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BACKGROUND OF THE INVENTION
This invention relates to an earth moving vehicle having a pressure oil tank and a battery arranged longitudinally along one lateral side of a swivel deck.
Known earth moving vehicles of this type have a driver's cabin disposed at a lateral side of the swivel deck opposite the pressure oil tank and the battery. Such a construction has a disadvantage that, since the cabin is provided together with the pressure oil tank and battery within a limited transverse dimension of the swivel deck, there is only a small space for the driver which hampers his free movements.
SUMMARY OF THE INVENTION
The object of this invention is to permit the driver to move inside the cabin without difficulty even if the swivel deck has a limited transverse dimension.
In order to achieve this object, an earth moving vehicle according to this invention comprises a driver's cabin extending substantially over an entire transverse dimension of the swivel deck, and covers disposed in the driver's cabin for covering the battery and the pressure oil tank, the covers including top surfaces lower than a height of elbows of a driver seated on a driver's seat. This construction has the following advantages.
The driver's cabin extending substantially over an entire transverse dimension of the swivel deck has a larger inside space than the driver's cabin according to the prior art construction. Furthermore, since the pressure oil tank and the battery disposed in the driver's cabin are covered by the covers, the driver does not get caught by the tank or the battery during his movement. The covers have top surfaces lower than a height of the elbows of the driver seated on the driver's seat, which permits the driver to utilize a space resulting therefrom and move freely within the cabin.
Thus, this invention provides an increased effective space for safe movements of the driver, and greater comfort for the driver, thereby improving his working efficiency in the cabin.
Other advantages of this invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate earth moving vehicles embodiying this inventio, in which:
FIG. 1 is a front view partly in section of a driver's cabin,
FIG. 2 is a plan view of the cabin with parts of the vehicle omitted,
FIG. 3 is a perspective view of one lateral side of the cabin,
FIG. 4 is a perspective view of the other lateral side of the cabin,
FIG. 5 is a side elevation of the earth moving vehicle,
FIG. 6 is a partly broken away view showing a modification,
FIG. 7 is a perspective view showing a further modification, and
FIG. 8 is a developed perspective view of pedal mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 5 illustrate a working vehicle embodying this invention, which vehicle is adapted mainly for excavating and earth moving operations. The vehicle comprises crawler traveling apparatus 1 carrying a vehicle frame to which a swivel deck 2 is attached through a rotary joint (not shown) to be swivellable on a vertical axis P. The swivel deck 2 carries a driver's cabin 6 extending substantially over an entire transverse dimension thereof and including a fuel tank 3, a driver's seat 4, and various control levers 5. The driver's cabin 6 further includes a pressure oil tank 7 and a battery 13 arranged along one lateral side of the cabin 2. As seen, the battery 13 is disposed forwardly of the tank 3. A motor section 8 is disposed rearwardly of the driver's cabin 6, which motor section 8 comprises an engine E and a hydraulic pump 14 covered by a bonnet. The vehicle further comprises a backhoe implement 9 connected through a bracket 10 to a forward end of the swivel deck 2, and a bulldozer implement 12 vertically movably attached to the vehicle frame. The backhoe implement 9 is vertically oscillatable and stretchable and bendable, and also swingable to right and left on a vertical axis P1 by a swing cylinder 11.
The battery 13 is disposed forwardly of the pressure oil tank 7 and is contained in a battery case 16 having a lid 15 at a lateral side thereof to open and close the case 16. The pressure oil tank 7 is covered at inner portions thereof opposed to the driver's cabin 6 by an interior cover 17.
A side wall 6A of the driver's cabin 6 along which the pressure oil tank 7 and the battery case 16 are arranged is cut out to define an opening 18 exposing the pressure oil tank 7 outwardly and an opening 19 which is opened and closed by the lid 15 of the battery case 16. The side wall 6A, an exposed lateral face of the pressure oil tank 7, and the lid 15 of the battery case 16 are all arranged to lie substantially on the same plane.
The interior cover 17 in the driver's cabin 6 has a top surface 17A which is, as best seen in FIG. 1, substantially equal in height to or lower than tops of armrests 21 provided laterally of the driver's seat 4. That is to say the top surface 17A is lower than the elbows 0' of the driver 0 seated on the seat 4. The battery case 16 has a top surface 16A lower than the top surface 17A of hte interior cover 17. Thus, the interior cover 17 and the battery case 16 do not interfere with movements of the driver during his control operation of the vehicle and provide an increased effective space in the driver's cabin 6.
A console box 20 including instruments and switches is provided on lateral sides of the interior cover 17 and the battery case 16 opposed to the driver's seat 4. The console box 20 has a top surface also lower than the top surface 17A of the interior cover 17.
The fuel tank 3 is disposed under the driver's seat 4. A side wall 6A of the driver's cabin 6 opposite the pressure oil tank 7 and the battery case 16 defines an opening 6B to permit access to a refilling port 3A of the fuel tank 3. A rubber partition element 31 is provided to extend between the refilling port 3A and the opening 6B to define a refilling passage sealed airtight to the interior of the driver's cabin 6. The rubber element 31 has one end thereof fitted on the refilling port 3A and secured thereto by a clamping band 37, thereby the rubber element 31 being rigidily connected to the refilling port 3A in a leakproof manner, and the other end thereof including a tubular periphery defining a peripheral groove 31A which is engaged by a peripheral edge of the opening 6B. A cover 33 is hinged as at 34 to the side wall 6A to open and close the opening 6B.
The described construction may be modified as follows: The cover 33 may be removably attached to the rubber partition element 31. The cover 33 will serve the purpose if it can close the opening 6B, and therefore the opening 6B is named herein an opening having an opening and closing cover. The rubber partition element 31 may be replaced by a partition element formed of a synthetic resin material. These elements are collectively named a resin partition element herein.
The lid 15 of the battery case may be attached to the side wall 6A of the cabin 6 to permit access to the battery 13. Thus, the opening 19 is just called an access opening having an opening and closing lid. The battery 13 may not be contained in the battery case 16, but instead may just be covered at inner portions thereof by the cover 17. Thus, the term cover herein used will be understood to include the battery case 16.
A further embodiment will now be described with reference to FIGS. 6 through 8. As shown in FIGS. 6 and 7, the pressure oil tank 7 is covered at portions thereof opposed to the driver's cabin 6 by a cover 17 surfacially coated with an insulating material 40 to restrain heat radiation from the pressure oil tank 7 heating the interior of the driver's cabin 6. A space S is defined between the cover 17 and a top surface 7A and a lateral surface of the pressure oil tank 7. It is in the interest of good appearance that the space S is invisible from outside. For this purpose an expanded metal 42 having good airpermeability is attached to the side wall 6A to cover up the space S.
Referring to FIG. 8, a pedal 43 is a control pedal for operating a service port of a valve for other loaders such as a crum-shell, which pedal is oscillated back and forth. A rotary shaft 44 extending transversely of the driver's cabin 6 carries at an end thereof a channel shaped bracket 45 opening away from the driver's seat 4. The pedal 43 is rigidly connected to the bracket 45 by a connecting pin 46. When the pedal 43 is not used, the pedal 43 is laid sideways away from the seat 4 locked in that position to the bracket 45 by the connecting pin 46 to be kept out of the way of the driver.
The cover 17 may be coated with the insulating mateial 40 over a back face thereof instead of the outer surface, or may be coated on both surfaces.
Instead of the expanded metal 42, a perforated metal be attached to the side wall 6A, or no such covering means may be provided thereby rendering the space S visible from outside through the opening 41. It will serve the purpose if the construction permits the heat of pressure oil to escape easily from the space S to the ambient.
This invention is applicable not only to illustrated earth moving vehicle having a backhoe implement but also to varied types of working vehicle such as one having a face shovel.
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There is disclosed an earth moving vehicle having a pressure oil tank and a battery arranged longitudinally along one lateral side of a swivel deck. A driver's cabin of the vehicle includes covers for covering the battery and the pressure oil tank. The covers have top surfaces at a certain height to provide a large space for the driver.
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RELATED APPLICATIONS
[0001] This application claims priority from earlier filed U.S. application Ser. No. 09/208,938, filed Dec. 10, 1998.
FIELD OF THE INVENTION
[0002] The present invention relates to a folded paper board device for carrying compact discs.
BACKGROUND OF THE INVENTION
[0003] Compact discs, which are commonly referred to as “CD's” are generally well known in the art. Standard CD's having a diameter of four and three quarters (4¾) inches are commonly used to store prerecorded music, prerecorded video, and data for reading by a computer. Due to technical advances, a CD can store an incredible amount of data and thus CD's are greatly preferred over other storage mediums, such as magnetic recording tape.
[0004] Most CD's are packaged in rigid plastic containers or boxes. The rigid containers serve to protect the CD from inadvertent damage, such as scratching or impact damage. However, in actuality the CD's stored therein are relatively durable and thus do not need such a rigid container. Moreover, the standard container is bulky, has many sharp corners, has a hinge which frequently comes apart or breaks altogether, and is generally disliked by many consumers. Accordingly, many consumers have long desired a more convenient, less bulky and altogether more user friendly alternative for storing CD's.
[0005] One solution has been to provide a CD carrier made from paper or from a paperboard material. Such containers are softer, less bulky, and have the added advantage of being made from recycled material. A variety of such folded paper CD carriers have been proposed. For example, U.S. Pat. Nos. 5,419,433 and 5,421,453 show paper board CD carriers formed from a sheet of material which is folded and then glued together to form a pocket sized to hold a CD. However, the gluing process is very difficult to control, and thus many such prior art CD carriers are not well suited for mass production.
[0006] Accordingly, there exists a continuing need for an improved paper board CD carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the course of the following detailed description, reference will be made to the attached drawings wherein like reference numerals identify like parts and wherein:
[0008] [0008]FIG. 1 is a perspective view of a CD carrier constructed in accordance with the teachings of the present invention;
[0009] [0009]FIG. 2 is a perspective view of the CD carrier of FIG. 1 shown in its unfolded state;
[0010] [0010]FIG. 3 is a perspective view of the CD carrier of FIGS. 1 and 2 shown in a partially folded state with the edge flaps folded along their respective fold lines;
[0011] [0011]FIG. 4 is a perspective view of the CD carrier of FIGS. 1 through 3 shown with the planar panels being folded along the central fold line and with the locking tab being folded along its fold line;
[0012] [0012]FIG. 5 is a cross-sectional view taken along lines 5 - 5 of FIG. 1 and showing a CD disposed in each of the spaced apart parallel enclosures; the CD carrier is shown attached to a conventional ring binder;
[0013] [0013]FIG. 6 is a perspective view of a CD carrier constructed in accordance with the teachings of a second embodiment of the present invention;
[0014] [0014]FIG. 7 is a perspective view of the CD carrier of FIG. 6 shown in its unfolded state;
[0015] [0015]FIG. 8 is a perspective view of the CD carrier of FIGS. 6 and 7 shown in a partially folded state; and
[0016] [0016]FIG. 9 is a perspective view of the CD carrier of FIGS. 6 through 8 shown with the planar halves being folded along the central fold line and with the locking tab being folded along its fold line; and
[0017] [0017]FIG. 10 is a cross-sectional view taken along lines 10 - 10 of FIG. 6 showing a CD disposed in each of the spaced apart parallel enclosures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The embodiment described herein is not intended to limit the scope of the invention to the precise form disclosed. The embodiment has been chosen and described in order to explain the principles of the invention and its practical use in order to enable others skilled in the art to follow its teachings.
[0019] Referring now to FIGS. 1 through 5 of the drawings, a CD carrier constructed in accordance with the teachings of the present invention is generally referred to by the reference numeral 10 . As shown in FIG. 2, the CD carrier 10 is constructed of a paper blank 12 , which is a single piece of stock and which is preferably constructed of eight (8) point stock. The blank 12 includes a central portion 14 which is generally divided or bisected by a fold line 16 to form a pair of planar panels 18 and 20 .
[0020] The panel 18 includes an inside edge 22 lying generally contiguous with the fold line 16 and also includes an outside edge 24 . The panel 18 also includes a pair of opposing edge flaps 28 , 30 , each of which is foldable along a fold line 32 , 34 , respectively. The fold lines 32 , 34 are preferably substantially perpendicular to the fold line 16 , with normal angular deviations therefrom being tolerated. The edge flap 28 includes an edge 29 , while the flap 30 includes an edge 31 . As shown in FIGS. 2 and 3, all or a portion of the outside edge 24 protrudes outwardly past the edges 29 , 31 to form a tab 26 .
[0021] The panel 20 includes an inside edge 36 lying generally contiguous with the fold line 16 and also includes an outside edge 38 . The panel 20 includes a pair of opposing end flaps 46 , 48 , each of which is foldable along a fold line 50 , 52 , respectively. The fold lines 50 , 52 preferably are substantially perpendicular to the fold line 16 . Again, normal angular deviations therefrom will be tolerated. The flap 46 includes an edge 47 , while the flap 48 includes an edge 49 . As shown in FIGS. 2 and 3, all or a portion of the outside edge 38 protrudes outwardly past the edges 29 , 31 to form a tab 40 . The tab 40 is preferably longer than the tab 26 and includes a fold line 42 , such that an outer portion of the tab 40 is foldable along the fold line 42 to form a retaining or locking tab 44 .
[0022] As shown in FIGS. 3 and 4, the edge flaps 28 and 30 are foldable along the fold lines 32 and 34 , respectively. Similarly, the flaps 46 and 48 are inwardly foldable along their respective fold lines 50 and 52 . When folded inwardly to the position of FIG. 3, the edge flaps 28 and 30 define with the panel 18 an enclosure 51 , while the edge flaps 46 and 48 define with the panel 20 an enclosure 53 . Each of the enclosures is sized to hold therein a standard CD such that movement of the CD is substantially prevented. The edge flaps may be slightly longer than ½ of the width of their corresponding panel 18 , 20 , such that the edge flaps 28 , 30 and 46 , 48 slightly overlap each other when folded inwardly to the position shown in FIG. 3. Alternatively, the edge flaps 28 , 30 and the edge flaps 46 , 48 may be sized such that they do not touch or engage each other when folded inwardly. Shorter flaps may be used, but the length disclosed is preferred in that such a length will minimize scratching of CD's held within the carrier 10 .
[0023] As shown in FIGS. 1 and 4, the blank 12 is folded along the fold line 16 (subsequent to the inward folding of the edge flaps 28 , 30 , 46 and 48 to create the enclosures 51 and 53 ).
[0024] Each of the panels 18 , 20 includes an insert aperture or cutout 54 , 56 , respectively (see FIG. 2). The cutout 54 includes a generally straight edge 58 with an interconnecting arcuate or curved edge 60 , while the cutout 56 includes a generally straight edge 62 with an interconnecting arcuate or curved edge 64 . Each of the cutouts 54 , 56 are sized so that a standard, commercially available CD having a nominal diameter of 4¾ inches will fit through the cutout. The cutouts 54 , 56 will provide an avenue for inserting a CD into the enclosures 51 and 53 , respectively.
[0025] As can be seen in FIG. 2, a pair of apertures 66 are located on the tab 26 adjacent the edge 24 of half 18 , while a pair of apertures 68 are located on tab 40 adjacent the edge 38 . Another pair of apertures 70 are located on the locking tab 44 . An aperture from each of the pairs of apertures 66 , 68 and 70 will be aligned with corresponding apertures from the other pairs when the CD carrier is in the folded state of FIGS. 1 and 5. The apertures 66 , 68 , and 70 are adapted to permit the CD carrier to be attached to the rings 71 of a ring binder (not shown) or other supporting structure.
[0026] Preferably, a cutout 72 is located between adjacent flaps 28 and 46 , while a cutout 74 is located between adjacent flaps 30 and 48 . Although the cutouts 72 and 74 may be dispensed with, the cutouts 72 and 74 provide for better folding along the fold line 16 by reducing buckling and or bunching of the paper stock when the blank 12 is folded. The cutouts 72 , 74 also permit the flap 28 to be folded independently of the flap 46 , and permit the flap 30 to be folded independently of the flap 48 . Also, preferably, each of the cutouts 54 , 56 , the apertures 66 , 68 , and 70 , and the cutouts 72 and 74 are formed by stamping of the blank 12 using well accepted and conventional practices.
[0027] It will be appreciated that the CD carrier 10 preferably is formed from a single paper blank 12 . The cutouts 54 , 56 , 72 , and 74 , as well as the apertures 66 , 68 and 70 are all preferably stamped or otherwise cut from the blank 12 using well accepted practices as previously mentioned. For purposes of efficiency in forming the CD carrier 10 , each of the fold lines 16 , 32 , 34 , 42 , 50 and 52 are preferably machine formed using well known and commercially available folding machines and techniques. Alternatively, each of the above-described fold lines may be formed using a series of aligned perforations, or by using other well known methods which may be well suited to forming a foldable line or hinge.
[0028] In operation, the CD carrier 10 may be prepared for use as follows. The enclosure 51 is prepared by folding the flaps 28 and 30 inwardly along the fold lines 32 and 34 , respectively, while the enclosure 53 is prepared by folding the flaps 46 and 48 inwardly along the fold lines 50 , 52 , which changes the CD carrier 10 from the configuration shown in FIG. 2 to the configuration shown in FIG. 3. The CD carrier 10 is then folded along the fold line 16 from the configuration shown in FIG. 3 to the configuration shown in FIG. 4, with the side edges 24 and 38 , and tabs 26 and 40 being generally adjacent to each other. In such a configuration, corresponding ones of the apertures 66 and 68 are aligned.
[0029] The locking tab 44 is then folded along the fold line 42 in order to overlap and thus secure the tab 26 in its position adjacent to the tab 40 with the side edges 24 and 38 also disposed adjacent each other. When the locking tab 44 is folded over, the apertures 70 are aligned with corresponding ones of the previously aligned apertures 66 and 68 . The CD carrier will now assume the configuration of FIG. 1 with the enclosures 51 and 53 being disposed in generally spaced apart, generally parallel relationship substantially as shown in FIG. 5. A CD (such as is shown in each of FIGS. 1 and 5) may now be inserted into each of the enclosures 51 and 53 through their respective insertion cutouts 54 and 56 . Preferably, the CD carrier may now be attached (with or without the CD's inserted therein) to the rings 71 of a ring binder (not shown) for storage and/or transport.
[0030] It will be appreciated that the CD carrier 10 , by virtue of the above-described construction, does not require any glues, adhesives or binders whatsoever, and further does not require any form of mechanical fasteners.
[0031] Referring now to the embodiment of FIGS. 6 through 10, a CD carrier constructed in accordance with the teachings of a second embodiment of the present invention is generally referred to by the reference numeral 110 . As shown in FIG. 7, the CD carrier 110 is constructed of paper blank 112 , which is formed from a single piece of stock and which as outlined above is preferably constructed of eight point stock. The blank 112 includes a central portion 114 which is generally divided or bisected by a fold line 116 to form a pair of planar portions or halves 118 and 120 . The planar half 118 includes an inside edge 122 lying generally contiguous with the fold line 116 and also includes an outside edge 124 . The planar half 118 also includes a pair of opposing flaps or panels 128 , 130 , each of which is foldable along a fold line 132 , 134 , respectively. The fold lines 132 , 134 are preferably substantially perpendicular to the fold line 116 , with normal angular deviations therefrom being tolerated. Each panel 128 , 130 also includes an end tab 129 , 131 , respectively. Each tab 129 , 131 is foldable along a fold line 133 , 135 , respectively. The fold lines 133 , 135 are generally parallel to the fold lines 132 , 134 .
[0032] The planar half 120 includes an inside edge 136 lying generally contiguous with the fold line 116 and further includes an outside edge 138 . A portion of the outside edge 138 protrudes outwardly to form a tab 140 . The tab 140 includes a fold line 142 , such that an outer portion of the tab 140 is foldable along the fold line 142 to form a retaining or locking tab 144 . The planar half 120 also includes a pair of opposing flaps or panels 146 , 148 , each of which is foldable along a fold line 150 , 152 , respectively. The fold lines 150 , 152 preferably are substantially perpendicular to the fold line 116 . Each panel 146 , 148 also includes an end tab 147 , 149 , respectively. Each tab 147 , 149 is foldable along a fold line 151 , 153 , respectively. The fold lines 151 , 153 are generally parallel to the fold lines 150 , 152 .
[0033] As shown in FIGS. 7 and 8, tabs 129 , 131 , 147 and 149 are inwardly foldable along their respective fold lines 133 , 135 , 151 , and 153 . Note that in FIG. 8, by virtue of the cutouts 188 , each of the tabs 129 and 131 are concealed from view. Subsequently, the panels 128 , 130 , 146 , and 148 are foldable along their respective fold lines 132 , 134 , 150 , and 152 . When folded inwardly to the position of FIGS. 8 and 9, each panel forms with an adjacent portion of its respective planar half an enclosure. Specifically, the panels 128 , 130 form enclosures 155 , 157 with their respective planar half 118 . Similarly, the panels 146 , 148 form with their respective planar half 120 the enclosures 159 , 161 . The end tab 129 serves to define a lateral edge of the enclosure 155 , while the tab 131 serves to define a lateral edge of the enclosure 157 . Similarly, the tab 147 serves to define a lateral edge of the enclosure 159 , while the tab 149 serves to define a lateral edge of the enclosure 161 . Each of the enclosures is sized to hold therein a standard CD such that movement of the CD is substantially prevented. Preferably, the panels 128 , 130 , 146 and 148 are all substantially equal to the diameter of a standard CD, or roughly equal to ½ of the lengthwise dimension of their corresponding planar half 118 , 120 .
[0034] As shown in FIGS. 6, 8 and 9 , the enclosures 155 , 157 , 159 , and 161 are created from the blank 112 by first inwardly folding the tabs 129 , 131 , 147 , and 149 , followed by the inward folding of the panels 128 , 130 , 146 , and 148 . As can be appreciated from FIGS. 7 through 9, when the components described above are folded, the enclosures 155 and 157 are generally coplanar, while the enclosures 159 and 161 are likewise coplanar. It will further be appreciated that the pair of enclosures 155 and 157 is disposed in spaced apart and parallel relationship with the pair of enclosures 159 and 161 . The CD carrier 110 is thus equipped to carry four (4) CD's.
[0035] The planar half 118 includes a pair of insertion apertures or cutouts 180 , 182 , while the planar half 120 includes a pair of insertion apertures or cutouts 184 , 186 , respectively. Each cutout 180 , 182 , 184 , and 186 is sized to receive a standard CD, and includes a generally straight edge 158 with an interconnecting arcuate or curved edge 160 . As can be seen in FIG. 7. each of the tabs 129 , 131 , 147 and 149 includes an arcuate cutout 188 , which is located and sized so that none of the tabs will interfere with their adjacent cutouts 180 , 182 , 184 , 186 when the tabs are in the inwardly folded position.
[0036] As can be seen in FIGS. 7 and 8, a series of apertures 168 is located on the tab 140 adjacent the edge 138 . Another series of apertures 170 is located on the locking tab 144 . As can be seen in FIG. 9, the series of apertures 168 , 170 will be aligned with each other when the locking tab 144 is folded to the position of FIG. 9. The apertures 168 and 170 are adapted to permit the CD carrier 110 to be attached to the rings of a ring binder (not shown) or other supporting structure.
[0037] Preferably, a cutout 172 is located between adjacent panels 128 and 146 , while a cutout 174 is located between adjacent panels 130 and 148 . Although the cutouts 172 and 174 may be dispensed with, the cutouts 172 and 174 provide for better folding along all of the fold lines by reducing buckling. The cutouts 172 , 174 also permit the panels and the tabs to be folded independently of each other.
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A folded paper board compact disc carrier for carrying a plurality of compact discs. A compact disc carrier formed from a single piece of stock comprises a paper board blank having a central portion divided by a fold line into first and second planar portions. Each portion includes a side edge having a tab and a pair of opposing flaps foldable along a fold line lying perpendicular to the central portion fold line. Each flap is foldable to an inward position wherein the flaps define with their corresponding planar half an enclosure adapted to receive a compact disc. Upon folding the first and second planar portions along the central portion fold line the enclosures are placed in spaced apart parallel relationship with the side edge tabs of each planar half disposed adjacent each other. The compact disc carrier so formed requires no glue or other adhesives and will hold a plurality of compact discs.
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BACKGROUND OF THE INVENTION
[0001] 1). Field of the Invention
[0002] This invention relates to a no-flow underfill material.
[0003] 2). Discussion of Related Art
[0004] A semiconductor package may be constructed from a package substrate having bond pads thereon and an integrated circuit die having bumps formed thereon. A fluxing agent is usually deposited over the package substrate and the bond pads and the bumps are then brought into contact with the bond pads. Subsequent heating in a reflow oven attaches the bumps to the bond pads. The fluxing agent removes oxides from surfaces of the bond pads and bumps to ensure a reliable joint between the bumps and the bond pads.
[0005] The fluxing agent is subsequently washed out in a defluxing machine. An underfill material is then dispensed next to the die on the substrate utilizing a dispensing machine. The underfill material then flows under capillary action into and fills a gap between the die and the substrate, with or without the help of heating. The underfill material serves to redistribute stresses on the bumps due to a mismatch in a coefficient of thermal expansion (CTE) of the substrate and a CTE of the die when the package is heated or cooled.
[0006] A so-called no-flow underfill material may be used instead of a conventional fluxing agent to eliminate the need for a defluxing machine and other machinery, and to significantly reduce throughput time. A no-flow underfill material is applied like a conventional fluxing agent and to an extent serves the purpose of a conventional fluxing agent. The no-flow underfill material cures while the package is transferred through a reflow oven, and, to an extent, can then serve the additional purpose of a conventional underfill material. Post cure of the material may be needed.
[0007] Existing no-flow underfill materials have been shown to be unsatisfactory because of one or more reasons such as a very high CTE, high moisture absorption, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is further described by way of example with reference to the accompanying drawings wherein:
[0009] [0009]FIG. 1 is a cross-sectional side view illustrating a partially assembled semiconductor package utilizing a no-flow underfill material;
[0010] [0010]FIG. 2 is a view similar to FIG. 1 after bumps formed on a die are located in the no-flow underfill material and in contact with bond pads on a substrate; and
[0011] [0011]FIG. 3 is a view similar to FIG. 2 after solder reflow.
DETAILED DESCRIPTION OF THE INVENTION
[0012] A no-flow underfill material is provided that includes at least:
[0013] (i) an epoxy siloxirane resin,
[0014] (ii) at least one agent acting as a cross-linking hardener capable of curing an epoxy resin and a curing catalyst capable of catalyzing the curing of the epoxy resin, and
[0015] (iii) a compatible fluxing agent.
