus includes using a Short Message Service (SMS) to send the confirmation message, using an application program in the portable communication apparatus to send the confirmation message, or using an Internet application program to send the confirmation message.
[0012] In an embodiment, the method further comprises the customer sending a taxi service request to a dispatching apparatus. The dispatching apparatus dispatches a taxi to the customer based on the taxi service request.
[0013] In an embodiment, the method further comprises determining whether the taxi service request includes a telephone number information of the portable communication apparatus. When the taxi service request includes the telephone number information, the confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus based on the telephone number information.
[0014] In an embodiment, the event is a lottery game.
[0015] In an embodiment, the method further comprises awarding points to the customer based on at least one of a location where the customer took the taxi, a location where the customer got out of the taxi, total miles, a message of taking the taxi or a message of getting out the taxi. The point award is linked with the telephone number of the portable communication apparatus.
[0016] In an embodiment, the method further comprises printing a coupon of stores located in the area where the customer gets out the taxi.
[0017] Accordingly, when a customer takes a taxi and the customer agrees to participate in an event, a real-time identification process is performed to obtain the customer data that is provided by the customer when he or she calls a taxi service. Subsequently, a confirmation message of participating in the event is sent to the customer. With the use of such a method, it is not necessary for the customer to write his or her information on an event ticket by hand. Therefore, the burden on the customer when desiring to participate in the event is significantly reduced. Moreover, such a method also help companies better target customers and thereby improve the effectiveness of distributing event tickets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In order to make the foregoing as well as other aspects, features, advantages, and embodiments of the present disclosure more apparent, the accompanying drawings are described as follows:
[0019] FIG. 1 illustrates a schematic block diagram of a lottery game system according to an embodiment of the present disclosure.
[0020] FIG. 2 illustrates a flow chart of a lottery game method according to an embodiment of the present disclosure, in which a lottery game is combined with a taxi service.
DETAILED DESCRIPTION
[0021] Reference will now be made in detail to the present embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0022] According to a method of the present disclosure, an event message, such as a lottery game message, is sent to a customer when the customer takes a taxi. Subsequently, a real-time identification process is performed to obtain customer data that is provided by the customer when he or she calls a taxi service. Such a method may reduce the burden placed on customers when desiring to participate in an event and also may help companies better target customers and thereby make the distribution of event tickets more effective. In the explanation to follow, a lottery game will be given by way of example. However, it is to be understood that the method can be applied to other types of events.
[0023] FIG. 1 illustrates a schematic block diagram of a lottery game system according to an embodiment of the disclosure. The lottery game system 100 includes a dispatching apparatus 101 , an identification apparatus 102 and a car communication apparatus 103 . The car communication apparatus 103 is disposed in a taxi. The dispatching apparatus 101 receives customer data and a request for a taxi service from a customer. According to the request, a taxi is dispatched to the customer by the dispatching apparatus 101 . In an embodiment, the customer may use a telephone, a mobile phone, a dispatching application program in a mobile phone or a network to communicate with the dispatching apparatus 101 to send the customer data and the request. When the dispatching apparatus 101 receives the customer data and the request from the customer, a taxi is dispatched by the dispatching apparatus 101 to the customer.
[0024] When the customer takes the dispatched taxi, the car communication apparatus 103 disposed in the taxi sends information to the identification apparatus 102 to inform the identification apparatus 102 that the customer has been picked up. This information includes the location where the customer was picked up and the time that the customer was picked up. In an embodiment, the car communication apparatus 103 is an automatic vehicle location apparatus with a GPS (global positioning system) function. When the taxi driver starts the car communication apparatus 103 to calculate the taxi fare, the car communication apparatus 103 automatically sends information of the customer that was picked up to the identification apparatus 102 . At this time, if the customer has agreed to participate in a lottery game when he or she sent his or her request to the dispatching apparatus 101 , the identification apparatus 102 sends a confirmation message of participating in the lottery game to the customer to inform the customer that he or she is in participating in the lottery game. In an embodiment, if the customer has a portable communication apparatus, when the request is sent to the dispatching apparatus 101 from the customer, the number of this portable communication apparatus may also be sent at this time, in which case the identification apparatus 102 sends the confirmation message of participating in the lottery game to the portable communication apparatus using the number for the same.
[0025] In an embodiment, sending the confirmation message to the portable communication apparatus includes using a Short Message Service (SMS) to send the confirmation message, using an application program in the portable communication apparatus to send the confirmation message, or using an Internet application program to send the confirmation message. Sending the number of the portable communication apparatus to the dispatching apparatus 101 includes the telecommunications company directly sending the number of the portable communication apparatus to the dispatching apparatus 101 , the customer telling staff at the dispatching apparatus 101 the number of the portable communication apparatus, using the application program in the portable communication apparatus to send the number of the portable communication apparatus to the dispatching apparatus 101 , or using the Internet application program for calling a taxi to send the number of the portable communication apparatus to the dispatching apparatus 101 .
[0026] In some instances, a customer may call the dispatching apparatus 101 to request a taxi service but will not leave the telephone number of the portable communication apparatus with the dispatching apparatus 101 . In other instances, a customer may flag down a taxi in the street. That is, in such instances, the customer does not leave any contact information with the dispatching apparatus 101 . In these cases, if the customer still wants to participate in the lottery game, the customer may use his or her portable communication apparatus after he or she gets in the taxi to dial a telephone number used for participating in the lottery game to thereby communicate with the identification apparatus 102 . Subsequently, the customer may input his or her private information, such as a telephone number of his or her portable communication apparatus or his or her identification number, to the identification apparatus 102 . In another embodiment, the customer may use his or her portable communication apparatus to start an application program or to enter a website to communicate with the identification apparatus 102 when he or she gets in a taxi. Subsequently, the customer may input his or her private information, such as a telephone number of his or her portable communication apparatus or his or her identification number, in the application program or in the website to send to the identification apparatus 102 . In a further embodiment, the customer may use the car communication apparatus 103 in a taxi to communicate with the identification apparatus 102 when he or she gets in the taxi. Subsequently, the customer may input his or her private information, such as a telephone number of his or her portable communication apparatus or his or her identification number, in the car communication apparatus 103 to send to the identification apparatus 102 .
[0027] When the identification apparatus 102 receives the private information of the customer, the identification apparatus 102 generates an identification code according to this private information and sends the identification code to the car communication apparatus 103 or the portable communication apparatus. Next, in an embodiment, the customer uses his or her portable communication apparatus to return this identification code to the identification apparatus 102 for reconfirmation. When the identification apparatus 102 confirms this identification code, the identification apparatus 102 generates a confirmation message of participating in the lottery game and sends the confirmation message to the customer's portable communication apparatus. In another embodiment, the customer uses the car communication apparatus 103 to return this identification code to the identification apparatus 102 for reconfirmation. In this case also, when the identification apparatus 102 confirms this identification code, the identification apparatus 102 generates a confirmation message of participating in the lottery game and sends the confirmation message to the customer's portable communication apparatus. In an embodiment, sending the confirmation message to the portable communication apparatus includes using a Short Message Service (SMS) to send the confirmation message, using an application program in the portable communication apparatus to send the confirmation message, or using an Internet application program to send the confirmation message.
[0028] It is noted that there are two possible points in time that the identification apparatus 102 can send the confirmation message to the customer's portable communication apparatus. One is after the identification apparatus 102 confirms the identification code. The other is after the identification apparatus 102 receives information that the customer has reached the destination and has exited from the taxi. The identification apparatus 102 may determine that the customer has reached the destination when the driver stops the car communication apparatus 103 to calculate the taxi fare.
[0029] Moreover, in another embodiment, the confirmation message is sent to the car communication apparatus 103 from the identification apparatus 102 , which has the advantage of avoiding communication fees. The confirmation message further includes an identification code that may be used as proof that the customer is participating in the lottery game.
[0030] In some embodiments, points are awarded to the customer by a dispatching company. In an embodiment, the customer is awarded different points by the dispatching company based on a location or region where a customer takes a taxi, a location or region where a customer gets out of a taxi, total distance (in miles or kilometers) travelled by a customer in a taxi, a time that a customer takes a taxi, or a time that a customer gets out of a taxi. The awarded points link to an account of a customer. The account links to the telephone number of the customer's portable communication apparatus. In another embodiment, points are awarded to a driver by a dispatching company. The awarded points link to an account of the driver.
[0031] For example, a dispatching company may award points to a customer when the customer takes a taxi associated with the dispatching company in a first region. Accordingly, when a customer takes a taxi associated with the dispatching company in this first region, the customer may obtain award points, which for example may be used to receive a discount on the taxi fare. In another embodiment, the dispatching company may also decide to award points to a customer when the customer takes a taxi associated with the dispatching company during a special time period, such as 11:00 AM˜noon. Accordingly, when a customer takes a taxi associated with the dispatching company during this special time period, the customer may get award points, which for example may be used to receive a discount on the taxi fare.
[0032] In another embodiment, promotion information of stores is provided to the customer. For example, the car communication apparatus 103 is an automatic vehicle location apparatus with a GPS function and a printer function. In an embodiment, stores may send their GPS information to the dispatching apparatus 101 . Based on the GPS information detected by the automatic vehicle location apparatus, the dispatching apparatus 101 is able to detect the location at the destination of the customer. The dispatching apparatus 101 subsequently controls the car communication apparatus 103 to print corresponding coupons or gift redemption certificates of stores located in the area of the destination for the customer. The customer can take the coupons or gift redemption certificates to buy things in the stores. In another embodiment, based on the GPS information, the dispatching apparatus 101 is able to detect the location where the customer takes the taxi. The dispatching apparatus 101 subsequently controls the car communication apparatus 103 to print coupons or gift redemption certificates of stores located at this location for the customer. The customer can take the coupons or gift redemption certificate to buy things in the stores.
[0033] In the above embodiment, the dispatching apparatus 101 can designate a special customer group to receive the coupons and gift redemption certificates. For example, the special customer group may include customers who provide their telephone number to the dispatching apparatus 101 or customers who have called a taxi service using a special number. A printer is connected to the car communication apparatus 103 to print the coupons and the gift redemption certificates of stores. In some embodiments, the stores may include those stores that are located along the route of the taxi. Because the car communication apparatus 103 has a GPS function, the dispatching apparatus 101 may know the real-time location of the taxi. In other words, when a store is located along the route of the taxi and this store also provides coupons, the dispatching apparatus 101 may control the car communication apparatus 103 to print the store's coupons for the customer. In some embodiments, information of the coupons and gift redemption certificates is sent to the portable communication apparatus or the car communication apparatus 103 , so that the customer can view this information first. That is, the customer can select the coupons or gift redemption certificates that he or she desires to have printed out.
[0034] In another embodiment, the coupon or gift redemption certificate may directly be transferred to the portable communication apparatus of the customer or E-mail address. In this case, it is not necessary to print the physical coupon or gift redemption certificate. The customer information may also be sent to the stores at this time.
[0035] FIG. 2 illustrates a flow chart of a lottery game method according to an embodiment of the present disclosure, in which a lottery game is combined with a taxi service. Reference is made to both FIG. 1 and FIG. 2 . The lottery game method 200 includes, in step 201 , a customer taking a taxi. Next, in step 202 , the identification apparatus 102 determines whether the customer wants to participate in a lottery game. If the customer does not want to participate in the lottery game, the lottery game process 200 is ended in step 203 . In contrast, if the customer wants to participate in the lottery game, in step 204 , the identification apparatus 102 determines whether the customer provided a telephone number of his or her portable communication apparatus when he or she called a taxi service.
[0036] If the customer provided a telephone number of his or her portable communication apparatus, in step 205 , the identification apparatus 102 sends a confirmation message of participating in the lottery game to the customer to inform the customer that he or she is participating in the lottery game. Sending the confirmation message to the portable communication apparatus includes using a Short Message Service (SMS) to send the confirmation message, using an application program in the portable communication apparatus to send the confirmation message, or using an Internet application program to send the confirmation message.
[0037] In contrast, if the customer does not provide a telephone number of his or her portable communication apparatus, in step 206 , the customer may use his or her portable communication apparatus to dial a telephone number associated with the lottery game to communicate with the identification apparatus 102 when he or she gets in a taxi. Alternatively, the customer may use his or her portable communication apparatus to start an application program or to enter a website to communicate with the identification apparatus 102 when he or she gets in a taxi. As another alternative, the customer may use the car communication apparatus 103 in the taxi to communicate with the identification apparatus 102 when he or she gets in the taxi. Subsequently, in step 207 , the customer may input his or her private information, such as a telephone number of his or her portable communication apparatus or his or her identification number, to send to the identification apparatus 102 .
[0038] When the identification apparatus 102 receives the private information of the customer, in step 208 , the identification apparatus 102 generates an identification code according to this private information and sends the identification code to the car communication apparatus 103 or the portable communication apparatus. Next, in step 209 , the customer inputs this identification code in his or her portable communication apparatus or the car communication apparatus 103 , and returns this identification code to the identification apparatus 102 for reconfirmation in step 210 . When the identification apparatus 102 confirms this identification code, in step 211 , it is subsequently determined whether or not to send the confirmation message to the customer's portable communication apparatus after the customer gets out of the taxi. If not, step 205 is performed to send the confirmation message to the customer's portable communication apparatus. If so, on the other hand, after the identification apparatus 102 receives information that the customer has reached the destination and has gotten out of the taxi in step 212 , the confirmation message is sent to the customer's portable communication apparatus in step 205 . Sending the confirmation message to the portable communication apparatus includes using a Short Message Service (SMS) to send the confirmation message, using an application program in the portable communication apparatus to send the confirmation message, or using an Internet application program to send the confirmation message. The information that the customer has reached the destination and has gotten out of the taxi includes the time, the total miles and the taxi fare.
[0039] Accordingly, when a customer takes a taxi and the customer agrees to participate in a lottery game, a real-time identification process is performed to obtain the customer data that is provided by the customer when he or she calls a taxi service. Subsequently, a confirmation message of participating in the lottery game is sent to the customer. With the use of such a method, it is not necessary for the customer to write his or her information on a lottery game ticket by hand. Therefore, the burden on the customer when desiring to participate in the lottery game is significantly reduced. Moreover, such a method also helps companies better target customers and thereby improve the effectiveness of distributing lottery game tickets.
[0040] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present disclosure without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the present disclosure cover modifications and variations of this disclosure provided they fall within the scope of the following claims. | A method for combining a taxi service with an event when a customer takes a taxi is disclosed. The customer has a portable communication apparatus. The taxi has a car communication apparatus. The method includes sending a message of the customer having taken a taxi to an identification apparatus. Next, a determination step is performed to determine whether the customer wants to participate in the event. When the customer wants to participate in this event, a communication connection with the identification apparatus is built. Finally, a confirmation message of participating in the event is sent to the portable communication apparatus from the identification apparatus. | 6 |
BACKGROUND
The present invention relates to a readherable, repositionable and reusable adhesive fabric paper that is used in color printers for personal computers, printing machines for indoor and outdoor advertisement, wide format printers, plotters, and so on to print colored images. The adhesive fabric paper according to the present invention can be easily printed using any printer, can be freely attached to and detached from many places several times, does not leave adhesive residue when it is detached, and does not damage a place where it is adhered (for instance, on a painted wall, on wallpaper, or on an existing advertising medium previously attached to any one place).
Particularly, the adhesive fabric paper according to the present invention can show the same effects as those of a rear side coating layer (gray coating layer or white coating layer), disclosed in a previous patent of the applicant, even though it does not have the rear side coating layer, and can be manufactured by a simpler process at reduced costs.
In general, paper and vinyl are mainly used for printing. However, with the recent development of various advertising techniques, the use of fibrous materials for printing has increased.
Typical examples of the fibrous materials include banners that have recently been used to output images through a wide format printer or a plotter.
However, such conventional fabrics for printing have a problem in that, because one side thereof is merely coated such that it can be printed with images, the degrees of clarity and detail are low due to a low printing quality. Further, the fabric is decolorized rapidly after printing. Also, the fabric requires thermal cutting that is expensive and takes much time since yarns of a cut portion come loose when the fabric is cut as much as a necessary size. In addition, it is inconvenient to attach and remove an advertising thing made of the fabric.
The present inventor previously disclosed a product that overcomes the above-described problems and a manufacturing method thereof (Korean Patent No. 1099813 (Dec. 21, 2011) and U.S. Pat. No. 8,123,893 (Feb. 28, 2012).
The manufacturing method disclosed by the present inventor includes the steps of: heating and rapidly cooling a woven fabric so that its width is shrunk by 10% to 15%; preparing a coating solution to be applied to the front side of the fabric and aging it for 3 days; coating the rear side of the fabric twice with a mixture of polyurethane resin with a white pigment, and coating the rear side once with a mixture of polyurethane resin with a grey pigment; coating the front face of the fabric twice with the prepared coating solution; and laminating an adhesive-coated backing material to the coated fabric.
In the above-described manufacturing method, the reason why the process of coating the rear side of the fabric twice with the polyurethane resin/white pigment mixture and coating the rear side once with the polyurethane resin/grey pigment mixture is performed is to prevent printed images from being decolorized rapidly by the volatile component of the adhesive of the backing material when the adhesive permeates the fabric. Further, the reason is to prevent the yarns of the fabric from becoming loose and to block sunlight (UV light). In addition, the reason is to prevent a background color or an already existing image in any place, to which the product disclosed by the present inventor was attached, from showing through the product.
However, this process of coating the rear side is very expensive and time-consuming, and for this reason, this process needs to be eliminated.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made in order to solve the above-described problems occurring in the prior art, and it is an object of the present invention to provide an adhesive fabric paper for printing and a manufacturing method thereof, in which the adhesive fabric paper can sufficiently show the above-described functions of the rear side coating layer, even though it does not have the rear side coating layer, and can be manufactured by a simpler process at reduced costs.
To achieve the above object, the present invention provides a method for manufacturing a readherable, repositionable and reusable adhesive fabric paper for printing images, the method comprising the steps of: weaving polyester DTYs (draw textured yarns) to prepare a woven fabric; heating and rapidly cooling the woven fabric to shrink the width of the fabric by 12-17%; coating the front side of the fabric with a coating solution containing at least one fixation-strengthening agent selected from among titanium dioxide, silicon oil, silicon dioxide, polyoxyethylene sorbitan trioleate, and polyvinyl alcohol; aging the coated fabric; and laminating an adhesive-coated backing material to the rear side of the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a flowchart showing a method for manufacturing an adhesive fabric paper according to the present invention;
FIG. 2 is an enlarged cross-sectional view of an adhesive fabric paper according to one embodiment of the present invention; and
FIG. 3 is an enlarged cross-sectional view of an adhesive fabric paper according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described in detail.
The manufacturing method according to the present invention generally comprises the steps of: preparing a fabric; shrinking the fabric; preparing a coating solution; coating the front side of the fabric; and laminating a backing material to the rear side of the fabric.
Each of the steps will now be described in further detail.
1. Preparation of Fabric
A fabric that is used in the present invention is prepared by weaving polyester DTYs (draw textured yarns).
When the fabric woven from polyester DTYs is used, it can more deeply absorb an ink-receiving coating solution than other fabrics in the coating process and enables the coating solution to exist between the yarn strands of the fabric, thereby preventing the coating solution from being separated from the fabric after coating.
Moreover, the fabric woven from polyester DTYs allows a print ink to be evenly and deeply distributed on the coating solution deeply absorbed into the fabric and on the coating solution existing between the yarn strands of the fabric to thereby provide excellent image resolution and vividness.
Specific examples of filaments that may be used to prepare the fabric in the present invention include polyester DTY filaments, polyester DTY satin bright filaments, polyester DTY satin semi dull bright filaments, polyester DTY full dull filaments and the like.
The thickness of the yarn may be selected in the range from 75 denier to 300 denier. In addition, yarns having a thickness larger than 300 denier may also be used, if the fabric density, the degree of shrinkage of the fabric, the thickness of the coating layer, and the like are controlled.
2. Shrinkage
In the next step, the fabric is heated and rapidly cooled so that the width thereof is shrunk. The object of the present invention is to satisfy the requirements of the printing paper without having to coat the rear side. Thus, in the present invention, the fabric is placed in a chamber and maintained in the chamber at a temperature of 180-190° C. for 7-8 hours while supplying steam, followed by cooling. Herein, the cooling process may be a natural cooling process, but is preferably an artificial rapid cooling process employing cold air, the efficiency with which the fabric is shrunk can be increased and the cooling time can be shortened.
By performing this step, the area of the fabric is reduced by 12-17%, and thus the density thereof is increased so that there is no gap between the yarn strands and the fabric is maintained in a very dense state. Thus, the fabric can maintain the functions thereof, even though the rear side thereof is not coated.
3. Preparation of Coating Solution
In the present invention, the following two types of coating solutions may be used: an “S” coating solution for solvent-based ink; and an “R” coating solution for dye-based ink, pigment-based ink and UV ink.
The coating solution is prepared 3 days before use. The reason is to age the coating solution for 3 days and enable different components in the coating solution to react with each other for a sufficient time.
Before use, the coating solution is sufficiently mixed in a container having a central rotating shaft at high speed for 30 minutes. By this mixing process, the viscosity of the coating solution can be sufficiently reduced and the white color thereof can be kept evenly.
In a particular embodiment of the present invention, the “S” coating solution is divided into two different coating solutions: first “S” coating solution; and second “S” coating solution. In addition, the “R” coating solution is applied twice.
The major components of the “S” coating solution and the “R” coating solution are shown in the following tables.