[0016] The siloxirane resin may in its pre-cure monomer state be represented by:
[0017] where m is the number of reactive oxirane groups on the surface of the O—Si—O domain and m ranges from 1 to 30. R′ is selected from the group consisting of phenylene, bisphenylene, carbonyl, and alkylene. The alkylene herein refers to a branched or unbranched saturated hydrocarbon group of 1 to 24 carbon atoms, such as methylene (“Me”), ethylene (“Et”), n-propylene, isopropylene, n-butylene, isobutylene, t-butylene, octylene, decylene, and the like. Preferred alkylene groups herein contain from 1 to 12 carbon atoms. An organic moiety may be used in the monomer in eq. 1 to link the SiO 2 group with the oxirane group.
[0018] The SiO 2 group (O—Si—O) in eq. 1 or 2 can be a surface-grafted fused silica particle with a size less than 50 micron. Alternatively, the SiO 2 group can be a cyclic SiO 2 domain.
[0019] The SiO 2 group has a low CTE, low moisture uptake, and a high distortion temperature. A cyclic SiO 2 group also provides polymer flexibility and a correspondingly higher toughness.
[0020] The oxirane group CH 2 CHCH 2 O in eq. 1 is a diglycidyl ether type oxirane group and the oxirane group in eq. 2 is a cycloaliphatic oxirane group. The oxirane group in eq. 1 or eq. 2 provides cross-linking of the monomer with good adhesion to different surfaces. Cross-linking density of an eventual polymer can be controlled by the number of oxirane groups on each SiO 2 group.
[0021] The agent acting as a cross-linking hardener and a catalyst may be a single material such as an imidazole or its derivative, triphenylphosphine, or an onium salt. The agent may include a separate hardener and catalyst. The hardener may for example be an amine, an anhydride, a poly arnide, a polyamide amine, or a phenolic resin and the catalyst may be an imidazolium salt, or a tertiary amine. The agent, during curing, creates a polymerized polymer out of the monomer with a three-dimensional cross-linked structure. The ratio at which the imidazole or its derivatives, or tripheylphosphine, or onium salt that is added in the formulation ranges from 0.01 wt % to 20 wt % of the weight of the siloxirane resin. The ratio at which amine, or polyamide, or polyamide amine that is added in the formulation is 1 reactive amine hydrogen equivalent to 0.1 to 10 epoxide equivalent of the siloxirane resin. The ratio at which anhydride that is added in the formulation is 1 anhydride ring equivalent to 0.1 to 10 epoxide equivalent weight of the siloxirane resin.
[0022] The fluxing agent can be any acid which can be dissolved in the siloxirane resin and the agent. The fluxing agent is preferably an organic carboxylic acid, or a polymeric fluxing agent, or an organic compound that contains one or more hydroxyl groups. The fluxing agent may for example be a glutaric acid or a trifluro acetic acid. The ratio at which a fluxing agent that is added in the formulation ranges from 0.1 wt % to 20 wt % of the weight of the siloxirane resin.
[0023] The material preferably further includes an adhesion promoter to further increase the adhesion strength between underfill material to all contact surfaces. The adhesion promoter may for example be a silane coupling agent, an organo-ziconate, or an organo-titanate. The ratio at which an adhesion promoter is added in the formulation ranges from 0.01 wt % to 10 wt % of the weight of the siloxirane resin.
[0024] The material preferably further including a non-ionic surfactant to help material flow and eliminate process voids. The surfactant may be a polyol, a siloxane compound, and a fluorinated compound such as FC-430 from 3M Corporation of St. Paul, Minn. The ratio at which an adhesion promoter is added in the formulation ranges from 0.01 wt % to 10 wt % of the weight of the siloxirane resin.
[0025] The material preferably further includes a de-foaming agent which prevents air entry and bubble formation during processing. The de-foaming agent may for example be BYK-066 from BYK-chemie of Wesel in Germany. The ratio at which a de-foaming agent is added in the formulation ranges from 0.01 wt % to 10 wt % of the weight of the siloxirane resin.
[0026] The material preferably further includes fused silica to further reduce CTE and moisture uptake, and increase modulus. The ratio at which a fused silica is added in the formulation ranges from 1 wt % to 300 wt % of the weight of the siloxirane resin.
[0027] The material preferably further includes silver flakes to provide electrical conductivity. The ratio at which a silver flake is added in the formulation ranges from 10 wt % to 500 wt % of the weight of the siloxirane resin.
[0028] The material preferably further includes thermally conductive particles to provide desired thermal conductivity. The thermally conductive particles may for example be silicon nitride, silicon borate, alumina, diamond, or silicon oxide. The ratio at whicha thermally conductive particles is added in the formulation ranges from 10 wt % to 500 wt % of the weight of the siloxirane resin.
Example 1 a. Siloxirane resin (eq. 1 or 2): 100 part (by weight) b. 2-ethyl-4-methyl imidazole acting as both 4 parts hardener and catalyst: c. Glutaric acid as a fluxing agent: 4.0 part d. FC-430 as a surfactant: 0.2 part e. BYK-066 (defoaming agent): 0.05 part f. 3-glycidoxy propyl methyl diisopropenoxy 0.2 part silane (adhesion promoter) g. fused silica filler 40 parts Example 2 a. Siloxirane resin (eq. 1 or 2): 100 part (by weight) b. methyl hexahydrophthalic anhydride 100 parts acting as a hardener: c. triphenyiphospine acting as a catalyst: 0.8 parts d. Glutaric acid as a fluxing agent: 8.0 part e. glycerol (assisting fluxing agent) 8.0 parts f. polyoxyethylene (surfactant): 0.4 part g. BYK-066: 0.1 part h. neopentyl (diallyl)oxy 0.6 part tri(N-ethylenediamineo) ethyl titanate (adhesion promoter) i. silicon nitride (thermally conductive 100 parts particles) Example 3 a. Siloxirane resin (eq. 1 or 2): 100 part (by weight) b 2-phenyl-4,5-dihydroxymethylimidazole: 6 parts c. trifluoro acetic acid as a fluxing agent: 4.0 part d. silicone as a surfactant: 0.4 part e. BYK-066: 0.05 part f. neopentyl(diallyl)oxy tri(dioctyl) 0.3 part pyrophosphato zirconate (adhesion promoter) g. silver flakes (electrically conductive filler) 300 parts
[0029] FIGS. 1 to 3 illustrate how the no-flow underfill material is used in the construction of a semiconductor package. FIG. 1 illustrates an initial stage in the assembly of the semiconductor package. The semiconductor package includes a package substrate 10 , bond pads 12 , a semiconductor die 14 , contact pads 16 , bumps 18 , and the no-flow underfill material 20 . The bond pads 12 are formed on an upper surface of the package substrate 12 . The contact pads 16 are formed on, as shown in FIG. 1, a lower surface of the die 14 and the bumps 18 are formed on the contact pads 16 according to the well known controlled collapse chip connect (C4) process. The no-flow underfill material 20 is deposited over the upper surface of the substrate 10 and covers all previously exposed surfaces of the bond pads 12 .
[0030] As shown in FIG. 2, the bumps 18 are then inserted into the no-flow underfill material 20 until each bump 18 contacts a respective bond pad 12 . The no-flow underfill material 20 then fills regions between the bumps 18 .
[0031] The assembly of FIG. 2 is then passed through a reflow oven or thermal compressive bonder to form a final assembly as shown in FIG. 3 of a semiconductor package 22 according to an embodiment of the invention. The bumps 18 reflow at a temperature higher than their melting point so that they reflow over the bond pads 12 . The material 20 serves to remove oxygen from the bumps 18 and the bond pads 12 . The removal of oxygen facilitates the formation of a more reliable electrical joint between each bump 18 and its respective bond pad 12 .
[0032] The temperature to which the assembly in FIG. 2 is cycled is also sufficiently high to cause cross-linking of oxirane groups to form a very strong polymer. The material 20 thus solidifies, as is required for purposes of distributing stresses which tend to shear the bumps 18 from the bond pads 12 and the contact pads 16 .
[0033] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative and not restrictive of the current invention, and that this invention is not restricted to the specific constructions and arrangements shown and described since modifications may occur to those ordinarily skilled in the art.
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A siloxirane based no-flow underfill material is provided. The material has a low coefficient of thermal expansion, low moisture uptake and a high distortion temperature. The material typically includes at least an epoxy siloxiane resin, a cross-linking hardener, a catalyst, and a fluxing agent.
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This is a continuation-in-part of application Ser. No. 840,152 filed Mar. 17, 1986, now U.S. Pat. No. 4,663,910.
BACKGROUND OF THE INVENTION
The present invention relates to a washer used to attach roofing insulation. The washer of the present invention is particularly useful in construction where single ply roofing membranes are placed over the insulation.
The problem addressed by the present invention involves the puncture of membrane material by fastener heads. This problem arises when screws which are used to secure washers and insulation to a roof substructure become loose and move upward out of their installed positions. Such upward movement is usually attributable to vibration of some sort.
Attempts to eliminate this problem have taken several forms. For example, U.S. Pat. No. 4,361,997 to DeCaro shows engagement between the threads of a screw and the walls of a bore in a washer. Another attempt is the Tap Deck-SP fastener in which an annular ring on the shank of a fastener snaps through the aperture in a washer. A third attempt is shown in FIG. 3 of U.S. Pat. No. 4,074,501 to Sandquist. Sandquist shows a groove formed in a beveled bore. The edges of a countersunk screw head fit into the groove, and tend to prohibit backward motion of the screw.
U.S. Pat. No. 4,380,413 to George G. Dewey, which is owned by the assignee of the present invention, shows a screw and washer combination in which the head of a screw is loosely captivated within a recess in the washer.
It is an object of the present invention to provide a roofing insulation washer which prevents backward motion of a screw during vibration.
Another object of the invention is to provide a washer with means to easily and positively engage the head of a fastener used therewith.
Another object of the present invention is to provide a washer with means for firmly and resiliently gripping the head of a fastener used therewith.
Another object of the invention is to provide a washer in which engagement between the washer and the head of a fastener is easily obtained.
SUMMARY OF THE INVENTION
These and other objects of the invention are obtained with an apertured washer having a generally flat laterally extending flange, at least one axially extending somewhat cylindrical gripping protrusion formed around an aperture in the washer. The protrusion is somewhat cylindrical, and is disposed within a recess in the upper surface of the washer. A radially inwardly extending lip is disposed on the inner portion of the free end of the gripping protrusion. In an alternative embodiment, a series of axial ribs guide the head of a fastener into engagement with a radially inwardly extending lip, which is formed at one end of the series of axial ribs. in all embodiments, a small resilient annular rib is disposed between the aperture and the gripping protrusion. The annular rib urges the fastener head against the lip.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will become apparent from the following specifications read with reference to the following drawings.
FIG. 1 is a top plan view of a washer embodying the present invention.
FIG. 2 is a side elevational view in partial section of the washer shown in FIG. 1.
FIG. 3 is a transverse sectional view of the washer taken along lines 3--3 of FIG. 1.
FIG. 4 is a top plan view of another embodiment of the present invention.
FIG. 5 is a bottom plan view of the embodiment shown in FIG. 4.
FIG. 6 is a side elevational view of the embodiment shown in FIGS. 4 and 5.
FIG. 7 is a transverse cross-sectional view taken along lines 7--7 of FIG. 4.
FIG. 8 is a plan view of the top of a third embodiment of the present invention.
FIG. 9 is a side elevational view of the washer shown in FIG. 8.
FIG. 10 is an enlarged sectional view of the third embodiment of a washer of the present invention taken along line 10--10 of FIG. 8.
FIG. 11 is a plan view of the top of a fourth embodiment of a washer of the present invention.
FIG. 12 is a plan view of the bottom of the washer shown in FIG. 11.
FIG. 13 is a sectional view taken along line 13--13 in FIG. 11.
FIG. 14 is a sectional view of the washer shown in FIGS. 11 through 13 in combination with a screw head retaining insert.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1, 2 and 3 show an embodiment of the invention in which the washer 10 is comprised of a laterally extending flange 11 having a central aperture 12 and a protruding hub 23. A recess 14 is formed in the upper side 22 of the flange 11. Within the recess 14 there is a cylindrical protrusion or boss 15 which extends in an axial direction upwardly from a shoulder 20. The boss 15 is spaced laterally from the aperture 12. Between the boss 15 and the aperture 12 there is a small axially extending protrusion in the form of a rib 17. An overhanging lip 16 is formed on the inner free end of the boss 15.
As shown in FIG. 2, a screw 30 has a head 31 which is gripped by the rib 17 and the boss 15. The rib 17 is a resilient tapering rib which engages the underside 32 of the screw head. At the same time, the lip 16 engages the peripheral edge 33 of the top side of the screw head.
The details of the shape of the boss 15 are important. The upper portion of the lip 16 is sloped to act as a guide for the screw head 31. The inner wall 18 of the boss 15 is generally parallel to the axis of the aperture 12, while the outside wall 19 of the boss 15 is sloped inwardly from bottom to top. By placing the boss 15 in the recess 14, two benefits are obtained. First, the upper end of the boss 15 has a space into which it may deflect during the movement of the screw head 31 passed the lip 16. It has been found that the shape as shown in FIG. 3 allows lateral deflection of the boss 15 without resultant damage thereto. Also, because the boss 15 is positioned well below the surface 22 on the upper side of the washer, if a screw head fails to snap pass the lip 16, it will not interfere with a membrane draped over the washer. Vibrations resulting from wind or from sources within a structure can cause loosening and backward motion of roofing screws. The present invention minimizes the possibility of a screw backing up to a point where the screw head 31 projects above the upper surface 22 of the washer.
FIGS. 4-7 show an alternative embodiment of the present invention. In FIGS. 4-7 the designation "a" following a reference numeral is used to designate elements which correspond to the embodiment shown in FIGS. 1--3.
The embodiment of FIGS. 4-7 is intended to be used with a batten strip, as shown in FIG. 7. Batten strips are used to attach edges of roofing membranes. The strips are then covered with a membrane sheet which is adhesively attached to a section of underlying membrane adjacent to the batten strip. Thus, the problem of screw heads tending to loosen and puncture overlying membrane sheets is present with the use of batten strips in a manner similar to the problem associated with insulation fastening as discussed above.
The embodiment of FIGS. 4-7 is similar to the embodiment of FIGS. 1-3 in that the washer 10a includes a laterally extending flange 11a and an axially extending cylindrical protrusion of boss 15a surrounds an aperture 12a extending through the washer. The washer further includes a hub 23a depending from the bottom side of the washer. However, the hub has two legs 24 and 25 which are separated by a slot 29. The legs 24 and 25 have a circumferential notch 26 formed on the outside surface thereof. The notch 26 forms a shoulder 27 which engages a batten strip 40 as the washer is inserted through an aperture 41 in the batten strip.
The cooperation between the boss 15a and a screw head is substantially the same as the cooperation described with reference to the boss 15 and the screw 30 shown in FIG. 2 and discussed above.
FIGS. 8, 9 and 10 show a third embodiment of the invention for which the designation "C" is used following reference numbers. The third embodiment is a washer designated generally with the reference number 10c. It includes a wide laterally extending flange 11a, and a central throughbore 12c. FIG. 8 is a plan view of the upper surface of the flange 11c. FIG. 9 shows a hub 23c depending from the bottom surface of the washer.
FIG. 10 is an enlarged view of a cross-section through the throughbore of the washer 10c. A shoulder 20c divides the throughbore into an upper portion 56c and a lower portion 57c is substantially less than the maximum latter dimension of any part of the upper portion 56c. The upper portion includes a shallow recess 14c in the extreme upper surface of the washer. Below the shallow recess 14c a series of axially extending spirally disposed ribs 61c. The spiral configuration of the series of ribs can best be seen in FIG. 8. The innermost edges of each of the ribs 61c is tapered such that the edges of the ribs form portions of a truncated cone having a wider opening at its upper end and a narrower opening at its lower end.
At the lower end of the series of ribs 61c there is an annular radially inwardly extending lip 16c, which operates in a manner similar to the lip 16 of the embodiment described earlier. The lip 16c cooperates with the rib 17c, which is disposed on the shoulder 20c, to resiliently retain the head of a fastener. The rib 17c deflects an amount sufficient to allow the head of a fastener to snap past the lip 16c, and rib 17c is resilient so that it can push the head of a fastener into gripping engagement with the lip 16c.
The spiral disposition of the ribs 61c is such that retrograde or upward motion of a threaded fastener is severly restricted. However, the insertion of a threaded fastener in a clockwise direction is facilitated by the orientation of the ribs as shown in FIG. 8. Specifically, a plane 70c which bisects a rib 61c is offset from a plane 71c which is parallel to claim 70c and which bisects the central axis 73c of the washer. It has been found that the offset between planes 70c and 71c should be approximately 0.05 inches when the ribs are shaped in a manner similar to those shown in FIG. 8.
FIGS. 11, 12, 13 and 14 show a fourth embodiment of the present invention for which a designation `d` is added to the reference numbers. This fourth embodiment, generally designated as washer 80d, combines elements of the embodiment of the FIGS. 4-7 and FIGS. 8-10. The washer 10d is comprised of two components, a central body 81d made of generally resilient material and a flange 82d carried by a central body 81d. The flange 82d contains an octagonal impression 83d formed therein. A mating octagonal configuration is formed on the under surface of the central body 81d to prevent relative rotation of the two components. As with the third embodiment shown in FIGS. 8, 9 and 10, the washer 10d is equipped with ribs 61d which are similar in shape and function to the ribs 61c described earlier, and lip 16d cooperates with rib 17d in substantially the same way in which lip 16c cooperates with rib 17c.
It should be noted that the undersurface of the flange 82d, shown in FIG. 12, includes edges 93d and corners 94d formed by the octagonal impression 83d in the upper surface of the flange 82d. The edges 93d and corners 94d project slightly below the outer clamping surfaces 95d. This enables the edges 93d and corners 94d to engage a roofing membrane and prevent lateral movement of that membrane. If substantial movement of the membrane occurs at the location of the edges 93d and corners 94d, stress concentration can occur at points of contact between the membrane and a threaded fastener, which can cause early failure of the membrane.
Another advantage of the third and fourth embodiments of the present invention is in the ability of the ribs 61c and 61d to melt. In some roofing application, lapping of adjacent membranes and heat sealing thereof causes roofing insulation washers, like those of the present invention, to be exposed to high temperatures. When washers like those of the third and fourth embodiment of the present invention are exposed to high temperature, the ribs 61c and 61d melt easily because of their large surface area. When the ribs melt, the material comprising them flows over the head of the fastener and further prevents rotation and backing out of the fastener.
While specific embodiments of the invention have been described in detail above, variations and modifications will become apparent to those skilled in the art. Such variations and modifications are intended to fall within the spirit and scope of the appendant claims.
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A washer for attaching insulation to a roof member over which roofing membrane is to be placed. The washer includes a laterally extending apertured flange and an upstanding hollow cylindrical protrusion adapted to snappingly engage the head of a fastener used with the washer. The protrusion has an inwardly extending lip on the inside surface of the free end of the protrusion. In an alternative embodiment sloping ribs guide a fastener head into snapping engagement with an inwardly projecting lip. In all embodiments a resilient rib is disposed on a shoulder formed in the aperture in the washer. The rib resiliently urges the head of the fastener into engagement with the lip. The washer includes a downwardly extending hub, which may be equipped with means for retaining the washer in a batten strip.
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RELATED APPLICATION
[0001] This application is related to commonly assigned U.S. patent application entitled “FACETED, TAG-BASED APPROACH FOR THE DESIGN AND COMPOSITION OF COMPONENTS AND APPLICATIONS IN COMPONENT SYSTEMS”, attorney docket no. YOR920080573US1 (8728-921), filed concurrently herewith, the disclosure of which is incorporated by reference herein in its entirety.
GOVERNMENT INTERESTS
[0002] This invention was made with Government support under Contract No.: H98230-07-C-0383 awarded by the U.S. Department of Defense. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The present invention relates to requirements engineering in information processing systems.
[0005] 2. Discussion of the Related Art
[0006] In general, it is difficult to elicit formal software requirements from end-users. For example, most software requirements tend to be captured in an informal manner in an unstructured document. This makes it difficult to concisely describe the requirements, to communicate the requirements to an IT or development team precisely, and then, to verify that the requirements have indeed been met by the developed IT artifacts.
[0007] Accordingly, there is a need for a technique of eliciting formal software requirements from end-users.
SUMMARY OF THE INVENTION
[0008] In an exemplary embodiment of the present invention, a method, comprises: providing a computer menu from which a processing goal can be created, wherein the menu includes a plurality of facets, and wherein each facet includes at least one tag; receiving a processing goal, wherein the processing goal includes a plurality of tags selected from the menu; executing at least one application that includes a plurality of components arranged in a processing graph to produce information that satisfies the processing goal; and outputting the information.
[0009] A facet is a category on the computer menu that presents at least one tag associated therewith when the facet is selected.
[0010] At least one tag is a keyword associated with an available resource.
[0011] The tags are organized in a hierarchy.
[0012] The hierarchy is a directed acyclic graph.
[0013] In an exemplary embodiment of the present invention, a method, comprises: receiving a software requirement; and representing the software requirement as a plurality of processing goals described by a goal pattern, wherein the goal pattern is described by a set of tags and facets, and wherein each facet is associated with a constraint that specifies how many tags in the facet should be part of a particular processing goal.
[0014] The method further comprises developing one or more applications that satisfy the processing goals.
[0015] The software requirement comprises a high-level software requirement.
[0016] An application includes a plurality of components capable of satisfying at least one of the plurality of processing goals.
[0017] The method further comprises: initiating at least one of the applications on a computer accessible to a user; receiving a processing goal from the user, wherein the processing goal includes at least one tag selected by the user, and wherein the tag is included in a facet selected by the user; executing the at least one application to produce information that satisfies the processing goal; and providing the information to the user.
[0018] In an exemplary embodiment of the present invention, a computer readable storage medium stores instructions that, when executed by a computer, cause the computer to perform a method, the method comprising: providing a computer menu from which a processing goal can be created, wherein the menu includes a plurality of facets, and wherein each facet includes at least one tag; receiving a processing goal, wherein the processing goal includes a plurality of tags selected from the menu; executing at least one application that includes a plurality of components arranged in a processing graph to produce information that satisfies the processing goal; and outputting the information.
[0019] A facet is a category on the computer menu that presents at least one tag associated therewith when the facet is selected.
[0020] At least one tag is a keyword associated with an available resource.
[0021] The tags are organized in a hierarchy.
[0022] The hierarchy is a directed acyclic graph.
[0023] In an exemplary embodiment of the present invention, a computer readable storage medium stores instructions that, when executed by a computer, cause the computer to perform a method, the method comprising: receiving a software requirement; and representing the software requirement as a plurality of processing goals described by a goal pattern, wherein the goal pattern is described by a set of tags and facets, and wherein each facet is associated with a constraint that specifies how many tags in the facet should be part of a particular processing goal.
[0024] The method further comprises developing one or more applications that satisfy the processing goals.
[0025] The software requirement comprises a high-level software requirement.
[0026] An application includes a plurality of components capable of satisfying at least one of the plurality of processing goals.
[0027] The method further comprises: initiating at least one of the applications on a computer accessible to a user; receiving a processing goal from the user, wherein the processing goal includes at least one tag selected by the user, and wherein the tag is included in a facet selected by the user; executing the at least one application to produce information that satisfies the processing goal; and providing the information to the user.
[0028] The foregoing features are of representative embodiments and are presented to assist in understanding the invention. It should be understood that they are not intended to be considered limitations on the invention as defined by the claims, or limitations on equivalents to the claims. Therefore, this summary of features should not be considered dispositive in determining equivalents. Additional features of the invention will become apparent in the following description, from the drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 shows a faceted navigation menu and a user-selected, tag-based goal, according to an exemplary embodiment of the present invention;
[0030] FIG. 2 shows a flow for a user-selected tag-based goal, according to an exemplary embodiment of the present invention;
[0031] FIG. 3 shows a service development lifecycle, according to an exemplary embodiment of the present invention; and
[0032] FIG. 4 shows a block diagram of a system in which exemplary embodiments of the present invention may be implemented.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0033] This disclosure incorporates by reference herein in its entirety, Bouillet et al. A tag-based approach for the design and composition of information processing applications. Object-Oriented Programming, Systems, Languages and Applications (OOPSLA) '08, to be published Oct. 19-23, 2008.
[0034] In this disclosure, we provide a novel technique for describing end-user requirements. In an exemplary embodiment, the technique utilizes faceted, tag-based functional requirements that are elicited from end-users. The facets represent different dimensions of both data and processing, where each facet is modeled as a finite set of tags that are defined in a controlled folksonomy. The faceted, tag-based functional requirements are the starting point of a top-down lifecycle where workflows and individual services are designed, explicitly keeping in mind the needs of the composition. The requirements are taken by enterprise architects who design workflow templates that are also associated with faceted, tag-based descriptions. These workflow templates can either reuse existing services of workflows, or they can be used to generate new service requirements, which are also described in terms of facets and tags. These new services are then developed by developers, and are tested individually in conjunction with other services as per the workflow templates.
[0035] In this disclosure, we focus on information processing workflows, which are workflows that retrieve and process information as desired by end-users. It is to be understood, however, that the exemplary embodiments of the present invention are not limited thereto. These workflows make available unified information, obtained or extracted from multiple data sources, in response to end-users' information inquiries. Examples of such workflows are those that obtain business intelligence for analysts and those that perform information integration and content management. The key drivers for these workflows are to facilitate better decision making by end-users and better information sharing between business operations.
[0036] In this disclosure, we focus on information processing workflows that extract data from one or more sources, process them after using one or more services, and produce useful information or knowledge. The key end-users of information processing workflows are analysts and decision makers in various enterprises. These end-users need to quickly obtain and update the business intelligence that guides their decision. For this, they need to collect the needed information from a potentially huge number of diverse sources, adapt and integrate that data, and apply a variety of analytic models, updating the results as the data changes. When new sources are discovered and/or new analytic models are developed—or simply when new ways of applying existing models are desired—users of information systems cannot and should not wait the days or months needed for development cycles to complete, to get the analysis results they urgently need. These users require the serendipitous assembly of new workflows from the available services to satisfy their dynamic and changing information processing goals.
[0037] Tags and Tag Hierarchies
[0038] The word “tag” comes from various collaborative tagging applications that have arisen in Web 2.0 (such as del.icio.us and Flickr) where users annotate different kinds of resources (like bookmarks and images) with tags. These tags aid search and retrieval of resources. A key aspect of the tagging model is that it is relatively simple, in comparison to more expressive models such as those based on Semantic Web ontologies and other formal logics. Hence, it offers a lower barrier to entry for different kinds of users to describe resources. In our case, the resources are different kinds of data artifacts, like files, input and output messages to services, etc.
[0039] Let T={t 1 , t 2 , . . . , t k } be the set of tags in our system. In most social tagging applications, the set of tags, T, is completely unstructured, i.e., there is no relation between individual tags. Introducing a hierarchy structure in T, however, enhances the expressivity by allowing additional tags to be inferred for resources. A tag hierarchy, H, is a directed acyclic graph (DAG) where the vertices are the tags, and the edges represent “sub-tag” relationships. It is defined as H=(T,S), where T is the set of tags and S T×T is the set of sub-tag relationships. If a tag t 1 εT is a sub-tag of t 2 εT, denoted t 1 t 2 , then all resources annotated by t 1 can also be annotated by t 2 . For convenience, we assume that ∀tεT, t t.
[0040] Facets
[0041] Facets represent dimensions for characterizing resources (data artifacts). Let F={f i } be the set of facets. Each facet is a set of tags, i.e., f i T. Tags may be shared across facets.
[0042] FIG. 1 shows an example of a faceted tag cloud interface for the weather and energy trading services domain. In this domain, end-users can specify different kinds of weather forecast processing goals. Some of the facets are Sources, Weather Forecast Model, Weather Metric, etc. Each facet includes a number of tags, e.g., the Weather Metric facet includes tags like Dewpoint, Temperature, etc. It is noted that some tags are larger, indicating that they are relevant to a larger number of user-specifiable goals. End-users can select one or more tags to formulate the processing goal; our interface also provides a natural language interpretation of the goal from the set of tags, to provide feedback to the end-user on how the system interprets the goal.
[0043] Dynamic End-User Processing Goals Expressed Using Tags
[0044] As shown in FIG. 1 , end-user processing goals are specified as a set of tags. For example, a commodities broker might want to watch for predicted extremes in relative humidity that might indicate a drought, indicating an opportunity to trade corn futures. He would express this as the goal GFS, Eta, RelativeHumidity, IA, WeightedAverage, ContourMapView, which represents a request for a workflow that delivers the weighted average of two relative humidity forecasts (produced using the GFS and Eta forecast models obtained from NOAA—the National Oceanographic and Atmosphere Association) for the state of Iowa presented on a contour map.
[0045] Each data artifact in our system, a is characterized by a set of tags d(a) T. The data artifacts include the input and output messages of web services, RSS feeds, web pages, files, etc. The tags only describe the semantics of the data artifacts, and not the actual syntax.
[0046] End-user goals describe the semantics of the desired data artifacts that may be produced by an information processing workflow. A goal, q T, is satisfied by a data artifact, a, iff ∀tεq∃t′εd(a), t′ t.
[0047] When a user selects a goal, a workflow is composed in a bottom-up manner from the available services. In our system, this bottom-up composition occurs through an AI planner, such as, for example, the planner described in, [A. Riabov and Z. Liu. Planning for stream processing systems. In American Association for Artificial Intelligence (AAAI), 2005 ], the disclosure of which is incorporated by reference herein in its entirety, that uses tag-based descriptions of individual services to come up with a workflow satisfying the goal. FIG. 2 shows an example of such as workflow. For example, FIG. 2 is a flow example for the “IA RelativeHumidity GFS Eta WeightedAverage ContourMapView” goal. The final Contour Map View service in the workflow is a Representational State Transfer (REST) service that end-users can access for real-time result information. Some services like NOAA GFS Forecast Data are instantiated with specific configuration parameters like Current Forecast. In other words, the boxes in FIG. 2 represent components of an application.
[0048] We model a workflow as a graph G(V, E) where G is a DAG (Directed Acyclic Graph). Each vertex vεV is a service instance. Each edge (u, v) represents a logical flow of messages from u to v. If a vertex, v has multiple incoming edges of the form (u 1 , v), (u 2 , v), . . . , then it means that the output message produced by u 1 , u 2 , . . . are used together to create an input message to v. The message corresponding to each edge, (u, v), can be described by a set of tags, d((u,v)). In this disclosure, we restrict the workflows to acyclic graphs since capturing the semantics of messages where there are loops is difficult.
[0049] Overview of Potential Lifecycle Based on Faceted, Tag-Based Requirements
[0050] For this purpose, we provide a service engineering lifecycle (see FIG. 3 ) that is driven by high-level faceted, tag-based functional requirements. In information processing systems, the functional requirements describe the general kinds of information the end-user desires. In our approach, these functional requirements are expressed as patterns of goals that the user would like to submit. Note that this disclosure focuses on functional requirements and not non-functional requirements like security, performance and cost. However, the exemplary embodiments of the present invention are applicable to both sets of requirements.
[0051] The functional requirements are taken by an enterprise architect who comes up with a high-level design of the overall workflow(s) and of individual services. The architect first constructs one or more workflow templates that satisfy the requirements. A workflow template is a high-level description of the flow structure and is modeled as a graph of processing stages, where each stage performs a certain segment of the overall required information processing. Each stage in turn consists of a graph of service classes, where a service class is an equivalence class of services that share similar properties and are substitutable in certain contexts. The services have a modular and substitutable nature and enable composition. In addition, the decomposition of the workflow into processing stages allows reuse of both services and entire sub-flows.
[0052] The architect can reuse existing services (and service classes) in designing the workflow. In some cases, new services may need to be developed, or existing services modified, to satisfy new end-user requirements. The architect defines the semantic requirements of the new services in terms of tags describing the input and output data. In addition, the architect defines the syntactic interfaces (e.g., using WSDL) to enable its interaction with other services in the processing stage, and in the workflow in general. These semantic and syntactic service requirements are passed to a developer, who develops the service and tests it both individually and in conjunction with other services. Finally, the new services are made available for composition and deployment. This may also result in changes to the end-user interface to include the new tags describing the outputs of workflows that contain the new service. Finally, as shown in FIG. 3 , the different stages of the lifecycle are iterative, and proceed in a spiral refinement manner to finally converge towards the required system.
[0053] In summary, some notable aspects of our approach are:
[0054] 1. The common, yet extensible, facets and tag hierarchies establish a simple, shared vocabulary that is used by architects, developers and end-users.
[0055] 2. End-user requirements are captured in a formal manner. This enables us to verify that the requirements are actually satisfied by a set of composable services.
[0056] Faceted, Tag-Based Requirements for Driving Composition
[0057] Workflow composition requires careful design of the services. The first need is to make sure that at least those flows are composed that meet certain business requirements, which are explicitly specified by the end-users. In addition, if they satisfy new requirements through serendipitous composition of services, that is a bonus.
[0058] Hence, in our approach, high-level end-user requirements drive the service engineering process. In any large-scale information processing system, there may be a large number of different kinds of information, and a large number of different ways of processing this information. Hence, requirements are not specified in terms of single goals but as whole classes of goals that are described by goal patterns.
[0059] A goal pattern is described as a set of tags and facets. Each facet is associated with a cardinality constraint. The cardinality constraint specifies how many tags in the facet should be part of the goal.
[0060] We first define the set of cardinality constraints, CC, as the set of all ranges of positive integers. Then a goal pattern, QP={(x, c)|xεF, cεCC}∪{t|tεT}. A goal pattern requirement means that end-users are interested in all data artifacts that can be described by a combination of tags that are drawn from the facets in the goal pattern, according to the cardinality constraints.
[0061] An example of a goal pattern is {Source[≧1], WeatherForecastModel[≧2], MultipleModelAnalysis[1], BasicWeatherMetric[≧1], Visualization[1]}.
[0062] This represents the class of all data artifacts that can be used to describe one or more tags that belong to the Source facet, two or more tags in the WeatherForecastModel facet, one tag in the MultipleModelAnalysis facet, one tag in the BasicWeatherMetric facet, and one tag in the Visualization facet.
[0063] A point to note is that the goal pattern can refer to a large number of possible goals. For example, if there are five tags in the Source facet, 50 tags in the Model facet, five in the MultipleModelAnalysis facet, 10 in the BasicWeatherMetric facet, and 10 in the Visualization facet, there are up to 2 5 ×2 5 °×5×2 10 ×10 possible kinds of data that may be producible by the information processing system. The goal pattern helps in succinctly expressing the combinatorial number of possible goals that can be submitted to the system.
[0064] In this disclosure, we described the use of faceted, tag-based descriptions as a means of specifying high-level end-user requirements, in accordance with an exemplary embodiment of the present invention. The requirements kick off a top-down service development lifecycle, where enterprise architects and service developers design abstract workflow templates, generate requirements for new services, develop and test the new services and workflows, and finally make available the services for manual or automatic composition in response to dynamic user goals.
[0065] A system in which exemplary embodiments of the present invention may be implemented is shown in FIG. 4 . As shown in FIG. 4 the system includes a computer system 100 , which can represent any type of computer system capable of carrying out the teachings of the present invention. For example, the computer system 100 can be a laptop computer, a desktop computer, a workstation, a hand-held device, a server, a cluster of computers, etc. End-user(s) 140 , architect(s) 125 , or developer(s) 130 can access the computer system 100 directly, or can operate a computer system that communicates with computer system 100 over a network 165 (e.g., the Internet, a wide area network (WAN), a local area network (LAN), a virtual private network (VPN), etc.).
[0066] Computer system 100 is shown including a processing unit 105 , a memory 115 , a bus 155 , and input/output (I/O) interfaces 110 . Further, computer system 100 is shown in communication with external devices/resources 145 and one or more storage system 150 . In general, processing unit 105 executes computer program code, such as AI planner 120 or an application 160 , that is stored in memory 115 and/or storage system 150 . While executing computer program code, processing unit 105 can read and/or write data, to/from memory 115 , storage system 150 , and/or I/O interfaces 110 . Bus 155 provides a communications link between each of the components in computer system 100 . External devices/resources 145 can comprise any devices (e.g., keyboard, pointing device, display (e.g., display 135 ), printer, etc.) that enable a user to interact with computer system 100 and/or any devices (e.g., network card, modem, etc.) that enable computer system 100 to communicate with one or more other computing devices.
[0067] Storage system 150 can be any type of system (e.g., database) that is capable of providing storage information for use with exemplary embodiments of the present invention. Such information can include, workflow templates, services and service classes, semantic and syntactic requirements, test results, etc. Shown in memory 115 (e.g., as a computer program product) is the AI planner 120 , which is used to develop workflows consisting of components configured to satisfy a user goal, and one or more application(s) 160 , which represent the developed workflows, that can be executed by the end-user(s) 140 , for example. The application(s) 160 can also be stored in the storage system 150 .
[0068] It should be understood that the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or a combination thereof. In one embodiment, the present invention may be implemented in software as an application program tangibly embodied on a program storage device (e.g., magnetic floppy disk, RAM, CD ROM, DVD, ROM, and flash memory). The application program may be uploaded to, and executed by, a machine comprising any suitable architecture.
[0069] It is to be further understood that because some of the constituent system components and method steps depicted in the accompanying figures may be implemented in software, the actual connections between the system components (or the process steps) may differ depending on the manner in which the present invention is programmed. Given the teachings of the present invention provided herein, one of ordinary skill in the art will be able to contemplate these and similar implementations or configurations of the present invention.
[0070] It should also be understood that the above description is only representative of illustrative embodiments. For the convenience of the reader, the above description has focused on a representative sample of possible embodiments, a sample that is illustrative of the principles of the invention. The description has not attempted to exhaustively enumerate all possible variations. That alternative embodiments may not have been presented for a specific portion of the invention, or that further undescribed alternatives may be available for a portion, is not to be considered a disclaimer of those alternate embodiments. Other applications and embodiments can be implemented without departing from the spirit and scope of the present invention.
[0071] It is therefore intended, that the invention not be limited to the specifically described embodiments, because numerous permutations and combinations of the above and implementations involving non-inventive substitutions for the above can be created, but the invention is to be defined in accordance with the claims that follow. It can be appreciated that many of those undescribed embodiments are within the literal scope of the following claims, and that others are equivalent.
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A method, including: providing a computer menu from which a processing goal can be created, wherein the menu includes a plurality of facets, and wherein each facet includes at least one tag; receiving a processing goal, wherein the processing goal includes a plurality of tags selected from the menu; executing at least one application that includes a plurality of components arranged in a processing graph to produce information that satisfies the processing goal; and outputting the information.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to wet strength resin compositions and a method for making them.
2. Description of the Related Art
Polyamine-epichlorohydrin resins have been used as wet strength resins for paper since the early 1950's. These resins are cationic by virtue of the fact that they contain quaternary ammonium functionalities and are, therefore, substantive to negatively charged cellulose pulp fibers. These resins are particularly useful because they are formaldehyde-free and develop wet strength at neutral or alkaline pH values. The polyamine-epichlorohydrin resins are normally made by reacting epichlorohydrin and a polyamine such as ethylenediamine, triethylenetetramine, bis-hexamethylenetriamine, and amine still bottoms which is a mixture of polyamines containing from about 35% to about 70% by weight bis-hexamethylenetriamine. While the reaction is usually carried out in water, U.S. Pat. Nos. 3,894,944; 3,894,945; Re. No. 28, 807; 3,894,946, 3,894,947, disclose that a water soluble alcohol may be used in place of part of the water. However, these patents also disclose that it is generally preferred to use water alone for economic reasons. U.S. Pat. No. 2,595,935 discloses the use of a water miscible solvent such as ethanol. The use of simple alcohols such as methanol and ethanol as cosolvents has been found to be unacceptable when polyamine-epichlorohydrin resin solutions are used as wet strength resin compositions because these alcohols have low flash points and they remain in the final product. It would be desirable, therefore, to use an alcohol that has a flash point high enough for use in commercial paper making operations and one that is not a health and safety hazard to those who handle it or those who use products produced by wet strength formulations containing it.
SUMMARY OF THE INVENTION
The present invention provides a wet strength resin composition comprising from about 48 weight % to about 89 weight % water, from about 1.0 weight % to about 7.0 weight of at least one polyol, and from about 10 weight % to about 45 weight % of a polyamine-epichlorohydrin resin.
The present invention also provides a method of making a polyamine-epichlorohydrin resin comprising the steps of: (a) providing a water-polyol-polyamine solution; (b) adding to said solution epichlorohhydrin at a rate sufficient to maintain the temperature of said solution in a range of from about 5° C. to about 15° C. to form a reaction mixture having an E/N ratio of from about 1.0 to about 1.4; (c) maintaining the temperature of said reaction mixture in a range of from about 50° C. to about 80° C. until a 35% solids solution of said reaction mixture has a viscosity of at least about 70 cps; and (d) adjusting the pH of said reaction mixture to from about 2 to about 3 with an aqueous acid solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One aspect of the present invention provides a wet strength resin composition for increasing the wet strength of cellulosic webs comprising from about 48 weight % to about 89 weight % water, from about 1 0 weight % to about 7.0 weight % of at least one polyol, and from about 10 weight % to about 45 weight % of a polyamine-epichlorohydrin resin.
The wet strength resin composition of the present invention is made by the process disclosed herein where an amine-epichlorohydrin resin is made by reacting a polyamine and epichlorohydrin in an aqueous polyol solution. A polyamine is any amine that has at least two amine functionalities such as a simple diamine as ethylene diamine or more than two amine functionalities such as diethylene triamine, triethylenetetramine, and bis-hexamethylenetriamine and the like. Preferably, the polyamine is a mixture of polyamines known as amine still bottoms which is a mixture of polyamines containing from about 35% by weight to about 70% by weight bis-hexamethylenetriamine. It has been found that at least one polyol is a necessary component of the reaction because it performs the dual function of a cosolvent and a moderator of the cross-linking reaction. The polyol component of the wet strength composition can be any aliphatic compound having 2 or more hydroxyl functionalities that is miscible with water or combinations thereof. Examples of such polyols include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, diethylene glycol, dipropylene glycol, triethylene glycol, 1,6-hexylene glycol, glycerol, monosaccharides such as glucose or fructose, disaccharides such as sucrose, and polyvinyl alcohol. The preferred polyols are 1,2-propylene glycol and dipropylene glycol because they are generally recognized as safe, have flash points >200° C., and are good cosolvents for the amine-epichlorohydrin reaction. A preferred wet strength resin composition contains about 60.2% by weight water, about 4.8% by weight of 1,2-propylene glycol, and about 35% by weight of a polyamine-epichlorohydrin resin.
Another aspect of the present invention provides a process for making a polyamine-epichlorohydrin resin comprising the steps of: (a) providing a water-polyol-polyamine solution; (b) adding to said solution epichlorohhydrin at a rate sufficient to maintain the temperature of said solution in a range of from about 5° C. to about 15° C. to form a reaction mixture having an E/N ratio of from about 1 0 to about 1.4; (c) maintaining the temperature of said reaction mixture in a range of from about 50° C. to about 80° C. until a 35% solids solution of said reaction mixture has a viscosity of at least about 70 cps; and (d) adjusting the pH of said reaction mixture to from about 2 to about 3 with an aqueous acid solution. The process of the present invention is generally carried out by first preparing a water-polyol-polyamine solution containing from about 41 weight % to about 59 weight % water, from about 10 weight % to about 16 weight % of at least one polyol, from about 31 weight % to about 43 weight % polyamine. It is preferred that the polyamine be an aqueous solution containing about 50% by weight polyamine and having a total alkalinity of from about 33% to about 43%. The resulting water-polyol-polyamine solution is then mixed while cooling to 5° C. until it is a single phase. The epichlorohydrin is then added at a rate sufficient to maintain the temperature of the solution in a range of from about 5° C. to about 15° C., preferably 5° C. to about 10° C. to form a reaction mixture having an E/N ratio of from about 1.0 to about 1.4. The E/N ratio is defined as ##EQU1## The total alkalinity is the number of equivalents of HCl required to neutralize 1.0 gram of polyamine. The E/N ratio can vary from about 1.0 to about 1.4 and is preferably 1.15 to 1.4. The absolute amount of amine + epichlorohydrin can be from about 52% by weight to about 64% by weight of the reaction mixture with about 56%-59% by weight being the preferred amount. The reaction is allowed to proceed in a temperature range of from about 50° C. to about 80° C., preferably from about 60° C. to about 70 C, until a 35% solids solution has a viscosity of at least 70 cps (Brookfield, spindle #2@160 r.p.m., 25° C.) The 35% solids solution is formed by diluting the reaction mixture with water until the non-volatile solids reaches about 35% by weight. The reaction is then quenched by adding water to bring the total solids to about 35% and the pH is adjusted to about 2-3 by addition of aqueous acid preferably 31.5% aqueous HCl.
In a preferred embodiment, a water-polyol-polyamine solution is prepared containing about 141.9 grams of a 51.5% solids amine bottoms solution having a total alkalinity of 36.08%, 32.4 grams of water and 23.8 grams of 1,2-propylene glycol. The water-polyol-polyamine solution is placed in a reactor, mixed until uniform, and cooled to 5° C. A total of 99.7 grams of epichlorohydrin is then added at a rate sufficient to maintain the reaction temperature between 5-15° C. The E/N ratio is 1.18. After all the epichlorohydrin is added, the reaction mass is allowed to exotherm freely to 55° C. and held there until the viscosity at 35% solids solution reaches about 82 cps (Brookfield, spindle #2@160 r.p.m., 25° C). The reaction mass is then quenched by adding water and 31.5% aq. HCl. The pH and the solids of the reaction mass is then adjusted to 3.1 and 35% respectively. The composition has a flash point (PMCC) of > 200° F.
The following examples will serve to illustrate but not limit the invention.
EXAMPLE 1
Preparation of polyamine-epichlorohydrin resin-Water-Propylene Glycol Solvent
Added to a suitable reactor was 141.9 parts of an amine bottoms solution having a total alkalinity of 36.08% and a solids content of 51.5%. Also charged were 32.4 parts of water and 23.8 parts of propylene glycol. The contents of the reactor were mixed until uniform, cooled to 5° C., at which time the epichlorohydrin was added over a 12 hour period The temperature was controlled between 5°-15° C. during the addition of 81.8 parts of epichlorohydrin. During the last 18 minutes of the epichlorohydrin feed, the cooling was shut-off and 17.9 parts of epichlorohydrin was added. The reaction mass was allowed to exotherm freely to 55° C. The reaction mass was held at 55° C. until the viscosity at 35% solids was 82.5 cps. The reaction mass was quenched by adding water and 31.5% aq. HCl. The pH and the solids of the reaction mass was adjusted to 3.1 and 35% respectively. The flash point (PMCC) of the resin was >200° F.
EXAMPLE 2
Preparation of Polyamine-Epichlorohydrin Resin-Water-Propylene Glycol Solvent
Added to a suitable reactor was 141.9 parts of an amine bottoms solution having a total alkalinity of 34.84% and a solids content of 47.05%. Also charged were 29.9 parts of water and 24.7 parts of propylene glycol. The contents of the reactor were mixed until uniform. The contents of the reactor were cooled to 5° C. at which time the epichlorohdyrin was added over a 12 hour period. The temperature was controlled between 5°-15° C. during the addition of 92.25 parts of epichlorohydrin. During the last 18 minutes of the epichlorohydrin feed, the cooling was shut-off and 20.25 parts of epichlorohydrin was added. The reaction mass was allowed to exotherm freely to 60° C. The reaction mass was held at 60°-65° C. until the viscosity at 35% solids was 85 cps. The reaction mass was quenched by adding water and 31.5 aq. HCl. The pH and the solids of the reaction mass was adjusted to 2.9 and 37% respectively. The flash point (PMCC) of the resin was >200° F.
EXAMPLE 3
Preparation of Polyamine-Epichlorohydrin Resin-Water-Ethylene Glycol Solvent
Added to a reactor was 121.7 parts of an amine bottoms solution having a total alkalinity of 35.62% and a solids contents of 45.1%. Also charged were 10.6 parts of water and 23.4 parts of ethylene glycol. The contents of the reactor were mixed until uniform while cooling to 6.5° C. 84.3 parts of epichlorohydrin was added over 55 minutes while maintaining the temperature between 5°-15° C. Once all the epichlorohydrin was added, the reaction mass was allowed to exotherm to 80° C. The reaction mass was held at 80° C. until the viscosity at 35% solids reached 105 cps. The reaction mass was quenched by adding water and 31.5% aq. HCl. The pH and the solids of the reaction mass was adjusted to 3.0 and 37.6% respectively.
EXAMPLE 4
Preparation of Polyamine-Epichlorohydrin Resin-Water-Hexylene Glycol Solvent
Added to a reactor was 116 parts of an amine bottoms solution having a total alkalinity of 35.62% and a solids content of 50.7%. Also charged were 23.1 parts of water and 20.5 parts of hexylene glycol. The contents of the reactor were mixed until uniform while cooling to 5° C. 80.4 parts of epichlorohydrin was added over 75 minutes while maintaining the temperature between 5°-15° C. Once all the epichlorohydrin was added, the reaction mass was allowed to exotherm to 80° C. The reaction mass was held at 80° C. until the viscosity at 35% solids reached 78 cps. The reaction mass was quenched with water and 31.5% aq HCl. The pH and the solids of the reaction mass was adjusted to 3.0 and 33.5% respectively.
COMPARATIVE EXAMPLE A
This example shows that without the aid of a glycol cosolvent, the reaction mass reacts uncontrollably to yield a water insoluble cross-linked gel.
Preparation of Polyamine-Epichlorohydrin Resin-Water Solvent
Added to a suitable reactor were 80 parts of amine bottoms concentrate and 119 parts of water. The contents of the reactor were mixed together. The % solids and % total alkalinity of the solution was determined as 34.1 and 29.2 respectively. The reaction mass was cooled at 2° C., at which time the epichlorohydrin feed was started 113 parts of epichlorohydrin was added over a 8.25 hour period while maintaining a temperature of 2°-15° C. Once the epichlorohydrin addition was complete, the cooling was shut-off and the reaction mass freely exothermed to 70° at which point the reaction mass instantly gelled in the reactor.
COMPARATIVE EXAMPLE B
This example shows that a wet strength resin composition comparable to those of Examples 1 and 2 but which contains methanol in place of a glycol has an unacceptable flash point.
Preparation of Polyamine-Epichlorohydrin Resin-Water-Methanol Solvent
Added to a suitable reactor were 80 parts of amine bottoms concentrate, 114.5 parts of water and 33.5 parts of methanol. The contents of the reactor were mixed to form a uniform solution. The % solids and % total alkalinity of the solution was determined as 34.7 and 28.5 respectively. The reaction mass was cooled at 0° C., at which time the epichlorohydrin feed was started. 126 parts of epichlorohydrin was added over a 7.5 hour period while maintaining a temperature of 0°-15° C. Once the epichlorohydrin addition was complete, the cooling was shut-off and the reaction mass freely exothermed to 70°. The reaction mass was held at 70° C. until the viscosity at 35% solids reached 118 cps. The reaction mass was quenched by adding water and concentrated HCl. The pH and solids of the reaction mass was adjusted to 2.8 and 35% respectively. The flash point (PMCC) of the resin was 150° F.
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An amine-epichlorohydrin resin is prepared in a water-polyol solvent in order to facilitate the polymerization and crosslinking reactions. The reaction product is useful as a wet strength resin composition which has a flash point high enough to be used in commercial paper making operations.
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BACKGROUND OF THE INVENTION
This invention relates to smoking articles such as cigarettes, and in particular to smoking articles having filter elements attached thereto.
Popular smoking articles such as cigarettes have a substantially rod shaped structure and include a smokable material such as strands of tobacco surrounded by a wrapping material such as paper thereby forming a tobacco rod. It has been desirable to provide cigarettes having cylindrical filters positioned at one end thereof. Typically, filters are constructed from fibrous materials such as cellulose acetate and are attached to the tobacco rod using tipping material.
Known cigarette filter elements generally have a white color, and upon use of the cigarette such filter elements can undergo a noticeable discoloration. In particular, cigarettes having filter elements which resemble hollow tubes (e.g., as proposed in U.S. Pat. No. 3,703,429, West German Pat. No. 2,107,850, and Japanese Patent Application No. 59-196,082) can undergo an unsightly discoloration within the visible inner region of the tube.
In view of the fact that conventional cigarette filter elements tend to exhibit unsightly discoloration during use of cigarettes containing such elements, it would be highly desirable to provide a cigarette filter region which exhibits a low amount of visible discoloration upon use.