TABLE 1
First “S” coating solution
Components
CAS NO
Content (wt %)
Ethylene vinyl acetate copolymer
24937-78-8
40-50
Plasticizer (DOP; di-octyl-
—
1
phthalate)
Titanium dioxide
3-8
Water
7732-18-5
To make 100 wt %
TABLE 2
Second “S” coating solution
Components
CAS NO
Content (wt %)
Polyurethane resin
51-79-6
20-30
Silicon oil
1-5
Silicon dioxide
1-5
Methyl alcohol
67-56-1
To make 100 wt %
TABLE 3
“R” coating solution
Components
CAS NO
Content (wt %)
Polyacrylate copolymer
67-56-1
10-15
Silicon dioxide (silica))
112945-52-5
8-12
Polyoxyethylene sorbitan trioleate
2-5
Polyvinyl alcohol
2-5
Low molecular alcohol
—
To make 100 wt %
According to the present invention, a fixation-strengthening agent functioning to fix the yarns of the fabric, like the functions of the rear side coating, is added to the surface coating solution disclosed in the previous patent of the present inventor. The fixation-strengthening agent serves to prevent the yarns of the fabric from becoming loose during processing operations such as cutting after manufacture of the adhesive fabric paper. One of the important functions of the rear side coating in the previous patent is to prevent the yarns from becoming loose, but in the present invention, the fixation-strengthening agent is used to strengthen the fixation of the yarns in order to provide the same functions as those of the rear side coating layer without forming the rear side coating layer.
With respect to the fixation-strengthening agent, the first “S” coating solution contains 3-8 wt % of titanium dioxide, the second “S” coating solution contains 1-5 wt % of each of silicon oil and silicon dioxide, and the “R” coating solution contains 2-5 wt % of each of polyoxyethylene sorbitan trioleate and polyvinyl alcohol.
4. Coating Process
In the next step, the fabric surface into which ink is to be absorbed is coated by a two-step coating process. In other words, the fabric surface is either coated once with each of the first “S” coating solution and the second “S” coating solution or coated twice with the “R” coating solution.
The first coating is performed, followed by drying. Then, the second coating is performed, followed by drying.
Compared to the case in which the fabric surface is coated with a mixture of the first coating and second coating solutions by a one-step coating process, the two-step coating process enables the coating solution to uniformly penetrate the fabric and allows the two coating layers to be separated from each other. In other words, the first coating layer serves as a primer coating and functions to fix the second coating solution to the fabric so as not to be detached from the fabric. In addition, the two coating layers on the fabric surface are prevented from being easily decolorized by penetration of water.
Particularly, according to the present invention, each of the coating solutions contains the fixation-strengthening agent. Specifically, the first “S” coating solution contains titanium dioxide as the fixation-strengthening agent and an ethylene-vinyl acetate copolymer functioning as an adhesive. The titanium dioxide in a fine particle state functions to strengthen the fixation and solidification of the ethylene-vinyl acetate copolymer during drying, and this mixture of titanium dioxide and the ethylene-vinyl acetate copolymer deeply penetrates the fabric and the yarns to strengthen the binding force between the yarns of the fabric. This mixture performs the function of the white coating or gray coating layer formed on the rear side of the fabric disclosed in the previous patent of the present inventor.
The titanium oxide functions to strengthen the fixation of the yarns of the fabric and also functions to reduce light reflection, block UV light to prevent yellowness and extend the life span of the coating layer, provide antibacterial activity and prevent contamination.
The second “S” coating layer functions to easily absorb ink and make color true to nature.
Particularly, because the second “S” coating is performed after drying and cooling the first “S” coating solution, it is possible to prevent the second “S” coating solution from being solidified immediately before being distributed uniformly, due to heat that penetrated the fabric in the first “S” coating step. In addition, it is possible to minimize the formation of coating lines on the fabric surface during coating. In other words, compared to the case in which the first and second coating solutions are used in a mixture, in the case in which the first and second coating layers are used separately, the two separate coating layers are formed to prevent the penetration of light, and the effects of each of the coating solutions are maximized, and the second “S” coating layer can be strongly fixed to the first “S” coating layer.
Particularly, according to the present invention, the second “S” coating solution contains silicon oil and silicon dioxide as the fixation-strengthening agents. These components have heat resistance, cold resistance, water repellence and the like, and thus are helpful in maintaining the life span of color images printed on the coating layer. In addition to such functions, these components function to prevent the yarns of the fabric from becoming loose.
In the present invention, the “R” coating solution may be applied in two steps in place of the first and second “S” coating solutions. The reason why the “R” coating solution is applied in two steps is to provide the same effects as those obtained when the first and second “S” coating solutions are applied.
The “R” coating solution of the present invention contains specific amounts of polyoxyethylene sorbitan trioleate and polyvinyl alcohol. These components function to strongly fix the yarns of the fabric in cooperation with silicon dioxide and serve to facilitate the printing of ink and protect printed color images.
After the “S” coating or “R” coating process, the fabric is required to be naturally aged for about 3-4 days.
This aging process is performed in order to prevent the fabric from shrinking on the backing material after lamination to cause curling of the fabric (curling phenomenon) and separation between the fabric and the backing material (tunneling phenomenon).
In other words, because the amount of absorption of water differs between the fabric and the backing material, the curling phenomenon and the tunneling phenomenon occur when the fabric comes into contact with the backing material. For this reason, the fabric is naturally aged for a sufficient time so that the fabric can be prevented from shrinking after the lamination process.
5. Lamination of Backing Material
Lamination of the backing material is carried out by a comma coater.
The major ingredients of a removable adhesive to be applied to the backing material before lamination are shown in Table 4 below.
TABLE 4
Ingredients
CAS NO
Wt %
Acrylic polymer
—
31-35
Ethyl acetate
147 -78 -6
35-45
Toluene
108 -88 -3
10-20
The backing material coated with the above adhesive is passed through a drying chamber, and then pressed against the fabric surface using rollers to form a laminate. Specifically, the adhesive-coated backing material is laminated directly to the rear side opposite the coated side of the fabric without forming a rear side coating layer.
After the lamination process, the product is aged at a temperature of about 50° C. for about one day, and then subjected to various cutting processes (roll cutting, and re-cutting). Herein, the product is rolled once more in a direction opposite the already rolled direction, and then cut 3-4 hours after the rolling process. In other words, the product rolled in one direction is rolled once more in the opposite direction in order to maintain the smoothness of the finished product at a constant level.
The adhesive fabric paper manufactured according to the present invention has a width reduced by 12-17% compared to that of the polyester DTY (draw textured yarn) fabric as a result of heating and rapidly cooling the yarn fabric.
As shown in FIGS. 2 and 3 , the structure of the coating layer formed on the surface of a fabric 1 differs between a first embodiment and a second embodiment of the present invention. In the first embodiment, a first “S” coating layer 21 is formed using a coating solution containing 3-8 wt % of titanium dioxide as a fixation-strengthening agent in addition to an ethylene-vinyl acetate copolymer and water as main components, and a second “S” coating layer 22 is formed on the first “S” coating layer using a second “S” coating solution containing 1-5 wt % of each of silicon oil and silicon dioxide as fixation-strengthening agents in addition to polyurethane resin and methyl alcohol as main components.
In the second embodiment, in place of the first “S” coating layer 21 and the second “S” coating layer 22 , first and second “R” coating layers 23 are formed by applying an “R” coating solution containing 2-5 wt % of each of polyoxyethylene sorbitan trioleate and polyvinyl alcohol as fixation-strengthening agents in addition to a low molecular alcohol and a polyacrylate copolymer as main components, twice to the fabric 1 .
In addition, a backing material 30 coated with an adhesive 31 is laminated to the rear side of the fabric 1 .
As described above, the adhesive fabric paper according to the present invention can be easily printed using any printer, can be freely attached to and detached from many places several times, does not leave adhesive residue when it is detached, and does not damage a place where it is attached. In addition, it can be reused several times, is made of a soft material, shows a high image resolution and a very excellent image quality, and prevents printed images from being decolorized. That is, the adhesive fabric paper has all the same effects as those of the previous patent of the applicant. Particularly, even though the adhesive fabric paper of the present invention does not a white coating layer and a gray coating layer on the rear side, it can show the major functions of the rear side coating layers, including preventing printed images from being decolorized rapidly by the volatile component of the adhesive of the backing material when the adhesive permeates the fabric, preventing the yarns of the fabric from becoming loose, blocking sunlight, and preventing a background color or an already existing image in any place from showing through the product.
Thus, the adhesive fabric paper of the present invention can be manufactured in a simpler process at reduced costs compared to the conventional product while having more excellent properties.
Although the preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Provided is an adhesive fabric paper that is used in color printers for personal computers, printing machines for indoor and outdoor advertisement, wide format printers, plotters, and so on to print colored images. In the invention, the rear side of the fabric is not subjected to gray coating and white coating, and the front side of the fabric is coated with a coating solution containing at least one fixation-strengthening agent selected from among titanium dioxide, silicon oil, silicon dioxide, polyoxyethylene sorbitan trioleate, and polyvinyl alcohol. The adhesive fabric paper shows the same functions as those of the rear side coating layer and can be manufactured by a simpler process at reduced costs. | 3 |
This application is a continuation of application Ser. No. 09/219,610, filed on Dec. 23, 1998, U.S. Pat. No. 6,421,499, the entire contents of which are hereby incorporated by reference and for which priority is claimed under 35 U.S.C. §120; and this application claims priority of application No. 98-36862 filed in Korea on Sep. 5, 1998 under 35 U.S.C. §119.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a rewriteable recording medium and a method and system for creating and recording data management information for a rewritable recording medium, and more particularly, but not by way of limitation, to creation and recording of video object presentation order management data accompanied by editing presentation order of still or moving pictures recorded on the recording medium.
2. Description of the Related Art
Optical disks have come into wide use since the advent of compact disc (CD) and the demand for optical disks is expected to grow steadily with popularization of digital versatile disk (DVD). Optical disks include read-only disks such as CD-ROM and DVD-ROM, write-once disks such as CD-R and DVD-R, and rewritable disks such as CD-RW and DVD-RAM. The specification of DVD-RTRW, which is standard writing/reading format of a rewritable disk, has not released yet and standardization for the DVD-RTRW is under way.
As rewritable optical disks like DVD-RAM are of immensely large capacity, users may store a variety of data such as moving pictures, still pictures, audio data, and the like on a single recording medium. Each time a new data file is recorded on a rewritable recording medium, navigation information for locating the data file after recording is created and recorded along with the data file on the recording medium. The recorded navigation information is referred to whenever the relevant data file is accessed.
Navigation information regarding all data files stored on a recording medium is contained in a navigation data table as shown in FIG. 1, which is recorded as a single navigation data file on the recording medium. Accessing the recording medium entails loading the navigation data file into a memory, wherein the navigation data reside all the time. When recording a moving or still picture on the recording medium, the area in which the picture file will be recorded is determined with reference to the navigation information. Recording a picture file always accompanies creating management information regarding the recorded picture file and updating the navigation data file to include the newly created management information.
Management data pertaining to moving pictures comprise movie video object information (M_VOBI) and movie video object presentation order information (movie Cell Information or simply CI). Suppose that a moving picture file is composed of n movie video objects (M_VOBs) M_VOB# 1 ˜M_VOB#n as shown in FIG. 3 . Since each M_VOB needs a M_VOBI and a CI, n M_VOBIs and n CIs are created in the same order that n M_VOBs are recorded. In FIG. 3, M_VOBI# 1 ˜M_VOBI#n correspond to M_VOB# 1 ˜M_VOB#n and C# 2 , C# 4 , . . . (shaded Cells in the box labeled ORG_PGC) correspond to M_VOB# 1 ˜M_VOB#n. The created M_VOBIs and CIs are stored in the movie A/V file information table (M_AVFIT) and the original program chain information table (ORG_PGCIT) of the navigation data shown in FIG. 1, respectively. As illustrated in FIG. 2A, Cell Information related to a movie VOB consists of several fields: Cell type (C_TY) indicating that the relevant VOB is moving picture data, the ID number of the relevant M_VOB (M_VOB_ID), the presentation start time (C_V_S_PTM) and presentation end time (C_V_E_PTM) of the relevant M_VOB, the index number of the text data connected with the CI (IT_TXT_N), and the index number of the thumbnail connected with the CI (THMNL_N).
When the recording medium is accessed, the navigation data file is read from the recording medium and loaded into a memory as mentioned before. If reproduction of a moving picture is requested, M_VOBIs and CIs relevant to the requested moving picture file are read from the M_AVFIT and ORG_PGCIT of the navigation data table, respectively. In reference to the M_VOBIs and CIs, the requested moving picture file can be located from the recording medium and reproduced.
On the other hand, management data pertaining to still pictures comprise still picture video object information (S_VOBI) and still picture video object presentation order information (still picture Cell Information or simply CI). Suppose that a still picture file is composed of n still picture video objects (S_VOBs) S_VOB# 1 ˜S_VOB#n as shown in FIG. 3 . Since each S_VOB needs a S_VOBI and a CI, n S_VOBIs and n CIs are created in the same order that n S_VOBs are recorded. In FIG. 3, S_VOBI# 1 ˜S_VOBI#n correspond to S_VOB# 1 ˜S_VOB#n and C# 1 , C# 3 , . . . (not shaded Cells in the box labeled ORG_PGC) correspond to S_VOB# 1 ˜S_VOB#n. The created S_VOBIs and CIs are stored in the still picture A/V file information table (S_AVFIT) and the original program chain information table (ORG_PGCIT) of the navigation data shown in FIG. 1, respectively. As illustrated in FIG. 2B, Cell Information related to a still picture VOB consists of several fields: Cell type (C_TY) indicating that the relevant VOB is still picture data, the ID number of the relevant S_VOB (S_VOB_ID), the playback time (C_PB_TM), presentation start time (C_V_S_PTM), and still time (C_STILL_TM) of the relevant S_VOB, the index number of the text data connected with the CI (IT_TXT_N), and the index number of the thumbnail connected with the CI (THMNL_N).
The procedure for reproducing a still picture is similar to that for reproducing a moving picture. If reproduction of a still picture is requested, S_VOBIs and CIs relevant to the requested still picture file are read from the S_AVFIT and ORG_PGCIT of the navigation data table, respectively. In reference to the S_VOBIs and CIs, the requested still picture file can be located from the recording medium and reproduced.
The navigation data file is used in the same manner when movie or still picture files recorded on the recording medium are edited. If a user makes or edits a list of moving or still pictures to reproduce them in a preferred order, management data regarding the list are created with reference to the navigation data loaded into the memory. The management data consist of a series of CIs corresponding to the selected pictures, which forms a user-defined program chain or PGC (UD_PGC) to be stored in the user-defined PGC information (UD_PGCI) of the user-defined PGC information table (UD_PGCIT) shown in FIG. 1 . UD_PGC#i is stored in UD_PGCI#i.
If reproduction of a play list of picture files is requested, the UD_PGC stored in the UD_PGCI corresponding to the requested play list is read from the UD_PGCIT of the navigation data in the memory. Then, the M_VOBIs and S_VOBIs corresponding to the CIs can be read from the M_AVFIT and S_AVFIT. Finally, the VOBs linked to the play list can be read out and the play list can be reproduced in reference to the VOBIs and CIs.
In the above method, the amount of the navigation data increases with the number of user-defined PGCs each of which contains information on a presentation order of VOBs, because each user-defined PGC is recorded in a user-defined PGCI in the navigation data table. It is an apparent drawback of the method, therefore, that the navigation data file may take excessive storage space as user-defined PGCs increase in number.
One possible solution to the above problem is to limit the maximum number of user-defined PGCs and the maximum number of CIs that a user-defined PGC can hold. This method, however, may give rise to other problems. Suppose that the number of CIs which a user-defined PGC can take is limited to N. In this case, some picture program to be reproduced continuously cannot be managed by a single user-defined PGC if the number of CIs contained in the picture program exceeds the prescribed bound N.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a rewritable recording medium and a method and system for creating and recording presentation order management data for a rewritable recording medium, which enables effective control of the amount of presentation order management information needed for managing user-defined play lists in the limited maximum size of navigation data.
The method of creating and recording presentation order management information for a rewritable recording medium according to the present invention comprises steps of: creating information tables classified by the types of presentation order management of recorded data; checking the amount of presentation order management information contained in said information tables on the request of new presentation sequence; and controlling creation and record of new presentation order management information based on the result of said checking.
The information table utilized in the present invention comprises an original program chain information table and a user-defined program chain information table. The former table contains management information for reproducing recorded data in the recording order of the data, while the latter table contains management information for reproducing data in a user-preferred order. More specifically, the user-defined program chain information table contains presentation order information units for storing user-defined data presentation sequence and user-defined program chains each of which consists of a plurality of the presentation order information units. The method according to the present invention enables effective management of the amount of presentation order management data by controlling the maximum number of presentation order information units and the maximum number of user-defined program chains.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention, illustrate the preferred embodiment of this invention, and together with the description, serve to explain the principles of the present invention.
In the drawings:
FIG. 1 is a table showing the navigation data file for managing data recorded on a rewritable recording medium;
FIGS. 2A and 2B are tables showing the configuration of Cell Information;
FIG. 3 is a schematic diagram illustrating the process of creating VOBIs and CIs generated with data recording and the process of creating CIs generated with editing of presentation orders of selected data;
FIG. 4 is a schematic diagram of an optical disk recording/reproducing apparatus according to an embodiment of the present invention; and
FIGS. 5A and 5B are flow charts depicting a method of creating and recording presentation order management data for a rewritable recording medium according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described in detail referring to the accompanying drawings.
FIG. 4 shows a schematic diagram of an optical disk recording/reproducing apparatus according to an embodiment of the present invention.
As shown, the apparatus comprises an optical pickup 10 for recording/reproducing information on/from a recording medium OD, an analog signal processing unit 20 for filtering and digitizing high-frequency analog signals reproduced from the recording medium OD and also converting digital data to be recorded on the recording medium OD into analog signals, a digital signal processing unit 30 for decoding and encoding digital data and yielding a control signal for data synchronism, an A/V data processing unit 40 for decoding audio/video (A/V) input data, hereinafter referred to simply as A/V data, and encoding audio/video input signals into A/V data, a control unit 50 for controlling a general operation of the apparatus in response to a user's requests, and a plurality of memories M 1 , M 2 , and M 3 for storing temporary data created in each signal processing phase. In this embodiment, the navigation data file is loaded into the memory M 1 or other accessible storage means.
When recording a moving or still picture on the recording medium OD in the apparatus shown in FIG. 4, first of all the control unit 50 loads the navigation data file recorded on the recording medium OD into the memory M 1 . Referring to the loaded navigation data, the control unit 50 records the picture data on the recording medium OD and creates management information composed of M_VOBIs or S_VOBIs and CIs corresponding to VOBs forming the picture file. The series of CIs is recorded sequentially in the ORG_PGCIT of the navigation data table shown in FIG. 1, wherein the CIs are arranged in the recording order of the relevant VOBs. For this reason, the ORG_PTCIT is also a sequential presentation information table.
A user can make and edit lists of moving or still pictures selected from among pictures recorded on the recording medium OD to reproduce them in a preferred order. If editing mode is requested, the control unit 50 reads the number of user-defined program chain search pointers (UD_PGC_SRP_Ns) stored in the user-defined program chain information table information (UD_PGCITI) of the UD_PGCIT in the navigation data table. The value of UD_PGC_SRP_Ns indicates the number of UD_PGCIs currently contained in the navigation data file. In the UD_PGCIT, CIs related to the lists made by a user are stored, arranged in the prescribed reproduction order of relevant VOBs. For this reason, the UD_PGCIT is also a prescribed-order presentation information table.
Referring to the number of UD_PGCIs, the control unit 50 searches each UD_PGCI for the user-defined PGC general information (UD_PGCGI), which includes the Cell Number field indicating the number of CIs contained in the corresponding UD_PGCI. Also, the control unit 50 adds up the Cell Number of every UP_PGCGI to obtain the total number of CIs contained in the UD_PGCIT. Provided the number of UD_PGCIs is less than a preset limit (for example, 99) and the calculated total number of CIs is less than another preset limit (for example 25,000), the control unit 50 allows editing of recorded data.
The operation of editing mode is explained with reference to FIG. 3 . If a user chooses S_VOBs, for example, S_VOB# 1 ˜S_VOB# 3 , the control unit 50 creates a CI, for example, C# 1 , wherein the presentation order information of the chosen S_VOBs is stored. And then, if the user chooses M_VOBs, M_VOB# 4 ˜M_VOB# 7 , the control unit 50 creates another CI, for example, C# 2 to include the presentation order information of the chosen M_VOBs. To be more precise, the unit of user's choice is not a VOB but a single picture or audio file formed by a plurality of VOBs. The control unit 50 repeats the same procedure as long as the total number of CIs does not exceeds the preset limit value. When the editing mode ends, the control unit 50 completes creation of the UD_PGC wherein the newly created CIs are contained.
The present invention limits both the maximum number of user-defined PGCs (for example, 99) and the total number of CIs contained in the UD_PGCIT (for example, 25,000), while the maximum number of CIs that a user-defined PGC can hold is not limited. Therefore, provided the number of CIs contained in a list of pictures remains within the preset limit value (for example, 25000), it is possible to manage the list by a single user-defined PGC.
The method of creating and recording presentation order management data for rewritable recording medium according to an embodiment of the present invention is explained below in detail with reference to the flow chart shown in FIGS. 5A and 5B.
If a recording medium is loaded into the information recording/reproducing apparatus, the control unit 50 reads the navigation data file from the recording medium and stores the file in the memory M 1 (S 11 ).
If recording of a moving or still picture has been requested, the control unit 50 begins execution of a recording control routine (S 13 ) and controls the A/V data processing unit 40 , the digital signal processing unit 30 , and the analog signal processing unit 20 , so that the moving picture or still picture data obtained from an external device is recorded on the recording medium OD (S 15 ). Subsequently, the control unit 50 groups the input picture data into VOBs (M_VOBs or S_VOBs), creates VOBIs regarding the grouped VOBs, and adds the VOBIs to the M_AVFIT or S_AVFIT of the navigation data stored in the memory M 1 . Also, the control unit 50 creates CIs regarding the recorded VOBs and adds the CIs to the ORG_PGCIT of the navigation data stored in the memory M 1 (S 17 ).
Completing the update of the navigation information table, the control unit 50 checks whether to end the recording mode (S 19 ). If not, the above recording process S 15 through S 17 is repeated. If so, the control unit 50 reads out the navigation data table contained in the memory M 1 and records the navigation data on the recording medium, thereby completing the recording control routine (S 21 ).
Meanwhile, if the recording control routine is not entered at step S 13 , the control unit 50 tests if editing of data recorded on the recording medium is requested (S 23 ). If so, the control unit 50 reads the UD_PGC_SRP_Ns stored in the UD_PGCITI of the navigation data table to look for the number of UD_PGCIs created so far. This number is represented herein as “P”. Also, the control unit 50 searches each UD_PGCI for the UD_PGCGI which includes the number of CIs contained in the corresponding UD_PGCI, and adds up the number of CIs of every UP_PGCGI to obtain the total number of CIs contained in the UD_PGCIT. The total number of CIs contained in the UD_PCGIT is represented herein as “Q”, which will be stored in an internal register (S 25 ).
The control unit 50 tests whether the number of UD_PGCIs (P) is less than a preset limit (i; for example, 99) and the total number of CIs (Q) is less than another preset limit (j; for example, 25,000) (S 27 ). Unless these conditions are satisfied, the requested editing operation cannot be accomplished and the control unit 50 , therefore, returns program control to step S 21 , which finishes the recording control routine by copying the navigation data table in the memory M 1 to the recording medium. If these conditions, however, are satisfied at step S 27 , the control unit 50 begins execution of the editing control routine (S 29 ) and awaits the user's input (S 31 ).
In response to the user's request received from step S 31 for creating reproduction order information, the control unit 50 creates a new UD_PGCI and CI, adding the UD_PGCI to the UD_PGCIT in the memory M 1 (S 33 ). And the control unit 50 creates a user-defined PGC search pointer (UD_PGC_RP) and makes it point to the created UD_PGCI, before incrementing the UD_PGC_SPR_Ns (P) stored in the UD_PGCITI by one (S 35 ). Next, the control unit 50 sets the number of CIs in the UD_PGCI with 1 and increments the number of CIs (Q) stored in the internal register by one, respectively (S 37 ).
Continuing at step S 39 , the control unit 50 tests whether a request for creation of additional reproduction order information has been received (S 39 ) and if so, checks whether the total number of CIs (Q) stored in the internal register is less than the preset limit (j; 25,000) (S 41 ). Unless this condition is satisfied, the control unit 50 returns program control to step S 21 , thereby completing the recording control routine. If the condition is satisfied at step S 41 , the control unit 50 creates a CI according to the request and adds it to the UD_PGCI (S 41 ). Next, the control unit 50 increments the number of CIs stored in the UD_PGCI and the total number of CIs (Q) stored in the internal register by one, respectively (S 45 ).
Continuing at step S 47 , the control unit 50 checks if a request for finishing editing of the current UD_PGC has been received (S 47 ). If so, step S 49 is performed, where it is tested whether a request for finishing the editing mode has been received. If not, the control unit 50 returns program control to step S 39 to repeat the above procedure. Unless a request for finishing the editing mode has been received at step S 49 , the program control is continued to step S 25 , where creation of a new user-defined PGC starts. However, if the request for finishing the editing mode has been received at step S 49 , then the process returns to step S 21 , where the navigation data stored in the memory M 1 is copied to the recording medium and the recording control routine is completed as discussed above.
The invention may be embodied in other specific forms without departing from the sprit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A rewritable recording medium and a system for creating or recording presentation order information for the recording medium are disclosed. The rewritable recording medium includes (a) a data area in which a data file is recorded, and (b) a navigation information area in which a navigation information file is recorded. The navigation information file includes a plurality of presentation order information units for defining a data presentation sequence and a plurality of presentation order information groups each of which including at least one of the presentation order information units. Recording of new data is permitted only when the total number of the presentation order information units for all the presentation order information groups is less than a predetermined value. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 496,782, filed May 20, 1983, now abandoned which is a continuation of Ser. No. 360,510, filed Mar. 22, 1982, now abandoned; which in turn is a continuation of Ser. No. 163,751, filed June 17, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to herbicidal compositions and methods of use. In particular, this invention relates to herbicidal compositions comprising an herbicidally active thiolcarbmate in combination with certain organophosphorus compounds, the latter serving to prolong the effectiveness of a single application of the thiocarbamate in controlling undesired plant growth.
Thiocarbamates are well known in the agricultural art as herbicides useful for weed control in crops such as corn, potatoes, beans, beets, spinach, tobacco, tomatoes, alfalfa, rice and others. Thiocarbamates are primarily used in pre-emergence application, and are particularly effective when incorporated into the soil prior to the planting of the crop. The concentration of the thiocarbamate in the soil is greatest immediately after application of the compound. How long thereafter the initial concentration is retained depends in large part on the particular soil used. The rate at which the thiocarbamate concentration declines following its application varies from one type of soil to the next. This is evident both in the observable extent of weed control and in the detectable presence of undegraded thiocarbamate remaining in the soil after considerable time has elapsed.
It is therefore an object of this invention to increase the soil persistence of thiolcarbmate herbicides and thus improve their herbicidal effectiveness.
BRIEF DESCRIPTION OF THE INVENTION
It has now been discovered that the soil persistence of certain herbicidally active thiocarbamates is significantly extended by the further addition to the soil of certain extender compounds in the form of organophosphorus compounds, which have little or no herbicidal activity of their own and do not decrease the herbicidal activity of the thiocarbamate. This improvement in the soil persistence of thiocarbamates manifests itself in a variety of ways. It can be shown, for example, by soil analyses taken at regular intervals, that the rate of decrease of the thiocarbamate content of the soil is substantially lessened. Improved soil persistence can also be shown by improvements in herbicidal efficacy, as evidenced by a higher degree of weed injury brought about when the extender compound increases the soil persistence of the thiocarbamate, prolonging its effective life.
Examples 1 and 2 below illustrate two different methods of proving the extending activity of the organophosphorus compounds of the instant invention. Example 1 provides chemical assay data whereas Example 2 provides bioassay data. The soil in both examples is pre-treated with a thiocarbamate herbicide to simulate field conditions wherein a field has been repeatedly treated with a thiocarbamate herbicide. However, instead of a year inbetween treatments as in the case of seasonally cultivated fields, the soil in the experiments herein were retreated with the herbicide within weeks of the first treatment. Such a short retreatment period provides a soil which is conditioned to degrade thiocarbamates rapidly for experimental purposes.
The chemical assay data of Example 1 shows by chromatographic analysis that the thiocarbamate herbicide's soil life is extended over time by evidencing that the parts per million of the herbicide is much greater when an organophosphorus extender is present than when it is absent.
The bioassay data of Example 2 shows the soil life extension of thiocarbamate herbicides by the extension of their herbicidal activity in soil also conditioned for rapid degradation of thiocarbamate herbicides.
In particular, this invention relates to a novel herbicidal composition comprising
(a) an herbicidally effective amount of a thiocarbamate having the formula ##STR2## in which R 1 , R 2 , and R 3 are independently C 2 -C 4 alkyl; and
(b) an amount of an organophosphorus compound sufficient to extend the soil life of said thiocarbamate, said organophosphorus compound having the formula ##STR3## in which R 4 is selected from the group consisting of C 1 -C 4 alkyl and C 1 -C 4 alkoxy,
R 5 is selected from the group consisting of C 1 -C 4 alkoxy and C 2 -C 4 alkynylthio,
R 6 is C 1 -C 4 alkylene,
R 7 is selected from the group consisting of methyl and phenyl,
X is oxygen or sulfur,
Y is oxygen or sulfur,
m is zero or one, and
n is zero or one.
Within the scope of the present invention, certain embodiments are preferred, namely:
In the thiocarbamate formula, R 1 is preferably n-propyl or ethyl and R 2 and R 3 are each preferably each n-propyl or each isobutyl.
In the organophosphorus compound formula, it is preferred that:
R 4 , R 5 , R 6 , X and Y are as defined above,
m is one, and
n is zero.
This invention further relates to a method of controlling undesirable vegetation comprising applying the above composition to the locus where control is desired.
The terms "alkyl," "alkoxy," and "alkynylthio" are used herein in their normal meanings and are intended to include both straight-chain and branched-chain groups. The term "alkylene" is used to denote a saturated bivalent hydrocarbon radical consisting of the --CH 2 -- group or multiples thereof, optionally substituted with alkyl groups and thereby including both straight-chain and branched-chain groups. Examples are --CH 2 --, --CH 2 CH 2 --, --CH 2 CH 2 CH 2 --, --CH(CH 3 )CH 2 --, --CH 2 CH(CH 3 )CH 2 --, etc. All carbon atom ranges are inclusive of their upper and lower limits.
The term "herbicide", as used herein, means a compound or composition which controls or modifies the growth of plants. By the term "herbicidally effective amount" is meant any amount of such compound or composition which causes a modifying effect upon the growth of plants. By "plants" is meant germinant seeds, emerging seedlings and established vegetation, including roots and above-ground portions. Such controlling or modifying effects include all deviations from natural development, such as killing, retardation, defoliation, desiccation, regulation, stunting, tillering, stimulation, leaf burn, dwarfing and the like.
The phrase "to extend the soil life of said thiocarbamate" as used herein means to retard the rate at which molecules of thiocarbamate are broken down into decomposition products when in contact with soil and/or to prolong the period of time following application in which herbicidal effects can be observed. This applies both to field sites where repeated applications of thiocarbamates have resulted in decreasing herbicidal effectiveness, and to field sites where a decline in activity is detected over time regardless of the prior history of herbicidal applications. An extended soil life can be manifest in a slower rate of decline of weed-killing activity, or an increased half-life of thiocarbamate concentration in the soil. Other techniques of determining soil life are readily apparent to one skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
The thiocarbamates within the scope of the present invention can be prepared by the process described in U.S. Pat. No. 2,913,327 (Tilles et al., Nov. 17, 1959). The organophosphorus compounds can be prepared by the process described in Netherlands Patent Application No. 6,409,877 (Bayer, Mar. 1, 1965) and U.S. Pat. No. 4,096,251 (Pitt et al., June 20, 1978).
The objects of the present invention are achieved by applying the organophosphorus extender compound to the soil at an agricultural field site in conjunction with the thiocarbamate herbicide. The two compounds can be applied simultaneously in a single mixture or in separate formulations, or they can be applied in succession, with either one following the other. In successive application, it is preferable to add the compounds as close in time as possible.
The herbicide extending effect is operable over a wide range of ratios of the two compounds. It is most convenient, however, to apply the compounds at a ratio of about 1:1 to about 20:1 (herbicide/extender) on a weight basis, preferably about 1:1 to about 10:1, and most preferably about 1:1 to about 5:1.
Thiocarbamate herbicides useful in the present invention include S-ethyl diisobutylthiocarbamate, S-n-propyl di-n-propylthiocarbamate, and S-n-propyl ethyl-n-butylthiocarbamate.
The variety of crops on which the present composition is useful can be significantly broadened by the use of an antidote to protect the crop from injury and render the composition more selective against weeds.
For antidote descriptions and methods of use, reference is made to U.S. Pat. No. 3,959,304, issued to E. G. Teach on May 25, 1976; U.S. Pat. No. 3,989,503, issued to F. M. Pallos et al. on Nov. 2, 1976; U.S. Pat. No. 4,021,224, issued to F. M. Pallos et al. on May 3, 1977; U.S. Pat. No. 3,131,509 issued to O. L. Hoffman on May 5, 1964; and U.S. Pat. No. 3,564,768, issued to O. L. Hoffman on Feb. 3, 1971.
Examples of useful antidotes include acetamides such as N,N-diallyl-2,2-dichloroacetamide and N,N-diallyl-2-chloroacetamide, oxazolidines such as 2,2,5-trimethyl-N-dichloroacetyl oxazolidine and 2,2-spirocyclohexyl-N-dichloroacetyl oxazolidine, and 1,8-naphthalic anhydride. For maximum effect, the antidote is present in the composition in a non-phytotoxic, antidotally effective amount. By "non-phytotoxic" is meant an amount which causes at most minor injury to the crop. By "antidotally effective" is meant an amount which substantially decreases the extent of injury caused by the herbicide to the crop. The preferred weight ratio of herbicide to antidote is about 0.1:1 to about 30:1. The most preferred range for this ratio is about 3:1 to about 20:1.
The following examples are offered to illustrate the utility of the present invention, and are intended neither to limit nor define the invention in any manner.
EXAMPLE 1
These examples show, by soil analysis, the effectiveness of the compounds of the present invention in extending the soil life of the thiocarbamate herbicides. The herbicide used in these tests was S-ethyl di-n-propylthiocarbamate, commonly known as EPTC. The soil was a sandy loam soil obtained from Sunol, Calif., containing approximately (on a weight basis) 64% sand, 29% silt, and 7% clay, determined by mechanical means. The total organic content of the soil was approximately 4% by weight and the pH was 6.8, both determined by chemical analysis.
The test procedure involved an initial pre-treatment of the soil to simulate field conditions where the soil had been previously treated with EPTC, followed by a soil persistence test, as described below.
A. Soil Pre-Treatment
An emulsion was prepared by diluting an emulsifiable liquid concentrate containing 6 lb/gal (0.72 kg/l) of the thiocarbamate in 100 ml of water, such that the concentration of thiocarbamate in the resulting emulsion was 4000 mg/l. Five ml of this emulsion was then added to 10 lb (4.54 kg) of soil and the mixture was mixed in a rotary mixer for 10-20 seconds.
Round plastic containers, 9 inches (22.9 cm) in diameter by 9 inches (22.9 cm) deep, were then filled with the sandy loam soil, which was tamped and leveled with a row marker to impress three rows across the width of each container. Two rows were seeded with DeKalb XL-45A corn Zea mays (L.), and one row was seeded with barnyardgrass Echinochloa crusgalli (L.). Sufficient seeds were planted to produce seveal seedlings per row. The containers were then placed in a greenhouse maintained at 20° C. to 30° C. and watered daily by sprinkler.
Five weeks after treatment, the soil was allowed to dry out and the plant foliage was removed. The soil was then passed through a 0.25 inch (0.64 cm) screen, followed by a 2 millimeter (mm) screen, to remove plant roots and clods.
B. Soil Persistence Test
A 100-gram quantity (air-dry basis) of the pre-treated soil was placed in an 8-ounce (0.25 liter) wide-mouth glass bottle. The same emulsifiable concentrate described in Part A above was approximately diluted in water such that a 5-ml portion added to the soil would produce a herbicide concentration of 6 ppm (weight) in the soil. This is equivalent to an application rate of 6 pounds per acre (6.7 kilograms per hectare) in a where the herbicide is incorporated into the soil through a depth of about 2 inches (5.08 cm) soon after application. A selected extender compound in technical (nonformulated) form was then diluted in an acetone-water mixture such that a one-ml portion added to the soil would produce a concentration of 4 ppm by weight, equivalent to 4 pounds per acre (4.5 kilograms per hectare). On these bases, the herbicide and extender were added to the bottle containing the soil. The bottle was then sealed with a lid and shaken manually for approximately 15 minutes.
Following such treatment, the soil was moistened with 20 ml deionized water. The bottle was then covered with a watch glass to maintain aerobic conditions and to prevent rapid soil drying, and placed in a controlled environmental chamber in darkness, where the temperature was maintained constant at 25° C.
Two days later, the bottle was removed from the environmental chamber and 50 ml of water and 100 ml of toluene were added. The bottle was then tightly sealed with a lid containing a cellophane liner, and vigorously shaken on a variable speed, reciprocating shaker (Eberbach Corp. Model 6000) set at approximately 200 excursions per minute for one hour. After shaking, the bottle contents were allowed to settle, and a 10 ml aliquot of toluene was transferred by pipette into a glass vial and sealed with a polyseal cap. The toluene extract was analyzed for herbicidal content by gas chromatography. The chromatogram data was then converted to equivalent soil concentrations in parts per million (ppm) by weight of the herbicide.
The results are shown in Table 1 below, where a variety of compounds were tested in two separately treated batches of soil. A control run without an extender compound was conducted for each soil batch, to show how the drop in herbicide concentration was affected by the extender compound. In each case, the quantity of herbicide remaining in the soil after two days was dramatically increased when the extender compound was added.
TABLE 1__________________________________________________________________________2-DAY SOIL PERSISTENCE DATAHerbicide: SEthyl di-n-propylthiocarbamate (EPTC) at 6 lb/A (6 ppm insoil)Extender: As shown at 4 lb/A (4 ppm in soil) EPTC Residue After 2 Days (ppm)Extender Compound No. Structural Formula With Extender Without Extender__________________________________________________________________________Soil Batch A: ##STR4## 0.63 0.422 ##STR5## 0.69 0.423 ##STR6## 0.47 0.424 ##STR7## 0.50 0.42Soil Batch B:5 ##STR8## 2.34 1.326 ##STR9## 3.81 0.22__________________________________________________________________________
EXAMPLE 2
BIOASSAY TEST RESULTS
The extender compounds tested by the procedures below have the following structures:
______________________________________ ##STR10##Exten-der positionCmpd. on pyri-No. R.sup.4 R.sup.5 X Y R.sup.6 dyl ring______________________________________5 C.sub.2 H.sub.5 CHCCH.sub.2 S S O CH.sub.2 meta6 C.sub.2 H.sub.5 O C.sub.2 H.sub.5 O S SC.sub.2 H.sub.4 para______________________________________
TEST PROCEDURES WITH ANTIDOTE
This example offers herbicidal activity test data for representative extender compounds within the scope of this invention showing their effectiveness in improving the herbicidal activity of thiocarbamates. The effect is observed by comparing the extent of weed control in test flats treated with a thiocarbamate against that occurring in similar flats treated with both the thiocarbamate and the extender. The soil used in these tests was a sandy loam soil from Sunol, Calif., which was pretreated with the herbicide to simulate a typical field which had received previous herbicide applications.
A. Soil Pre-Treatment
The soil was pre-treated in each instance at 3 lb/A. Where the thiocarbamate tested was S-ethyl diisobutylthiocarbamate, a 6.7 lb/gal (85.2%) emulsifiable liquid concentrate in a 24:1 ratio with the antidote N,N-diallyl-2,2-dichloroacetamide was employed. Where the thiocarbamate was S-propyl N,N-dipropylthiocarbamate, the soil was pretreated with an emulsifiable liquid concentrate of the herbicide alone. In each instance, the emulsifiable liquid concentrates were diluted in 200 ml of water, such that the resulting concentration of herbicide in the solution was 2000 mg/l. Two hundred ml of this solution was then added to 200 lb (90.8 kg) of soil to which 17--17--17 fertilizer (N--P 2 O 5 --K 2 O on a weight basis) had been previously added to a concentration of 50 ppm by weight with respect to the soil. The mixture was mixed in a rotary mixer for 10 to 30 minutes.
The soil was then placed in round plastic containers, 7.5 inches (19.0 cm) in diameter by 7.5 inches (19.0 cm) deep. The soil was tamped and leveled with a row marker to impress one row across the width of each container. This row was seeded with watergrass (Echinochloa crusgalli). Sufficient seeds were planted to produce several seedlings. The containers were then placed in a greenhouse maintained at 20° C. to 30° C. and watered daily by sprinkler.
Five weeks after treatment, the soil was allowed to dry out and the plant foliage was removed. The soil was then passed through a 0.25 inch (0.64 cm) screen to remove plant roots and clods. The soil was then treated according to the procedure of (B) below. The soil pre-treated with S-propyl N,N-dipropyl thiocarbamate alone was not employed for one or more months, whereas the thiocarbamate plus antidote conditioned soil was then used shortly as follows in in (B).
B. Herbicide Test
Solutions were prepared by diluting those emulsifiable liquid concentrates described above as containing the antidote N,N-diallyl-2,2-dichloroacetamide and thiocarbamate in 650 ml of water such that the resulting concentration of herbicide in the solution was 1.48 mg/ml. Five ml of this solution when added to three pounds of soil yielded a quantity in the soil equivalent to three pounds per acre.
The extender compounds were used in technical form. Forty mg of Compound No. 5 was added to 1 ml acetone, 2 ml of dimethylsulfoxide (DMSO), 2 ml of chloroform and 21 ml water such that the resulting concentration of the extender in the solution was 1.54 mg/ml. Compound No. 6 was added to 5 ml acetone and 21 ml water, resulting in the same concentration (1.54 mg/ml.) The acetone contained 1% of an emulsifier/surfactant. Five ml of this solution when added to three pounds of soil yielded a quantity in the soil equivalent to four pounds per acre.
Five ml of the extender solution and 5 ml of the herbicide solution were tank-mixed. The resultant mixture of 10 ml was then added to 3 lbs of soil and incorporated into the soil by a rotary mixer. Thus, 10 ml of the mixture and 3 pounds of soil were placed in rotary mixer and incorporated.
The treated soil was then placed in aluminum flats which were approximately 2.5 inches deep, 3.5 inches wide, and 7.5 inches long. The soil was tamped and leveled with a row marker to impress six rows across the width of the flat. The test weeds were as follows:
______________________________________COMMON NAME ABBREVIATION SCIENTIFIC NAME______________________________________watergrass WG Echinochloa crusgalli (L.)wild oats WO Avena fatua (L.)wild cane WC Sorghum bicolor (L.) Moench______________________________________
R-10 milo (Sorghum bicolor) was also used as a plant growth indicator. Two rows of watergrass were planted. One row of each of the other weeds and plant growth indicator were planted.
Sufficient seeds were planted to produce several seedlings per inch in each row. The flats were then placed in a greenhouse maintained at 70° to 85° F. (21° to 30° C.) and watered daily by sprinkler.
Sixteen days after treatment, the degree of weed control and corn injury were estimated and recorded as a percentage compared to the growth of the same species in a check flat of the same age which had been seeded in conditioned soil but not treated with either an herbicide or an extender. The rating scale ranges from 0 to 100%, where 0 equals no effect with plant growth equal to the untreated check, and 100 equals complete kill.
The test results are recorded in Table 2. An asterisk in Table 2 indicates that the treatment was run in soil pre-treated with the thiocarbamate S-propyl N,N-dipropyl thiocarbamate, alone, that is, without an antidote.
The average percentage of weed control is the average for the above-identified weed species and plant growth indicator. Control experiments (herbicide alone with no extender present) were included in each batch for comparison. Substantial improvements in average percent weed control over the control experiments are evident. The herbicidal efficacy of the thiocarbamate three weeks after application was much improved by the use of the extender.