SUMMARY OF THE INVENTION
This invention relates to a filter cigarette having in combination a cylindrical rod of smokable material, a cylindrical filter element having a front face and a back face and axially aligned in an end-to-end relationship with the rod such the front face of the filter element is adjacent one end of the rod, and a cylindrical mouthpiece element having a substantially tubular shape and axially aligned in an end-to-end relationship with the filter element. During draw on the cigarette, air and smoke entering the filter element from the rod exits the opposite end of the filter element. The filter element includes a path of least resistance therethrough such that air and smoke exits the filter element at the back face thereof and in a region towards the periphery thereof. The mouthpiece element has a longitudinally extending hollow region and a circumscribing wall having a thickness such that the wall is axially aligned with the region where smoke and air exits the filter element. The mouthpiece element and the filter element are positioned in a spaced apart relationship such that substantial amounts of air and smoke exiting the back face of the filter element travels through the hollow region of the mouthpiece element.
The filter region of a cigarette of this invention exhibits a low amount of visible staining (i.e., in a region capable of being viewed by the consumer) when the cigarette is used. Additionally, the cigarettes exhibit the desirable properties of a filter cigarette. When the air and smoke from the tobacco rod exits the peripheral region of the filter element, substantial amounts thereof follow the path of least resistance provided by the spaced apart configuration of each of the filter element and the mouthpiece elements. Thus, substantial amounts of air and smoke travel through the hollow region of the mouthpiece element thereby providing less staining of the visible region of the filter and mouthpiece than if the two elements are positioned in an abutting relationship. As a result, the visible filter region of a cigarette of this invention substantially maintains its characteristic color and appearance during use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic cross sectional illustration of a cigarette showing the rod of smokable material, the filter element having a barrier region and the second tubular shaped element at the mouthend portion of the cigarette.
DETAILED DESCRIPTION OF THE EMBODIMENTS
An embodiment of this invention shown in FIG. 1 is a smoking article 3 in the form of a cigarette including a generally cylindrical rod 6 of smokable material 9 contained in wrapping material 12. Cylindrical rod 6 will be referred to as a "tobacco rod." Typically, the smokable material is a charge of cured or processed tobacco, reconstituted tobacco, tobacco substitute, or blend thereof; and is provided as conventionally employed in the manufacture of cigarettes (i.e., as strands of material provided at about 32 cuts per inch and treated with flavorants and humectants). Typically, the wrapping material is a conventional cigarette wrapping paper. The wrapping material has a tubular shape so as to contain the smokable material. The size of the tobacco rod can vary, and typically ranges from about 55 mm to about 85 mm in length, and from about 20 mm to about 26 mm in circumference.
The smoking article further includes first mouthend element in the form of filter element 15 positioned adjacent to one end of the tobacco rod such that the filter element is axially aligned with the tobacco rod in an end-to-end relation. Filter element 15 has a substantially cylindrical shape, and the diameter thereof is substantially equal to that of the tobacco rod. Preferably the filter element substantially abuts the tobacco rod. For example, the front face 16 of the filter element can substantially abut the tobacco rod. The ends of the filter element permit the passage of air and smoke therethrough.
The filter element includes filter material 18 which is provided from fibrous material such as cellulose acetate or the like, and an overwrap of circumscribing wrap 21 such as air permeable (i.e., porous) paper plug wrap or substantially air impermeable (i.e., nonporous) paper plug wrap. The length of the filter element can vary, and typically ranges from about 10 mm to about 30 mm.
The filter element includes substantially smoke impervious region 24 (i.e., a barrier region) positioned near the central portion (with respect to the cross section) of the filter element and near the end of the filter element opposite that end adjacent to the tobacco rod (i.e., near the back face 25 of the filter element). Typically, the substantially smoke impervious region extends longitudinally along filter element in amount ranging from the total length of the filter element to as little as a film on the back face 25 thereof. Typically, the substantially smoke impervious region 24 covers from about 25 percent to about 50 percent of that cross sectional area of the filter element. Preferably, the substantially smoke impervious region covers the portion of the cross section of the filter element near the central region of the cross sectional area or portion of the back face of the filter element. Additionally, the barrier region preferably forms a substantially circular shape on the back face of the filter element (i.e., as would be viewed from the end of the smoking article along the longitudinal axis thereof).
The barrier region is provided by any material which can produce a substantially smoke impervious or impermeable region when positioned in contact with the filter material 18. For example, the material forming the barrier region can be an adhesive such as a water based polyvinylacetate adhesive, a hot melt adhesive such as a mixture of paraffin wax, a polyterpene and an ethylene vinylacetate resin, or other such adhesives. Such glues can be applied to the desired region on the back face 25 of the filter element 15 thereby providing impervious region 24 which is essentially positioned on the back face of the filter element. Alternatively, the barrier region can be formed from a material which dries to form a substantially smoke impervious film. For example, a mixture of cellulose acetate and acetone, or a variety of the "dopes" described in U.S. Pat. No. 3,930,077 to Levers et al can be applied to the back face of the filter element and allowed to dry to form an air impermeable barrier. Generally, any material which can adhere to or be compatible with the filter material 18 while providing the desired barrier to smoke permeability can be employed as a barrier material. Most desirably, the barrier material exhibits a color which very nearly approximates that of the first filter material (e.g., a white color).
If desired, the barrier region can be provided by a molded material such as air impermeable polypropylene, polystyrene, or the like. If desired the air impermeable material can be employed as a closed cell foam. For example, the molded material can be positioned within the filter element in order that the air and smoke passing through the filter material passes around the molded material. If desired the molded material can be in the form of a substantially air impermeable cylinder which extends over the longitudinal length of the filter element thereby providing for passage of air and smoke through the filter element in the smoke and air permeable region 33 towards the periphery of the filter element.
The barrier region is positioned such that the air and smoke traveling through the smoking article from the lit end 27 to the mouthend 30 is channeled away from smoke impervious region 24 and through smoke and air permeable region 33 near the periphery of the filter element. In particular, the air and smoke traveling through the first filter material follows the desired path of least resistance therethrough.
The smoking article further includes second element (i.e., mouthpiece element) 34 positioned adjacent to the output end (i.e., back face) of the first filter element such that the filter element 15 and the mouthpiece element are aligned in an end-to-end relation. Mouthpiece element 34 has a substantially cylindrical shape, and the diameter thereof is substantially equal to that of the tobacco rod. The mouthpiece element includes a hollow region 36 which extends along the longitudinal length thereof, thereby providing a tube-like shape thereto. The hollow region is most preferably positioned with respect to the cross section of the filter element so as to be near the central region of the cross sectional area. The hollow region most preferably has a circular cross sectional shape.
The second element or mouthpiece element 34 conveniently is provided from a fibrous material such as cellulose acetate, or the like, and an overwrap of circumscribing wrap 21. Preferably, both the first filter element and second mouthpiece element share a common wrap. Most desirably, the mouthpiece element exhibits a color which very nearly approximates that of the first filter material and the barrier material providing the barrier region. Preferably, the mouthpiece element can be provided by severing tubular rods which are manufactured as described in U.S. Pat. No. 3,095,343 to Berger.
The cross sectional area covered by the hollow region 36 relative to the total cross sectional area of the second mouthpiece element can vary. Typically the cross sectional area of the hollow area ranges from about 25 to about 50 percent of the total cross sectional area of the mouthpiece element. The thickness of the wall (i.e., the thickness of the outer most portion of the mouthpiece element surrounding the hollow region) can vary and is preferably thick enough to expose only barrier region of the filter element when the cigarette is viewed end-on. The length of the mouthpiece element can vary, and typically ranges from about 5 mm to 15 mm.
The filter element and mouthpiece element are positioned in a spaced apart relationship and attached to rod 6 by tipping material 39 which circumscribes each of the mouthpiece element 34, the airspace 42, the filter element 15, and an adjacent region of the rod. The inner surface of the tipping material is fixedly secured to the outer surface of the wrap 21 (which preferably circumscribes the mouthpiece element, the airspace and the filter material) and to the outer surface of the wrap 12 of the rod. The tipping material circumscribes the rod over a longitudinal length which can vary but is typically that length sufficient to provide good attachment of the filter region to the rod. Typically, the tipping material is either a conventional air permeable tipping material or a conventional substantially air impermeable tipping material such as tipping paper. If desired, openings such as slits, holes, or perforations in the substantially air impermeable tipping material (and underlying wrap) can provide a means for air dilution of the cigarette.
Smoke and air leaving the back face 25 of the filter element 15 is desirably routed in a pathway through the hollow center region 36 of mouthpiece element 34. A particularly convenient means for routing the smoke and air through the aforementioned hollow center region is to provide airspace 42 between the output end of the filter element and the foremost portion of the mouthpiece element. The airspace is most conveniently provided by spacing the adjacent elements apart from one another in a spaced apart relationship. Generally, the airspace extends a distance longitudinally along the smoking article over that distance sufficient for the air and smoke passing through the filter region to pass from the peripheral region of the first filter element to the hollow center region of the mouthpiece element. Preferably, the airspace extends from about 1 mm to about 10 mm, more preferably from about 1 to about 3 mm along the longitudinal length of the smoking article.
Typical pressure drop values for cigarettes of this invention are comparable to conventional cigarettes. For example, it is most desirable to employ a filter element, barrier region and mouthpiece element such that the pressure drop of the resulting cigarette ranges from about 75 mm to about 200 mm of water pressure drop at 17.5 ml/sec of air flow rate using a pressure drop tester sold commercially as Model No. FTS-300 by Filtrona Corporation.
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Filter cigarettes exhibiting a low amount of visible staining have a tobacco rod, an axially aligned filter element having a barrier region positioned on the back face thereof such that air and smoke traveling through the filter element exits the filter element towards the periphery thereof, and an axially aligned tubular mouthpiece element positioned in a spaced apart relationship with the filter element such that air and smoke exiting the filter element travels through the path of least resistance provided by the spaced apart region and the hollow region of the tube.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for effecting chemical reactions in the presence of fluidized solids. The apparatus includes at least one centrifugal separator of the cyclone type for removing entrained solids from effluent gas and vapors, a conduit or dip-leg for returning separated solid particles from the cyclone to the fluidized system, and a unidirectional valve positioned at the lower end of the dip-leg. More particularly, the invention relates to an improved apparatus which reduces erosion damage to the unidirectional valve by the fluidized solids.
2. Description of the Prior Art
Systems wherein a chemical reaction is carried out in the presence of fluidized finely divided solid particles are well known and have found wide acceptance in a variety of fields. A particularly important application involves the conversion of various feedstocks by contact with fluidized finely divided catalyst particles as, for example, in the fluidized catalytic cracking of hydrocarbon feedstocks. Alternatively, the fluidized solid particles may themselves comprise a reactant as in the fluidized combustion of finely divided particles of coke or coal. In addition, the fluidized particles can be substantially inert and serve merely as a heat transfer medium and/or a substrate upon which reaction products may deposit.
A bed of fluidized solids is produced by the upward passage of a fluidizing gas through a bed of finely divided solid particles. The upward flow of gas through the solid particles exerts an upward or suspending force on the particles and serves to lift and agitate the particles. In a vessel containing a fluidized bed of solids, the lower portion of the vessel will contain a phase of high particle density having a fairly well defined upper surface. This lower dense phase behaves in many respects like a liquid. A dilute phase or disengaging space is located above the dense phase wherein the particle density is low and a separation of solid particles from the fluidizing gas is largely completed. Particle fluidization comprises a highly effective gas-solid contacting process. The particles are maintained in a suspended, turbulent state by the fluidizing gas and migrate more or less freely to all portions of the dense bed.
Ordinarily, it is desirable to separate effluent gases from solid particles as completely as possible prior to the discharge of these gases from a vessel which contains a fluidized bed. A substantial separation of gases and solids occurs within the vessel, but small amounts of solids are entrained by the fluidizing gases, are carried into the dilute phase, and are discharged together with the gases if additional separation means are not provided. Centrifugal separators of the cyclone type have been widely used to provide such additional separation.
A cyclone separator functions by allowing the particle laden gases to enter a cylindrical or conical chamber tangentially at one or more points, and the gases are discharged through a central opening. The solid particles are forced to the walls of the separator as a consequence of centrifugal acceleration and are led to a particle return conduit or dip-leg for return to the vessel. Frequently, the dip-leg extends into the lower dense phase but can also terminate in the upper dilute phase. If necessary, improved efficiency can be achieved by passing the particle laden gases through two or more cyclone separators which are joined in series.
A unidirectional valve is frequently positioned either within the dip-leg or at its lower end. This valve serves to permit the flow of separated solids from the cyclone while preventing a reverse flow of gases and solids into the cyclone from the dip-leg. A trickle valve is a widely used unidirectional valve comprising a pivotally mounted valve closure means at the end of the dip-leg which is exposed to the fluidized solids. This exposure to the fluidized solids subjects the valve to erosion as a consequence of mechanical action by the solid particles. After a period of time, this erosion damage may be severe enough to result in a complete failure of the valve. Such failure permits a significant flow of gases and solid particles up the cyclone dip-leg. This reverse flow of solids into the cyclone will, in turn, result in an increased discharge of particulate material with the effluent gases from the cyclone. If these effluent gases are discharged directly into the atmosphere, the additional particulate content is environmentally undesirable. If, instead, the effluent gases are discharged into associated process equipment for further treatment or separation, the increased particulate content is undesirable because of its erosive effect on the gas transfer lines and the need for removal of the solids during the subsequent processing steps. In addition, when the fluidized solid is a catalyst, the loss of such solid can be undesirable for the additional reason that such catalytic materials are frequently quite costly.
U.S. Pat. No. 2,838,063 has suggested that trickle valves be shielded from below. In addition, U.S. Pat. Nos. 2,838,062 and 2,901,331 teach the use of a perforated tubular shroud or housing which encloses the trickle valve on both top and bottom. The prior art does not, however, suggest the desirability of placing a conical shroud above the trickle valve to provide protection from the downward impingement of solid particles.
SUMMARY OF THE INVENTION
This invention is directed to an improved apparatus for carrying out a chemical reaction in the presence of fluidized solids comprising a vessel adapted to contain a dense phase of fluidized solid particles in its lower portion and a dilute phase in the upper portion, inlet means for introducing fluidizing gas into the lower portion of said vessel, outlet means for removing product vapors from the upper portions of said vessel, at least one centrifugal gas-solids separator in association with said outlet means and adapted to remove solid particles from said product vapors, a conduit in association with said separator for returning separated solid particles downward into said vessel, and a unidirectional valve means positioned at the end of said conduit which comprises a pivotally mounted valve closur means having said pivotal mounting attached to the exterior of said conduit. The improvement of the present invention comprises a conical body surrounding and attached to the lower end of the conduit with its base directed downward, wherein said conical body extends laterally at its base a distance from the conduit wall which is further than a vertical line passing through any portion of the pivotal mounting or valve closure means when in a closed position.
The conical body or shroud of this invention serves to protect the valve means from erosion by downward moving fluidized solid particles. Accordingly, it is an object of this invention to provide a pivotally mounted valve closure means which is resistant to erosion by fluidized solids. Other objects, aspects and advantages of the invention will be readily apparent from the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawings is a schematic representation of a fluidized catalytic cracking process employing the improvement of the present invention.
FIG. 2 of the drawings is a detail of a trickle valve and the conical shroud of the present invention.
FIG. 3 of the drawings is another view of the trickle valve and the conical shroud of this invention shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered that erosion damage to a trickle valve by fluidized solid particles can be primarily the result of impingement by particles which have a downward vector to their motion. According to the present invention, erosion damage to a trickle valve can be reduced by placing a conical shroud above the trickle valve. The conical shroud has its base directed downward and forms an angle with the wall of the dip-leg which is less than about 50°. Preferably, this angle is about 45°. The conical shape of the shroud serves to protect the trickle valve from erosion caused by particles which are moving downward at an angle as well as from particles which are moving vertically downward. In addition, it is believed that erosion of the shroud is minimized when the shroud forms an angle with the dip-leg of about 45°.
Desirably, the conical shroud of this invention is not perforated. With this preferred embodiment, surprisingly, a region of stagnent or poorly fluidized solids does not form under the nonperforated shroud and impair the operation of the trickle valve when immersed in a dense bed of fluidized particles. In addition, the collection of fluidizing gases under the nonperforated shroud does not hinder the operation of the trickle valve and, indeed, is believed to assist in preventing erosion damage to the trickle valve by upward moving solid particles. Although the mechanism of such assistance is unclear, it is believed that the shroud and trapped gases serve to create a region of turbulent fluidization below the shroud and around the trickle valve wherein solid particles having an upward motion are redirected laterally away from the trickle valve.
Although the conical shroud of this invention can have the shape of a general cone, it desirably has the shape of a circular cone and preferably of a right circular cone. When the shroud has the shape of a right circular cone, it is desirably coaxial with the dip-leg which it surrounds and to which it is attached.
The conical shroud of this invention extends laterally at its base a distance from the dip-leg wall which is further than a vertical line passing through any portion of the pivotal mounting or valve closure means when in a closed position. The largest cross sectional dimension or diameter of the shroud at its base is desirably from about 2 to about 5 times the largest cross sectional dimension or diameter of the dip-leg to which it is attached. In those embodiments wherein the dip-leg has a circular cross section and the shroud has the shape of a circular cone, the shroud has a diameter at its base which is from about 2 to about 5 times that of the dip-leg cross section.
The base of the conical shroud of this invention is located near the end of the dip-leg, and its base may be located either above or below the pivotally mounted valve closure means and its pivotal mounting or at intermediate positions. In that embodiment wherein the base of the shroud is below the valve closure means and its pivotal mounting, the trickle valve is completely protected from impingement by particles which have any downward vector to their motion. In a preferred embodiment, the base of the shroud is located above the pivotally mounted valve closure means by a distance which is less than about the largest cross sectional dimension or diameter of the shroud at its base. More preferably, this distance above the valve closure means is less than about one half of the largest cross sectional dimension or diameter of the shroud at its base.
The conical shroud of this invention is particularly useful for protecting trickle valves which are used in the reactor vessel of a system for the fluid catalytic cracking of hydrocarbons wherein a transfer line extends into the reactor vessel and discharges catalyst particles and cracked hydrocarbon products downwardly into said vessel from a position above the trickle valves. In such an embodiment, the shroud is desirably constructed of a heat resistant metal, for example carbon steel or stainless steel, and is desirably coated with refractory.
The invention can best be understood by reference to the preferred embodiment depicted in the attached drawings. It will be understood, however, that the invention is not limited to the embodiment shown, and that the invention includes alternatives, modifications and equivalents which are within the scope of the appended claims.
FIG. 1 of the attached drawings is illustrative of the use of this invention in the fluid catalytic cracking of hydrocarbons. A hydrocarbon feedstock from line 1 is contacted with hot regenerated catalyst from standpipe 2 in the inlet portion of transfer line 3. The resulting mixture of catalyst and hydrocarbon vapor passes upward through transfer line 3 and into reactor vessel 4. Transfer line 3 terminates in a downward directed discharge head 5. The upper surface 6 of the dense phase of catalyst particles is generally maintained below discharge head 5, thereby allowing cracked hydrocarbon products to disengage from the catalyst particles without substantial contact with the dense phase. However, if desired, the location of catalyst phase interface 6 may be varied from a position below discharge head 5 to a position above discharge head 5. In the latter case, increased conversion of the hydrocarbon feedstock will occur as a consequence of additional cracking taking place in the dense bed of catalyst in reactor vessel 4.
Vapors and entrained catalyst particles passing upward through reactor vessel 4 enter primary cyclone separator 7. Most of the entrained catalyst particles are separated in the first stage cyclone 7 and are discharged downwardly through dip-leg 8, through trickle valve 9, and into the dense phase bed. Conical shroud 10 is attached to dip-leg 8 near its lower end and above trickle valve 9. Gases and remaining catalyst particles are passed through interstage cyclone line 11 to second stage cyclone separator 12 where substantially all of the remaining catalyst is separated and passed downwardly through dip-leg 13, through trickle valve 14, and into the dense phase bed. Conical shroud 15 is attached to dip-leg 13 near its lower end and above trickle valve 14.
Conical shrouds 10 and 15 serve to protect trickle valves 9 and 14 from the erosive effect of fluidized catalyst particles and, in particular, those which are downwardly directed by distributor head 5. If desired, the location of catalyst phase interface 6 may be varied from above trickle valves 9 and 14 to a position below trickle valves 9 and 14. The surface of conical shrouds 10 and 15 is desirably covered by a refractory coating so as to protect the shrouds from erosion by catalyst particles.
Effluent vapors pass from cyclone 12, through line 16, into plenum chamber 17, and are discharged from the reactor vessel 4 through line 18. Vapor line 18 conveys the hydrocarbon vapors to a fractionation zone, not shown, wherein the vapors are separated into product fractions by methods well known in the art.
Catalyst particles from the dense phase in the lower portion of the reactor vessel 4 pass downwardly into stripping zone 19. Baffles 20 are situated in stripping zone 19, and steam from line 21 is discharged through steam ring 22 into the lower portion of stripping zone 19. Steam rising through the stripping zone 19 removes volatile hydrocarbons from the catalyst particles and serves to fluidize the catalyst in the stripping zone 19 and in the dense phase of reactor vessel 4.
Stripped spent catalyst is withdrawn from the bottom of stripping zone 19 through spent catalyst standpipe 23 at a rate controlled by valve 24, and discharges through standpipe 25 into spent catalyst transfer line 26. Spent catalyst from standpipe 25 is fluidized with air from line 27 and passes upwardly through transfer line 26 and into regenerator vessel 28. Transfer line 26 terminates in a downwardly directed discharge head 29, and effluent from transfer line 26 is discharged below the surface 30 of the dense phase of fluidized catalyst particles in regenerator vessel 28. Catalyst within the regenerator vessel 28 is fluidized by the flow of combustion air through line 31 to air ring 32, whereupon coke on the spent catalyst is burned and the catalytic activity of the spent catalyst is restored. Combustion gases continuously pass upwardly from the dense phase and into the dilute phase above the catalyst phase interface 30. These combustion gases together with entrained catalyst enter primary cyclone separator 33. Most of the entrained catalyst particles are separated in the first stage cyclone 33 and are discharged downwardly through dip-leg 34, through trickle valve 35, and into the dense phase. Combustion gases and remaining catalyst particles are passed through interstage cyclone line 36 to second stage cyclone separator 37 where substantially all of the remaining catalyst is separated and passed downwardly through dip-leg 38, through trickle valve 39, and into the dense phase. If desired, trickle valves 35 and 39 can be protected from erosion damage with a conical shroud in the same manner as trickle valves 9 and 14. Effluent gases from cyclone separator 37 pass through line 40, into plenum 41, and are discharged from regenerator vessel 28 through line 42. Effluent combustion gases from line 42 can be discharged directly to the atmosphere or, alternatively, can be passed through conventional heat exchange means prior to such discharge into the atmosphere.
Regenerated catalyst is withdrawn from the bottom of regenerator vessel 28 through line 43 at a rate controlled by valve 44 to supply hot regenerated catalyst to standpipe 2 as described above.
FIGS. 2 and 3 of the attached drawings illustrate a preferred embodiment of the invention. Solid particles separated by a cyclone separator are conveyed downward from the cyclone through dip-leg 101. At the end of dip-leg 101, these solid particles encounter a trickle valve. The trickle valve comprises conduit 102 which is attached to the lower end of dip-leg 101 and at an angle to the dip-leg 101. The T-shaped bracket 103 is attached to the outer surface of dip-leg 101, and the head of said T-shaped bracket 103 is a flat bar which is spaced somewhat from the dig-leg. The head of said T-shaped bracket 103 contains two circular openings 104 and 105 through which circular hinges 106 and 107 are inserted. Circular hinges 106 and 107 are constructed of rod having a diameter appreciably smaller than the diameter of openings 104 and 105 so that the hinges 106 and 107 can move freely through the openings 104 and 105. A flat valve plate 108 is supported by hinges 106 and 107, with the circular hinges passing through respective circular openings 109 and 110. Circular hinges 106 and 107 are constructed of rod having a diameter appreciably smaller than the diameter of openings 109 and 110 so that the hinges 106 and 107 may move freely through the openings 109 and 110. Valve plate 108 seats against valve seat 111 which comprises the edge surface of discharge opening 112. The pivotal mounting of valve plate 108 by hinges 106 and 107 permits facile valve operation. The plane of valve seat 111 is oriented at a slight angle from vertical so that valve plate 108 is normally in a closed position as a consequence of the action of gravity. Valve plate 108 will remain closed until the amount of solids accumulated in dip-leg 101 exerts a sufficient downward force to rotate valve plate 108 from a closed position and permit the discharge of these solids through discharge opening 112. Stop 113 serves as a control to limit the extent by which valve plate 108 can rotate open on hinges 106 and 107. Conical body or shroud 114 surrounds and is attached to dip-leg 101 near the lower end of said dip-leg 101 with its base above valve plate 108.
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An apparatus for effecting chemical reactions in the presence of fluidized solids comprising at least one centrifugal separator for removing entrained solids from effluent gas, a dip-leg depending from the separator for returning separated solids to the fluidized system, and a unidirectional valve at the lower end of the dip-leg which is protected from erosion damage by a conical shroud.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/408,154, filed Sep. 3, 2002, entitled “A Method to Grow [100] Oriented CaF 2 Single Crystals” and from U.S. Provisional Application Ser. No. 60/408,116, filed Sep. 3, 2002, entitled “A Method to Grow [110] Oriented CaF 2 Single Crystals.”
BACKGROUND OF INVENTION
[0002] Microlithography is used in semiconductor manufacturing to define patterns on integrated circuits. A microlithography system includes an illumination system and a projection system. The illumination system typically includes an excimer laser, which is used to irradiate a mask containing a circuit pattern. The projection system typically includes several projection lenses with highly complex objectives for imaging the circuit pattern onto a wafer. The smallest feature size, F, that can be imaged is determined by the following expression:
F = k 1 λ N A ( 1 )
[0003] where k 1 is a process-dependent parameter, typically having a value of 0.5, λ is the illumination wavelength, and NA is the numerical aperture of the objective. From equation (1), the resolution of the microlithography system, i.e., the smallest feature size that can be imaged, can be increased by decreasing the illumination wavelength, λ, and/or increasing the numerical aperture, NA. However, because the depth of focus decreases as numerical aperture increases, it is usually easier to increase resolution by decreasing illumination wavelength.