TABLE 2______________________________________HERBICIDAL ACTIVITY TESTSTreatment Average % ControlHerbicide Extender of 4 Grass Species______________________________________A -- 15*(average of3 trials)A 6 59*B -- 6(average of3 trials)B 5 96______________________________________ Herbicide A: S--propyl N,N--dipropyl thiocarbamate in a 12:1 weight ratio with the antidote N,N--diallyl2,2-dichloroacetamide Herbicide B: S--ethyl N,N--diisobutyl thiocarbamate in a 24:1 weight rati with the antidote N,N--diallyl2,2-dichloroacetamide Extender: Indicated by Compound No. (see Table 1) Herbicide Application Rate: 3 lb/Acre Extender Application Rate: 4 lb/Acre
TEST PROCEDURES WITHOUT ANTIDOTE
The same procedures (A) and (B) were followed as stated above under the procedure with antidote except that no antidote was present in any of the herbicidal emulsifiable liquid concentrates, the ratings were taken 22 rather than 16 days after treatment and that the soil was conditioned immediately before use in all instances.
TABLE 3______________________________________HERBICIDAL ACTIVITY TESTSTreatment Extender Average % ControlHerbicide Extender Application Rate of 4 Grass Species______________________________________A -- -- 18(average of3 trials)A 5 2 15A 5 4 21A 6 2 56A 6 4 55B -- -- 31(average of3 trials)B 5 2 40B 5 4 46B 6 2 39B 6 4 46______________________________________ Herbicide A: S--propyl N,N--dipropyl thiocarbamate Herbicide B: S--ethyl N,N--diisobutyl thiocarbamate Extender: Indicated by Compound No. (see Table 1) Herbicide Application Rate: 3 lb/Acre Extender Application Rate: 4 lb/Acre
METHODS OF APPLICATION
The herbicidal compositions of the present invention are useful in controlling the growth of undesirable vegetation by pre-emergence or post-emergence application to the locus where control is desired, including pre-plant and post-plant soil incorporation as well as surface application. The compositions are generally embodied in formulations suitable for convenient application. Typical formulations contain additional ingredients or diluent carriers which are either inert or active. Examples of such ingredients or carriers are water, organic solvents, dust carriers, granular carriers, surface active agents, oil and water, wager-oil emulsons, wetting agents, dispersing agents, and emulsifying agents. The herbicidal formulations generally take the form of dusts, emulsifiable concentrates, granules and pellets, or microcapsules.
A. DUSTS
Dusts are dense powder compositions which are intended for application in dry form. Dusts are characterized by their free-flowing and rapid settling properties so that they are not readily windborne to areas where their presence is not desired. They contain primarily an active material and a dense, free-flowing, solid carrier.
Their performance is sometimes aided by the inclusion of a wetting agent, and convenience in manufacture frequently demands the inclusion of an inert, absorptive grinding aid. For the dust compositions of this invention, the inert carrier may be either of vegetable or mineral origin, the wetting agent is preferably anionic or nonionic, and suitable absorptive grinding aids are of mineral origin.
Suitable classes of inert solid carriers for use in the dust compositions are those organic or inorganic powders which possess high bulk density and are very free-flowing. They are also characterized by low surface area and poor liquid absorptivity. Suitable grinding aids are natural clays, diatomaceous earths, and synthetic mineral fillers derived from silica or silicate. Among ionic and nonionic wetting agents, the most suitable are the members of the group known to the art as wetting agents and emulsifiers. Although solid agents are preferred because of ease of incorporation, some liquid nonionic agents are also suitable in the dust formulations.
Preferred dust carriers are micaceous talcs, pyrophyllite, dense kaolin clays, tobacco dust and ground calcium phosphate rock. Preferred grinding aids are attapulgite clay, diatomaceous silica, synthetic fine silica and synthetic calcium and magnesium silicates.
Most preferred wetting agents are alkylbenzene and alkyl-naphthalene sulfonates, sulfated fatty alcohols, amines or acid amides, long chain acid esters of sodium isothionate, esters of sodium sulfosuccinate, sulfated or sulfonated fatty acid esters, petroleum sulfonates, sulfonated vegetable oils, and ditertiary acetylenic glycols. Preferred dispersants are methyl cellulose, polyvinyl alcohol, lignin sulfonates, polymeric alkylnaphthalene sulfonates, sodium naphthalenesulfonate, polymethylene bisnaphthalenesulfonate, and sodium-N-methyl-N-(long chain acid) taurates.
The inert solid carriers in the dusts of this invention are usually present in concentrations of from about 30 to 90 weight percent of the total composition. The grinding aid will usually constitute 5 to 50 weight percent of the compositions, and the wetting agent will constitute from about 0 to 1.0 weight percent of the composition. Dust compositions can also contain other surfactants such as dispersing agents in concentrations of up to about 0.5 weight percent, and minor amounts of anti-caking and antistatic agents. The particle size of the carrier is usually in the range of 30 to 50 microns.
B. EMULSIFIABLE CONCENTRATES
Emulsifiable concentrates are usually solutions of the active materials in nonwater-miscible solvents together with an emulsifying agent. Prior to use, the concentrate is diluted with water to form a suspended emulsion of solvent droplets.
Typical solvents for use in emulsifiable concentrates include weed oils, chlorinated hydrocarbons, and nonwater-miscible ethers, esters, and ketones.
Typical emulsifying agents are anionic or nonionic surfactants, or mixtures of the two. Examples include long-chain alkyl or mercaptan polyethoxy alcohols, alkylaryl polyethoxy alcohols, sorbitan fatty acid esters, polyoxyethylene ethers with sorbitan fatty acid esters, polyoxyethylene glycol esters with fatty or rosin acids, fatty alkylol amide condensates, calcium and amine salts of fatty alcohol sulfates, oil soluble petroleum sulfonates, or preferably mixtures of these emulsifying agents. Such emulsifying agents will comprise from about 1 to 10 weight percent of the total composition.
Thus, emulsifiable concentrates of the present invention will consist of from about 15 to about 50 weight percent active material, about 40 to 82 weight percent solvent, and about 1 to 10 weight percent emulsifier. Other additives such as spreading agents and stickers can also be included.
C. GRANULES AND PELLETS
Granules and pellets are physically stable, particulate compositions containing the active ingredients adhering to or distributed through a basic matrix of a coherent, inert carrier with macroscopic dimensions. A typical particle is about 1 to 2 millimeters in diameter. Surfactants are often present to aid in leaching of the active ingredient from the granule or pellet.
The carrier is preferably of mineral origin, and generally falls within one of two types. The first are porous, absorptive, preformed granules, such as preformed and screened granular attapulgite or heat expanded, granular, screened vermiculite. On either of these, a solution of the active agent can be sprayed and will be absorbed at concentrations up to 25 weight percent of the total weight. The second, which are also suitable for pellets, are initially powdered kaolin clays, hydrated attapulgite, or bentonite clays in the form of sodium, calcium, or magnesium bentonites. Water-soluble salts, such as sodium salts, may also be present to aid in the disintegration of granules or pellets in the presence of moisture. These ingredients are blended with the active components to give mixtures that are granulated or pelleted, followed by drying, to yield formulations with the active component distributed uniformly throughout the mass. Such granules and pellets can also be made with 25 to 30 weight percent active component, but more frequently a concentration of about 10 weight percent is desired for optimum distribution. The granular compositions of this invention are most useful in a size range of 15-30 mesh.
The surfactant is generally a common wetting agent of anionic or nonionic character. The most suitable wetting agents depend upon the type of granule used. When preformed granules are sprayed with active material in liquid form the most suitable wetting agents are nonionic, liquid wetters miscible with the solvent. These are compounds most generally known in the art as emulsifiers, and comprise alkylaryl polyether alcohols, alkyl polyether alcohols, polyoxyethylene sorbitan fatty acid esters, polyethylene glycol esters with fatty or rosin acids, fatty alkylol amide condensates, oil solution petroleum or vegetable oil sulfonates, or mixtures of these. Such agents will usually comprise up to about 5 weight percent of the total composition.
When the active ingredient is first mixed with a powdered carrier and subsequently granulated, or pelleted, liquid nonionic wetters can still be used, but it is usually preferable to incorporate at the mixing stage one of the solid, powdered anionic wetting agents such as those previously listed for the wettable powders. Such agents will comprise from about 0 to 2 weight percent of the total composition.
Thus, the preferred granular or pelleted formulations of this invention comprise about 5 to 30 percent by weight active material, about 0 to 5 weight percent wetting agent, and about 65 to 95 weight percent inert material carrier, as these terms are used herein.
D. MICROCAPSULES
Microcapsules consist of fully enclosed droplets or granules containing the active materials, in which the enclosing material is an inert porous membrane, arranged to allow escape of the enclosed materials to the surrounding medium at controlled rates over a specified period.
Encapsulated droplets are typically about 1 to 50 microns in diameter. The enclosed liquid typically constitutes about 50 to 95% of the weight of the entire capsule, and may contain a small amount of solvent in addition to the active materials.
Encapsulated granules are characterized by porous membranes sealing the openings of the granule carrier pores, trapping the liquid containing the active components inside for controlled release. A typical granule size ranges from 1 millimeter to 1 centimeter in diameter. In agricultural usage, the granule size is generally about 1 to 2 millimeters in diameter. Granules formed by extrusion, agglomeration, or prilling are useful in the present invention as well as materials in their naturally occurring form. Examples of such carriers are vermiculite, sintered clay granules, kaolin, attapulgite clay, sawdust, and granular carbon.
Useful encapsulating materials include natural and synthetic rubbers, cellulosic materials, styrene-butadiene copolymers, polyacrylonitriles, polyacrylates, polyesters, polyamides, polyurethanes, and starch xanthates.
E. IN GENERAL
Each of the above formulations can be prepared as a package containing both the herbicide and the extender together with the other ingredients of the formulation (diluents, emulsifiers, surfactants, etc.). The formulations can also be prepared by a tank mix method, in which the ingredients are obtained separately and combined at the grower site. The herbicide and extender may both be used in the same type of formulation or a different formulation may be used for each, e.g. the herbicide may be in microcapsule form while the extender may be an emulsifiable concentrate, or vice versa.
As a further alternative, the herbicide and extender can be applied sequentially, with either being applied first. This is a less preferred method, however, since more effective results are obtained with simultaneous application.
In general, any conventional method of application can be used. The locus of application can be soil, seeds, seedlings, or the actual plants, as well as flooded fields. Soil application is preferred. Dusts and liquid compositions can be applied by the use of powder dusters, boom and hand sprayers, and spray dusters. The compositions can also be applied from airplanes as dusts and sprays because they are effective in very low dosages. In order to modify or control the growth of germinating seeds or emerging seedlings, as a typical example, the dust and liquid compositions are applied to the soil according to conventional methods and are distributed in the soil to a depth of at least one-half inch below the soil surface. It is not necessary that the phytotoxic compositions be admixed with the soil particles. Instead, these compositions can be applied merely by spraying or sprinkling the surface of the soil. The phytotoxic compositions of this invention can also be applied by addition to irrigation water supplied to the field to be treated. This method of application permits the penetration of the compositions into the soil as the water is absorbed therein. Dust compositions, granular compositions or liquid formulations applied to the surface of the soil can be distributed below the surface of the soil by conventional means such as discing, dragging or mixing operations.
The herbicide/extender compositions can also be applied to the soil through irrigation systems. According to this technique, the compositions are added directly to irrigation water immediately prior to irrigation of the field. This technique is applicable in all geographical areas regardless of rainfall, since it permits supplementation of the natural rainfall at critical stages of plant growth. In a typical application, the concentration of the herbicide/extender composition in the irrigation water will range from about 10 to 150 parts per million by weight. The irrigation water can be applied by the use of sprinkler systems, surface furrows, or flooding. Such application is most effectively done before the weeds germinate, either early in the spring prior to germination or within two days after cultivation of the field.
The amount of the present composition which constitutes a herbicidally effective amount depends upon the nature of the seeds or plants to be controlled. The rate of application of active ingredient varies from about 0.01 to about 50 pounds per acre, preferably about 0.1 to about 25 pounds per acre with the actual amount depending on the overall cost and the desired results. It will be readily apparent to one skilled in the art that compositions exhibiting lower herbicidal activity will require a higher dosage than more active compounds for the same degree of control. | Herbicidally active thiolcarbamates are employed in combination with certain organophosphorus compounds having the formula ##STR1## in which R 4 is selected from the group consisting of C 1 -C 4 alkyl and C 1 -C 4 alkoxy; R 5 is selected from the group consisting of C 1 -C 4 alkoxy and C 2 -C 4 alkynylthio; R 6 is C 1 -C 4 alkylene; R 7 is selected from the group consisting of methyl and phenyl, X is oxygen or sulfur; Y is oxygen or sulfur; m is zero or one; and n is zero or one. As a result, the herbicidal effectiveness of the thiocarbamate is enhanced and prolonged, rendering a single application of the herbicide effective over a longer period of time. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S.A. provisional application Ser. No. 60/759,170, filed on Jan. 12, 2006, all disclosures are incorporated therewith. This application also claims the priority of Taiwan application serial no. 95124777, filed Jul. 07, 2006. All disclosure of the Taiwan application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention is related to a technology of bio-chip, and more particular to a bio-chip using the surface acoustic wave (SAW) mechanism, capable of detecting a bio sample.
[0004] 2. Description of Related Art
[0005] The surface acoustic wave (SAW) technology has been used in wide application. According to its design mechanism, it can be used to detect various changes in physical or chemical properties, and can be used to design a detector for detecting, for example, temperature, pressure, twist, or even the volatile of gas or chemical material.
[0006] Certainly, the SAW apparatus can also be used in bio-chemical or biomedical detection. Due to the design with high sensitivity and simple structure, the SAW apparatus has been well considered in applications. Generally, the SAW apparatus needs to be covered with a bio-recognition coating layer for detecting the bio sample, such as a specific bio-chemical or biomedical material.
[0007] In the bio-chemical or bio-medical field, several type of biomarkers have been known to help the estimation or diagnosis of various diseases or the relating symptoms. As a result, the prevention or precaution on developing or worsening of diseases can be made. For example, the status of cardiovascular diseases can be estimated or diagnosed by using markers of CK-MB (CK, Myoglobin) and Troponin-I/T. If the Troponin-I/T is the sample to be detected, generally, since the concentration of Troponin-I/T in blood is very low, it therefore needs to be detected by a sensor with high sensibility. However, in the conventional technology, the detecting sensibility for the Troponin-I/T is relatively low. This conventional technology for detecting the Troponin-I/T still has disadvantages to be further solved.
[0008] Reviewing the prior art, U.S. Pat. Nos. 6,321,588; 5,306,644; and 5,992,215 have disclosed relating detection tools in combination with SAW for signal amplification. The signal is then detected by circuit. These prior arts are concentrating on analyzing the chemical material and gas molecules. Although the U.S. Pat. No. 4,598,224 also discloses a relating technology but the quantity analysis and noise treatment are not considered. The publications or published patents are generally on the application of communication and high frequency device but not on the application of bio-sensor. In addition, some of them may be used to detect the micro change in physical quantity, such as analysis of existence of gas or chemical material in small quantity.
[0009] In addition, the conventional SAW apparatus can use, for example, the Inter-Digital Transducer (IDT) design. The publication of “The 30 th Annual Conference of the IEEE Electronics Society, Nov. 2-6, 2004, Busan, Korea; pp 1546-1549” by Gi-Beum Kim et al. has also introduced the SAW sensor. The SAW sensor includes the IDT's on a piezoelectric substrate. The IDT's are formed from thin metal film. When an electric signal with appropriate frequency is applied to the input IDT, SAW is launched on the surface of the substrate due to the reverse piezoelectric effect. The SAW propagates across the surface of the substrate and is converted back into an electric signal by the output IDT. The operating frequency f, is determined by the IDT finger spacing ω s , finger width ω f , wavelength λ, and SAW velocity ν s according to the relation of f=ν s /λ where λ=2(ω s +ω f ). The SAW velocity However, if a mass load is disposed on the path of the SAW, the SAW velocity ν s ∝√ c/ρ is proportional to the elasticity and density of the substrate and the associated mass load on it. Therefore, the mass load can be detected. The detail can be referred to Gi-Beum Kim et al. and can be understood by the person with ordinary skill. The further detail is omitted here.
[0010] However, due to the improper implementing structure of IDT in the SAW apparatus, the performance is not good and could be affected by the noise and echo phenomenon, and then the discerning capability and sensitivity get low. Since the quantity analysis in micro-amount is strongly needed in the current trend, it is strongly desired to have high precision with the least amount of sample.
[0011] The conventional design of IDT sensor has many disadvantages, such as easily producing noise. Since the IDT is very sensitivity, the surface is easily affected resulting in several issues. For example, the IDT cannot be integrated into an integrated circuit and it is not easy to handle on property under batch production. As a result, the development is quite limited. In these reasons, some experts in this field change the concerning point and develop the applications of SAW technology on the electronic filter. This technology has been developed for about half century. The efforts from experts on developing this technology are not much in recent years. However, based on the IDT mechanism, the bio-chip with better performance is still needed in continuous development.
SUMMARY OF THE INVENTION
[0012] Generally, the present invention uses the SAW device to have further applications on, for example, biomedical and bio-chemical detection, and pharmacology application such as the selection of target medicine.
[0013] The present invention uses a SAW bio-chip, having a SAW device with a sensing region and a signal processing circuit on a substrate.
[0014] In the present invention, a SAW bio-chip, which can amplify the signal different and filter the noise.
[0015] In the present invention, a testing sample region and a referencing sample region are provided under the same background conditions in measurement. By input from single acoustic signal generator, the testing sample region and the referencing sample region are arranged in symmetrical implementation, such as left-right symmetry. By detecting the difference between two signals from the testing sample region and the referencing sample region, the discerning precision with respect to the reference sample can be improved.
[0016] In the present invention, an absorption region can be located at the corresponding periphery of the SAW device. Under proper design and selection on material and size of the absorption region, the echo can be effectively absorbed or cancelled.
[0017] The present invention provides a SAW bio-chip, including a substrate having a property of piezoelectric material. An insulating layer is implemented on the substrate. A SAW generating region is implemented on the insulating layer, wherein a first SAW signal and a second SAW signal, being substantially identical, are generated by interaction with the substrate and travel on the insulating layer. A first SAW transduction region is implemented on the insulating layer to receive the first SAW signal for producing a first electric signal. A second SAW transduction region is implemented on the insulating layer to receive the second SAW signal for producing a second electric signal. When the bio-chip is in operation, a reference sample and a testing sample are disposed on the insulating layer and respectively on the routes of the first SAW signal and the second SAW signal. The two routes are symmetric with respect to the SAW generating region.
[0018] The present invention also provides SAW bio-chip, including a substrate having a property of piezoelectric material. An insulating layer is implemented on the substrate. A first Inter-Digital Transducer (IDT) unit is implemented on the insulating layer, wherein a first SAW signal and a second SAW signal, being substantially identical, are generated by interaction with the substrate and travel on the insulating layer. A second IDT unit is implemented on the insulating layer to receive the first SAW signal for producing a first electric signal. A third IDT unit is implemented on the insulating layer to receive the second SAW signal for producing a second electric signal. When the bio-chip is in operation, a reference sample and a testing sample are disposed on the insulating layer and respectively on the routes of the first SAW signal and the second SAW signal. The two routes are symmetric with respect to the SAW generating region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0020] FIG. 1 is a cross-sectional view, schematically illustrating a structure of SAW bio-chip, according to an embodiment of the present invention.
[0021] FIGS. 2A-2B are top view and cross-section view, schematically illustrating a structure of SAW bio-chip, according to an embodiment of the present invention.
[0022] FIG. 3 is a circuit diagram, schematically illustrating the circuit structure of the SAW bio chip, according to another embodiment of the present invention.
[0023] FIGS. 4A-4C are cross-sectional views, schematically illustrating a fabrication process for a SAW bio-chip, according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention proposes a SAW bio-chip, capable of improving quantity precision in detecting a bio sample, in which the noise and the echo signal can at least be reduced. The present invention further uses a reference sample for producing a reference signal, so as to measure the signal difference of the measuring signal from the testing sample. As a result, under the same operation condition, the error in conventional method, caused by the separating measurements with different background conditions, can be reduced. Further, the noise and the residual echo of the acoustic signals can be further reduced by a filter and an acoustic absorbing structure. The precision can be further improved. In addition, since the measured quantity is the difference between the testing sample and the reference sample, the difference can be quantified, so as to determine the probability about whether or not the testing sample is the same as the reference sample. Some embodiments are provided for descriptions but the present invention is not just limited to the embodiments.
[0025] FIG. 1 is a cross-sectional view, schematically illustrating a structure of SAW bio-chip, according to an embodiment of the present invention. In FIG. 1 , a substrate 100 is divided into a middle region 120 and two side regions 110 at a symmetrical arrangement with respect to the middle region 120 . The substrate 100 includes the property of piezoelectric material. For example, the substrate 100 is a block layer of piezoelectric material, or a structural block layer having a piezoelectric layer disposed on a bottom layer. The middle region 120 can be implemented with a SAW generating structure, such as an IDT structure, capable of converting an alternative electric signal into surface acoustic wave based on the piezoelectric property of the substrate 100 . For example, the surface acoustic waves are generated and travel in two opposite directions as shown by the wavy arrows. An insulating layer is implemented between the substrate 100 and the IDT unit, for isolation and serving as a wave guide layer. As a result, the physical wave generated from the middle region 120 can propagate out. This physical wave in the present invention is called surface acoustic waves 116 and 118 . The two side regions 110 are also implemented with the IDT units for respectively receiving the two surface acoustic waves 116 and 118 in two directions. In order to have better comparison effect, the middle regions is distant to the two side regions 110 in equal distance, and the IDT units at the two side regions 110 are identical, so as to again convert the received SAW signals into the electric signals for analysis. In other words, the two side regions 110 corresponding to the single middle region 120 have the symmetrical routes, preferably a symmetrical disposition in left-to-right symmetry. Certainly, the two side regions with respect to the middle region 120 may have an including angle. However, the two routes for the two side regions 120 to the middle region 120 are still in symmetric arrangement.
[0026] In operation, for example, a position at the left side of the middle region 120 can be disposed with a reference sample 112 , such as a bio reference sample. At the same time, a corresponding position at the right side of the middle region 120 can be disposed a bio testing sample 112 , such as a bio sample to be detected. Further, for example, the foregoing positions of the bio reference sample 112 and the bio testing sample 114 can be exchanged. The changes, when the SAW passes the bio testing sample and the bio reference samples, can be simultaneously measured by the IDT units at the two side region 110 . Since the operation condition are the same, the measured signals from the IDT unit at the two side regions 110 can be, for example, analyzed in difference. This can at least reduce the error caused in conventional method by separating measurement under different operation conditions. The structure of SAW bio-chip is to be described in further detail as follows.
[0027] FIG. 2A and FIG. 2B are top view and cross-section view, schematically illustrating a structure of SAW bio-chip, according to an embodiment of the present invention. In FIG. 2A and FIG. 2B , an insulating layer 230 is formed on a substrate 200 , and also serves as a wave guide layer, called SAW propagation layer. The substrate 200 , as previously described, is a substrate having the property of piezoelectric material. In FIG. 2A and FIG. 2B , a piezoelectric layer is taken as the example for description. The middle region 220 of the insulating layer 230 is formed with SAW generating structure 240 a. Via the medium of the insulating layer 230 , a first surface physical wave 116 and a second surface physical wave 118 being substantially identical are generated, and preferably propagating in two opposite directions. The SAW generating structure 240 a is, for example, a pair of metal bar layers, that is, IDT unit. The two terminals 280 of the SAW generating structure 240 a can be applied an alternative electric signal to the IDT unit. The alternative electric signal can be, for example, a period wave such as semi-period wave, sine wave, square wave, triangle wave. The generated electric field would generate the stress on the piezoelectric material, so as to produce the SAW. Further, according to the geometric shape of the metal bar layer, such as the length, width, bending gap, and size with the piezoelectric property of material, a specific propagation mode of the SAW can be generated.
[0028] Further, another two identical SAW transduction structure 240 b and 240 c are implemented on the insulating layer at the two side regions 210 , so as to receive the two SAW signals and convert them into two electric signals, which are output at the terminal 280 . In addition, after the SAW signals pass the SAW transduction structure 240 b and 240 c at two side regions 210 , it may have residual SAW signals in continuous propagation. In this situation, for example, an acoustic absorbing structure 250 can be additionally implemented, so as to avoid the improper reflection (or called echo) from the SAW signals in the insulating layer, causing measurement error.
[0029] When the bio-chip is in operation, the reference sample can be disposed on one of the two routes of the SAW signals, such as the position of the reference sample region 260 , by a contact layer. In addition, the testing sample can be disposed on another one of the routes of the SAW signals, such as the position of the testing sample region 270 . It preferably has the same distance for the position of the reference sample region 260 and the position of the testing sample region 270 in corresponding to the position of the SAW generating structure 240 a. As a result, when the reference sample is compared with the testing sample in measuring difference, most of system error can be removed due to the operation condition being substantially the same.
[0030] It can be noted that the reference sample and the testing sample are disposed on the insulating layer 230 . Further, the SAW generating structure 240 a is used to generate the SAW signals while the SAW transduction structures 240 b and 240 c are used to receive the measuring SAW signals. Here, the SAW generating structure 240 a and the SAW transduction structures 240 b, 240 c can be, for example, designed by the IDT structure. However, the other mechanism with similar function can be use, too. The present invention is not limited to the IDT design.
[0031] In addition, generally, the three regions 210 , 220 are preferably arranged in a straight line and symmetry. However, this is not the only way in arrangement. It can be modified into other arrangements while the reference sample and the testing sample can be measured under the operation condition. For example, the three regions 210 , 220 are not necessary to be in straight line. Further, according to the design by implementing the IDT unit at the region 220 , if the SAW signal is generated in isotropic direction, such as the structure in circular shape, then several side regions 210 with respect to the middle region 220 can be set, and several testing samples can be measured at the same time. The present invention proposes the comparison between the testing sample and the reference sample, such as the analysis on difference, so as to quantify the measured results. Under this principle, various designs can be made and it is not necessary to restrict to a specific design.
[0032] Continuously, the signals measured by the SAW transduction structures 240 b, 240 c can be further processed and analyzed. FIG. 3 is a circuit diagram, schematically illustrating the circuit structure of the SAW bio chip, according to another embodiment of the present invention. In FIG. 3 , the signals measured from SAW transduction structures 240 b, 240 c can be, for example, processed and analyzed by using external circuit in association with computer system. However, in order to have convenient use in bio-chip, a portion of circuit can be formed on a substrate 300 .
[0033] In FIG. 3 , in addition to the structure as described in FIGS. 2A-2B , a portion of circuit structure can be also formed on the substrate 300 . In other words, the implementation of the circuit structure allows the bio-chip itself already carries a signal processing circuit, so as to have convenient use. However, the circuit structure is not absolutely necessary to be formed on the substrate 300 . In other words, the bio-chip can, for example, output the electric signals to the external circuit unit for processing. In the following example for descriptions, a portion of the circuit is formed on the substrate 300 . For example, a conducting wire structure 380 and the SAW sensor 310 lead the output signals from the SAW transduction structures 240 b, 240 c at the side region 210 to a differential amplifier 320 . The SAW sensor 310 and the differential amplifier 320 can be integrated into a circuit unit 325 . The differential amplifier 320 can take out the signal difference between the testing sample and the reference sample and properly amplifies the difference. Alternatively, the differential amplifier 320 can be a subtracting device for subtracting the two input signals. After the differential amplifier 320 , according to the actual need, the signal is further input to a signal processing unit 330 and a filter 340 . The signal processing unit 330 can further adjust the signal or even digitized the signal, and so on. The filter 340 can filter the noise. In other words, some signal processing circuits can be pre-formed on the substrate 300 . The signal can be output at the terminal 350 for the analysis by the external computer system 370 . The computer system 370 may need to process several bio-chips at the same time, wherein an interface of multiplexer 360 can be used to select the one to be analyzed. However, the foregoing analysis is just the example for the subsequent analyzing and processing, the process flow is not necessary to be the same as the embodiment.
[0034] In addition, form the fabrication point of view, for example, the semiconductor fabrication process can be used, including deposition, photolithography, etching, and so on. Further for example, the IDT unit at the regions 210 , 220 can be patterned at the same time, so as to obtain the desired structure. The detail can be understood by the one in ordinary skill and is not further described.
[0035] In the following descriptions, an example for fabricating the FIGS. 4A-4C are cross-sectional views, schematically illustrating a fabrication process for a SAW bio-chip, according to an embodiment of the present invention. In FIG. 4A , substrate 400 , such as ST-Cut Quartz with the piezoelectric property, is provided. A metal layer, such as gold layer, is formed and patterned by photolithographic and etching processes on the substrate, so as to form the IDT 402 . Here, the direction of the crystal lattice needs in consideration. In FIG. 4B , an insulating layer such as silicon oxide layer is deposited over the substrate 400 . The insulating layer is, for example, 1 micron in thickness. In FIG. 4C , another metal layer, such as gold layer, is formed and patterned by photolithographic and etching process to form the metal layer 406 on the insulating layer 404 to serve as a contact layer for adapting the sample.
[0036] Remarkably, the elements of surface Love wave usually have advantages of low attenuation and high sensitivity. However, the surface Love Wave is not always generated by any kind of layered structure. In order to generate the surface Love wave for the need of SAW, it needs the wave guiding layer on the substrate. The usual material for the wave guide layer can be silicon oxide, zinc oxide, or PMMA, in which silicon oxide is preferred because of low wave loss and resistance in alkalinity and acidity. In other words, the insulating layer 404 also servers as the wave guiding layer for the SAW.
[0037] The SAW bio-chip of the present invention has the analysis in high quality and quantity. The acoustic wave is converted in to AC output by the IDT. The IDT, the insulating layer and the structures at the regions of testing sample and reference sample can be formed by film deposition. The testing sample can be chemical product, food, agricultural product, or bio sample. The physiology analytes or bio sample can be blood, plasma, saliva, cerebral spinal fluid, lymph, urine, immunoglobulins, the immunoglobins complementary analytes, viruses, therapeutic drugs, hormones, proteins, steroids, neurotransmitters, receptors, glycosylated proteins, carbonhydrates, neucleic acids, cells, cancer markers, neucleotides, or heptens.
[0038] When the AC signal is input, the input terminal is connected to the periodic wave in fix frequency. The selection of the periodic wave can be adjusted according to the substrate, the insulating layer, and the IDT in a distance and width. The periodic wave with fix frequency can be semi-period wave, sine wave, square wave, triangle wave and so on. The alternating electric field can be generated between the electrodes. The piezoelectric crystal in responding to the electric filed produces deformation, so that the electric energy is converted into acoustic energy. Further, the signal passes the testing sample and the reference sample and the signals frequency is changed due the mass effect. Then, the signal processing circuit output the changes acoustic signal and convert the acoustic signal into the electric signals, which are further amplified and filtered in noise, and then output for the external measurement.
[0039] According to the preferred embodiment of the present invention, the signal difference between the testing sample and the reference sample is collected, so as to obtain the result. In the present invention, the noise and the echo between phase and phase can be significantly reduced by the design at the absorption region in material and size, and a symmetric design for the sample region (testing sample region and reference sample region) of the bio-chip. In addition, since the film deposition is used to form the sample regions, the amount of the samples in detection can be reduced. Since the only small amount of the sample is needed, the precision and the subsequent management and analysis on signal can be simplified and more quantified, so as to improve the competition on chip performance.
[0040] The present invention employs the proper symmetry design for the absorption region, the IDT with selected material and size under test and specific design, and the symmetric design for the testing sample region and reference sample region. Further, the structure formed by the fabrication process allows the simultaneous measurements for the testing sample region and reference sample region. As a result, the key factors of insufficient analyses in quantity and quality for the conventional method can be overcome by the present invention. The insulating layer can be formed by film deposition process. The signal processing circuit and the absorption region surrounding at the symmetric periphery of the SAW bio-chip can together reduce the noise and echo. The quantity analysis can be done by the differential circuit to discern the signal difference, and the signal can be amplified by signal processing circuit. In order for adapt various physiology analytes, they can be adapted by simply changing the materials at the sample regions.
[0041] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing descriptions, it is intended that the present invention covers modifications and variations of this invention if they fall within the scope of the following claims and their equivalents. | A surface acoustic wave (SAW) bio-chip is designed with signal processing circuits. The chip can achieve precise measurements or detection quantitatively via the difference between the experiment-control mode, and followed by amplification and filtering of the signal processing circuits. By changing the designs of the substrate, quantitative detection toward different analyses can be achievable. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a dredging apparatus for extracting bottom-dwelling shellfish such as clams, oysters, mussels, cockles, and crabs from a sea, lake, or riverbed, and for continuously transporting the extracted shellfish to the surface.
[0003] More specifically, the invention relates to a hydraulic dredging apparatus that includes a source of pressurized water, at least one water jet arranged to receive water from the pressurized water source and direct it at shellfish-containing sediments, sorting plates for receiving the shellfish-containing sediments excavated by the water jet or jets and separating the shellfish from the sediments, a collection chamber for receiving the separated shellfish, and dual lifting compartments, one of which is connected to the pressurized water source for lifting shellfish from the collection chamber and entraining the shellfish for transport to the surface, and the other of which is arranged to received pressurized air for increasing the transport speed and lifting power while cushioning the shellfish as they are transported to the surface. Unlike previous hydraulic transport mechanisms, the dual-compartment air/water transport arrangement of the invention permits precise control of excavation and transport pressure, without the need for multiple air or water sources and/or manifolds.
[0004] 2. Description of Related Art
[0005] Numerous attempts have been made to devise mechanical harvesters that move or that can be towed along the bottom of a body of water in order to harvest shellfish that live in colonies at the bottom. All of these devices seek to dredge shellfish such as clams, oysters, cockles, mussels, and/or crabs from the bottom of the body of water and either trap the shellfish for retrieval after the device is brought to the surface, or continuously transport the shellfish to the surface as the dredge is being towed along the bottom.
[0006] Common problems that the designers of these devices have attempted to solve include problems of efficiency, i.e., the relationship between power or effort expended and the amount of shellfish harvested, problems related to the cost and reliability of the device, which are often a function of complexity, and problems related to environmental damage caused by the device as it is towed across the sea, lake, or riverbed.
[0007] The earliest attempts at large-scale shellfish harvesting devices undoubtedly date back to prehistoric times and most likely involved diggers or tongs dragged along the bottom for scooping shellfish into a collection cage or basket that could then be brought to the surface and emptied. More sophisticated but nevertheless fundamentally similar examples of dredges of this type are still being used and are disclosed, for example, in U.S. Pat. Nos. 4,827,635, 4,425,723, and 3,226,854. Such dredges have the advantage of simplicity, but are relatively inefficient because of inherent limitations in the effectiveness of mechanical dredging devices, and the need to repeatedly bring the dredges to the surface to be emptied.
[0008] As early as Greek times, high pressure jets of water capable of slicing horizontal layers of sediment were being used to hydraulically harvest shellfish, the loosened or liquified mass of shellfish-containing sediments being sifted to separate the shellfish from the sediments, and the remaining shellfish being collected in a collection cage or basket before being brought to the surface. Such harvesters, which are also still in use, have the advantage of being able to dredge a relatively large area in less time than a purely mechanical harvester, although they still require the collection cage or basket to be periodically brought to the surface for emptying.
[0009] In order to avoid the need to periodically bring the dredge to the surface for removal of harvested shellfish, numerous generally unsuccessful attempts have been made to add conveyors that continuously and automatically convey recovered shellfish to the surface, either in connection with a purely mechanical harvester, or in connection with a harvester that uses a hydraulic digging action. These conveyors initially involved purely mechanical conveyance systems in the form of conveyor belts or escalators, but were limited to use in relatively shallow waters since systems of greater length involved intractable problems in handling and complexity. A recent example of a non-hydraulic dredge with a mechanical conveyor is disclosed in U.S. Pat. No. 4,464,851, while examples of hydraulic dredges with mechanical conveyors are disclosed in U.S. Pat. Nos. 2,508,087, 3,462,858, and 3,521,386.
[0010] In theory, hydraulic means of conveying extracted shellfish to the surface through pipes or hoses appear to offer greater simplicity and ease-of-handling than purely mechanical conveyance systems, and therefore the possibility of use at greater depths. However, in practice, most of the previously proposed hydraulic conveyance systems have suffered from slow speed, excess energy consumption and, in the case of systems that share water jets for both excavation and transport, difficulties in controlling excavation and transport pressures. For example, the system disclosed in U.S. Pat. No. 3,624,932 requires separate pumps, two corresponding pressurized water lines, and a transport hose to carry out excavation and transport of shellfish to the surface, resulting in relatively high power consumption and an increased possibility of tangling or breakage. The system disclosed in U.S. Pat. No. 3,184,866 utilizes both air and water for excavation as well as transport, and therefore requires even more hydraulic lines including, as illustrated in FIG. 1 appended hereto, two pressured water lines 49 and 50 with corresponding manifolds 43 and 46 , two pressurized air lines 48 and 51 , and a transport hose 20 to carry the excavated shellfish to the surface. Possibly because of the number of lines required, the system of U.S. Pat. No. 3,184,866 requires both a tow boat and a receiving boat or installation.
[0011] More recently, it has been proposed to use the same source of pressurized water for both the excavating jets and transport system of a hydraulic dredging apparatus, thereby eliminating the need for separate hydraulic lines and/or sources. The decrease in water pressure available for transport is compensated for by an improved transport system in which collected shellfish are siphoned rather than pushed or swept out of the collection chamber. Examples of systems in which jets of water are used to hydraulically separate shellfish from sediments, and also to create a siphon or Venturi effect that lifts the separated shellfish into a stream of water and carries them to the surface, are disclosed in British Patent Publication GB1,156,547 and U.S. Pat. No. 6,237,259. The latter system is illustrated in FIGS. 2 and 3, appended hereto.
[0012] In the system disclosed in U.S. Pat. No. 6,237,259, which was developed by the present inventor, the dredging apparatus includes a sled having a main frame 40 and a digging blade 21 that is inclined forwardly and downwardly relative to the frame so as to extend below the bottom of the frame into the sediments to be dredged. A digging jet pipe 22 is fixed relative to the front surface of the digging blade 21 and is arranged to discharge water under pressure on to the surface of the seabed immediately ahead of the digging blade to fluidize the sediments as they pass onto the blade. The angle of the digging blade 21 is such that a surface section of the seabed cut by the blade travels up the slope of the blade and into the open end or mouth 23 of the frame 40 . Water to the digging jet 22 is supplied by a pump situated on a vessel through a hose 24 connected by suitable fittings to the digging jet. Extending rearwardly from digging blade 21 is a first separating device 25 made up of a plurality of horizontal bars 26 , 27 , 28 arranged in a direction generally parallel to a direction of travel of the apparatus as it is towed by a vessel, for separating shellfish collected by the digging blade from sediments in which the shellfish are entrained, and also for separating out immature shellfish having a size smaller than that of the shellfish to be collected. To the rear of the first separating device 25 is a second separating device 29 in the form of a plate 30 having a plurality of openings 31 arranged to permit passage of shellfish while excluding larger objects, including clumps of sediment not completely liquified by the digging water jet.
[0013] The hydraulic transport system of the apparatus illustrated in FIGS. 1 and 2 includes a plate 30 that forms the top of a suction chamber 32 at the rear of the sled, and includes an opening 33 having a larger diameter than any of openings 31 . Opening 33 is provided with a fitting for attachment of a transport tube 34 extending to the towing vessel. Transport tube 34 is connected by a hose or pipe 35 to the hose 24 that also supplies water to the digging jet. Nozzles 36 serve to direct pressurized water from hose or pipe 35 towards the surface in the direction of conveyance. The stream of water from the nozzles creates a siphon effect in the direction of arrow B to draw shellfish present in the suction chamber into the conveyance tube for transport to the towing vessel. A reduced diameter portion 37 of tube 34 situated immediately below the nozzles 36 increases the velocity of water being drawn past the nozzles so as to decrease the pressure in tube 34 in the area above suction chamber 32 and thereby increase the suction force and the efficiency by which shellfish in the suction chamber are transported to the surface.
[0014] While more energy efficient, versatile, easy-to-handle, and reliable than prior dredging apparatuses, the dredging apparatus illustrated in FIGS. 2 and 3 has the disadvantage that, in order to control the suction and lifting power of the transport conveyor to enable use of the conveyor at greater depths and in a wider variety of marine environments, it is necessary to increase or decrease the pressure supplied to the digging jet 22 . The resulting variations in digging or excavation pressure make it difficult to control extraction, and may lead to excess energy use, undue disturbance of the bottom, and possibly damage to extracted shellfish or other marine organisms.
SUMMARY OF THE INVENTION
[0015] It is accordingly a first objective of the invention to provide a relatively low cost, high performance arrangement for harvesting shellfish from the bottom of a body of water, and for continuously conveying the harvested shellfish to a boat.
[0016] It is a second objective of the invention to provide an arrangement for harvesting shellfish from the bottom of a body of water in which conveyance of harvested shellfish to the surface is carried out primarily by the same source of hydraulic pressure that is used to extract shellfish from sediments, and yet that includes a secondary source of hydraulic pressure independent of the excavation pressure source that can be used to increase or control the transport pressure without varying the excavation pressure, thereby minimizing disturbance of the bottom and damage to the beds from which the shellfish are extracted, and/or to the shellfish being extracted, while permitting the apparatus to be used at arbitrary depths.
[0017] It is a third objective of the invention to provide an arrangement for conveying shellfish from a dredge to the surface at increased speeds and with minimal damage to the shellfish being conveyed.
[0018] It is a fourth objective of the invention to increase the lifting pressure of a hydraulic conveyor so as to minimize clogging or blockage.
[0019] It is a fifth objecting of the invention to provide a combined hydraulic excavation and transport system that offers a common source of excavation pressure and transport pressure, efficient suction-based lifting of excavated materials into the transport stream, and separate control of excavation and transport pressures.
[0020] These objectives are achieved by providing a shellfish harvesting apparatus in the form of a sled towed and equipped with hydraulic lines that direct pressurized water rearwardly relative to the direction of travel of the sled. The pressurized water sweeps sediments and shellfish towards a separator device that separates the shellfish from the sediments, after which the pressurized water sweeps the separated shellfish towards a suction chamber where the pressurized water creates a Venturi effect, causing shellfish entering the chamber to be transported to the surface through a trunk line.
[0021] According to the principles of a preferred embodiment of the invention, the suction chamber includes dual lifting compartments. The first compartment is situated above a collection chamber in the dredge and is arranged to receive a stream of pressurized water, which creates a Venturi effect that lifts shellfish from the collection chamber into the stream for transport through a hose to the surface. The second compartment is situated above the first compartment and is arranged to receive one or more air jets for adding velocity and lifting power to the transport stream, and for cushioning the shellfish as they make their way up the hose to the surface.
[0022] As a result, the present invention combines the efficiency and ease-of-handling of a siphon-based hydraulic dredging/transport system of the type disclosed in U.S. Pat. No. 6,237,259, with the enhanced excavation and transport pressure control potentially offered by a systems having separate excavation and transport lines, such as the one disclosed in U.S. Pat. No. 3,184,866.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a schematic side view of the conventional shellfish dredging apparatus disclosed in U.S. Pat. No. 3,184,866.
[0024] [0024]FIG. 2 is a schematic side view of the conventional shellfish dredging apparatus disclosed in U.S. Pat. No. 6,237,259.
[0025] [0025]FIG. 3 is a plan view of the conventional shellfish dredging apparatus illustrated in FIG. 2.
[0026] [0026]FIG. 4 is a schematic side view of a dredging apparatus corresponding to the dredging apparatus illustrated in FIG. 2, but modified to include a dual compartment suction chamber in accordance with the principles of a preferred embodiment of the present invention.
[0027] [0027]FIG. 5 is a schematic side view showing details of the dual compartment suction chamber of the preferred embodiment of the present invention.