[0004] The industry presently uses 248-nm microlithography systems to image feature sizes larger than 0.25 μm and is preparing to transition to 193-nm microlithography systems that can image feature sizes 0.25 μm and smaller. The industry is also actively developing 157-nm microlithography systems to image feature sizes as small as 100 nm. Successful transition to the 193-nm systems and development of the 157-nm systems depend on the availability of lens materials with high transparency at these wavelengths as well as low birefringence, low residual index inhomogeneity, low anisotropy, and ability to withstand prolonged irradiation without changes in optical properties. Unfortunately, there are not many lens materials that meet these requirements at wavelengths below 200 nm. Fused silica, which is used as lens material in the 248-nm microlithography system, can be used in 193-nm microlithography, although the safety margin for absorption at this wavelength is very small. Fused silica is not transparent enough to be used in 157-nm microlithography.
[0005] Up to date, calcium fluoride (CaF 2 ) single crystal is the most viable lens material for 157-nm microlithography. CaF 2 has high transparency at this wavelength and the ability to withstand prolonged irradiation at this wavelength without its optical properties changing. As a cubic crystalline material, a CaF 2 single crystal is generally presumed to be isotropic and non-birefringent. However, recent findings indicate that a CaF 2 single crystal has anisotropic, birefringent behavior at short wavelengths because of symmetry-breaking. According to Burnett et al., intrinsic birefringence in CaF 2 single crystal at 157 nm is 11.2±0.4 nm/cm in the [110] direction, which is more than ten times the 1 nm/cm target birefringence for 157-nm microlithography. (Burnett, John. H., Levine, Zachary. H., & Shirley, Eric. L. “Intrinsic Birefringence in Crystalline Optical Materials: A New Concern for Lithography.” Future FAB International 12 (2002): 150-154.) Fortunately, intrinsic birefringence has symmetry and specific orientations with respect to the crystallographic orientations, which can be exploited to achieve birefringence reduction. For example, intrinsic birefringence can be compensated for in lens design by combining and clocking [111]- and [100]-oriented CaF 2 single crystal lens elements. (Dana, Stephane. “Progress Report: 157-nm Lithography Prepares to Graduate.” OE Magazine Feb. 2003: 12-14.) Intrinsic birefringence may also be compensated for in lens design by combining and clocking [100]- and [110]-oriented CaF 2 single crystal lens elements.
[0006] From the foregoing, it is obvious that high-quality [111]-, [110]-, and [100]-oriented CaF 2 single crystals are needed to enable flexibility in microlithography lens design. [111]-oriented CaF 2 single crystals are readily available and are commonly grown using the Bridgman-Stockbarger process. The process involves a crucible containing CaF 2 feedstock in a hot zone in a two-zone vertical furnace. A [111]-oriented seed crystal is mounted in a seed crystal holder at the bottom of the crucible with the upper portion of the seed crystal in contact with the feedstock. The crucible is heated to melt the feedstock. The crucible is then slowly lowered into a cold zone in the vertical furnace, the cold zone being at a lower temperature than the hot zone. As the crucible moves into the cold zone, the molten fluoride passes through a temperature gradient zone. A crystal front conforming to the crystallographic orientation of the seed crystal is created as the temperature of the molten fluoride drops below the melting point. The crystal propagates inside the crucible, within the molten fluoride, as long as the crucible continues to move downwardly into the cold zone. The crystal is usually annealed once the crucible is fully in the cold zone and/or post-annealed in a separate furnace to reduce stress-induced birefringence to an acceptable level.
[0007] Due to difficulty and low yield of [110]- and [100]-oriented CaF 2 single crystal growth, [110]- and [100]-oriented CaF 2 single crystals are usually made by cutting them out of [111]-oriented CaF 2 single crystals. This method of making [110]- and [100]-oriented CaF 2 single crystals is not only inefficient but also greatly limits the size of the [110]- and [100]-oriented lens elements that can be obtained and increases the cost of production. Another challenge for the [110]- and [100]-oriented CaF 2 single crystal growth is high stress-induced birefringence. Due to a higher stress optical coefficient in the [110] and [100] directions, [110]- and [100]-oriented CaF 2 single crystals are expected to yield a higher stress-induced birefringence. (Burnett, J. H., Levine, Z. H., & Shirley, E. L. Intrinsic Birefringence in Calcium Fluoride and Barium Fluoride. Physical Review B 64, 241102 (2001).) It would be beneficial to have the average stress-induced birefringence of [110]- and [100]-oriented CaF 2 single crystals be as low as that of the [111]-oriented CaF 2 single crystals. [111]-oriented CaF 2 single crystals with average stress-induced birefringence better than 1 nm/cm are now available.
[0008] From the foregoing, there is desired a method of economically growing CaF 2 single crystals along the [110] and [100] directions, respectively, the grown crystals preferably having stress-induced birefringence sufficiently low to allow their usage in making optical elements for 157-nm microlithography process.
BRIEF SUMMARY OF INVENTION
[0009] In one aspect, the invention relates to a method of making oriented calcium fluoride single crystal which comprises loading calcium fluoride feedstock on top of a seed crystal having a specific crystallographic orientation, heating the calcium fluoride feedstock to a temperature sufficient to form a melt, and growing a calcium fluoride crystal on the seed crystal by progressively moving the melt and the seed crystal through a temperature gradient zone having an axial temperature gradient in a range from approximately 2° C./cm to approximately 8° C./cm, wherein a growth direction of the calcium fluoride crystal substantially conforms to the crystallographic orientation of the seed crystal.
[0010] In another aspect, the invention relates to a calcium fluoride crystal for making optical elements for transmitting below 200-nm ultraviolet light having a [100] crystallographic orientation and a diameter greater than or equal to approximately 250 mm and exhibiting a mean birefringence no greater than approximately 1.2 nm/cm and inhomogeneity no greater than approximately 1.1 ppm.
[0011] Other features and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0012] [0012]FIG. 1A- 1 D illustrate a method of making [110]- and [100]-oriented calcium fluoride crystals according to an embodiment of the invention.
[0013] [0013]FIG. 2 is a graph showing centerline temperature and temperature gradient versus axial direction as crystal is formed.
[0014] [0014]FIG. 3 is a graph of an annealing and cooling profile for a calcium fluoride crystal according to an embodiment of the invention.
DETAILED DESCRIPTION
[0015] The invention will now be described in detail with reference to a few preferred embodiments, as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention may be practiced without some or all of these specific details. In other instances, well-known features and/or process steps have not been described in detail in order to not unnecessarily obscure the invention. The features and advantages of the invention may be better understood with reference to the drawings and discussions that follow.
[0016] In the background discussion, the inventors mentioned that [110]- and [100]-oriented CaF 2 single crystals are usually cut out of [111]-oriented CaF 2 single crystals. One would expect that like [111]-oriented CaF 2 single crystals, which are grown directionally using [111]-oriented seed crystals, it should be fairly straightforward to grow [110]- and [100]-oriented CaF 2 single crystals directionally using [110]- and [100]-oriented seed crystals, respectively. However, while not wishing to be bound by theory, the inventors argue herein that CaF 2 single crystals likely exhibit preferential growth in the [111] direction. According to the general solidification theory, once a nucleus is formed, crystal growth is limited by (a) the kinetics of atom attachment to the solid-liquid interface, (b) capillarity, and (c) diffusion of heat and mass. (Kurz, W. & Fisher, D. J. Fundamentals of Solidification. Aedermannsdorf-Suitzerland: Trans Tech Publications, 1986.) The relative importance of each of these factors depends on the substance in question and upon the growth conditions. For CaF 2 single crystals, growth in the [111] direction appears to be favored when the dominant control factor is kinetics of atom attachment to the liquid-solid interface or diffusion of heat and mass.
[0017] CaF 2 single crystal very likely grows with a microscopically faceted interface, which actually consists of many atomically-flat facets, due to its high (higher than metals) entropy of fusion. These atomically-flat facets generally choose a low-index plane with the lowest interface energy. As a result, the faceted growth mode tends to give different atomic attachment kinetics in different interface planes, and therefore might show an anisotropy in growth velocity for different orientations. Since CaF 2 crystals exhibit (111)-faceted surfaces it is reasonable to assume that the interface energy and attachment rate of CaF 2 are lowest in the (111) planes. From the standpoint of atomic attachment kinetics, it means that CaF 2 has very slow (axial) growth rate in [111] direction and very quick spreading (radial) speed in (111) plane. The growth in the [111] direction looks like layer-by-layer spreading in (111) plane. This growth mode makes it easier to maintain [111] orientation because any nucleation and growth in other directions will be suppressed by the rapid spreading (radial growth) in (111) plane.
[0018] However, growth in the [110] or [100] direction shows a different behavior from the one described above for the [111] direction in that the axial growth rate along the [110] or [100] direction could be higher than the radial growth rate along the solid-liquid interface. The slower radial growth will make the nucleation in other directions easier to propagate into the [110] or [100] direction and result in loss of singularity. It should be pointed out that this mechanism is applicable only for those growth processes where kinetics of atom attachment to the liquid-solid interface is the dominant control factor. From the point of view of diffusion of heat and mass, growing CaF 2 crystals along the [111] direction should also be easier than growing along the [110] or [100] direction. According to McCurdy, the thermal conductivity of CaF 2 is highest along the [111] direction and lowest along the [100] direction, with the difference being as much as 40% (McCurdy, A. K. “Phonon Conduction in Elastically Anisotropic Cubic Crystals.” Physical Review B 26 (1982): 6971.) This suggests that [111] might be the preferential direction for growing CaF 2 crystals.
[0019] Embodiments of the invention provide a method of encouraging CaF 2 single crystal growth in or “near” the [110] or [100] direction. “Near” could be 3 to 5 degrees from the [110] or [100] direction but is preferably less than 1 degree from the [110] or [100] direction. The CaF 2 single crystals grown by the method of the invention have low stress-induced birefringence and low residual index inhomogeneity and can be used for making optical elements for 157-nm microlithography process and below 200-nm microlithography processes in general. Referring to FIG. 1A, the crystal growth process starts with a seed crystal 100 having [110] or [100] crystallographic orientation. A [110]-oriented seed crystal is used to grow [110] crystals, and a [100]-oriented seed crystal is used to grow [100]-oriented crystals. Typically, the seed crystal 100 is CaF 2 crystal. However, it may also be possible to use SrF 2 crystal or other materials having a similar phase and melting point to CaF 2 . The seed crystal 100 is placed in a seed crystal holder 102 at the base of a crucible 104 . In the illustrated embodiment, the crucible 104 has multiple crystal growth chambers 106 . The crucible 104 may have any number of crystal growth chambers, typically in a range from 1 to 20. The crystal growth chambers 106 are in communication through holes 108 in the crystal growth chambers 106 .
[0020] Each crystal growth chamber 106 contains CaF 2 feedstock 110 . Preferably, the feedstock 110 is pretreated to remove impurities such as oxides that can have a detrimental effect on the optical performance of the grown crystal. An oxide scavenger may also be mixed with the feedstock 110 . The crucible 104 with the feedstock 110 is supported in a vertical furnace 112 . The vertical furnace 112 has a melting chamber 114 and an annealing chamber 116 . Heaters 118 , 120 are disposed in the melting and annealing chambers 114 , 116 , respectively, to maintain a prescribed temperature profile inside the melting and annealing chambers 114 , 116 . Insulation 122 may be provided around the heaters 118 , 120 to assist in controlling the temperature in the melting and annealing chambers 114 , 116 . An annular diaphragm 124 , made of insulating material, partially isolates the melting chamber 114 from the annealing chamber 116 , creating a temperature gradient zone 125 between the melting chamber 114 and the annealing chamber 116 . A lift mechanism 126 is coupled to the crucible 104 . As an example, the lift mechanism 126 could be a fluid-powered actuator, such as a hydraulic or pneumatic actuator, or a mechanical actuator. The lift mechanism 126 can be operated to move the crucible 104 along the axial length of the furnace 112 .
[0021] In one embodiment, temperature probes 128 , 130 are provided inside the melting chamber 114 and annealing chamber 116 , respectively. In operation, the output of the temperature probes 128 , 130 may be supplied to a control system (not shown) that will automatically adjust the input to the heating elements 118 , 120 such that a desired temperature profile is maintained in the melting and annealing chambers 114 , 116 . Preferably, the heaters 118 , 120 can be controlled independently to achieve the desired temperature profiles inside the melting and annealing chambers 114 , 116 , respectively. The heaters 118 , 120 may be made of a single heating element or multiple heating elements. Various alternate heater configurations are possible. See, for example, U.S. Pat. No. 6,562,126 (issued to Price) for possible alternate configurations.
[0022] In operation, the furnace 112 is hermetically sealed with vacuum, inert, fluorinating or other atmosphere suitable for crystal growth. The melting chamber 114 is then heated to a temperature sufficient to melt the feedstock 110 in the crucible 104 , as shown in FIG. 1B. For example, for CaF 2 , the temperature is typically set at about 1500° C. The crucible 104 with the molten feedstock 110 is slowly translated from the melting chamber 114 , through the diaphragm 124 , into the annealing chamber 116 . The annealing chamber 116 is maintained at a temperature lower than the temperature of the melting chamber 114 so that there is a temperature gradient across the diaphragm 124 . As shown in FIG. 1C, as the crucible 104 passes through the diaphragm 124 , the molten feedstock 110 goes through the temperature gradient zone 125 . As the crucible 104 passes through the temperature gradient zone 125 , the temperature transition inside the molten feedstock 110 creates a solid-liquid growth front 134 . The solid-liquid growth front 134 propagates inside the crucible 104 , within the molten material 110 , as long as the crucible 104 continues to move downwardly into the annealing chamber 116 to form crystal 132 , which conforms to the crystallographic orientation of the seed crystal 100 . In order to secure crystal growth in the orientation of the seed crystal 100 , an initial position of the crucible 104 should be established so that the seed crystal 100 is partially, preferably half, melted prior to growing the crystal on the seed crystal.
[0023] The method of the invention is based in part on a contradictory fact about temperature gradient in crystal growth: high axial temperature gradient is good for growing crystals and bad for reducing stress-induced birefringence. This issue is particularly delicate for [110]- and [100]-oriented CaF 2 crystal growth because while the growth in these directions seems more difficult and therefore needs higher axial temperature gradient to ensure the singularity, the higher stress optical coefficient in these directions requires lower temperature gradient to produce a low stress-induced birefringence. It has been demonstrated that growing [110]- and [100]-oriented crystals under an axial temperature gradient above 1° C./cm, especially above 4° C./cm, is particularly preferred. It has also been demonstrated that the upper limit for growing [110]- and [100]-oriented single crystals with reduced stress-induced birefringence is 8° C./cm, preferably 6° C./cm. Combining these two opposite effects of axial temperature gradient on the singularity and stress-induced birefringence, a desired temperature gradient for growing [110]- and [100]-oriented crystals with a low stress birefringence is 2° C./cm to 8° C./cm, preferably 2° C./cm to 6° C./cm, more preferably 3° C./cm to 5° C./cm.
[0024] [0024]FIG. 2 is an example of a graph showing centerline temperature and temperature gradient as a function of axial direction as the crystal is grown. The zero position on the axial direction axis corresponds to the solid-liquid interface ( 134 in FIG. 1C). Returning to FIG. 1C, the probability of obtaining [110] or [100] crystals is enhanced when the solid-liquid interface is within, preferably in the middle of, the insulation (diaphragm 124 ) zone. By doing this, the stress-induced birefringence and small-angle grain boundaries can be reduced. The solid-liquid interface can be constrained within the insulation zone by appropriately choosing the temperature set-points of the melting chamber 114 and the annealing chamber 116 . The axial temperature gradient is largely controlled by the temperatures of the melting chamber 114 and the annealing chamber 116 as well as the configuration of the furnace 112 , the length of the insulation (diaphragm 124 ) zone, and the material and size of the crucible 104 . For the temperature gradient at the solid-liquid interface 134 , the growth velocity also has an effect. The temperature gradient in the crystal tends to increase with the growth velocity due to the latent heat released during solidification. However, this effect could be negligible if the translation speed of the crucible 104 during crystal growth is below 3 mm/hr. Preferably, the translation speed of the crucible 104 is in a range from 0.5 mm/hr to less than 3 mm/hr. Preferably, the translation speed does not vary by more than 0.1 mm/hr.
[0025] For illustration purposes, 300-mm diameter [110]- and [100]-oriented CaF 2 crystal growth experiments were carried out separately in a vertical Bridgman furnace. The feedstock was first mixed with scavengers and then put in a graphite crucible with a [110]-oriented CaF 2 seed crystal for [110] crystals and a [100]-oriented CaF 2 seed crystal for [100] crystals. The axial temperature gradient and the growth rate were set at around 6° C./cm and less than 3 mm/hr, respectively. Under these growth conditions, [110]- and [100]-oriented single crystals were successfully obtained. The crystals were cooled down using a conventional annealing process, typically including a rapid cooling rate of 6° C./hr from about 1500° C. down to about 1100° C., a slow cooling rate of about 1.5° C./hr from about 1100° C. down to about 750° C., an increased cooling rate of about 5° C./hr from about 750° C. to about 450° C., and an even faster cooling rate of 10° C./hr from about 450° C. to about 20° C. Table 1 below shows the inhomogeneity and birefringence measurements for the crystals.
TABLE 1 Birefringence Inhomogeneity (ppm) Crystal (nm/cm) with without Orientation Mean RMS Power Power [110] 5.8 6.6 3.2 1.4 [100] 8.2 12.5 3.7 3.5
[0026] The stress-induced birefringence shown in Table 1 for [110]- and [100]-oriented CaF 2 single crystals is relatively high in comparison to that of [111]-oriented CaF 2 single crystals. The stress-induced birefringence of the [110]- and [100]-oriented CaF 2 single crystals could be reduced by growing the crystals at a lower axial temperature gradient and/or using an improved annealing process. A separate annealing process can also be used to reduce the birefringence in the crystals.
[0027] In one embodiment, an in-situ annealing method is used to cool the crystals once the crucible 104 is fully inside the annealing chamber 116 , as shown in FIG. 1D. The in-situ annealing method uses two temperature regimes to cool down the crystal. The first temperature regime is between the melting temperature (approximately 1420° C.) and approximately 1200° C. In this temperature regime, a decreasingly fast cooling profile and an increasingly slow cooling profile are applied to the melting chamber 114 and the annealing chamber 116 , respectively, to reduce or diminish the temperature difference between the melting chamber 114 and the annealing chamber 116 which is required for crystallization. This temperature difference is preferably less than 50° C., more preferably less than 30° C., at the first temperature regime. This step is designed to minimize the temperature gradient in the annealing chamber 116 as early as possible. After the primary cooling stage, a substantially constant cooling rate is applied to both zones from the first temperature (in a range from about 1300° C. to 1100° C., preferably in a range from about 1250° C. to 1150° C.) to a final temperature in a range from about 300° C. to about 20° C., more preferably to room temperature. As shown in FIG. 3, both cooling curves should be as smooth as possible to avoid any undesirable thermal disturbance. For crystals with a diameter greater than 250 mm, it has been demonstrated that desirable inhomogeneity and birefringence can be achieved using a cooling rate of less than 3° C./hr, preferably 2° C./hr or less in the linear portion of the annealing.
[0028] For illustration purposes, 300-mm diameter [100]-oriented CaF 2 crystal growth experiments were carried out in a vertical furnace. The feedstock was first mixed with scavengers and then put in a graphite crucible with a [100]-oriented CaF 2 seed crystal. The axial temperature gradient and the growth rate were set at around 6° C./cm and less than 3 mm/hr, respectively. Under these growth conditions, [100]-oriented single crystals were successfully obtained. The crystals were annealed in-situ using the linear annealing method described above. For the linear annealing method, the cooling rate after the initial cooling down of the melting and annealing chambers was approximately 2° C./hr. Table 2 below shows the inhomogeneity and birefringence measurements for the [100]-oriented single crystals.
TABLE 2 Birefringence Annealing (nm/cm) Inhomogeneity (ppm) Method Mean RMS with Power without Power Linear 1.2 1.8 1.1 1.1 Conventional 8.2 12.5 3.7 3.5
[0029] The invention provides one or more advantages. First, [110]- and [100]-oriented CaF 2 single crystals can be grown economically. Secondly, combining an appropriate annealing method with the crystal growth method of the invention allows [110]- and [100]-oriented CaF 2 single crystals having low birefringence and low inhomogeneity to be manufactured. With the in-situ annealing method described above, [110]- and [100]-oriented CaF 2 single crystals having low birefringence and low inhomogeneity can be grown in a single furnace run. The results above show that birefringence as low as 1.2 nm/cm has been achieved for [100]-oriented CaF 2 single crystals. Birefringence may be further reduced by choosing a lower temperature gradient and cooling rate for the crystal growth and annealing, respectively. Multiple crystals can be grown in a single furnace run using a multi-chamber crucible (or a stack of single-chamber crucibles) to increase the yield of the crystal growth process. The grown [110]- or [100]-oriented CaF 2 single crystals can be used to design lens systems for below 200 nm microlithography.
[0030] 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.
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A method of making an oriented calcium fluoride single crystal includes loading calcium fluoride feedstock on top of a seed crystal having a specific crystallographic orientation, heating the calcium fluoride feedstock to a temperature sufficient to form a melt, and growing a calcium fluoride crystal on the seed crystal by progressively moving the melt and the seed crystal through a temperature gradient zone having an axial temperature gradient in a range from approximately 2° C./cm to approximately 8° C./cm, wherein a growth direction of the calcium fluoride crystal substantially conforms to the crystallographic orientation of the seed crystal.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application claims the benefit under 35 USE 119(3) of U.S. Application No. 60/857,348, filed Nov. 7, 2006, incorporated herein by reference in its entirety.
The United States Government has certain rights in this invention pursuant to grants from the National Science Foundation by Grant Numbers DMR-0451589 and DBI-0629584.
This invention is directed to a fully integrated holographic microfabrication system and method. More particularly, the invention is directed to an optical system for assembling and dynamically controlling complex three dimensional structures from objects suspended in a fluid, the objects being, for example, colloidal particles, macromolecules, nanoclusters, nanowires and biological materials, such as cells. Such objects can be of any size and shape which are readily assembled and manipulated for a selected commercial purpose.
BACKGROUND OF THE INVENTION
The use of optical traps or tweezers has undergone substantial development over recent years. This technique can manipulate matter, including very small objects and small portions of larger objects, with great precision. Recent progress has resulted in the ability to create large arrangements of optical traps to perform simultaneously many tasks at various spatial locations. These traps can also be individually specified as to trapping strength, optical character and size, given the needs of the situation. In view of all these degrees of freedom, however, little has been accomplished in terms of complex commercial applications.
SUMMARY OF THE INVENTION
One Three dimensional assembly, micromanipulation and dynamic configuring of objects is accomplished by use of computer generated holograms which can trap objects, exert precision force at selected system locations and assemble complex arrangements of objects in any selected three dimensional configuration, including extensive stacks of objects. Collectively the assembly of optical traps can execute processing and manufacturing protocols for a wide variety of commercial purposes. This system can carry out such manufacturing steps as assembling three dimensional functional structures from various building blocks, such as microscopic fluid-borne objects (colloidal particles, e.g.), macromolecules, nanoclusters, nanowires and various biological media, such as biological cells. The system can carry out assembly, processing, testing and inspection of the assembled particle array or an object, execute chemical processing steps, as well as perform mechanical and optical processing using a selectable range of light wavelengths, including white light to perform these functions. Further, the system can be used as a sensor or probe for optical, electrical, chemical, biological and force gradient properties. In addition the system employs a holographically focused microscope with each image itself being a hologram, incorporating volumetric data and in effect is three dimensional versus conventional holographic microscopy where images are two dimensional.
Various aspects of the invention are described hereinafter, and these and other improvements are described in detail hereinafter, including the drawings described in the following section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a schematic diagram of a holographic optical trapping system;
FIG. 2A illustrates a computer generated hologram (CGH); FIG. 2B illustrates a light array at an intermediate focal plane; and FIG. 2C illustrates a resulting optical trap array;
FIG. 3A illustrates an assembly of 173 colloidal silica spheres in a quasicrystal layer array; FIG. 3B illustrates the trapped particles translated into a desired three dimensional configuration; FIG. 3C shows reduction of the scale to create an optically dense material which can then be gelled; and FIG. 3D shows a laser diffraction pattern at 633 nm wavelength which shows 10 fold diffraction peaks;
FIG. 4A illustrates a helical phase mask transformation of a TEM 00 mode to a helical mode with winding number, l; FIG. 4B illustrates the helical mode focused to a ring of light of radius R e ∝l with l=30; and FIG. 4C shows a multiply exposed photograph of a single colloidal silica sphere dispersed in water and circulating around the optical vortex of FIG. 4B ;
FIGS. 5A-1 and 5 A- 2 illustrate a phase holograph for encoding a microfluidic gear pump using counter-rotating optical vortices with topological charge l ± =±30; FIG. 5B illustrates the projected light pattern and processing with the holograph before adaptive optimization; FIG. 5C shows after adaptive optimization; and FIG. 5D shows an operating microfluidic pump filled with 700 nm diameter silica spheres and pumping water through a central channel at 5 μm/s;
FIG. 6 shows a general system for optical processing;
FIG. 7 shows a holographic optical trapping module;
FIG. 8 shows a holographic 3D imaging module;
FIG. 9 shows a white light based optical processing system; and
FIG. 10 shows a multipoint force monitoring/processing module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A system constructed in accordance with an embodiment of the invention is shown generally at 100 in FIG. 1 . The system 100 uses a computer-designed diffractive optical element (DOE) 110 to split a single collimated laser beam 120 into multiple independent beams, each of which subsequently is focused into an optical trap or tweezers 130 (see FIG. 2C ) preferably by a strongly converging objective lens 140 in FIG. 1 . The DOE 110 preferably takes the form of a spatial light modulator (SLM) to create a computer-generated hologram (CGH) as shown in FIG. 2A . This CGH creates a plurality of light beams 125 in FIG. 2B specifically designed to create a particular pattern of the optical tweezers 130 (see FIG. 2C ). Projecting a sequence of computer-designed holograms with an SLM reconfigures the projected traps 130 , thereby translating trapped particles or manipulating objects along selected independent paths. The optical tweezer 130 is created in a conventional manner by bringing an intense beam of light, such as the laser beam 120 , to a diffraction-limited focus. The light's electric field polarizes nearby dielectric objects; and the induced dipoles are drawn up intensity gradients toward the focus. Radiation pressure due to absorption and surface scattering competes with this optical gradient force and tends to repel an optically trapped particle. Stable trapping is only possible if the gradient force dominates. For this reason, optical tweezer systems often are built around the microscope objective lens 140 (see FIG. 1 ) whose large numerical aperture and well-corrected aberrations optimize axial intensity gradients.