[0028] [0028]FIG. 6 is a schematic top view of the suction chamber compartments illustrated in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] As in the conventional shellfish dredging arrangements of FIGS. 1 - 3 , the preferred dredging apparatus illustrated in FIGS. 4 - 6 is a hydraulic dredging apparatus that uses a common source of hydraulic pressure for both the excavation or digging jet or jets and the stream of water that transports excavated shellfish to the surface. The transport stream passes through a suction chamber to create a siphon effect that lifts the shellfish from a collection chamber for transport to a surface vessel or installation. The improvement provided by the invention is to include a dual compartment suction chamber that permits pressurized air to be injected into the transport stream so as to enable fine control of transport velocity and pressure without affecting the pressure of water supplied to the digging jet or jets.
[0030] Those skilled in the art will appreciate that the dual-compartment suction chamber of the preferred embodiment of the invention is not necessarily limited to use in connection with a particular dredging apparatus structure. Nevertheless, for purposes of illustration and in order to described the best mode of practicing the invention, the preferred embodiment will be described with reference to the dredging apparatus structure disclosed in U.S. Pat. No. 6,237,259, which shares some features with British Patent Publication No. 1,115,547, both of which are incorporated herein by reference. Initially, the excavation and separation portion of the dredging apparatus will be described in detail with reference to FIG. 4. This description will be followed by a description of the transport system shown in FIGS. 4 - 6 , including a detailed description of the dual compartment suction chamber best illustrated in FIGS. 5 and 6. It is noted that all elements shared by the respective conventional and preferred dredging apparatuses of FIGS. 2 and 4 have been given common reference numerals.
[0031] As illustrated in FIG. 4, the dredging apparatus of the preferred embodiment of the invention is made up of a sled including a casing or frame 20 and a digging blade 21 that is inclined forwardly and downwardly relative to the main frame 20 of the sled so as to extend below the bottom of the frame into the sediments to be dredged. The sled may be supported by runners (not shown) in a manner similar to that illustrated in British Patent Publication No. 1,115,547, herein incorporated by reference, or other features designed to facilitate towing of the sled across the seabed, and may be of any construction suitable for supporting the elements described below in the appropriate marine environment.
[0032] A digging jet pipe 22 is fixed relative to the front surface of the digging blade 21 and is arranged to discharge water under pressure on to the surface of the seabed immediately ahead of the digging blade to fluidize the sediments as they pass onto the blade. The angle of the digging blade 21 is such that a surface section of the seabed cut by the blade travels up the slope of the blade and into the open end or mouth 23 of the frame 20 . Water to the digging jet 22 is supplied by a pump situated on a vessel (not shown) through a hose 24 connected by suitable fittings to the digging jet in a manner similar to that disclosed in the aforementioned British publication.
[0033] Extending rearwardly from digging blade 21 is a first separating device 25 made up of a plurality of horizontal bars 26 , 27 , 28 arranged in a direction generally parallel to a direction of travel of the apparatus as it is towed by a vessel for separating shellfish collected by the digging blade from sediments in which the shellfish are entrained, and also for separating out immature shellfish having a size smaller than that of the shellfish to be collected. Horizontal bars 26 , 27 , 28 may optionally be arranged in three or more staggered layers to provide a more efficient sorting effect and facilitate movement of appropriately sized shellfish past the separating device, although those skilled in the art will appreciate that the use of multiple staggered layers is not essential, and that the structure of the separating device may be varied without departing from the scope of the invention.
[0034] To the rear of the first separating device 25 is a second separating device 29 in the form of a plate 30 having a plurality of openings of the type illustrated in FIG. 3 and arranged to permit passage of shellfish while excluding larger objects, including clumps of sediment not completely liquified by the digging water jet. Plate 30 forms the top of a collection chamber 32 at the rear of the sled.
[0035] Plate 30 also includes a collection chamber exit opening (not shown) having a larger diameter than any of the shellfish collection openings. The exit opening is provided with a fitting for attachment of a transport tube 34 extending to the towing vessel.
[0036] According to the principles of the preferred embodiment of the invention, transport tube 34 is surrounded by a suction chamber 99 that includes two compartments or sections 100 and 101 . Compartment 100 is connected by a hose or pipe 35 to the hose 24 that also supplies water to the digging jet, and is separated from compartment 101 by a partition 102 . One or more nozzles or other water directing devices 36 serve to direct pressurized water from hose or pipe 35 towards the surface in the direction of conveyance to create a suction effect and thereby siphon water from the collection chamber in the direction of arrow B with sufficient velocity to draw shellfish present in the collection chamber into the transport tube for conveyance to the towing vessel.
[0037] In order to increase or control the suction force, transport tube 34 is also supplied with air through a hose 103 connected between compartment 101 and an air compressor on the surface vessel or installation, and nozzles 104 which connect the interior of compartment 101 with the interior of transport tube 34 . Air entering compartment 101 via hose 103 is injected into the transport tube, thereby providing the ability to vary the transport speed/pressure simply by varying the air pressure supplied to hose 103 , without affecting the pressure of water supplied to the digging jets 22 .
[0038] It will of course be appreciated by those skilled in the art that the construction, materials, and dimensions of the dual compartment suction chamber, and all constituents thereof, including the number and arrangement of the respective inlets and nozzles, will depend on the requirements of the specific application in which the suction chamber is to be used. For example, different types of shellfish will require different excavation and transport pressures, as well as different diameters of transport tube. As a result, the invention is not to be limited in any way by any dimensions and specific parameters that might be listed herein, except as provided in the appended claims.
[0039] With the foregoing caveat in mind, a version of suction chamber 99 that is especially suitable for the harvesting of clams will now be described in terms of specific dimensions and parameters. The suction chamber is in the form of a rectangular box split into equal halves and having side dimensions of 16″ each and a height of 24″. Transport tube 34 is a 10″ pipe that runs through the center of the box. In the water compartment 100 , 20 3″×⅝″ nozzles 36 are placed around the pipe 34 at the same height in a ring formation. The nozzles 36 extend into the pipe such that ends of the nozzles are flush with the interior of the pipe, and are oriented at an angle relative to the transport direction of anywhere from zero to 90°, inclusive, so as to minimize interference between the streams of water exiting the jets and achieve optimal transport efficiency. Similarly, in the air compartment 101 , 20 3″×½″ nozzles 104 are placed around pipe 34 at the same height in a ring formation such that the ends of nozzles 104 that enter the pipe are flush with the interior of the pipe, and oriented at an angle corresponding to the angle of the water jets. Water is pumped into the water compartment of this illustrative implementation at a pressure of 2000 GPM, causing a vacuum to be created and thus pulling the clams into the pipe and forcing them upward. Air is pumped into the second compartment at the rate of 750 CFM and flows through nozzles 104 into pipe 34 where the water and clams are moving past.
[0040] Having thus described a preferred embodiment of the invention in sufficient detail to enable those skilled in the art to make and use the invention, it will nevertheless be appreciated that numerous variations and modifications of the illustrated embodiment may be made without departing from the spirit of the invention. For example, the air assist of the present invention may be used in connection with the specific shellfish harvesting device described in British Patent Publication No. 1,115,547 rather than the one described in U.S. Pat. No. 6,237,259, or in connection with any other shellfish harvesting system that utilizes a suction chamber or siphon effect to lift shellfish from a collection chamber and entrain the shellfish for transport to the surface. Consequently, it is intended that the invention not be limited by the above description or accompanying drawings, but that it be defined solely in accordance with the appended claims. | Apparatus for dredging shellfish from the bottom of a body of water includes a source of pressurized water, at least one water jet arranged to receive water from the pressurized water source and direct it at shellfish-containing sediments, sorting plates for receiving the shellfish-containing sediments excavated by the at least one water jet and separating the shellfish from the sediments, a collection chamber for receiving the separated shellfish, and dual lifting compartments, one of which is connected to the pressurized water source for lifting shellfish from the collection chamber and entraining the shellfish for transport to the surface, and the other of which is arranged to received pressurized air for increasing the transport speed and lifting power while cushioning the shellfish as they are transported to the surface. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a storage capacitor, in particular one that can be used for 1T-, 2T- and 3T-memory cells in, for example, system-on-chip applications, which provides the highest possible capacity with low surface area usage.
BACKGROUND OF THE INVENTION
[0002] In dynamic RAM memories, the information to be stored by a memory cell is generally held on a capacitor known as a storage capacitor. In system-on-chip applications in a pure logic technology, storage capacitors are often created by means of the gate capacity of an MOS transistor (e.g. a MoSyS-1T-SRAM, a 1T-cell of a static random access memory from MoSys Inc.) or by means of connection in parallel of gate and diffusion capacity (e.g. IFX-2T concept, a 2T-cell concept from Infineon).
[0003] Because of the leakage currents, a storage capacitor slowly loses its charge which can lead to the loss of the information stored on the capacitor. In order to counter this, in microelectronic circuits the charge of all storage capacitors is refreshed again at certain intervals, so that the information is retained. This interval depends, amongst other things, on the size of the memory capacity.
[0004] As a result of increasing integration the leakage currents in the abovementioned system-on-chip applications are becoming ever greater and new leakage current sources such as the gate leakage currents are arising due to the increasingly thin oxide coatings. The total memory capacity is also becoming smaller.
[0005] An object of the invention is to provide a storage capacitor with the highest possible memory capacity and the lowest possible surface area usage, which in particular in a pure logic technology can be created without additional, and thus more expensive, process steps.
SUMMARY OF THE INVENTION
[0006] Within the context of the present invention, the storage capacitor comprises coupling capacitances of metals. Here, according to the invention, an inner electrode and an outer electrode of the storage capacitor are constructed from stacks enclosing metal pieces and the contact elements connecting these metal pieces. In addition, according to the invention several outer electrodes are grouped around an inner electrode, in order to maximise the capacity for the storage capacitor and to guarantee screening from the adjacent storage capacitors or memory cells.
[0007] In a memory cell arrangement, several storage capacitors according to the invention of uniform shape can be arranged next to one another, with joint use being made of the outer electrodes of the adjacent storage capacitors. For production considerations and because of the better screening from adjacent storage capacitors a hexagonal shape is preferred here. All outer electrodes of the memory cell arrangement can be connected together with a further metal part that is applied to a reference potential or a supply voltage. The present invention is preferably suited to use in microelectronic circuits in order, for example in system-on-chip applications, to create 1T-, 2T- or 3T-memory cells. The invention is obviously not restricted to this preferred area of application, however.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will now be explained in more detail with reference to the attached drawing and using preferred embodiments.
[0009] [0009]FIG. 1 shows a side view of a storage capacitor according to a preferred embodiment of the invention.
[0010] [0010]FIG. 2 shows a top view of a storage capacitor according to the invention.
[0011] [0011]FIGS. 3A-3C show examples of even arrangements of outer (second) electrodes and inner (first) electrodes in storage capacitors according to the invention.
[0012] [0012]FIGS. 4A and 4B show examples of connections between the outer electrodes of adjacent storage capacitors.
[0013] [0013]FIGS. 5A-5C show examples of the control of a storage capacitor according to the means of 1T-, 2T- and 3T-memory cells.
DETAILED DESCRIPTION
[0014] [0014]FIG. 1 shows a side view of a storage capacitor with an inner (first) electrode 1 in the centre, two adjacent outer (second) electrodes 2 and a metal part 3 connecting the outer electrodes.
[0015] In a manner according to the invention, lateral capacities between adjacent conductors are used to construct the storage capacitor. For this purpose, in each case a stack of metal parts 5 and contact elements 6 connecting these metal parts 5 is constructed, in order to form the corresponding electrode 1 or 2 of the storage capacitor, as shown in FIG. 1. Between a stack and an adjacent stack the desired memory capacity is then created, with the two stacks in particular being arranged in parallel.
[0016] When used in microelectronic circuits the metal parts 5 are so-called landing-pads and are each positioned in a metal layer 4 . The contact elements 6 connecting the metal parts 5 are so-called vias and are positioned between the metal layers 4 .
[0017] Advantages of this solution compared with the normal design of a storage capacitor in microelectronic circuits include the reduction in leakage currents within the memory capacity itself, by avoiding MOS or diffusion capacitances, and simple implementation by means of standard metallization in a purely standard CMOS process.
[0018] In order to maximise the memory capacity and to guarantee screening from adjacent storage capacitors, several outer electrodes 2 are arranged around an inner electrode 1 , as shown by way of example in FIG. 2.
[0019] [0019]FIG. 2 shows a top view of a storage capacitor according to the invention without metal part with an inner electrode 1 in the centre and four adjacent outer electrodes 2 in the shape of a diamond, indicating the lateral memory capacities between the outer electrodes 2 and the inner electrode 1 .
[0020] The outer electrodes 2 are connected via contact elements with a metal part 3 , which is applied to a reference potential or a supply voltage (see FIG. 1). The inner electrode is coupled with a selection circuit (e.g. a selection transistor) via a contact element.
[0021] Several of the storage capacitors described above can be arranged alongside one another to form a memory cell arrangement, with joint use of the outer electrodes being made by the adjacent storage capacitors.
[0022] It is, furthermore, possible to assign a storage capacitor not just one inner electrode, but several, which are then connected in parallel by means of separate connections, in order to thereby increase the capacity of the storage capacitor. Essentially, however, the principle according to the invention can be put into practice by just one inner (first) electrode and one outer (second) electrode, each with a stack-like construction as described.
[0023] The outer electrodes of a storage capacitor can be arranged in various forms around the corresponding inner electrode. Since in microelectronic circuits as a rule the metal landing-pads are used as a basis for the construction of the stacks described above, a rectangular shape, a diamond shape and a hexagonal shape are the most advantageous shapes. FIGS. 3A-3C show these three most advantageous shapes for an even arrangement of the outer electrodes 2 around inner electrodes 1 in a memory cell arrangement according to the invention.
[0024] The three shapes shown in FIGS. 3A-3C differ essentially by the space used. Taking the side length of a landing pad as a reference length A and also selecting the same distance between two adjacent landing-pads, then the necessary relative area for the rectangular shape (FIG. 3A) comes to 16A 2 , the relative area for the hexagonal shape (FIG. 3B) comes to 12A 2 and the relative area for the diamond shape (FIG. 3C) comes to 8A 2 . Because it is easier lithographically and can be created with a higher yield, the hexagonal shape, which in its three-dimensional form looks like a honeycomb, is preferred for production considerations over the other two shapes. In addition, the screening from the adjacent cells is better with the hexagonal shape than with the other shapes.
[0025] Through further connections of the outer electrodes, as shown for example in FIGS. 4A and 4B, the capacity of a storage capacitor can be further increased. Here, the connection between adjacent outer electrodes 2 within a storage capacitor can be achieved both in just one of the metal layers 4 and also in several or all metal layers 4 . The same applies to a possible connection between storage capacitors arranged adjacently between outer electrodes 2 . It is likewise also in principle conceivable to connect in this way several inner electrodes 1 of a storage capacitor.
[0026] In microelectronic circuits through the connection of two adjacent outer electrodes, in FIGS. 4A and 4B respectively vertical or horizontal, in each metal layer the storage capacity of the rectangular shape is increased without loss of surface area (see FIG. 4A). Likewise, by connecting two outer, each horizontal, electrodes in each metal layer the memory capacity in the hexagonal shape is increased without loss of surface area (see FIG. 4B). Furthermore, the hexagonal shape has lower surface area usage than the rectangle.
[0027] [0027]FIGS. 5A-5C shows possible applications of a storage capacitor 7 according to the invention in 1T-, 2T- and 3T-semiconductor memories or corresponding memory cell arrangements.
[0028] According to FIG. 5A, the storage capacitor 7 is controlled via its inner electrodes via a selection transistor 10 , which in turn is addressed via a bit line 8 and a word line 9 . Furthermore, the outer electrodes of the storage capacitor 7 are connected with a reference potential Vref (1T-memory cell concept).
[0029] According to FIG. 5B, the storage capacitor is controlled via two selection transistors 10 a , 10 b . Selection transistor 10 a is addressed via a first bit line 8 a and a first word line 9 a, while selection transistor 10 b is addressed via a second bit line 8 b and a second word line 9 b (2T-memory cell concept). The storage capacitor 7 is connected via its inner electrodes with the two selection transistors 10 a , 10 b , while the outer electrodes are again applied to the reference potential Vref.
[0030] According to FIG. 5C, three transistors 10 a , 10 b and 10 c are used, which are connected to the storage capacitor 7 as shown. The first bit line 8 a and first word line 9 a assigned to selection transistor 10 a serve to write or store information in the storage capacitor 7 , which is applied to a first reference potential Vref 1 . The second bit line 8 b and second word line 9 b assigned to selection transistor 10 c serve to read out the information stored in the storage capacitor. The transistor 10 b connecting the storage capacitor 7 with the selection transistor 10 c is applied to a second reference potential Vref 2 (3T-memory cell concept).
[0031] Of course, the connections of the inner and outer electrodes of the storage capacitor to the selection transistor(s) and the reference potential (or the supply potential) can also be swapped over.
[0032] Although exemplary embodiments of the invention are described above in detail, this does not limit the scope of the invention, which can be practiced in a variety of embodiments. | A storage capacitor includes at least one first electrode adjacent to at least one second electrode, whereby a lateral capacity is formed between these electrodes. The electrodes comprise stacks of metal parts and connecting contact elements. The second electrodes can be arranged around the first electrodes, and at least some of the second electrodes can be used jointly with adjacent ones of the first electrodes to form adjacent storage capacitors. | 7 |
TECHNICAL FIELD
[0001] This invention relates generally to non-ionic X-ray contrast agents. It further relates to an alternative process for the production of an intermediate used in the synthesis of non-ionic X-ray contrast agents. In particular, it relates to an alternative downstream process for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”), a key intermediate in the production of iodixanol and iohexol, which are two of the biggest commercially available non-ionic x-ray contrast media agents.
BACKGROUND OF THE INVENTION
[0002] Non-ionic X-ray contrast agents constitute a very important class of pharmaceutical compounds produced in large quantities. 5-[N-(2,3-dihydroxypropyl)-acetamido]-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide (“iohexol”), 5-[N-(2-hydroxy-3-methoxypropyl)acetamido]-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide (“iopentol”) and 1,3-bis(acetamido)-N,N′-bis[3,5-bis(2,3-dihydroxypropyl-aminocarbonyl)-2,4,6-triiodophenyl]-2-hydroxypropane (“iodixanol”) are important examples of such compounds. They generally contain one or two triiodinated benzene rings.
[0003] The industrial production of non-ionic X-ray contrast agents involves a multistep chemical synthesis. To reduce the cost of the final product, it is critical to optimize the yield in each step. Even a small increase in yield can lead to significant savings in a large scale production. In particular, iodine is one of the most expensive reagent in the process. It is thus especially important to obtain a high yield with few by-products and minimal wastage for each synthetic intermediate involving an iodinated compound. Furthermore, improved purity of a reaction intermediate, especially at the latter stage of synthesis, is essential in providing a final drug substance fulfilling regulatory specification such as those expressed on US Pharmacopeia. In addition to economic and regulatory concerns, the environmental impact of an industrial process is becoming an increasingly significant consideration in the design and optimization of synthetic procedures.
[0004] One process by which iodixanol (1,3-bis(acetamido)-N,N′-bis[3,5-bis(2,3-dihydroxypropylaminocarbonyl)-2,4,6-triiodophenyl]-2-hydroxypropane) can be prepared is according to Scheme 1 below starting from 5-nitroisophthalic acid. See also U.S. Pat. No. 6,974,882. As part of the established acetylation process, intermediate 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-1,3-benzenedicarboxamide) (“Compound B”) is acetylated to give overacetylated 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”). Subsequently overacetylated Compound A is deacetylated to remove O-acetyl groups formed during the previous acetylation reaction to give Compound A. After deacetylation, Compound A can be purified (e.g., by crystallization). The purified Compound A can then be isolated. The isolated Compound A can then be dried for storage or it may be used directly in the production of iodixanol (e.g., dimerization of Compound A in the presence of epichlorohydrin results in the formation of iodixanol).
[0000]
[0005] Consequently, the conversion of Compound B to Compound A is a key and important step in the both the small-scale and industrial scale production of iodixanol.
[0006] There exists a need for effective and efficient processes for the industrial scale production of intermediates such as 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”). The present invention, as described below, answers such a need by providing alternative downstream semi-continuous processes for the production of Compound A that gives a significant increase in yield and significant reduction in energy consumption and process time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates downstream continuous processing of the solution comprising crude Compound A resulting from the alternative acetylation process described herein and simple crystallization of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”).
[0008] FIG. 2 illustrates downstream continuous processing of the solution after deacetylation with alternative acetylation and no crystallization and drying of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”).
SUMMARY OF THE INVENTION
[0009] The present invention provides an alternative process for the acetylation of 5-amino-N, N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-1,3-benzenedicarboxamide) (“Compound B”) to form Compound A followed by an alternative continuous downstream process for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) comprising precipitation, purification (e.g., a separation system such as microfiltration or centrifuge, a membrane filtration system (e.g., nanofiltration system)), and drying.
[0010] The present invention provides an alternative process for the acetylation of 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-1,3-benzenedicarboxamide) (“Compound B”) to form Compound A followed by an alternative continuous downstream process for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) comprising a membrane filtration system (e.g., nanofiltration system) without the need for crystallization and drying.
[0011] The present invention provides an alternative continuous downstream process for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) comprising precipitation, purification (e.g., a separation system such as microfiltration or centrifuge, a membrane filtration system (e.g., nanofiltration system)), and drying.
[0012] The present invention provides an alternative continuous downstream process for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) comprising a membrane filtration system (e.g., nanofiltration system) without the need for crystallization and drying.
[0013] The present invention provides a process comprising the steps of:
[0014] (i) reacting 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound B”) with a mixture of acetic anhydride/acetic acid to form a first slurry;
[0015] (ii) heating said first slurry to about 60° C.;
[0016] (iii) adding an acid catalyst (preferably, para-toluene sulfonic acid (PTSA)) to said slurry at a rate such that the reaction temperature is maintained at a temperature range of about 65-85° C.;
[0017] (iv) adding a deacetylating agent to the reaction mixture of step (iii) to form a reaction mixture comprising Compound A;
[0018] (v) purifying the reaction mixture of step (iv) comprising Compound A wherein said purifying step comprises the steps of:
[0019] (vi) passing said reaction mixture of step (iv) comprising Compound A through a separation system to create a second slurry and a liquid;
[0020] (vii) collecting the second slurry of step (vi) and repeating step (v);
[0021] (viii) collecting the liquid of step (vi) and passing it through a membrane filtration system;
[0022] (ix) collecting the retentate of step (viii) and repeating step (v); and
[0023] (x) continuously repeating steps (v)-(ix).