The optical trap 130 can be placed anywhere within the objective lens' focal volume by appropriately selecting the input beam's direction of propagation and degree of collimation. For example, a collimated beam 135 passing straight into an infinity-corrected form of the objective lens 140 comes to a focus in the center of the lens' focal plane, while another beam (not shown) entering at an angle comes to a focus proportionately off-center. A diverging beam focuses downstream of the focal plane and a converging beam focuses upstream. By the same token, multiple beams entering the lens' input pupil simultaneously form multiple ones of the optical trap 130 in the focal volume, each at a location determined by its degree of collimation angle of incidence.
Using the system 100 of FIG. 1 , FIG. 3A shows 173 colloidal silica spheres arranged in a single plane within a three-dimensional sample volume. Comparable planar rearrangements also can be implemented with a conventional single rapidly scanned optical tweezer in a time-shared configuration. Unlike these other conventional techniques, however, holographic trapping also can create three-dimensional structures. The images in FIGS. 3B and 3C show the same spheres being reorganized into the third dimension, their images changing appearance as they move along an optical axis 145 . Other three-dimensional optical trapping techniques, such as the generalized phase contrast (GPC) method require two-sided optical access and cannot stack objects along the optical axis 145 . By contrast, the system 100 can stack micrometer-scale objects at least 12-14 deep along the optical axis 145 .
In addition to arbitrary three-dimensional control, the holographic traps 130 offer other advantages over conventional scanned tweezers. HOT patterns have extensive degrees of freedom than time-shared arrays which must periodically release and retrieve each trapped object. Additionally, the lower peak intensities required for continuously illuminated traps are less damaging to photosensitive samples.
A laboratory-scale implementation of a dynamic form of the holographic optical tweezers 130 preferably used a Hamamatsu X8267 parallel-aligned nematic SLM for the DOE 110 to reshape the laser beam 120 from a frequency-doubled diode-pumped Nd:YVO 4 laser (Coherent Verdi) into a designated pattern of beams. Each is transferred to the entrance pupil of a 100×NA 1.4 oil immersion objective lens 140 mounted in a Nikon TE2000U inverted optical microscope 150 and then focused into the optical 130 trap. A dichroic mirror 160 reflects the laser beam 120 into the objective lens 140 while allowing images of the trapped particles to pass through to a video camera (not shown). When combined with a 0.63× widefield video eyepiece, this optical train offers a 86×65 μm 2 field of view, with a magnification of 135 nm per pixel at the video camera.
The collimated laser beam 120 initially has planar wavefronts with a uniform phase profile φ({right arrow over (ρ)})=0. The DOE 110 imprints them with the phase profile φ({right arrow over (ρ)}) at each 40 μm wide pixel in a 768×768 array. The DOE's calibrated phase transfer function imparts one hundred fifty distinct phase shifts ranging from 0 to 2π at the operating wavelength of λ=532 nm. The phase shift imposed at each pixel is specified through a computer interface with an effective refresh rate of 2 Hz for the entire array. Despite the DOE's inherently limited spatial bandwidth, it can project such sophisticated trapping patterns as illustrated by considering FIGS. 2A-2C and 3 A- 3 D.
Three-dimensional control is attained by integrating the objective lens' phase
φ
z
(
ρ
→
)
=
π
ρ
2
z
λ
f
2
,
(
1
)
profile, into the phase hologram, φ({right arrow over (ρ)}), encoding an array of the optical traps 130 . This translates the optical trap 130 by z along the optical axis 145 (see bottom edge view of FIG. 3C-2 taken from FIG. 3C-1 ). Here f is the focal length of the objective lens 140 . The algorithms we have developed for computing trap-forming phase holograms can separately specify φ({right arrow over (ρ)}) for each trap-forming beam, thereby allowing each of the optical traps 130 to move independently with respect to the focal plane.
Engineering the individual traps' wavefronts imparts additional functionality. For example, the helical phase profile
φ l ({right arrow over (ρ)})= l θ mod 2π (2)
converts an ordinary Gaussian laser beam into a helical mode, and its corresponding optical tweezer into a so-called optical vortex. Here θ is the polar coordinate in the DOE plane, and the integer l describes the helical wavefront pitch and is known as the topological charge. Destructive interference along the helical screw dislocation cancels the beam's intensity along its axis all the way to the focus. As shown in FIG. 4B , optical vortices 170 thus focus to bright rings of light, rather than points. The image in FIG. 4B was obtained by placing a mirror (not shown) in the microscope's focal plane and collecting the reflected light with the conventional imaging train. These dark form of the optical tweezers 130 have proved useful for trapping objects that are not compatible with conventional optical tweezers 130 , including ultra-high-index particles for photonic applications (such as assembling the icosahedral quasicrystal of FIGS. 3A-3C ). These optical tweezers 130 also can trap reflecting, absorbing and low-index particles that are useful for biomedical applications.
Combining φ l ({right arrow over (ρ)}) with a phase hologram encoding an array of the optical tweezers 130 yields an array of optical vortices 170 (see FIGS. 5A-1 , 5 A- 2 and 5 D). Our algorithms for computing phase-only hologram also can imprint vortex-forming helical phase fronts onto individual traps ones of the optical 130 in an array, creating mixed patterns with different winding numbers, such as the array shown in FIG. 5B-5D .
Because of their helical phase profile, the optical vortices 170 carry orbital angular momentum, independent of polarization, that they can transfer to trapped materials. The resulting torque can drive trapped objects around the trap's circumference, as shown in FIG. 5D . The optical vortices 170 are useful, therefore, for creating motion at small length scales, for example in rotating semiconductor nanowires during assembly. Arrays of the optical vortices 170 can act as pumps and mixers, which also are useful for preparing and processing materials for characterization and assembly. A typical pump is shown operating in FIG. 5D . The optical vortices 170 can further act as conveyor belts for a manufacturing operation.
Holographic wavefront engineering lends itself to other advantageous applications, with virtually any mode of light having potential applications. For example, the axicon phase profile φ γ ({right arrow over (ρ)})=γρ creates an approximation of a Bessel mode which focuses to an axial line trap whose length is controlled by γ. Arrays of Bessel beam line optical traps can pass through quite deep microfluidic channels and thus improve optical fractionation of fluid-borne samples.
All of these trapping capabilities are controlled by the phase profile imprinted on the input laser beam 120 by the DOE 110 (preferably the spatial light modulator). Thus, they can be selected and changed in real time under computer control, without requiring any hardware modifications. A single computer-designed phase hologram can project distinct patterns of the optical traps 130 in multiple wavelengths of laser light. Multi-color trapping and photochemical processing is very useful for assembling multi-component tissues, materials and devices.
FIG. 6 illustrates a system 200 which includes modular subsystems that comprise the proposed integrated fabrication and characterization system. Included in the system 200 can be holographic trapping subsystem 210 and holographic microscopy subsystem 220 . The primary assembly system 200 and the subsystems 210 , 220 can be supported by various spectroscopy components in both transmission and reflection, and an advantageous form of force spectroscopy.
Rapid and precise fabrication of photosensitive materials requires appropriate choice of wavelength. Earlier holographic trapping systems have been based on high-powered visible lasers, both for their ease of use, and also for their comparatively high trapping efficiency for micrometer-scale objects. Longer wavelength lasers are less likely to damage biological materials, however, and can be more effective for trapping semiconductor nanowires and related nanomaterials.
In the subsystem 210 of FIG. 6 , recent advances in commercial fiber lasers make these a particularly attractive class of infrared sources for trapping applications. The subsystem 210 preferably uses an IPG YLD-10-LP linearly polarized single-mode continuous wave fiber laser 240 operating at 1075 nm. This laser 240 provides up to 10 W, which can power up to 2000 independent traps. The laser beam 250 can be expanded to 5 mm diameter using a standard fiber-coupled beam expander (IPG) to illuminate the DOE 110 (preferably a spatial light modulator).
A preferred embodiment of the holographic optical trapping subsystem 210 projects the optical traps 130 using a Holoeye HEO-1080p liquid crystal on silicon (LCoS) SLM tuned to provide 2π phase shift at the proposed laser wavelength. This SLM (a preferred form of the DOE 110 ) comprises an array of 1920×1080 phase pixels, each 8 μm across. In selecting a suitable SLM for a given application, several optimization criteria may be considered. For example, larger numbers of phase pixels, higher rates of phase pattern changes and finer resolution of phase modulation a 1 improves the performance of the holographic optical trapping subsystem. Smaller phase pixels allow for more compact design of the holographic optical trapping subsystem 210 .
In a most preferred embodiment, trapping and imaging will be based on a choice of Nikon CFI Plan Apo 100× and 60× oil immersion IR objective lenses 140 . These lenses 140 have proved excellent for optical trapping both because of their high numerical aperture (NA 1.4), and also because of their excellent aberration correction. The IR variants of these lenses 140 are designed for operation at infrared and visible wavelengths.
In a preferred embodiment shown in FIG. 7 , laser power will be fine tuned with a half-wave plate 300 in a precision rotation mount and a polarizing beam splitter 310 . This also will improve diffraction efficiency by improving the beam's polarization. The beam splitter 310 also provides a port for a second laser 320 at a different wavelength, useful for multicolor holographic trapping.
The role of the relay optics is to project an appropriately scaled image of the DOE 110 face onto the input pupil of the objective lens 140 . The field and depth of view for the trapping system then is set by the number of pixels spanning the projected aperture. With the 60× objective lens 140 , the proposed system 200 will be able to place traps at arbitrary locations over a 120 μm×120 μm area and at ±50 μm with respect to the focal plane. Three-dimensional placement resolution is roughly 30 nm, and deliberately exploiting high-order diffraction will allow us to extend this range by nearly a factor of two, with limitations set by reduced diffraction efficiency.
As shown in FIG. 8 , the optical train 400 that projects the holographic traps 130 is readily modified to work as an imaging system 410 . As shown schematically in FIG. 8 , light gathered by the objective lens 140 is projected onto a video camera 420 by a relay lens 430 whose transfer function is controlled by a second phase-only spatial light modulator 440 . The two physical relay lenses 430 , 450 are arranged as a standard 4f telescope, transferring the wavefronts of light emerging from the objective lens' pupil to the face of the SLM 440 . A virtual lens φ z (ρ), encoded on the SLM 440 then selects the desired focal plane.
In the simplest implementation, the imaging train is focused to a plane at height z above the objective's focal plane by imprinting the same phase pattern, (see Eq. (1) used to displace the optical trap 130 ). In this case, the imaging plane can be effectively scanned through a three-dimensional sample without physically moving the sample relative to the objective lens 140 . The focusing hologram also can be used to adaptively correct for geometric aberrations in the imaging train.
Employing the same class of the SLM 440 for imaging and trapping ensures that the field of view and depth of focus for imaging will cover the same range as the trapping system. This SLM's updates will be synchronized to the video camera 420 to gather volumetric data at video rates.
Images are most preferably acquired with a Roper Cascade 512B electron-multiplied charge-coupled device (EMCCD) camera. This camera 420 incorporates field-effect amplifiers at each pixel so that it can offer both low-light level imaging and also extremely low-noise bright-field imaging. It also offers flexible triggering and electronic shuttering, as well as adjustable resolution and frame rate. Low-noise operation is particularly useful for particle tracking and deconvolution microscopy, whose accuracy degrades rapidly with decreasing signal-to-noise ratio.
Unwanted diffraction orders due to the SLM's pixelated structure can be eliminated with an appropriate set of pupils mounted with the ocular lens (not shown). Additionally, a small beam block 425 (shown in phantom in FIG. 8 ) introduced into the relay lens' intermediate focal plane can be used to convert the optical train to dark-field operation. Other amplitude- and phase-modifying elements introduced in this plane will provide additional modes of operation, including variants of phase-contrast microscopy.
Commercially available SLMs 440 impose different degrees of phase modulation on light of different wavelengths. This means that the holographically focused system 410 would suffer from chromatic aberration were it used with white light illumination. This is a principal reason for replacing standard microscope illumination with a monochromatic source for bright-field and dark-field imaging. The system 440 preferably is based on a 200 mW fiber-coupled laser diode 460 , operating at 860 nm by SDL, Inc. Bending fiber 470 to scramble the wavefront yields uniform speckle-free illumination. The laser diode 460 also can be rapidly gated for short exposures and multiple stroboscopic exposures.
The fiber-coupled laser 460 can be collimated with a commercial fiber collimator 480 and focused onto sample 465 with a second 60× objective lens mounted as a condenser. The beam will be reflected into the condenser 490 preferably using a dielectric multilayer mirror (Chroma Technology) mounted at 45°, thereby providing additional optical access to the condenser 490 at other wavelengths. In particular, this arrangement will provide access for a standard white light illuminator, which can be convenient for some applications. In this case, the SLM 440 will likely not play an active role, and the imaging system 410 will produce standard two-dimensional images.
Volumetric image reconstruction can best be performed using standard algorithms of deconvolution microscopy implemented in the IDL programming language. Simple deblurring operations with the nearest-neighbor algorithm can proceed in near-real time on a standard workstation. This will be ideal for on-line inspection of systems being assembled through holographic trapping. More accurate reconstructions will proceed either with myopic deconvolution or with constrained maximum entropy algorithms, depending on the nature of the sample. These more computationally intensive algorithms are useful for quantitative structural measurements on finished objects.
The condenser and illumination system 410 can be mounted on a spring-loaded rack-and-pinion translation stage both to facilitate Köhler alignment and also to provide access to samples.
The samples 465 can be mounted on an integrated translation stage with three-axis control. Coarse focusing is performed with a precision spring-loaded rack-and-pinion drive to minimize drift. Precise computer-controlled focusing and lateral translation can be performed with a conventional Mad City Labs Nano-View LP200, which combines stepping-motor two-axis coarse translators with piezoelectric three-axis controllers. The fine controllers offer 200 μm range in each axis with 0.4 nm resolution and better than 1 nm repeatability.
A major application area for the proposed fabrication instrument is in holographic assembly of photonic materials and devices. Another involves organization and monitoring of living biological samples. Consequently, a preferred system 500 shown in FIG. 9 incorporates a fiber spectrometer 510 and a pair of white light sources 520 to provide transmission and reflection spectra in real time. Spectroscopic information then can be used to fine tune structures before they are permanently set in place. It also can be used to assess trapped cells' viability and their response to external stimuli. For optoelectronic applications, the spectroscopy subsystem 530 can be used to analyze samples' fluorescence when exposed to the trapping laser. Some semiconductor nanowires are observed to fluoresce brightly when trapped, and this fluorescence can be useful for selecting nanowires for assembly.
The spectroscopy subsystem 500 most preferably includes an Ocean Optics USB4000 fiber optic spectrometer, which offers better than 4 nm wavelength resolution over the range 300 to 1000 nm. Some regions in this wavelength range will be suppressed by the transmission characteristics of the dielectric multilayer mirrors used in the holographic trapping and imaging train. Mounting the spectrometer's input coupler below the microscope permits simultaneous holographic trapping, three-dimensional imaging and real-time spectroscopy, however. This type of coordination is essential for creating precise photonic structures under interactive control and also will be useful for characterizing biological systems during optical micromanipulation. The loss of sensitivity in selected wavelength ranges, therefore, is compensated by the additional functionality. Two Ocean Optics R-LS-1-LL rack-mounted halogen light sources will provide broad-band illumination for transmission and reflection spectroscopy. The entire system can be calibrated with standard samples.
In another form of the invention, multi-point force spectroscopy and manipulation can be performed using a calibrated arrangement of optical tweezers' potential energy wells. An object's instantaneous displacement from the trap's equilibrium point can be used to measure the instantaneous force making it move. Most effectively, the potential energy well of a single one of the optical tweezers 130 can be calibrated by tracking the thermally driven motions of a trapped particle. This general approach avoids the necessity of characterizing and calibrating an externally applied reference force. Statistically optimal methods can be used for analyzing trajectories of optically trapped particles to obtain time-resolved measurements of the forces on multiple holographically trapped particles simultaneously. These methods can be applied also to video microscopy data obtained in the proposed system. Imaging measurements of forces, however, only work when the trapped particles' displacements are large enough and slow enough to track with a video camera. They also require accurate calibrations for each one of the optical traps 130 .
Light scattered out of the optical trap or tweezer 130 by a trapped particle interferes with the unscattered portion of the beam to yield an interference pattern in the far-field forward-scattering direction. This interference transforms small particle motions into large intensity variations. Measuring these variations with a quadrant photodiode records the particle's displacement with sub-nanometer resolution over a bandwidth of tens of kilohertz. Once translated into equivalent forces, this technique can attain attonewton force resolution and can measure forces as large as several piconewtons. These specifications greatly exceed what is possible through imaging-based measurements.
It is noted that an alternative technique has been developed that relaxes the requirement to calibrate the optical tweezer 130 for force measurements and also is amenable to parallelization. In a further embodiment of the invention, the trapped particle deflects the trapping beam by an amount that depends on its displacement from the center of the trap. The beam's mean deflection corresponds to an average change in momentum imparted to the trap's photons by the particle, and thus to a force when normalized by the flux of photons in the beam. The effective force deflecting the beam equals the force displacing the particle by Newton's third law. A single calibration of the trapping beam's intensity and the imaging train's magnification therefore calibrates the force transducer, independent of the optical tweezer's trapping characteristics.
An individual trapping beam's displacement can therefore be measured by imaging the far-field scattering pattern through the condenser in a plane intermediate between the objective's front and back focal planes. Thus, optical deflection force spectroscopy can be applied to multiple optical traps 130 simultaneously, provided that the traps' images are resolved in the intermediate plane. The individual traps' deflections can be measured with sufficient precision with a conventional video camera 600 (see FIG. 10 ) to provide sub-femtonewton resolution over a ten piconewton range at a bandwidth limited by the camera's frame rate. The benefit over previously described approaches is that holographic trapping force spectroscopy provides information from a large number of traps simultaneously. The implementation then uses the video camera 600 , protected with neutral density filters to detect the holographic traps' forward scattered beams 610 . The camera 600 is focused with a tube lens 620 to optimize the trade-off between force resolution and spatial resolution. Output from the camera 600 will be digitized and analyzed with a conventional analysis software of the Applicant.
In yet another aspect of the invention, raw materials can be introduced to the optical fabrication system and finished products removed using microfluidic sample handling. Pioneered with conventional microlithography, microfluidics systems have since been implemented in polymeric materials with soft lithographic techniques that permit rapid prototyping at extremely low costs. Polymer-based microfluidic systems also permit integration of microscopic pumps and valves. Pulsating flows from such pumps can be compensated by phase-locked modulation in laser intensity to maintain optimal conditions for optical fractionation. Integrated microfluidic systems also are compatible with electrokinetic driving technologies developed for capillary electrophoresis.
In still another embodiment of the invention, a single optical processing instrument can be combined with a large number of distinct microfluidic chips to generate a range of different optical fabrication and fractionation applications, such as manufacturing microfluidic chips through soft lithography in polydimethysiloxane (PDMS).
Another embodiment of the invention enables manufacture and quality assurance in fabricating three-dimensional structures out of dielectric building blocks. One application is to assemble and characterize three-dimensional photonic bandgap materials. These “semiconductors for light” have been demonstrated for radio and microwave wavelengths using macroscopic assembly techniques, and have been demonstrated for visible wavelengths in one and two dimensional lithographically defined microstructures. Processing high-index materials into three-dimensional photonic bandgap microstructures for optical applications has proved challenging. Creating appropriate small-scale structures with the proposed optical fabrication instrument therefore would open up new avenues for research and development in photonics as well as in biomolecular spectroscopy.
Very recently, icosahedral quasicrystals have been identified as the best candidate structure for achieving three-dimensional photonic bandgaps. These pose even greater challenges to conventional fabrication techniques than periodic structures. These structures can be holographically assembled and typical results appear in FIG. 2C . These colloidal quasicrystals were assembled from silica spheres and then gelled into solid structures by photopolymerizing the surrounding fluid medium.
We also can use the optical fabrication and characterization instrument to organize ultra-high-index titania spheres into comparable permanent structures, and to measure their transmission and reflection spectra at optical wavelengths. Three-dimensional holographic microscopy will be particularly important for guiding and assessing the assembly process. Bulk photopolymerization of prototype structures can take advantage of ultraviolet light-emitting diodes (LED's) arranged as a ring illuminator around the condenser lens. Properties of the gel can be assessed with force spectroscopy on the spheres themselves.
In yet another application of the invention the optical tweezers 130 can manipulate and process semiconductor nanowires into three-dimensional structures to enable creating electronic and optoelectronic devices from chemically nanostructured materials. Heretofore, nanowire devices were created by randomly depositing the wires onto substrates and then defining functional structures through painstaking lithographic techniques. Now, devices can be assembled to order and use the systems described herein to build functional devices out of silicon nanowires, with a particular emphasis on sensor applications for biological and environmental monitoring.
In yet another embodiment, infrared holographic trapping is useful for manipulating living biological cells. Holographic trapping, in particular, is useful for arranging multiple disparate cells into specific three-dimensional configurations. This kind of structuring is crucial for the proper growth and development of cells in living tissues. Optically organized cellular assemblies have been demonstrated in model systems, including hepatocytes as a liver progenitor and islet cells for creating pancreatic implants. The three-dimensional cellular assemblies are transformed into artificial tissues by synthesizing a biodegradable gel around them.
Holographic trapping coupled with holographic microscopy within microfluidic environments will greatly facilitate and accelerate the optical assembly of artificial tissues. For example, the systems herein can be used to organize chondrocytes and osteoblasts into three-dimensional models for developing teeth, with the intention of creating transplantable artificial dentin.
The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.
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A method and system for micromanipulation of objects of any shape. The method and system creates various forms of holographic optical traps for a variety of commercial purposes. Some alternate forms of traps include a dark form of optical traps, optical vortices with different helical winding numbers and optical traps with variable phase profiles imprinted thereon.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to pumps and, more particularly, to a positive displacement pump which impels fluid through a series of annular chambers defined by multiple reciprocating annular rings.
2. Description of the Prior Art
It is known to pump fluid through a deformable member, such as a resilient tube, by compressing the tube to seal the flow path at a point and moving the point of compression axially along the tube to force fluid therethrough. While such tube pumps are valuable for metering precise amounts of fluid and for handling abrasive, toxic and other hard-to-handle fluids, such pumps are limited in that they can handle only a very low volumetric throughput at moderate temperatures and low pressures.
A particular problem has been encountered in pumping large volumes of fluids while minimizing suction vaporization defines the intake reliability of a pumping system. Sludge with entrapped air, hot or volatile fluids in a high speed system are prone to cavitate with attendant performance degradation. Conversely, a smaller mechanical system of equivalent fluid performance permits a greater strength to weight ratio. Thus, a positive, high capacity unit with a low net positive suction head requirement which can operate in a broad range of speeds and viscosities is desirable.
SUMMARY OF THE INVENTION
The present invention provides a positive displacement pump capable of metering an accurate amount of fluid at a relatively high volumetric flow rate. The pump comprises a plurality of concentric annular rings arranged to reciprocate in the direction of the concentric axis in an enclosure including at least one end plate. In the preferred embodiment, a pair of parallel end plates are sealed by a wall which is spaced apart from the outermost annular ring to form an outer plenum. At least one port through the wall provides for fluid communication between the outer plenum and the exterior of the pump. An inner plenum is defined generally by the interior cylindrical wall of the innermost ring and the opposed faces of the parallel plates. One or more additional ports are provided at or near the center of one or both the parallel end plates (in communication with the inner plenum) and fluid flows between said first ports and said additional ports, in either direction, depending on the sequence in which the annular rings are reciprocated.
Assuming that the fluid is to be pumped from the outer plenum to the inner plenum, the pumping sequence begins with the outer ring moving away from the end plate, leaving an open volume into which fluid in the outer plenum is allowed to flow. As the outer ring approaches the full extent of its travel away from the end plate, the middle ring begins to move away from the end plate, opening a new volume so that the fluid flowing into the volume overlying the outer ring continues to flow inwardly into the volume overlying the middle ring. In the meantime, the outer ring is moving back toward the end plate to provide a seal so that the water overlying the middle ring cannot flow radially outwardly, and as the middle ring approaches the full extent of its travel the inner ring begins to move away from the end plate, allowing the fluid to continue to flow inwardly into the inner plenum and then out through the outlet. Pumping action from the inner plenum to the outer plenum can be accomplished by simply reversing the sequence.
In the preferred embodiment, three rings are provided with the center ring having twice the annular area of the outer and inner rings to assure the smooth flow of fluid through the pump. The rings are reciprocated 120° out of phase with the outermost ring leading the middle and innermost ring by 120° and 240°, respectively. By driving the rings in that sequence, fluid flows from the outer plenum to the inner plenum. By reversing the drive so that the outer adjacent rings lag, fluid will flow from the inner plenum to the outer plenum.
An advantage of the pump is a very low inlet pressure requirement when compared to conventional positive displacement pumps. To operate at full capacity requires only sufficient pressure to assure that volume beneath the initial annular ring be filled with fluid as the ring moves away from the opposed parallel plate. Since the inlet port to either the inner or outer chamber can be made virtually as large as the chamber, there will be very little pressure drop to impede the operation. Thus the present pump will be useful in pumping viscous and volatile fluids in high capacity applications with a low net positive suction head requirement. It should be noted that if the differential pressure between the inlet and output becomes great enough to overcome the drive-shaft torque the pump will motor.
The novel features which are characteristic of the invention as to organization and method of operation together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings, in which a preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the description and the drawings are for the purposes of illustration only and are not intended as a definition of the limits of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional elevational view of the preferred embodiment of the pump of the present invention.
FIG. 2 is an end view of the eccentric cam shaft utilized in the embodiment of FIG. 1.
FIG. 3 is an end view of a single eccentric cam of the first embodiment mounted on a driving rod.
FIG. 4 is a graph illustrating the position of each annular ring as a function of cycle time.
FIGS. 5A-5D illustrate the relative movement of the annular rings during one-half cycle of operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a pump 10 comprising an enclosure 12, three annular rings 14, 16, 18, and a drive assembly 20 for reciprocating the rings within the enclosure are illustrated. The enclosure 12 comprises first and second parallel end plates 22, 24 and a cylindrical wall 26 extending between the parallel plates to form a generally fluid-tight chamber. A first port 28 is provided through the cylinder 26 and will typically include a boss 29 or the like for forming a process connection. The first port 28 communicates with an outer plenum 32 defined by the outer cylindrical surface 18a of ring 18, the interior surface of cylindrical wall 26, and the parallel plates 22, 24. A second port 30 is provided through the second parallel plate 24 (generally at the center thereof) and communicates with an inner plenum 34 defined generally by the inner cylindrical surface 14b of ring 14. The second port 30 also includes a boss 31 or the like for making a process connection and fluid flow through the pump 10 can be either from the first port 28 to the second port 30, or in the opposite direction, depending on the manner in which the pump is operated, as described more fully hereinafter.
Each of the annular rings 14, 16, 18 is mounted on a pair of connecting rods 36 which form a part of the drive assembly 20, as described more fully hereinafter. The rings 14, 16, 18 are arranged so that their radial planes lie substantially parallel to the planes of the parallel plates 22, 24. The rings 14, 16, 18 are arranged coaxially and are free to reciprocate along their common axis which is perpendicular to said planes. Adjacent cylindrical faces (i.e., 14a, 16b and 16a, 18b) of the rings are sufficiently close to form a substantially fluid-tight seal between the rings. Alternatively, the rings 14, 16, 18 may be provided with "rings" (not shown) similar to those found on piston engines and other reciprocating equipment to prevent leakage.
The pumping action is achieved by formation of a radially propagated annular cavity defined by the relative motions of the annular rings 14, 16, 18. In the particular embodiment, such cavities will be formed both above and below the annular rings 14, 16, 18, and each will contribute to the total throughput of the pump 10, as described in detail in connection with FIGS. 4 and 5A-5D, hereinbelow. The following description relates to the flow between the rings and the second plate 24, but applies equally to the flow adjacent the first plate 22.
For proper operation, it is necessary that the sum of the radial areas of rings 14 and 18 be equal to the radial area of ring 16 so that the volume of the entire displacement bounded by the radial areas of rings 14, 16 and 18 and the end plate 24 be constant throughout the entire cycle. In embodiments having more than three rings the radial areas of the inner ring and outer ring shall each be one half the radial area of each one of the enclosed rings.
For proper operation it is also necessary that the radial face of each of the rings 14, 16, 18 form a seal with the adjacent parallel plate 22 or 24 during a portion of the pump cycle. The seal is formed by an annular locking ridge 40 projecting outward from both radial faces of each ring 14, 16, 18 and associated channels 42 formed in both of the parallel plates 22, 24. The height of the locking ridge determines the duration of the seal. A longer seal time, and thus a higher locking ridge 40, is necessary as the number of rings in the pump is reduced, as will be described more fully hereinafter.
The drive assembly 20 reciprocates the connecting rods 36 in a predetermined phase relationship for operating the pump 10. The assembly 20 can take any form which meets this objective, for example, various types of solenoids would be adequate. The preferred embodiment employs an eccentric cam shaft 50 having three pairs of eccentric cams 52, 54, 56 mounted thereon. Referring to FIGS. 1, 2 and 3, the eccentric cams are arranged on the shaft rotationally spaced-apart by 120°. The cam length l (FIG. 2) is the distance between the center of the cam and the center of the cam shaft 50 and is equal for each of the six cams 52, 54, 56. Each cam is mounted in a cage 58 (FIG. 3) which is directly connected to the connecting rod 36. The shaft 50, in turn, is mounted in a pair of support brackets 60 (FIG. 1) extending upward from the exterior surface of the first parallel plate 22. The brackets are joined by a top plate 62 extending therebetween and secured thereto, said plate having six holes 64 adapted to receive an extension rod 66 projecting upward from the cage 58. The first parallel plate 22 includes six holes 68 which are generally aligned with the six holes in the top plate. The cages 58 are mounted so that the extension rod 66 projects through the hole 64 in the top plate and the connecting rod 36 projects through the corresponding hole 68 in the first parallel plate 22. Thus, by rotating the cam shaft 50, the connecting rods 36 may be reciprocated 120° out of phase with a total displacement of twice the cam length 2 l.
The cams 52, 54, 56 will typically include a bearing ring 72 supported on the central portion of the cam by a plurality of ball bearings 74. Adequate lubrication is provided so that the cam may move within cage 58 freely as the shaft 50 is rotated.
Referring now to FIGS. 4 and 5A-5D, the operation of a pump having three rings will be explained in detail. The operation of a pump having a greater number of rings will be analogous although certain of the parameters, including the height of the locking ridge 40 and the phase relationship of the various rings, will vary. In general, for a pump having n number of rings, the rings will be driven out of phase by 360/n degrees. The operation of the pump 10 will be described for fluid flow from the first port 28 to the second port 30. Such flow corresponds to rotation of the cam shaft 50 in the clockwise direction (as shown by the arrow in FIG. 2).
FIG. 4 illustrates the displacement of each of the annular rings 52, 54, 56 as a function of the pump cycle shown as the degree of rotation of shaft 50 where the position of the shaft shown in FIG. 2 has been arbitrarily chosen as 0°. This position (0°) corresponds to the locations of the annular rings as shown in FIG. 5A. The displacement is shown in multiples of cam length l measured from the interior surface of plate 24 to the opposed radial face of the particular ring. A scale indicating the length of displacement is included on each of FIGS. 5A-5D for cross-reference.
FIG. 4 includes three sine waves 14w, 16w, 18w corresponding to the positions of the rings 14, 16, 18, respectively. At 0°, ring 18 is in its fully raised position corresponding to a height 2 l above the second plate 24. At the same time, both rings 14 and 16 are raised a height 0.5 l above the plate 24 with ring 14 descending and ring 16 ascending, as indicated by the arrows in FIG. 5A. (The length of the arrows indicating generally the magnitude of the distance to be covered over the next 60° of pump cycle.) At this point, an annular cavity, shown generally at 78, is defined beneath (as viewed in FIGS. 5A-5D) the lower cylindrical surface of ring 18. The cavity 78 has a volume generally equal to the radial area of the ring 18 multiplied by the height 2 l above plate 24.
Over the next 60°, ring 18 descends to a height of 1.5 l over plate 24, while ring 16 rises to the same height, as illustrated in FIG. 5B. A slightly larger cavity 80 is formed between the lower radial faces of rings 16, 18 and the plate 24. The fluid entering the pump through inlet port 28 and outer plenum 32 will flow into this cavity 80 under a minimal inlet pressure.
As the pump cycle continues, the outermost annular ring 18 continues downward until reaching a height 0.5 l at 120° as shown in FIG. 5C. At this point the locking ridge 40 on ring 18 engages the associated channel 42 formed in plate 24 to seal the fluid beneath ring 16 from the outer plenum 32. The locking ridge 40 on the innermost ring 14 continues to engage its associated channel 42 and for a brief instant of time the quantity of fluid is trapped in a cavity 82 formed by all three of the rings and the interior surface of plate 24. At this point also, the central ring 16 is in its most raised position, and the volume formed beneath ring 16 is generally equal to the radial surface area of the ring times the height, 2 l.
As the pump cycle continues, outermost ring 18 continues downward with the seal formed between locking ridge 40 and channel 42 remaining intact. Ring 16 begins its downward stroke, which impels the fluid beneath it to flow inward toward a cavity 84 of increasing volume being formed beneath ring 14 which is moving upwardly, as illustrated in FIG. 5D. During the remainder of the cycle, ring 16 will continue downward until sealing against plate 24 while ring 14, which lags ring 16 by 120°, continues its upward stroke and returns downward, sealing with plate 24 before the seal with ring 16 has been broken. In this way, the fluid is positively displaced into the inner plenum 34.
The height of the locking ridge 40 is an important parameter since it determines the portion of the cycle during which the associated ring is sealed against the plates 22, 24. For the three-ring embodiment described herein, the height must be a minimum of one-half the cam length (0.5 l) shown in FIG. 2. With this height, each ring is sealed against each of the parallel plates 22, 24 during one third (or 120°) of the pump cycle. This can be seen best in reference to FIG. 4, where the ring displacement (measured from the radial face of the ring) is less than 0.5 l during one third of each 360° cycle and greater than 1.5 l during a separate one-third of the cycle. This is necessary for two reasons. First, one of the rings 14, 16 or 18 is sealed against each of the plates 22 and 24 at all times to prevent back flow through the pump. Second, a seal such as 40 on ring 18, as shown in FIG. 5C, must be maintained behind the sum of the volume displacements of each of the rings 14, 16 and 18 and end plate 24 so that the fluid flows in the desired (inward) direction. This is understood best in reference to FIGS. 5C and 5D where ring 18 seals against plate 24 just at the moment ring 16 is in its uppermost extension. Thus, as ring 16 descends, and the seal on ring 14 is broken, the fluid must flow inward to the expanding cavity beneath ring 14. Meanwhile, ring 18 remains sealed until the point when the lock ridge 40 of ring 16 reaches sealing engagement with plate 24 at 240° in the pump cycle. At that point, ring 18 ascends to take on an additional charge of fluid to being impelled through the pump 10.
For pumps having more than three rings, the height of the locking ridge will be less. The height (h) may be found using the following formula:
h=l(1-cos(180°/n))
where
l=cam length
n=number of rings
A second parameter of interest is the radial width of the annular rings 14, 16, 18. As mentioned hereinabove, the radial surface area of the center ring 16 must be twice that of the radial surface area of either ring 14 or ring 18. This ratio comes about from the pecularity in which the three rings simultaneously contribute to the volume displacement. Referring to FIG. 5C and in particular to cavity 88, the sum of the decreasing volume displacements of rings 16 and 18 above end plate 24 is greater than the increasing volume displacement of ring 14 above end plate 24 resulting in a net output volume decrease. The resulting net volume displacement (q) for a 60 degree advance of the cycle may be found using the formula
a=A l/2
where A=radial area of inner ring 14
Each 60 degree advance of the cycle displaces an equal amount of fluid toward the output. The radial area of ring 14 can vary with a larger area corresponding to a greater volumetric throughput per pump cycle. Once the area (i.e., throughput) has been selected, the radial width of the innermost ring 14 can be calculated based upon a value for the inner diameter of the innermost ring, typically chosen to correspond to the diamter of the port 30. The dimensions of the remaining rings 16, 18 can be calculated according to well-known geometric principles.
The axial width of the annular rings 14, 16, 18 is less critical. It is necessary only that adjacent rings overlap at all times during the pump cycle to prevent leakage therebetween. Thus, an axial width greater than 2 l sin (180°/n) is necessary. Sufficient overlap should be provided so that adjacent rings will seal. The distance between the parallel walls 22, 24 will equal the width of the rings plus the distance 2 l.
A final parameter of interest is the radial location of the locking ridges 40 on the annular rings 14, 16, 18. It is desirable that the flat radial surface areas on adjacent annular rings bounded by the locking ridges 40 be maintained equal. Referring to FIG. 5A, radial face 86 defined between locking ridge 40 on ring 14 and the outer cylindrical face thereof should be equal to radial face 88 on ring 16. In this way, during the instant when a small pocket of fluid is trapped between the locking ridges (as shown in FIG. 5A), such fluid will not experience undesirable compression or expansion since the incremental change in volume (dV/dt) at that moment is zero. While this feature is desirable when handling sensitive fluids, it is not necessary for the operation of the pump and the pump would function equally well if the locking ridges were placed elsewhere on the radial faces of the rings, such as at the outermost diameter thereof.
The foregoing description of operation has been made in reference to fluid flow between the lower (as viewed in FIGS. 1 and 5A-5D) radial faces of the rings 14, 16, 18 and the plate 24. Fluid will also be caused to flow between the upper radial faces and plate 22 in an identical manner. No additional description is necessary.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be appreciated that variations and modifications may be made without departing from what is regarded to be the subject matter of the present invention.
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A positive displacement pump comprising an enclosure having parallel walls and a plurality of concentric annular rings reciprocally mounted between said walls is disclosed. By reciprocating the rings in a predetermined sequence, fluid is caused to flow through a series of radially propagating chambers defined by the rings.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cloth for ribbons, scarves or slide fasteners which can have patterns dyed onto it.
2. Description of the Related Art
Conventional cloth for ribbons, scarves or slide fasteners is usually dyed the same color on both sides.
The cloth used with these kinds of garments is considered to be decorative. The fact that conventional slide fastener tape used in sweaters, for example, is the same color on both sides will therefore cause the following two problems. Although sweaters, for example, may have slide fasteners which go all the way up to the collar, people will often wear them with the slide fastener not fully done up and the collar open. This means that the color of the neck cannot be varied, although whether or not this is a hindrance depends on the personal preference of the wearer. Also, this kind of garment can also often be worn either way out. However, the selection of colors for the garment is greatly restricted by the fact that whichever way out the garment is worn, the color of the slide fastener tape will remain the same.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a cloth which can be dyed a different color on each side.
According to the present invention, there is provided a cloth composed of first and second threads, said first thread being dyeable by a first dye and being much more exposed on a front surface of the cloth than a back surface thereof, said second thread being not dyeable by said first dye and able to be dyed by a second dye and being much more exposed on the back surface than the front surface.
This cloth can then be made suitable for use as a slide fastener tape. Further, the slide fastener tape may has a belt-shaped portion in which the second thread is much more exposed on a part of the front surface than the back surface longitudinally thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view describing the woven structure of the cloth in this invention;
FIG. 2 is a large-scale sectional view of the arrangement of individual threads in the cloth;
FIG. 3 is a front view of the cloth employed as slide fastener tape; and
FIG. 4 is view describing the woven structure of the portion A in FIG. 3.
DETAILED DESCRIPTION
A more detailed description of this invention will now be given by referring to one part of the twill woven structure in FIGS. 1 and 2. A warp thread W1 indicated by the hatching lines runs over weft threads F1, F2 and F3 and then runs under the weft thread F4. Next, the warp thread W2 indicated by the dot pattern runs under the weft thread F1, over the weft thread F2 and then under weft threads F3 and F4. The warp thread W3 then runs under the weft thread F1 and over weft threads F2, F3 and F4. Then, the warp thread W4 runs under weft threads F1 and F2, over the weft thread F3 and under the weft thread F4.
The warp threads W1 and W3 are made of the same thread and are out of step with each other by one pitch. The warp threads W2 and W4 are also made of the same thread although this thread is different to the thread used for the warp threads W1 and W3 and are also out of step with each other by one pitch. As the warp threads W1 and W3 are more prominent on the first side and the warp threads W2 and W4 are more prominent on the second side, the cloth has two distinct sides, and is therefore reversible.
In this woven structure the first threads 1 which make up every second warp thread W1 and W3 are made from rayon and the second threads 2 which make up every other second warp thread W2 and W4 are made from polyester. The weft threads F1, F2, F3 and F4 are all made from polyester.
This example takes advantage of the properties of the materials rayon and polyester. If using dispersible dyes, for example, one kind of dye could be used which would dye the polyester threads but would not dye the rayon threads. These rayon threads could then be dyed using a further kind of dye. When weaving, a choice could also then be made between using a dyeable fiber thread and a non dyeable fiber thread for the first system, thus giving two distinct kinds of thread.
There are many well known dyes by which a pattern could then be dyed onto the rayon. These include direct dyes, basic dyes, vat dyes, sulfide dyes and sulfide vat dyes.
FIG. 3 shows an example of a slide fastener. Here, a belt shaped portion 3 runs down both outside edges of the slide fastener tape T, with E being fastener elements. This belt shaped portion 3 is woven using the system shown in FIG. 4 from a warp thread W5 and a weft thread F5, which are weaved from polyester having the same material properties as the aforementioned second thread 2. The material used in this belt shaped portion 3 could also be used form a pattern on, for example, scarves or ribbons.
If the cloth formed using the above method is now soaked in a bath of, for example, dispersible dye, only the second threads 2 made from polyester will be dyed. As these second threads 2 are more prominent on the second side, only this second side, along with the belt shaped portion of the first side in which these second threads are also prominent, will be dyed. The first threads 1 which are more prominent on the first side will remain their original color. This first surface could then be dyed using the spray or ink jet dying methods, or could have a pattern put onto it by using the ink jet dying method.
In the cloth in the present invention there are first threads 1 which can only be dyed by using a dye for a first system of dying, and second threads 2 which can be dyed using a dye for a second dying system but cannot be dyed by the dye from the first system of dying. These first threads are more prominent on the first side of the cloth while the second threads are more prominent on the second side of the cloth. This system differs from other systems in that the dying process is carried out twice, but rather than the whole of the cloth being dyed in one go, each side of the cloth can actually be dyed to a desired color. With, for example, a reversible sweater, either side of any slide fastener tape used could be dyed so as either side of the slide fastener tape would match with the color of the sweater. This would improve the quality and increase the value of any goods made.
If the cloth in this invention is used as slide fastener tape, the belt shaped portions at the edges of the first surface can act as sewing margin guides, thus making it very easy to attach.
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A cloth composed of first and second threads, the first threads being dyeable by a first dye and being much more exposed on a front surface of the cloth than a back surface thereof, the second threads being not dyeable by said first dye and dyeable by a second dye and being much more exposed on the back surface than the front surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of commonly owned, copending PCT Application Ser. No. PCT/US2012/037740, filed May 14, 2012. The PCT Application claims priority from commonly owned, copending, U.S. Provisional Patent Application Ser. No. 61/486,429, filed May 16, 2011. The disclosures of these applications are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the production of high purity silicon metal.
BACKGROUND OF THE INVENTION
[0003] Silicon metal is useful both as the basis for semiconductors, and as the key constituent of the majority of photovoltaic (PV) cells. Silicon metal for these applications is required to be extremely pure, typically 99.9999% (6N) or higher purity for PV cells, and typically 9N or higher purity for semiconductor applications. Silicon of this purity is usually manufactured in large and extremely capital-intensive facilities, in which gas phase chemical vapor deposition is used to build up high purity silicon metal from silicon-containing gases. The two main gases used are trichlorosilane (SiHCl 3 ), and silicon hydride or silane (SiH 4 ).
[0004] In this invention, a method of manufacture is described that uses liquid phase reduction of silicon hydride, to produce silicon metal. Working in liquid phase permits a more compact plant design and offers significantly lower capital costs.
SUMMARY OF THE INVENTION
[0005] The invention relates to the production of silicon metal, for which the production process is particularly well-suited and also economically advantageous.
[0006] One preferred process of the present invention comprises:
[0007] introducing silane gas into a reactor vessel containing a reductant, preferentially an alkali or alkaline earth metal or combinations thereof, and most preferentially sodium metal, potassium metal, and alloys thereof, at a temperature sufficient to ensure the reductant is liquid;
[0008] separating the reaction product (a mixture of silicon metal and excess reductant) from the reductant in the reactor vessel;
[0009] heating the reaction product to a temperature to cause any reductant hydride to break down into reductant and hydrogen gas; and removing any excess reductant from the silicon metal.
[0010] The metal thus produced is in the form of a metal powder or extended aggregate structure with internal porosity.
[0011] The particle size produced by this process is controlled by a number of factors, including the reaction temperature, the relative concentrations of the reagents, and the melting point of silicon metal.
[0012] The metal produced by this methodology can be densified by melting to produce silicon of high purity. By controlling the purity of the silane and the reductant, silicon of a purity suitable for use in photovoltaic cells and even semiconductor devices can be produced.
[0013] Finally, all the processes described herein can be accomplished using a gas phase reductant in place of the preferred liquid phase reductant.
[0014] One embodiment of the present invention is a process to convert silane gas (SiH 4 ) to silicon metal by a liquid or vapor comprising reacting the silane gas with one or more alkali or alkaline earth metals. In certain preferred embodiments, the alkali or alkaline earth metals comprise either sodium, or potassium, or alloys thereof. In certain embodiments, the alkali or alkaline earth metal is captured and recovered for reuse in the process.
[0015] In certain embodiments, the reaction product of this process comprises silicon metal, and at least 0.1% metallic sodium. In certain embodiments, the reaction product of this process comprises silicon metal, and at least 1% metallic sodium. Yet another reaction product is hydrogen gas. The hydrogen generated in the process may be recovered and used in commercial applications, if desired.
[0016] In certain embodiments, the silicon metal, after removal of the excess sodium, has a purity of at least 99.9%. In certain embodiments, the silicon metal, after removal of the excess sodium, has a purity of at least 99.99%. In certain embodiments, the silicon metal, after removal of the excess sodium, has a purity of at least 99.999%. In certain embodiments, the silicon metal, after removal of the excess sodium, has a purity of at least 99.9999%. In certain embodiments, the silicon metal, after removal of the excess sodium, has a purity of at least 99.99999%. In certain embodiments, the silicon metal has a primary particle diameter of less than 1 micron.
[0017] Silicon metal having a purity as provided herein may be employed in a photovoltaic device. Silicon metal having a purity as provided herein may be employed in a semiconductor device. Silicon metal having a purity as provided herein may be employed in a sputtering target.
[0018] It should be appreciated by those persons having ordinary skill in the art(s) to which the present invention relates that any of the features described herein in respect of any particular aspect and/or embodiment of the present invention can be combined with one or more of any of the other features of any other aspects and/or embodiments of the present invention described herein, with modifications as appropriate to ensure compatibility of the combinations. Such combinations are considered to be part of the present invention contemplated by this disclosure.
[0019] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0020] As described above, silane can be injected into molten reductant, and reduced therein to silicon metal in particulate form. The typical size of the silicon particle is a function of the temperature of the reaction, the flow rates of the reagents, and the diffusion characteristics of silicon. By careful control of the reaction conditions, one can select for a range of typical metal particle sizes. The surface area of the metal is related to the particle size, and the surface area of the metal particle determines many important physical characteristics of the metal in commercial applications. Particle sizes are summarized in the following table:
[0000]
Reaction temperature, degrees Celsius
275
550
775
Primary particle size, nm
20-40
50-80
100-200
Aggregate size, microns
0.5-1
0.9-2
1-5
[0021] The reaction produces silicon powder incorporating a fraction of the reductant, and potentially also the hydride of the reductant. Hydrogen gas is also produced and in fact can be captured and used or sold. This reaction product can be removed from the reactor and then be treated to remove the reductant and any reductant hydride, or can first be treated before removing the silicon metal. There are many specific implementations of this technology, illustrated by the following representative but non-exhaustive examples.
Example 1
[0022] Silane gas is injected into a reactor vessel containing molten sodium and is allowed to flow until the evolved hydrogen indicates the presence of unreacted silane gas, at which point the flow of silane is stopped.
[0023] The reactor vessel is then heated to a temperature of at least 300 degrees centigrade and a partial vacuum of 100 ton or less is applied to the vessel to remove any hydrogen produced by the breakdown of sodium hydride.
[0024] Once the remnant hydrogen has been removed, the temperature is raised to above the boiling point of sodium, and the sodium vapor is removed and condensed to recover the sodium. This step can be accomplished at lower temperatures by the application of a partial or full vacuum (100 torr or less) to the reactor vessel.
[0025] Finally, the silicon metal can be removed from the reactor vessel for further processing or sale, or else can be heated to above the melting point of silicon in order to produce a dense solid of silicon.
[0026] The sodium is not consumed in the reaction, instead acting as a catalyst to promote the decomposition of silane gas, and can be re-used with obvious beneficial impact on the economics of the process.
Example 2
[0027] Silane gas is injected into a stream of sodium-potassium alloy (NaK) and decomposes to silicon, hydrogen, and potentially some hydrides of sodium and potassium.
[0028] The solid silicon is removed from the NaK stream by filtration. Hydrogen gas produced in the decomposition of silane is vented from the NaK stream and is recovered for disposal, sale or other use. The reactor products are captured without exposure to air or moisture.
[0029] The reaction products are then heated to break down any sodium or potassium hydrides into hydrogen and either sodium or potassium, and the hydrogen is captured for sale, use or disposal. This step can be facilitated by the application of a full or partial vacuum of 100 torr or less.
[0030] Next, the reaction product is heated to a temperature sufficient to remove as a vapor the NaK present with the silicon. Once again, a full or partial vacuum of 100 torr or less reduces the temperature required to remove the excess NaK.
[0031] Finally, the silicon metal can be taken for further processing or sale, or else can be heated to above the melting point of silicon in order to produce a dense solid of silicon.
[0032] The NaK is not consumed in the reaction, instead acting as a catalyst to promote the decomposition of silane gas, and can be re-used with obvious beneficial impact on the economics of the process.
Example 3
[0033] In either of Examples 1 or 2 above, the removal of the sodium or the NaK can be achieved by use of a non-aqueous solvent (for example, ammonia, and alcohols such as methanol, ethanol etc, and other polar solvents) that does not dissolve the silicon metal.
[0034] The dissolved sodium or NaK can then be removed from the solvent for recycling, and the solvent can be recycled also. The silicon metal can then be recovered as described in Examples 1 and 2.
[0035] The above examples are intended only to be illustrative of the wide range of metals and alloys and their applications, made accessible by the invention described herein.
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A method of manufacture is described that uses liquid phase reduction of silicon hydride, to produce silicon metal. Working in liquid phase permits a more compact plant design and offers significantly lower capital costs.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to data processing systems and more particularly to better utilization of memory resources and of segment metadata nodes in data snapshots in such systems.
2. Description of the Related Art
A snapshot of data in a data processing system at a time “t” creates, in a target data volume, a logical copy of data in a source data volume. Physical copying of the data from the source volume to the target volume can then subsequently take place, with any intervening changes (“writes”) to data in the source volume being momentarily delayed. During this momentary delay, the original version of the data sought to be changed is preferentially copied from the source volume to the target volume, prior to writing the change. Thus, the snapshot of data in the target volume represents the exact state of the data in the source volume at the time “t.”
Snapshots as defined above are useful for backing up data and for testing. For example, taking a snapshot of frequently changing data facilitates the execution of test applications against the snapshot of the data, without changes to the data unduly interfering with the test application execution. Moreover, the snapshot mechanism facilitates faster data backups by a storage subsystem as compared to file system-based backups, which entail host CPU processing and which require the allocation of relatively high network bandwidth.
Existing snapshot systems are, however, unduly restrictive. Most, for instance, permit write access only to the source volume in order to coordinate data in the system. Further, the limitations of existing snapshot systems prohibit the undertaking of concurrent snapshots or of distributed snapshots, and they do not support cyclical and transitive snapshot operations. Concurrent snapshots, distributed snapshots, and cyclical and transitive snapshot operations can be very useful for test purposes. Moreover, existing systems fail to account for the above-recognized considerations. In view of this, the costs of reads and writes are not optimized in existing snapshot systems in the case of multiple storage volumes that are involved in multiple concurrent snapshot operations.
A typical data snapshot management system needs to record persistently (as long as the snapshot relationship between source and target data volumes is active) the metadata segments that carry information about where to get the t 0 data from. In practical systems where this is implemented, the metadata segments consume large amounts of a valuable resource, either non-volatile random access memory (or NVRAM) space, or storage on drives. This imposes a limitation on how much of such metadata segments can be maintained through the backup creation. Owing to this limitation, a snapshot system cannot handle a specific pattern of writes that consumes a large or unlimited number of metadata segments.