[0024] According to the process of the invention, the process may further comprise the step of: (xii) drying the reaction mixture of step (iv) comprising Compound A.
[0025] The present invention provides a process comprising the steps of:
[0026] (i) reacting 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound B”) with a mixture of acetic anhydride/acetic acid to form a slurry;
[0027] (ii) heating said slurry to about 60° C.;
[0028] (iii) adding an acid catalyst (preferably, para-toluene sulfonic acid (PTSA)) to said slurry at a rate such that the reaction temperature is maintained at a temperature range of about 65-85° C.;
[0029] (iv) adding a deacetylating agent to the reaction mixture of step (iii) to form a reaction mixture comprising Compound A;
[0030] (v) purifying the reaction mixture of step (iv) comprising Compound A wherein said purifying step comprises the steps of:
[0031] (vi) passing said reaction mixture of step (iv) comprising Compound A through a membrane filtration system;
[0032] (vii) collecting the retentate of step (vi) and repeating step (v); and
[0033] (viii) continuously repeating steps (v)-(vii).
[0034] According to the process of the invention, the membrane filtration system comprises a nanofiltration system as described herein.
[0035] According to the process of the invention, the process may further comprise the step of: alkylating the reaction mixture of step (iv) comprising Compound A.
[0036] According to the process of the invention, the process may further comprise the step of: bis-alkylating or dimerizing the reaction mixture of step (iv) comprising Compound A.
DETAILED DESCRIPTION OF THE INVENTION
[0037] In the established industrial scale process, Compound B is added to a mixture of acetic anhydride and acetic acid. The resulting slurry is then heated to approximately 60° C. When the temperature is achieved, an acid catalyst (e.g., para-toluene sulfonic acid (PTSA)(s)) is added in one portion in catalytic amounts. Despite maximum cooling in the reactor jacket, the temperature of the reaction mixture increases rapidly to about 120-125° C. due to the exothermic acetylation reaction. The main part of the acetylation reaction will accordingly occur at 120-125° C. Because of the high reaction temperature, considerable levels of the following by-products I, II, and III in addition to Compound A are formed:
[0000]
[0038] According to the present invention, an alternative acetylation process is provided. According to the present invention, Compound B is added to a mixture of acetic anhydride and acetic acid. The resulting slurry is then heated to approximately 60° C. At this temperature, a catalytic amount of an acid catalyst is added. Examples of a suitable acid catalyst include, for example, a sulfonic acid such as methanesulfonic acid, para-toluenesulfonic acid (PTSA) and sulphuric acid. Of these, para-toluenesulfonic acid (PTSA) is preferred. According to the invention, the acid catalyst can be added as a solid or as a solution. Examples of suitable solvents to form such a solution include acetic acid, acetic anhydride or a mixture of acetic acid and acetic anhydride. The addition is performed carefully while the temperature is controlled. In one embodiment, the PTSA is added as a solid in several portions. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of acetic acid. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of acetic anhydride. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of a mixture of acetic acid and acetic anhydride. The rate/speed of the addition of the acid catalyst, preferably PTSA, is such that the maximum reaction temperature is maintained at about 65-85° C.
[0039] In a preferred embodiment, the rate/speed of the addition of the acid catalyst, preferably PTSA, is such that the maximum reaction temperature is maintained at about 70-80° C.
[0040] According to the present invention, addition of the acid catalyst, preferably PTSA, over time to control temperature produces a reaction mixture comprising overacetylated Compound A with lower levels of by-products as described herein compared to the established acetylation process. The reaction mixture comprising overacetylated Compound A can then be deacetylated using a deacetylating agent. There is no particular restriction upon the nature of the deacylating agent used, and any deacylating agent commonly used in conventional reactions may equally be used here. Examples of suitable deacylating agents include aqueous inorganic bases including alkali metal carbonates, such as sodium carbonate, potassium carbonate or lithium carbonate; and alkali metal hydroxides, such as sodium hydroxide, potassium hydroxide or lithium hydroxide. Of these, the alkali metal hydroxides, particularly sodium hydroxide or potassium hydroxide, and most preferably sodium hydroxide are preferred. For example, the reaction mixture comprising overacetylated Compound A can be deacetylated by the addition of base, such as sodium hydroxide, to form Compound A which in turn can then be purified (e.g., crystallization) and isolated by techniques known in the art.
[0041] According to the invention, as a result of the alternative acetylation process described herein, the by-product profile is improved, which makes it possible to simplify the post deacetylation purification of the 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) and to isolate purified Compound A in higher yields.
[0042] As described above, by-products are formed during the acetylation of 5-amino-N, N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-1,3-benzenedicarboxamide) (“Compound B”). In the established acetylation process, the by-products that form are at such a level that a crystallization step is necessary to remove them from 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) prior to using Compound A in the synthesis of x-ray contrast media agents such as iodixanol and iohexol. If no crystallization step is performed, then additional purification steps need to be included later in the process which results in more production costs which is not ideal for industrial scale production.
[0043] It has now been found that the purity of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) before crystallization measured as HPLC [area %] with the original acetylation is 97.7% and with the alternative acetylation process described herein 99.2%. The alternative acetylation process reduces the formation of by-products.
[0044] In the alternative acetylation process, the process temperature is decreased from about 115-125° C. to about 65-85° C. and the ratio between acetic anhydride and acetic acid in the process solution is reduced significantly as well. Table 1 summarizes the change in by-product profile and the corresponding HPLC [area %] between the original and alternative acetylation process.
[0000] TABLE 1 By-products prior to crystallization with original and alternative acetylation Original Alternative acetylation process acetylation process Compound [HPLC area %] [HPLC area %] Compound A Purity 97.7 99.2 Compound B remaining 0.13 0.03 post acetylation By-products I and II 1.25 0.25 By-product III 0.33 0.01
In the established acetylation process, salt by-products (e.g. sodium chloride and sodium acetate) are removed from 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) during a crystallization and filtration step. pH and temperature in solution is under strict control. Seeding to control crystallization is executed at a certain pH and temperature. The pH is adjusted to about 2.0-8.0, preferably about 5.0-8.0 and most preferably about 7. The temperature is maintained at about 10-25° C., preferably about 20° C. Then the crystallization process is allowed to run for approx. 24 hours before the slurry is carefully transferred to a pressure filter. On the pressure filter, the mother liquor is removed. Then the filter cake is carefully agitated before washing liquid is applied. The filter cake is partly dried on the filter by blowing a huge amount of hot gas through the cake. Total residence time on the pressure filter is approx. 24 hours. Partly dried filter cake is then transferred to an indirect batch dryer. Dry 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) is then milled to destroy lumps generated during drying.
[0045] The present invention now provides two alternative continuous purification processes that eliminate the need for the established crystallization step. Each of the purification processes of the present invention can be used with either the established or alternative acetylation process. In a preferred embodiment, each of the purification processes is used subsequent to the alternative acetylation process described herein.
[0046] It has now been found that purification of Compound A can be achieved by using membrane filtration where low molecular weight by-products and salts are collected in the permeate and 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) is collected in the retentate.
[0047] According to a process of the invention, the separation system can be any separation system capable of providing a liquid as particle free as possible prior to passing the liquid through the membrane filtration system, as described herein. In one embodiment of the invention, the separation system comprises a microfiltration system (e.g., crossflow microfiltration). In one embodiment of the invention, the separation system comprises a centrifuge. According to the invention, any microfiltration system known in the art may be used. According to the invention, any centrifuge capable of separating particles from the liquid may be used (e.g., a decanter centrifuge).
[0048] According to the invention, a suitable “membrane filtration system” includes any membrane filtration technique known in the art. In one embodiment of the invention, the membrane filtration system comprises a nanofiltration system. Any nanofiltration system known in the art may be used.
[0049] The alternative continuous downstream processes of the invention allows for an increase in the overall yield of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”), reduce process time and labour costs. The alternative continuous downstream processes of the invention further offer the advantage of providing a stabilized process by removing a complex and manual crystallization and isolation step used in the established acetylation process to form Compound A as described above.
Alternative Process 1:
[0050] Alternative process 1, exemplified in FIG. 1 , includes a simple precipitation step to reduce pH and viscosity in the solution comprising desired Compound A. Particle size and distribution of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) is not critical as it is in the established acetylation process because no filter cake is going to be handled.
[0051] After precipitation, the slurry can, if needed, be filtered using an appropriate particle-liquid separation technique known in the art (e.g. crossflow microfiltration or decanter centrifuge) to separate the reaction mixture into 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) solids (i.e. slurry) and liquid. The removed solids (i.e., slurry) are circulated back to the reactor. Removal of slurry is performed to protect the membrane filtration system (e.g., nanofiltration membrane) through which the liquid is passed and increase its capacity.
[0052] The liquid from the separation system contains dissolved 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”), salts and by-products. The liquid is then passed through a membrane filtration system (e.g., nanofiltration membrane of the cross flow type) that is resistant to methanol at neutral to acidic pH and has a cut-off that allows the passing of low molecular weight by-products (<app. 300 dalton) or small molecules as salts to be collected in permeate together with only small amounts of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”). The membrane filtration system (e.g., nanofiltration membrane) reduces 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) yield loss to a minimum as it is separated into the retentate while effectively removing by-products in the permeate. The retentate produced by the membrane filtration system contains the majority of the 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) and is fed back into the reactor.
[0053] Any remaining salts and other low molecular weight by-products in the retentate can be removed with methanol, water, or a mixture thereof. Methanol, water, or a mixture thereof is added to reactor during circulation of the solution via the separation system and the membrane filtration system, each as described herein. Volume and pH in the reactor is monitored to keep suitable conditions for optimized membrane filtration.
[0000] To further reduce the amount of by-products, parts of the liquid where by-products are concentrated, can optionally be removed as mother liquor from the system, see FIG. 1 .
[0054] When the levels of salts and by-products have been achieved, the product slurry may be concentrated even more by stopping the methanol addition into the reactor while the circulation of the solution via the separation system and the membrane filtration system is still going. This alternative downstream process is performed continuously until the level of salts is not more than (NMT) 1.5 wt % and the level of by-products is NMT 2.0 area % in the dry Compound A obtained.
[0055] Once Compound A has achieved a such a purity profile, it can be dried using a continuous, direct dryer to give a lump free powder of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) which can then be subsequently stored. According to the invention, this alternative process 1 can be automated.
Alternative Process 2:
[0056] In Alternative process 2, as illustrated in FIG. 2 , the crude reaction solution after deacetylation is fed into a reactor and kept at pH>11 to keep 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) dissolved. In order to prepare the solution for directly use in the syntheses of iohexol and iodixanol, the water in the solution has to be replaced by solvents such as methanol, which in turn can optionally be replaced by 2-methoxyethanol in a nanofiltration system with a membrane with appropriate cut-off that withstands solvents and high pH. The salts and low molecular weight by-products are collected in the permeate. 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) is collected in the retentate. The use of a nanofiltration system allows for concentration adjustment of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) before being fed back into the reactor. By adjusting the concentration and process time, production capacity and investments cost/operational costs can be optimized. Alternative process 2 is continuous until the level of salts is NMT 1.5 wt % and the level of by-products is NMT 2.0 area % in the Compound A solution.
[0057] Once such a purity profile of Compound A is achieved, then the Compound A can be directly used to synthesize x-ray contrast media agents such as iohexol and iodixanol via alkylation and bis-alkylation (dimerization) respectively. Alternative process 2 eliminates the need for a drying step as used in the established process and in alternative process 1. Since the drying step can be eliminated, Alternative process 2 also offers the advantage of the need for storage of Compound A. According to the invention, this alternative process 2 can be automated.
[0058] As illustrated in Table 2, Alternative process 1 and Alternative process 2, provide comparable quality and yields as compared to the established original process. In addition, the processes offer the advantage of improved energy savings and reduction in overall production time.
[0000]
TABLE 2
Changes in key parameters in the modified processes
Original
Alternative
Alternative
process
process 1
process 2
Compound A Purity
99.5%
99.2-99.5%
Ca. 99.2%
Yield
96.2%
97-99%
99.2%
Energy savings*
—
Much
Very much
Reduction of process
—
Ca. 25%
>60%
time*
*as compared to the already established process. | Alternative continuous downstream processes for the production of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) are described. Compound A is a key intermediate in the production of iodixanol and iohexol, which are two of the biggest commercially available non-ionic x-ray contrast media agents. | 2 |
TECHNICAL FIELD OF THE INVENTION
The field of the invention is that of wrinkle-resistant garments and more particularly a novel apparatus and method of manufacturing wrinkle-resistant garments.
BACKGROUND OF THE INVENTION
Wrinkle-resistant fabrics and methods of imparting wrinkle resistance to cotton and cotton-blend fabrics are well known in the textile industry and have been used to manufacture wrinkle-resistant or permanent press garments. Typically, wrinkle-resistant fabrics are produced by applying to or otherwise impregnating a fabric with resins or other crosslinking agents and, in the presence of a catalyst, heating the fabric to a temperature at which cross-linking of the reactive fibers, i.e. curing, will occur at the desired rate. Several examples of durable press compositions and processes are discussed below.
U.S. Pat. No. 4,336,023 to Warburton, Jr. discloses a process for treating a fabric for the purpose of rendering the fabric wrinkle-resistant. The disclosed process includes the steps of saturating the fabric with a durable press treatment solution containing an activated bis-vinyl compound, a copolymer, and an aqueous base; passing the fabric through pad rolls; drying the fabric; and curing the fabric.
U.S. Pat. No. 4,623,356 to Hendrix discloses a process to prevent yellowing of durable press fabrics which have been treated with a non-formaldehyde finishing agent such as glyoxal, polymers of glyoxal and higher aldehydes. This process includes exposing a moist finished fabric to an oxidation solution at an elevated temperature, followed by neutralization, rinsing and drying operations. The oxidative treatment may be performed either during or immediately after curing of the finished fabric in a continuous process, or at a later time as a totally separate process.
U.S. Pat. No. 3,488,701 to Herbes discloses a crease-proofing composition comprising certain imidazolidinones. The crease proofing composition of the Herbes patent is applied to cellulosic textile materials. A catalyst or accelerator may also be employed. Following the application of the crease proofing agent and curing catalyst, the material is subjected to drying and curing operations.
U.S. Pat. No. 4,323,624 to Hunsucker discloses using certain urea-aldehyde compositions to treat textiles and nonwoven cellulose products so as to impart wrinkle resistance and durable press properties. Hunsucker further discloses that catalysts such as magnesium chloride and zinc nitrate may also be used. The cellulosic materials are saturated with the composition, pressed and then heated to cure the resin. Hunsucker discloses that the treated fabrics have much improved hand when the treatment is conducted in the presence of nitroalkanes or nitroalkanols, and the residual aldehyde is much reduced, thereby improving the environment.
U.S. Pat. No. 3,656,246 to Lord discloses a method of making a durable press garment which may be conducted in the home. This method includes the steps of pressing an assembled garment to form at least one crease therein, impregnating the garment with a liquid containing a crease proofing agent, permitting the garment to dry and then heating the garment to cure the crease proofing agent. Lord further discloses that the method may also include the initial fabrication of the garment by cutting and sewing together suitable pieces of fabric and/or repressing the garment after the drying step and before the curing operation.
Other examples of durable press agents and processes are disclosed in U.S. Pat. No. 3,632,296 to Pandell and No. 3,181,927 to Roth and in copending patent application Ser. No. 08/078,608.
While known methods of manufacturing durable press garments generally result in garments having satisfactory permanent press or wrinkle-resistant properties, these methods require the use of excess resins which add to the cost of manufacture and pollute the environment and, in most cases, produce garments which exhibit undesirable hand (i.e. excessive stiffness).
The present invention provides a method and apparatus which eliminate the use of excess durable press resins and other chemicals and which yield wrinkle-resistant garments having excellent hand (i.e., softness).
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, an apparatus for use in the manufacture of wrinkle-resistant garments comprises a housing enclosing a drum which is rotatable on a generally horizontal axis, whereby when the drum is rotated with garments disposed therein a tunnel defined by the garments is formed. Hingedly secured to the housing is a door. A blower and a heating element are arranged to provide heated airflow from the top of the apparatus through the drum in a vertically downward direction. A vent located below the drum is provided for the exhaustion of the heated air. Known commercial tumble dryers may be used for this aspect of the invention. Mounted on the door, exterior to the housing and drum when the door is in a closed position, is an atomizer unit positioned to discharge a durable press resin in the form of a mist through a hole in the door and into the garment tunnel when the door is closed. Preferably, the apparatus includes a dampener or other means for controlling the exhaustion of air in order to achieve a more uniform wetting of the garments with durable press resin. In practice, durable press resin is fed into the atomizer unit while the garments are being tumbled until the garments are sufficiently wetted with the resin. The wetted garments are then ready for curing to impart wrinkle-resistant properties to the garments.
In another embodiment of the present invention a programmable controller is used for controlling the dampener, the blower and the heating element. Further, a second atomizer unit may also be used and mounted to the door to improve the efficiency of the apparatus.
In a particular embodiment of the method of the present invention, a durable press garment is manufactured by inserting garments constructed of a cellulose fiber-containing fabric (such as cotton) into an apparatus capable of tumbling the garments in such a manner as form a tunnel defined by the garments. While the garments are being tumbled a durable press resin is injected into the tunnel in the form of a mist, impregnating (i.e., wetting) the garments with durable press resin. The wetted garments are then dried and cured, resulting in a wrinkle-resistant garment. Further, prior to curing, the garments may be pressed to impart creases and shape to the garments as is often desired.
These an other aspects of the present invention are described with greater specificity in the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete description of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a front perspective view of a modified tumbler/dryer apparatus embodying features of the present invention,
FIG. 2 is a rear perspective view of a modified tumbler/dryer apparatus embodying features of the present invention,
FIG. 3 is a detailed view of the dampener system of the present invention,
FIG. 4 depicts aspects of the present invention in operation, and
FIG. 5 is a front perspective view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION
In accordance with the subject invention, a novel apparatus and process is provided for producing garments having wrinkle-resistant properties and excellent hand.
In the exemplary embodiment of the invention, as disclosed in FIGS. 1-4, a commercial tumble dryer generally designated 10 is shown to comprise an external housing 12, within which is mounted a tumbling drum 14 having a forward access opening 16. The tumbling drum 14 may be mounted in any usual or preferred manner to be driven rotatably by suitable power means, most typically an electric motor and control circuitry well known in the construction of commercial tumble dryers. A preferred commercial dryer is the Huebsch Model JT120FG 120 lb. capacity commercial dryer. Hingedly mounted on the front of the dryer housing 12 is an access door 18.
During the operation of the dryer 10, a blower (not shown) causes air to be circulated into the tumbling drum 14 through upper portion of the dryer. Suitable air heating means (not shown) are also provided such as those heating means typically included on commercial dryers, including the preferred dryer identified above, all well known in the art. Referring to FIGS. 1 and 2, provided at the bottom of the dryer and in communication with the interior of the tumbling drum 14 is a lower vent opening 20 through which the circulated air is vented from the tumbling drum 14. The vented air is exhausted exteriorly of the tumbling drum through suitable duct means 22. This construction which circulates air from the top of the dryer and vents through the bottom of the drying apparatus has been found to be particularly suitable for most efficiently wetting garments with durable press resins and other chemicals. This vertically downward airflow configuration is typical with commercial dryers. In contrast, in a typical noncommercial home dryer, air is circulated from the rear or back wall of the drum.
Referring to FIGS. 2 and 3, disposed within the exhaust duct means 22 is a dampener 26 to control the flow of air through the tumbling drum 14. The dampener 26 is pneumatically controlled through a programmable controller 28 which is operably connected to the dryer circuitry. A more detailed illustration of the dampener system is provided in FIG. 3.
Referring to FIG. 3, an electronically controlled valve 30 receives signals from the controller 28 (FIG. 2), opening and closing air ports A and B in the valve 30. More particularly, an electronic signal from the controller 28 will energize a solanoid (not shown) in valve 30, allowing air to be supplied by a suitable pressurized air source (not shown) through port B and conduit 32. The air flow from open port B causes air cylinder piston 34, which is operably connected to dampener control arm 36, to move the dampener control arm 36 downwardly, thereby closing the dampener 26. As the control arm 36 and piston 34 move downwardly air is exhausted from the cylinder 38 through conduit 40, which is attached to port A. Conversely, the dampener 26 is moved to the open position, allowing air to flow through the drum and to be exhausted, by removing the electronic signal from the solanoid valve 30, thereby causing air to be supplied through port A. Air supplied through port A and conduit 40 into cylinder 38 moves the piston 34 and arm 36 upwardly, moving the dampener 26 to an open position. Preferably an adjustable stop collar 42 is provided on the air cylinder piston 34 allowing the dampener position to be better controlled. The dampener 26 is adjustable from full open (i.e., maximum exhaust flow) to full close (i.e., no exhaust flow). The use of a dampener (or other suitable means to control the exhaustion of air from the drum) is a significant component of the apparatus, since it has been found that without the dampener (i.e., exhaust fully open) the durable press resin was unevenly distributed on the garments.
In the preferred embodiment of the invention the programmable controller 28, identified by numeral 28 in FIG. 2, may also control all original dryer functions provided on typical commercial dryers, such as heat settings, cycle times, reversing and non-reversing tumbler rotation and air only/cool down cycles. Added functions, both pneumatic and electric, can also be controlled by the controller, such as dampener control, safety circuits, chemical level sensors, and atomizer control. A suitable programmable controller is an Omron Sysmac C28K programmable controller.
In the exemplary embodiment of the invention the tumbling drum 14 is rotating in a clockwise direction as shown in FIG. 4. As shown, the garments to be treated are carried adjacent to the drum 14 until they reach approximately the 10 o'clock position and then fall away from the surface of the tumbling drum 14, descending toward the lower right quadrant of the drum. Thus, when a sufficient amount of garments are loaded into the tumbling drum and the drum is rotated, the garments form a tunnel or cavity 44, i.e., a vortex, as shown in FIG. 4. The formation of this tunnel 44 has been found to be significant in obtaining the most effective treatment and wetting of the garments with durable press resins.
Thus, for optimum performance, it is necessary that there are enough garments to create a "tunnelling" effect but not to many garments so as to fold the tunnel. It has been found that the modified Huebsch commercial dryer described above having a 120 lb. capacity and revolving at about 30 revolutions per minute provides an extremely suitable tumbling apparatus. For example, 75 to 110 pounds of dry garments placed in such commercial apparatus will provide a suitable tunnel into which the durable press resin can be injected.
Referring again to FIG. 1, garment access door 18 includes a window 46. Preferably, the original glass window on the Huebsch JT120FG is replaced with a window made of a Lexan material approximately 3/16" thick. Attached to the garment access door window 46 is a support bracket 48 for mounting an atomizer unit 50. The bracket 48 may be attached by any means. For example, holes may be drilled into the access door window 46 to accept the atomizer support bracket 48. The atomizer unit 50 is attached to the door 18 of the tumbling apparatus 10, and is in communication with the interior of the tumbling drum 14. For the purpose of this disclosure, the phrase atomizer unit is defined broadly as a device capable of projecting a liquid in the form of a mist or fine spray. Off the shelf atomizer units are generally suitable and are readily available and well known. A preferred atomizer unit is the Flowtron Model No. MS100B10-Mister Electric Bug Sprayer.
The atomizer unit 50 injects chemicals (i.e., durable press resins used to impart wrinkle-resistant properties to garments or other articles) through nozzle 52 into the tumbling drum 14 through a hole in the garment access door window 46. An access hole measuring 3/4" in diameter should be suitable. The access hole and atomizer unit 50 are preferably positioned off center and to the left side of the door in order to inject the durable press resins into the tunnel formed by the tumbling garments, as shown in FIG. 1. Most preferably, the atomizer unit 50 is positioned such that chemicals are injected toward the lower left, rearward portion of the garment tunnel when the garments are tumbled in a clockwise direction, as shown in FIG. 4. It has been found that by targeting the lower left portion of the tunnel substantially all of the chemical resin is absorbed by the garments and the walls of the tumbler remain substantially dry.
It is believed that when the chemical resin is injected into the garment tunnel the pressure in the tunnel is higher than the pressure adjacent the exhaust vent 20 at the bottom of the dryer 10. It is believed that this pressure differential causes the resin to flow from the inside of the tunnel through the garments toward the low pressure area adjacent the exhaust vent 20. This high pressure-low pressure flow pattern is believed to result in improved wetting by removing the air trapped in the garment and replacing it with chemical. Further, this process is particularly effective with cotton fibers which are hollow and porous, since the pressure differential is believed to result in the removal of air within the hollow cotton fibers and the replacement of such air with durable press resin, thereby resulting in more thorough wetting of the garments and enhanced wrinkle-resistant properties.
Referring to FIGS. 1 and 2, the exemplary embodiment the present invention also includes an external power switch box 54 which includes replaceable in-line fuses to protect against voltage overloads, as well as an emergency on-off switch. The external power switch box 54 also allows the apparatus to be portable within the production facility. Also, mounted to the tumbling apparatus is a manually controlled 120 volt electric outlet 56 for controlling the required voltage to the atomizer unit 50.
A support bracket 58 is mounted on the top of the modified dryer 10 for attaching a main chemical storage tank 60 to the apparatus. In the exemplary embodiment (FIG. 1) the main chemical storage tank 60 has capacity of 10 gallons. Attached to the main chemical storage tank 60 is pipe 62 or other suitable conduit which runs to a mix/measure chemical storage tank 64. In the exemplary embodiment (FIG. 1) the pipe or conduit 62 attaches to the mix/measure chemical storage tank 64 on the top or inlet side 66 of the mix/measure chemical storage tank 64.
The mix/measure chemical storage tank 64 preferably should have sufficient capacity for operating the apparatus for at least a single load, which in the exemplary embodiment described herein equates to about 5-8 minutes operating time. The mix/measure chemical storage tank 64 is attached to the housing 12 by a support bracket 68 preferably mounted on the front side of the housing 12, above the garment access door 18 next to the manually controlled 120 volt outlet 56. In communication with and connected to the bottom of the mix/measure chemical storage tank 64 is tubing 70 connected to the atomizer or misting unit 50 for transferring chemicals to the atomizer unit 50.
Mounted in-line between the main chemical storage tank 60 and the mix/measure storage tank 64 is a manual control ball valve 72 for controlling the flow of chemical between the main chemical storage tank 60 and the mix/measure chemical tank 64. A second manual control ball valve 74 is mounted in line between the mix/measure chemical tank 64 and the atomizer unit 50 for controlling the flow of chemicals therebetween.
The apparatus further includes a process control switch 76 enabling the operator to change from one program to another stored in the program controller 28. In the preferred embodiment, the process control switch 76 allows the operator to change between chemical wetting operations and standard dryer operations.
Referring to FIG. 5, there is shown an alternative embodiment of the present invention wherein two atomizer units 50 and 50A are mounted to the access door window 46. The construction of this alternative embodiment is essentially the same as that shown in FIGS. 1-4 except that a second conduit 70A is incorporated to permit flow of resins and other liquids from mix/measure tank 64 to atomizer unit 50A. Additionally, a second manual control ball valve 74A is connected to conduit 70A to control liquid flow to atomizer unit 50A. Also shown in FIG. 5 are noise suppressors 78 connected to atomizer units 50 and 50A at the air inlets thereof. The noise suppressors 78 shown each comprise a 2" PVC elbows 80 having attached thereto a portion of common flexible electrical conduit 82. The inclusion of a second atomizer unit increases the efficiency of the apparatus by decreasing the amount of time needed to completely wet the garments with resin, while still obtaining maximum utilization of the resin.
The operation of the above-described apparatuses in the manufacture of wrinkle-resistant garments is as follows. Garments or other articles constructed of a cellulose fiber-containing fabric, such as cotton or a cotton-blend garment, are placed into the tumbling drum 14 through access door 18. The door 18 is closed and the tumbling operation is commenced by selecting the proper control commands via the programmable controller. In the operation shown in FIG. 4 the drum is rotating in a clockwise direction and the garments form a tunnel or cavity 44.
While the garments are being tumbled, a durable-press resin or agent is fed into the atomizer unit 50 through the mix/measure storage tank 64 and injected into the tumbling drum 14 in the form of a mist. For the purposes of this disclosure, the phrase durable press resin is intended to include any suitable resin, agent or other chemical or chemical compound which imparts wrinkle-resistant properties to fabrics. Suitable durable press resins are well known in the industry and the subject process and apparatus is not limited by the type of durable press resin used. For example, satisfactory results have been achieved using durable press resins produced and sold by Highpoint Chemical Company.
The tumbling and resin injection process is continued until the garments are completely impregnated with resin. Preferably, no excess resin is injected. For example, with the modified Huebsch dryer described above, it has been found that approximately 50 pairs of pants (75 to 110 lbs.) will be 100% wetted by injecting 31/2 gallons of resin and tumbling for 15 minutes, without any excess resin accumulating in the tumbling apparatus.
After the garments have been wetted in the subject apparatus, the garments are dried to about 10% moisture by switching the apparatus to the standard drying operation and tumble drying the garments for approximately 20 minutes at 140° F. The garments are then pressed to impart the desired creases and shape to the garment. Pressing the garments at 310° F. for 5 to 30 seconds has been found to be suitable. Next, the garment is placed in a curing oven to cure the resin and thereby impart wrinkle-resistant properties to the garment. Depending on the weight of the garments and the type of fabric, curing temperatures typically range from 280° F. to 310° F. and curing times from 5 to 15 minutes.
Various modifications to and uses of the present apparatus and method have been recognized. For example, various additional treatment fluids may be used in the present invention to get the desired end product, such as denim wash components, softeners and other compounds well known in the art. One "denim wash" compound which has been used in connection with the apparatus disclosed herein and has resulted in the desired garment characteristics is Virco Quickstone 50 manufactured by the Virkler Company. Similar results have been achieved using the present apparatus without the use of enzyme treatments by heating the durable press resin to about 130° F. prior to injection into the drum. To maintain the 130° F. temperature of the durable-press resin, the main chemical storage tank can be insulated.
Although the present invention has been illustrated in the accompanying drawings and described in the foregoing detailed description in terms of certain exemplary and preferred alternative embodiments, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention. | An apparatus for the manufacture of wrinkle-resistant garments is disclosed which includes a housing enclosing a drum which is rotatable on a generally horizontal axis, whereby when the drum is rotated with garments disposed therein a tunnel defined by the garments is formed. Mounted on a door secured to the housing is an atomizer unit positioned to discharge a durable press resin in the form of a mist through a hole in the door and into the garment tunnel when the door is closed. In practice, durable press resin is fed into the atomizer unit while the garments are being tumbled until the garments are sufficiently wetted with the resin. The wetted garments are then ready for curing to impart wrinkle-resistant properties to the garments. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/181,744 filed Feb. 11, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to a light tube illuminated-by LEDs (light emitting diodes) which are packaged inside the light tube and powered by a power supply circuit.
BACKGROUND OF THE INVENTION
[0003] Conventional fluorescent lighting systems include fluorescent light tubes and ballasts. Such lighting systems are used in a variety of locations, such as buildings and transit buses, for a variety of lighting purposes, such as area lighting or backlighting. Although conventional fluorescent lighting systems have some advantages over known lighting options, such as incandescent lighting systems, conventional fluorescent light tubes and ballasts have several shortcomings. Conventional fluorescent light tubes have a short life expectancy, are prone to fail when subjected to excessive vibration, consume high amounts of power, require a high operating voltage, and include several electrical connections which reduce reliability. Conventional ballasts are highly prone to fail when subjected to excessive vibration. Accordingly, there is a desire to provide a light tube and power supply circuit which overcome the shortcomings of conventional fluorescent lighting systems. That is, there is a desire to provide a light tube and power supply circuit which have a long life expectancy, are resistant to vibration failure, consume low amounts of power, operate on a low voltage, and are highly reliable. It would also be desirable for such a light tube to mount within a conventional fluorescent light tube socket.
SUMMARY OF THE INVENTION
[0004] A light tube for illumination by a power supply circuit including a bulb portion and a pair of end caps disposed at opposite ends of the bulb portion. A plurality of light emitting diodes are disposed inside the bulb portion and in electrical communication with the pair of end caps for illuminating in response to electrical current to be received from the power supply circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0006] FIG. 1 is a line drawing showing a light tube, in perspective view, which in accordance with the present invention is illuminated by LEDs packaged inside the light tube;
[0007] FIG. 2 is a perspective view of the LEDs mounted on a circuit board;
[0008] FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3 - 3 ;
[0009] FIG. 4 is a fragmentary, perspective view of one embodiment of the present invention showing one end of the light tube disconnected from one end of a light tube socket;
[0010] FIG. 5 is an electrical block diagram of a first power supply circuit for supplying power to the light tube;
[0011] FIG. 6 is an electrical schematic of a switching power supply type current limiter;
[0012] FIG. 7 is an electrical block diagram of a second power supply circuit for supplying power to the light tube;
[0013] FIG. 8 is an electrical block diagram of a third power supply circuit for supplying power to the light tube;
[0014] FIG. 9 is a fragmentary, perspective view of another embodiment of the present invention showing one end of the light tube disconnected from one end of the light tube socket; and
[0015] FIG. 10 is an electrical block diagram of a fourth power supply circuit for supplying power to the light tube.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 1 is a line drawing showing a light tube 20 in perspective view. In accordance with the present invention, the light tube 20 is illuminated by LEDs 22 packaged inside the light tube 20 . The light tube 20 includes a cylindrically shaped bulb portion 24 having a pair of end caps 26 and 28 disposed at opposite ends of the bulb portion. Preferably, the bulb portion 24 is made from a transparent or translucent material such as glass, plastic, or the like. As such, the bulb material may be either clear or frosted.
[0017] In a preferred embodiment of the present invention, the light tube 20 has the same dimensions and end caps 26 and 28 (e.g. electrical male bi-pin connectors, type G13) as a conventional fluorescent light tube. As such, the present invention can be mounted in a conventional fluorescent light tube socket (not shown).
[0018] The line drawing of FIG. 1 also reveals the internal components of the light tube 20 . The light tube 20 further includes a circuit board 30 with the LEDs 22 mounted thereon. The circuit board 30 and LEDs 22 are enclosed inside the bulb portion 24 and the end caps 26 and 28 .
[0019] FIG. 2 is a perspective view of the LEDs 22 mounted on the circuit board 30 . A group of LEDs 22 , as shown in FIG. 2 , is commonly referred to as a bank or array of LEDs. Within the scope of the present invention, the light tube 20 may include one or more banks or arrays of LEDs 22 mounted on one or more circuit boards 30 . In a preferred embodiment of the present invention, the LEDs 22 emit white light and, thus, are commonly referred to in the art as white LEDs. In FIGS. 1 and 2 , the LEDs 22 are mounted to one surface 32 of the circuit board 30 . In a preferred embodiment of the present invention, the LEDs 22 are arranged to emit or shine white light through only one side of the bulb portion 24 , thus directing the white light to a predetermined point of use. This arrangement reduces light losses due to imperfect reflection in a convention lighting fixture. In alternative embodiments of the present invention, LEDs 22 may also be mounted, in any combination, to the other surfaces 34 , 36 , and/or 38 of the circuit board 30 .
[0020] FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3 - 3 . To provide structural strength along the length of the light tube 20 , the circuit board 30 is designed with a H-shaped cross-section. To produce a predetermined radiation pattern or dispersion of light from the light tube 20 , each LED 22 is mounted at an angle relative to adjacent LEDs and/or the mounting surface 32 . The total radiation pattern of light from the light tube 20 is effected by (1) the mounting angle of the LEDs 22 and (2) the radiation pattern of light from each LED. Currently, white LEDs having a viewing range between 6° and 45° are commercially available.
[0021] FIG. 4 is a fragmentary, perspective view of one embodiment of the present invention showing one end of the light tube 20 disconnected from one end of a light tube socket 40 . Similar to conventional fluorescent lighting systems and in this embodiment of the present invention, the light tube socket 40 includes a pair of electrical female connectors 42 and the light tube 20 includes a pair of mating electrical male connectors 44 .
[0022] Within the scope of the present invention, the light tube 20 may be powered by one of four power supply circuits 100 , 200 , 300 , and 400 . A first power supply circuit includes a power source and a conventional fluorescent ballast. A second power supply circuit includes a power source and a rectifier/filter circuit. A third power supply circuit includes a DC power source and a PWM (Pulse Width Modulation) circuit. A fourth power supply circuit powers the light tube 20 inductively.
[0023] FIG. 5 is an electrical block diagram of a first power supply circuit 100 for supplying power to the light tube 20 . The first power supply circuit 100 is particularly adapted to operate within an existing, conventional fluorescent lighting system. As such, the first power supply circuit 100 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket. Accordingly, a light tube 20 particularly adapted for use with the first power supply circuit 100 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
[0024] The first power supply circuit 100 also includes a power source 46 and a conventional magnetic or electronic fluorescent ballast 48 . The power source 46 supplies power to the conventional fluorescent ballast 48 .
[0025] The first power supply circuit 100 further includes a rectifier/filter circuit 50 , a PWM circuit 52 , and one or more current-limiting circuits 54 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 of the first power supply circuit 100 are packaged inside one of the two end caps 26 or 28 of the light tube 20 .
[0026] The rectifier/filter circuit 50 receives AC power from the ballast 48 and converts the AC power to DC power. The PWM circuit 52 receives the DC power from the rectifier/filter circuit 50 and pulse-width modulates the DC power to the one or more current-limiting circuits 54 . In a preferred embodiment of the present invention, the PWM circuit 52 receives the DC power from the rectifier/filter circuit 50 and cyclically switches the DC power on and off to the one or more current-limiting circuits 54 . The DC power is switched on and off by the PWM circuit 52 at a frequency which causes the white light emitted from the LEDs 22 to appear, when viewed with a “naked” human eye, to shine continuously. The PWM duty cycle can be adjusted or varied by control circuitry (not shown) to maintain the power consumption of the LEDs 22 at safe levels.
[0027] The DC power is modulated for several reasons. First, the DC power is modulated to adjust the brightness or intensity of the white light emitted from the LEDs 22 and, in turn, adjust the brightness or intensity of the white light emitted from the light tube 20 . Optionally, the brightness or intensity of the white light emitted from the light tube 20 may be adjusted by a user. Second, the DC power is modulated to improve the illumination efficiency of the light tube 20 by capitalizing upon a phenomenon in which short pulses of light at high brightness or intensity to appear brighter than a continuous, lower brightness or intensity of light having the same average power. Third, the DC power is modulated to regulate the intensity of light emitted from the light tube 20 to compensate for supply voltage fluctuations, ambient temperature changes, and other such factors which effect the intensity of white light emitted by the LEDs 22 . Fourth, the DC power is modulated to raise the variations of the frequency of light above the nominal variation of 120 to 100 Hz thereby reducing illumination artifacts caused by low frequency light variations, including interactions with video screens. Fifth, the DC power may optionally be modulated to provide an alarm function wherein light from the light tube 20 cyclically flashes on and off.
[0028] The one or more current-limiting circuits 54 receive the pulse-width modulated or switched DC power from the PWM circuit 52 and transmit a regulated amount of power to one or more arrays of LEDs 22 . Each current-limiting circuit 54 powers a bank of one or more white LEDs 22 . If a bank of LEDs 22 consists of more than one LED, the LEDs are electrically connected in series in an anode to cathode arrangement. If brightness or intensity variation between the LEDs 22 can be tolerated, the LEDs can be electrically connected in parallel.
[0029] The one or more current-limiting circuits 54 may include (1) a resistor, (2) a current-limiting semiconductor circuit, or (3) a switching power supply type current limiter.
[0030] FIG. 6 is an electrical schematic of a switching power supply type current limiter 56 . The limiter 56 includes an inductor 58 , electrically connected in series between the PWM circuit 52 and the array of LEDs 22 , and a power diode 60 , electrically connected between ground 62 and a PWM circuit/inductor node 64 . The diode 60 is designed to begin conduction after the PWM circuit 52 is switched off. In this case, the value of the inductor 58 is adjusted in conjunction with the PWM duty cycle to provide the benefits described above. The switching power supply type current limiter 56 provides higher power efficiency than the other types of current-limiting circuits listed above.
[0031] FIG. 7 is an electrical block diagram of a second power supply circuit 200 for supplying power to the light tube 20 . Similar to the first power supply circuit 100 , the second power supply circuit 200 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket 40 . Accordingly, a light tube 20 particularly adapted for use with the second power supply circuit 200 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
[0032] In the second power supply circuit 200 , the power source 46 supplies power directly to the rectifier/filter circuit 50 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . The rectifier/filter circuit 50 , the PWM circuit 52 , and the one or more current-limiting circuits 54 of the second power supply circuit 200 are preferably packaged inside the end caps 26 and 28 or the bulb portion 24 of the light tube 20 or inside the light tube socket 40 .
[0033] FIG. 8 is an electrical block diagram of a third power supply circuit 300 for supplying power to the light tube 20 . Similar to the first and second power supply circuits 100 and 200 , the third power supply circuit 300 includes a conventional fluorescent light tube socket 40 having two electrical female connectors 42 disposed at opposite ends of the socket 40 . Accordingly, a light tube 20 particularly adapted for use with the third power supply circuit 300 includes two end caps 26 and 28 , each end cap having the form of an electrical male connector 44 which mates with a corresponding electrical female connector 42 in the socket 40 .
[0034] The third power supply circuit 300 includes a DC power source 66 , such as a vehicle battery. In the third power supply circuit 300 , the DC power source 66 supplies DC power directly to the PWM circuit 52 . The PWM circuit 52 and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . In the third power supply circuit 300 , the PWM circuit 52 is preferably packaged in physical location typically occupied by the ballast of a conventional fluorescent lighting system while the one or more current-limiting circuits 54 and LEDs 22 are preferably packaged inside the light tube 20 , in either one of the two end caps 26 or 28 or the bulb portion 24 .
[0035] FIG. 9 is a fragmentary, perspective view of another embodiment of the present invention showing one end of the light tube 20 disconnected from one end of the light tube socket 40 . In this embodiment of the present invention, the light tube socket 40 includes a pair of brackets 68 and the light tube 20 includes a pair of end caps 26 and 28 which mate with the brackets 68 .
[0036] FIG. 10 is an electrical block diagram of a fourth power supply circuit 400 for supplying power to the light tube 20 . Unlike the first, second, and third power supply circuits 100 , 200 , and 300 which are powered through direct electrical male and female connectors 44 and 42 , the fourth power supply circuit 400 is powered inductively. As such, the fourth power supply circuit 400 includes a light tube socket 40 having two brackets 68 disposed at opposite ends of the socket 40 . At least one bracket 68 includes an inductive transmitter 70 . Accordingly, a light tube 20 particularly adapted for use with the fourth power supply circuit 400 has two end caps 26 and 28 with at least one end cap including an inductive receiver or antenna 72 . When the light tube 20 is mounted in the light tube socket 40 , the at least one inductive receiver 72 in the light tube 20 is disposed adjacent to the at least one inductive transmitter 70 in the light tube socket 40 .
[0037] The fourth power supply circuit 400 includes the power source 46 which supplies power to the at least one inductive transmitter 70 in the light tube socket 40 . The at least one transmitter 70 inductively supplies power to the at least one receiver 72 in one of the end caps 26 and/or 28 of the light tube 20 . The at least one inductive receiver 72 supplies power to the rectifier/filter circuit 50 . The rectifier/filter circuit 50 , PWM circuit 52 , and the one or more current-limiting circuits 54 operate as described above to power the one or more arrays of LEDs 22 . In this manner, the light tube 20 is powered without direct electrical connection. | The present invention provides a light tube for illumination by a power supply circuit including a bulb portion and a pair of end caps disposed at opposite ends of the bulb portion. A plurality of light emitting diodes are disposed inside the bulb portion and in electrical communication with the pair of end caps for illuminating in response to electrical current to be received from the power supply circuit. | 5 |
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