An example system where the above-identified problems may be encountered occurs in systems where the source and target volumes are made available through most of the backup operation. These systems are described, for example, in a co-pending, commonly owned U.S. patent application: “System and Method for Concurrent Distributed Snapshot Management”, Ser. No. 09/376,832, filed Aug. 18, 1999, (filed as IBM Case No. AM9-99-052).
In data processing systems, certain system interfaces permit techniques which allow the formation in memory of what are known as sparse files. Files are created having lengths greater than the data they actually contain, leaving empty spaces for future addition of data. Data is written in relatively small portions into a number of memory locations which are not contiguous. Certain portions of the computer memory in the area of these memory locations, however, never have data written in them, although other memory files receive data. Data written into sparse files is known as sparse data. Snapshot systems when sparse data is present have been a problem, in that they rapidly consume large numbers of metadata segments and memory resources.
It would be desirable to have an ability to have continuing records available about metadata segments in data processing systems while not consuming memory resources of the data processing system.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a data processing system and method of maintaining usage data about data snapshots of data write operations to storage media of the data processing system and keep record of data overwrites without unduly consuming memory resources of the data processing system.
It is a further object of the present invention to provide a computer program product enabling a data processing system to maintain usage data about data snapshots of data write operations to storage media of the data processing system and keep record of data overwrites without unduly consuming memory resources of the data processing system.
It is still a further object of the present invention to provide a memory product stored in a memory of a data processing system to better utilize memory resources of the data processing system, particularly those relating to usage metadata nodes.
The above as well as additional objectives, features, and advantages of the present invention will become apparent in the following detailed written description.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of the architecture of a data processing system according to the present invention.
FIG. 2 is a schematic diagram of a computer program product.
FIG. 3 is a flow chart of a typical snapshot management process in a data processing system like that of FIG. 1 .
FIGS. 4A and 4B are schematic representations of topology of a metadata log formed using the techniques of FIG. 3 .
FIG. 5 is a flow chart of a process of updating segment metadata according to the present invention.
FIG. 6 is a schematic representation of a bitmap according to the present invention and used during the process of FIG. 5 .
FIG. 7 is a schematic representation of topology of a metadata log formed using the techniques of FIG. 5 .
FIG. 8 is a schematic representation of the topology of FIG. 7 after a data overwite has been performed on portions of the data indicated by the metadata log represented therein.
FIG. 9 is a schematic representation of the bitmap of FIG. 6 representing modification of the data node from FIG. 7 to FIG. 8 according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, a system is shown, designated 10 , for invoking and executing transitive distributed snapshot relationships between plural data storage volumes C, D, and E, such that a read or write can be made to any storage volume. As shown, the system 10 can include a computer 12 including a respective input device 14 such as a keyboard with, e.g., a point and click device, and an output device 16 , such as a monitor, printer, other computer, or computer network. Also, the computer 12 accesses a software-implemented snapshot module 18 for undertaking the inventive steps of the process according to the present invention described herein.
The computer 12 can be a personal computer made by International Business Machines (IBM) of Armonk, N.Y. Other digital processors, however, may be used, such as a laptop computer, mainframe computer, palmtop computer, personal assistant, or any other suitable processing apparatus. Likewise, other input devices, including keypads, trackballs, and voice recognition devices can be used, as can other output devices, such as data storage devices.
In any case, the processor of the computer 12 accesses the snapshot module 18 to undertake the logic of the present invention, which may be executed by a processor as a series of computer-executable instructions. The instructions may be contained on a data storage device with a computer readable medium, such as a computer diskette 20 shown in FIG. 2 having a computer usable medium 22 with code elements 22 A, 22 B, 22 C and 22 D stored thereon. Or, the instructions may be stored on random access memory (RAM) of the computer 12 , on a DASD array, or on magnetic tape, conventional hard disk drive, electronic read-only memory, optical storage device, or other appropriate data storage device. In an illustrative embodiment of the invention, the computer-executable instructions may be lines of C++ code.
Indeed, the flow charts herein illustrate the structure of the logic of the present invention as embodied in computer program software. Those skilled in the art will appreciate that the flow charts illustrate the structures of computer program code elements including logic circuits on an integrated circuit, that function according to this invention. Manifestly, the invention is practiced in its essential embodiment by a machine component that renders the program code elements in a form that instructs a digital processing apparatus (that is, a computer) to perform a sequence of function steps corresponding to those shown.
Co-pending, commonly owned U.S. patent application: “System and Method for Concurrent Distributed Snapshot Management.” Ser. No. 09/376,832, filed Aug. 18, 1999, (filed as IBM Case No. AM9-99-052), which is incorporated herein by reference, provides a system and method for managing data snapshots among storage volumes in a data processing system such as that shown in FIG. 1 . The present invention provides an ability to have continuing records available about metadata segments in data processing systems of this type while not unduly consuming memory resources of the data processing system.
FIG. 3 represents a flow diagram of logic in the data processing 10 for forming metadata nodes according to techniques of the above-referenced co-pending, commonly owned U.S. patent application Ser. No. 09/376,832. Block 36 represents the association at a time t 0 of a source drive in any one of the data volumes C, D or E with a snapshot target drive in one of the same data volumes. Block 40 represents the copying of the time t 0 data from the source drive to the target drive in units of segments. Also, during block 40 the snapshot module 18 updates in memory in the computer system 10 to form segment metadata nodes as represented in FIGS. 4A and 4B, as will be described below.
At times, as indicated at 44 in FIG. 3, non-uniform or sparse write operations are made to regions of the source drive that are not yet copied to the target drive. In such an event, as indicated at 48 , the host write operations are momentarily backed off or delayed. This is done to allow the time t 0 data formed during block 40 to be copied to the target drive, at which time a segment metadata table in memory is updated, as shown in the previously identified co-pending, commonly owned U.S. patent application Ser. No. 09/376,832. Also, as indicated at 52 , at times read requests for data which were the subject of processing according to block 40 may be made. In that case, as block 56 indicates, the read requests of the time t 0 data are serviced. This is done by directing the read operation to either the source drive or the target drive based on the segment metadata table entry corresponding to the offset which is the subject of the read request.
FIG. 4A illustrates the topology of a conventional relationship between metadata nodes and subsequent logs formed by the snapshot module 18 in NVRAM, flash memory, disk blocks, micro drives or other kinds of non-volatile stable storage media available or present as memory of the data processing system 10 . The topology of an example metadata log of nodes N 1 , N 2 and N 3 is shown in the conventional manner of depicting metadata nodes. The metadata tree of FIG. 4A represents a data snapshot relationship in its early stage, when not much data has been copied over from the source drive to the target as part of the snapshot copy, nor have the source drive contents changed much since time t 0 , the time at which the data snapshot was established. Thus, much of the t 0 data is still available at the source drive. The only portions of the data that have been copied over are:
Offset 0, Extent 600,
Offset 728, Extent 472,
Offset 3048, Extent 200.
Node N 1 represents metadata about a storage area having an offset in disk space of 1200 data blocks and an extent of 1848 data blocks which has not yet been overwritten. Node N 2 represents metadata about a storage area having an offset in disk space of 3248 data blocks and an extent of 1,024,000 data blocks which is not yet subject to an overwrite, indicative of large areas which have not been overwritten during early stages. Further, node N 3 represents metadata about a storage area having an offset of 600 data blocks and an extent of 128 data blocks which have not yet been copied over.
FIG. 4B represents the topology of metadata nodes of FIG. 4A as modified by a write operation to the source drive at an offset of 1400, with an extent of 64 data blocks. The node N 1 at an offset of 1200 now has an extent of 200 data blocks. As can be seen, logging portions of time t 0 data not copied over, a new node as indicated at N 4 must be formed, having an offset of 1464 and an extent of 1784 data blocks. Subsequent write operations of sparse data to the source drive increase the number of nodes correspondingly and consume considerable NVRAM or other memory storage in the data processing system 10 .
FIG. 5 of the drawings is a flow diagram illustrating a process according to the present invention for updating a metadata segment table. The process of FIG. 5 is implemented as a further procedure to the procedure of block 40 performed by snapshot module 18 . The metadata nodes used in connection with the process of FIG. 5 have two additional bit fields or storage locations.
A first location SSValid (FIGS. 7 and 8) is one indicating whether a data write operation is to an area of storage volume in the data processing system 10 which has been the subject of an earlier data write operation. A TRUE indicator designates that at least a portion of the storage volume is the subject of an earlier data write, and a FALSE indicator represents the opposite.
A second location in the metadata nodes used in the process of FIG. 5 is SSIndex (FIG. 8 ), used to designate which entry in a bitmap B contains indicators of those portions of storage volume in the data processing system 10 which contain data present as a result of overwrites. The storage areas indicated may overlap fully or partially areas of earlier data as a result of overwrites, or an exact match of offset and extent may occur.
During block 60 of the process of FIG. 5, metadata tree nodes like those of FIGS. 7 and 8 are scanned for the offset and extent of a requested write operation. If a node is found with a matching or overlapping range, as indicated at 64 , a decision is made as indicated at 68 . The decision made as indicated at 68 is whether or not the range of the requested write operation is within the extent represented within the node located during the procedure of block 64 .
If this is found to be the case, a decision is then made as indicated at 72 whether the node extent is a multiple of the subsegment size. If an affirmative result is indicated, an inquiry is made, as indicated at 76 , of the status of the SSValid indicator (FIGS. 7&8) in the metadata node. If the result is an affirmative, the SSIndex portion of the metadata node is updated, as indicated at 80 , to identify the index I in the bitmap B identifying the portions of the memory storage volume which are overlapped at least in part as a result of the requested write operation. When the result of block 76 indicates that the subsegment log is not valid for that node, a block 78 performed by the snapshot module 18 causes a new subsegment index to be formed in the subsegment log or bitmap B.
If the scan operation of block 60 , however, finds no matching or overlapping node, a block 84 causes the snapshot module 18 to form a new metadata node to track the new range indicated by the offset and extent of the write operation in block 60 . The procedure of block 84 is also performed if the result of decision 68 is a negative, or if the result of decision 72 is a negative.
FIG. 6 of the drawings represents a schematic diagram of the subsegment log or bitmap B according to the present invention formed in VRAM or other memory storage of the data processing system 10 . The storage capacity of storage volumes C, D and E in the data processing system 10 is partitioned into x blocks or storage segments, each of an assigned size of data storage units, typically some binary multiple such as 64, 128, 256 or higher.
The relationship between the subsegment size and the extent of the metadata node can be expressed as:
SS_Size=Metadata_Extent/Bits_Per_SSIndex.
As an example, for a Metadata_Extent of 1024 blocks and 8 bits per SSIndex, the subsegment size, SS_Size is 128 blocks.
The bitmap B contains across its lateral extent a data space of one bit for an indicator for each of the storage segments which are so mapped. If some or all of the memory 20 in the subsegment represented by that indicator has been overwritten, the indicator at that site in the bitmap B is changed, for example from a 0 to a 1. Until an overwrite occurs, the indicator is unchanged from its original state. The bitmap B has an index I of log entries counting in ascending order from 0 and capable of being up to M in number. As entries are required into the bitmap B during block 78 of the process of FIG. 5, it is assigned the next higher number in sequence which contains no indicators that one of the storage segments 1 through x has been written over in it.
FIG. 7 represents the topology of example metadata nodes configured according to the present invention. It is to be noted that a first node 100 contains an indicator SSValid=False. Such an entry indicates that the bitmap B contains no indicators that one of the storage segments at offset 1024 and having an extent of 2048 data blocks has been overwritten the time t 0 of the write operation. Similarly a second node 102 for a write operation at offset 8192 and a third node for a write operation at offset 100 also bear an SSValid=False indicator for the same reason.
As an example, for a metadata node offset of 100 and using 8 bits per SSIndex as mentioned previously, then for a node having metadata as follows:
(Offset100:Extent 1024:SSValid TRUE:SSIndex1) and the contents of SSIndex 1 are as follows:
Bit 0 represents (Offset100:Extent128)
Bit 1 represents (Offset228:Extent128)
Bit 2 represents (Offset356:Extent128)
Bit 3 represents (Offset484:Extent128)
Bit 4 represents (Offset612:Extent128)
Bit 5 represents (Offset740:Extent128)
Bit 6 represents (Offset868:Extent128)
Bit 7 represents (Offset996:Extent128)
It is to be noted the Offset:Extent represented by each bit is implicit, and relative to that of the metadata node, and no storage except for the single bit itself is required. In a worst case situation, for example, if there occurred writes at offsets 228, 484, 740, 996, what potentially could have been new metadata nodes used in prior techniques can be represented by the eight bits in the bitmap example above. Bits 1 , 3 , 5 and 7 are a “1” value should such a sequence of writes occur after a snapshot has been established.
In the topology depicted in FIG. 7, a write operation to source drive at offset 1536 for an extent, for example, of 56 data blocks entails that the subsegment index for that node be modified in the bitmap B for node 100 . Node 100 is then modified according to the present invention to the form shown in FIG. 8 . Node 100 as modified indicates SSValid=True and the first SSIndex identifier 0 corresponding to the first index in the bitmap B (FIG. 9 ). In the bitmap B, a bitmap position indicated at 120 corresponding to the offset and extent of the write operation is the third one, as indicated. This signifies that a small extent within the large extent of the node 100 has been copied over to the target drive.
Subsequent write operations to different extents within node 100 do not require formation of new and additional metadata nodes or that an additional index be formed. Rather, the SSIndex already present in the bitmap B is updated. Those portions of the bitmap B corresponding to the offset and extent of a new write operation are assigned a “1” value, and the SSIndex indicator is modified, as well. The newly assigned “1” value replaces an initial “0,” thus now signifying that those segments previously not copied over have now been the subject of a write operation, and thus have changed at the source drive since time t 0 . Subsequent read operations look to the bitmap B to determine whether the time t o data is available from the target drive, or should be obtained from the source drive. At the time all t 0 data in the range of a node has been copied from the source to the target, all of the bits in an SSIndex indicator have been changed to “1” from “0”. This is an indication that the entire extent of the metadata node represented in the bitmap B by that particular SSIndex has been copied over and the bitmap at that SSIndex can be freed. In the topology that metadata node itself can in effect be deleted. The metadata tree is then modified appropriately to represent the new situation. In this manner when there is no need for a metadata node any longer, its associated subsegment table entry in the bitmap B is cleared.
Thus, with the present invention, the bitmap B indicates in conjunction with the process of FIG. 6, in the metadata nodes which of those nodes have data which has been overwritten. This is done without requiring formation of additional metadata nodes for the overwritten data. It is not necessary to form extra metadata nodes to keep track of small changes due to sparse writes to the source drive.
Various modifications of the disclosed embodiment, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined in the appended claims.
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A data processing system and method manage usage metadata nodes about data snapshots of data write operations among storage volumes of the system while conserving metadata nodes. Metadata sublogging is achieved by dividing metadata segments into subsegments and tracking them by use of a bitmap.
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BACKGROUND
[0001] The present application relates to a system for inserting and removing cables from computer receptacles and in particular to a system for inserting and removing entire rows of cables.
[0002] One issue in the design of high-performance computing or networking equipment is the issue of interconnection between printed circuit boards (PCBs), i.e., from one PCB to another PCB. Within a PCB, electronic processing circuitry can be interconnected using wiring layers within the printed circuit board. This type of interconnect can provide high performance and density—supporting up to thousands of interconnection wires, operating at rates potentially greater than 1-10 Gbps. However, interconnections between PCBs are more difficult, requiring either backplane-style boards that the interconnecting circuit boards plug into using backplane connectors, or cables. This results in the use of cable connectors (or backplane-style connectors) and bulk cable with wires or flex circuitry. As processing circuitry has steadily improved in performance and density, these board-to-board interconnection methods have become an increasingly-large bottleneck in design, since the density and bandwidth performance of cable connectors and electrical backplane connectors has not increased at the same rate as the processing circuitry.
BRIEF SUMMARY
[0003] In accordance with an embodiment, a method is provided. The method includes providing an installation tool having a first body with a plurality of arms extending from one side, the plurality of arms being configured to receive a cable connector body, the plurality of arms including at least one first projection extending from one of the plurality of arms. The installation tool is moved onto a row of cables held coupled together by a bracket, each of the cables in the row of cables having a cable connector body. The connector bodies are engaged into receptacles. The bracket is moved with the at least one first projection.
[0004] Another embodiment is directed to a tool for installing a row of cables from a cable array is provided. Each cable includes a connector configured to couple with a receptacle and a tab member configured to disengage the connector from the receptacle. The tool includes a body. A plurality of arms extending from one end of the body, the plurality of arms defining a plurality of openings, each of the plurality of openings sized to receive one of the connectors. At least one projection extends from an end of at least one of the plurality of arms.
[0005] Still another embodiment is directed to a tool for removing a row of cables from a cable array is provided. Each cable includes a connector configured to couple with a receptacle and tab member configured to disengage the connector from the receptacle. The tool includes a body. A handle portion is arranged on one side of the body. A plurality of engagement members extend from one side of the body, each of the plurality of engagement members having a first projection and a second projection separated by a slot, the slot being configured to receive one of the tab members.
[0006] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 illustrates an exemplary row of cables in accordance with one or more embodiments;
[0009] FIG. 2 illustrates an exemplary array of cables coupled to a receptacle block in accordance with one or more embodiments;
[0010] FIG. 3 illustrates a perspective view of an exemplary installation tool in accordance with one or more embodiments;
[0011] FIG. 4 illustrates a reverse perspective view of the installation tool of FIG. 3 ;
[0012] FIG. 5 illustrates an end view of the installation tool of FIG. 3 ;
[0013] FIG. 6 illustrates a perspective view of the installation tool of FIG. 3 being coupled to a row of cables in accordance with one or more embodiments;
[0014] FIG. 7 illustrates the installation of a row of cables into receptacles using the installation tool of FIG. 3 in accordance with one or more embodiments;
[0015] FIG. 8 illustrates a perspective view of the row of cables installed in the receptacles using the installation tool of FIG. 3 in accordance with one or more embodiments;
[0016] FIG. 9 illustrates a perspective view of an exemplary removal tool in accordance with one or more embodiments;
[0017] FIG. 10 illustrates a perspective view of the removal tool of FIG. 10 ;
[0018] FIG. 11 illustrates an end view of the removal tool of FIG. 10 ;
[0019] FIG. 12 illustrates a perspective view of the removal tool of FIG. 10 being coupled to a row of cables tool in accordance with one or more embodiments;
[0020] FIG. 13 illustrates a perspective view of the removal tool of FIG. 10 coupled on a row of cables tool in accordance with one or more embodiments; and
[0021] FIG. 14 illustrates a perspective view of the row of cables being removed from the receptacles using the removal tool of FIG. 10 tool in accordance with one or more embodiments.
DETAILED DESCRIPTION
[0022] Embodiments of the disclosure may be used in connection with interconnection networks for computers, switches and other information technology equipment, such as high-density networks for large clustered systems, high-performance computing and supercomputing systems, and cloud computing systems, for example. Embodiments of the disclosure may be applied in the area of electrical backplanes or optical backplanes, arrays of cables, connector arrays, and cable harnesses that interconnect, e.g., dozens or hundreds of switching elements, also termed switches or switch ICs or switch chips.
[0023] Embodiments of the disclosure may be used in connection with so-called “all-to-all” or “full mesh” networks, in one or more levels, where a multiplicity of switching elements (on the order of 16 to 64 or 128 switching elements in some embodiments) each have links to most or all of the other switching elements. Such networks, with ports interconnecting each switching element or with a large number of other switching elements (i.e., “high-radix” switching elements) are only recently technically feasible and cost-effective. Previously, integrated circuit switching chips could only be cost-effectively constructed using commonly-available CMOS integrated circuit technology, with a moderate number (e.g., 8-24) of ports. Such “all-to-all” or “full mesh” networks may be used to avoid or mitigate against deficiencies, such as congestion and extra latency that may be inherent in Multi-stage Interconnection networks using other topologies, such as Torus (in 2, 3, 4, 5, 6, or more dimensions), or Omega (also called “Butterfly” or “Clos”, or “Fat Tree”) topologies, where traffic must traverse several intermediate switching elements to traverse the network.
[0024] While all-to-all or full-mesh networks may have advantages over other network topologies in terms of performance, routing simplicity, and robustness against link failures, they might have several disadvantages or deficiencies. Such deficiencies may include one or more of: (a) each switching element must support a large number of ports, which must be tightly-packed, requiring high-density connector packing, (b) the network requires a large number (on the order of n 2 ) of interconnecting cables, and (c) the interconnecting cables form a complex topology, since the links connecting to each of the switching elements are “shuffled” and distributed across all of the other switching elements.
[0025] In order to address or alleviate one or more of the aforementioned deficiencies, embodiments of the disclosure may be used to simplify the construction and manufacturing of such all-to-all interconnection networks. In some embodiments, a generic decomposition of a single all-to-all interconnection network topology into a multiplicity of smaller all-to-all interconnection network elements may be provided, which can be replicated in a modular fashion, to construct the full topology. In this manner, an all-to-all topology may be broken down into units that can be replicated, where each unit may be larger or include more connections than a base-unit of a wire.
[0026] In the specific illustrative instance of optical networks with even numbers of drawers or books or blades, each containing a multiple of four (4) switching elements, use of multiple “shuffle cables” may be provided, where each shuffle cable may implement a 4×4 all-to-all topology, with a link width of one (1) or more fibers per link direction. Illustrative embodiments described herein show a topology with a drawer that contains eight (8) switching elements, and each link encompasses (6+6) fibers (i.e., six (6) fibers in each of the two directions), which implies that the entire structure may incorporate a modular aggregation of twenty-four (24) shuffle cables, with each shuffle cable implementing a 4×4×(6+6) all-to-all topology, incorporating one-hundred ninety-two (192) separate optical fibers or waveguides channels. Since each of the twenty-four (24) shuffle cables incorporates four (4) connectors on each of the two (2) ends, this complete optical backplane assembly may incorporate a total of one-hundred ninety-two (192) connectors, each of which may be a 48-fiber connector, using a standard “MT” or “MPO” Multi-fiber Push On/Pull Off optical connector design.
[0027] Embodiments of the disclosure may be used to enclose all (e.g., 4,608) fibers in 192 connectors and 24 “shuffle cartridges” in a high-density aggregation of approximately 4″×16″×8″. An enclosure may incorporate both rigid and flexible components, providing: (a) close mechanical tolerances for connector plugging within each of the drawers (i.e., to approximately +/−0.1 millimeters in each of the 3 dimensions), while simultaneously maintaining looser mechanical tolerances (i.e., to approximately +/−5 millimeters) among the drawers, (b) robust protection of delicate optical fibers within a rigid shell, casing, or enclosure, and (c) incorporation of “gang-plug” handles that each actuate a multiplicity of the MPO.
[0028] Embodiments of the disclosure may include one or more cables, such as a fiber optic cable 102 for example. A cable may be configured to convey multiple arrays of signals from multiple multi-fiber optical connectors associated with a first printed circuit board (PCB) to multiple multi-fiber optical connectors associated with a second or another PCB.
[0029] An illustrative set of cables 100 is shown in FIG. 1 . The cable 100 may contain a number of optical fibers. For example, in some embodiments the set of cables 100 may be arranged in rows of eight cables 102 , each having a connector 104 on each end. The cables may be those described in U.S. patent application Ser. No. 12/614,391 entitled “Removable Sleeve for Fiber Optic Connectors for High Density Applications” filed on Nov. 6, 2009, which is incorporated herein by reference. Each row of cables may be grouped together with eight other rows to form an 8 × 8 matrix or block as shown in FIG. 2 that couple with receptacles 106 in a drawer 110 . It should be appreciated that the drawer 110 includes a corresponding number of receptacles 106 . To assist in organizing, aligning and maintaining the connectors 104 , a bracket 108 or grouper member may be used for holding the connectors 104 during insertion and removal.
[0030] Each of the connectors 104 includes a body 112 that is configured to couple the cable 102 to the receptacle 106 to allow signals to pass therebetween. The body 112 further includes an attachment mechanism, such as a snap fit for example, which mechanically couples the connector 104 to the receptacle 106 . To facilitate the coupling and uncoupling of the body 112 from the receptacle 106 a tab member 114 , sometimes called a “push/pull tab,” is provided that allows the operator to engage and disengage the attachment mechanism. In the exemplary embodiment, by moving the tab member 114 away from the receptacle 106 the attachment mechanism is disengaged.
[0031] Referring now to FIGS. 3-5 , an insertion tool 116 is provided that provides advantages in facilitating the insertion of a row of cables 102 into a row of receptacles 106 in drawer 110 . The insertion tool 116 includes a generally planar body 118 that has a U-shaped portion 120 that extends from one side. The U-shaped portion 120 defines an opening 122 that is sized to receive the operator's fingers. During use, the operator inserts their fingers through the opening 122 and grasps the U-shaped portion 120 to allow the operator to firmly hold the insertion tool 116 .
[0032] Opposite the U-shaped portion 120 , the insertion tool 116 includes a plurality of arms 124 that extend outward from the body 118 (e.g. away from the U-shaped portion 120 ). In the exemplary embodiment, the insertion tool includes N+1 arms, where “N” is the number of cables 102 in the row being inserted. The plurality of arms 124 are spaced apart to define openings 126 that are sized to receive the connectors 104 . In the exemplary embodiment, the plurality of arms 124 includes a plurality of second arms 128 , a plurality of third arms 130 and a fourth arm 132 . Each of the plurality of third arms 130 includes a projection 134 that extends from an end opposite the body 118 . In the exemplary embodiment, the plurality of second arms 128 is interspersed between the plurality of third arms 130 . For example, the arm 130 A is arranged between the arms 128 B, 128 C while the arm 130 B is between the arms 128 C, 128 D and the arm 130 C is between the arms 128 D, 128 E.
[0033] The arms 128 each have a body portion 136 having a height 138 that is generally the same as the body 118 and a width 140 . In one embodiment, the width 140 is larger on some arms 128 to accommodate non-uniform receptacle 106 spacing due to walls 141 ( FIG. 7 ). In one embodiment, the arm 128 A has a width 144 that is larger than the width 140 of the other arms 128 to provide additional structural support. Further, each arm 128 includes a flange 142 that extends generally perpendicular to the body portion 136 in a direction towards the arm 132 . The flange 142 forms an L-shaped structure that allows the arms 128 to fit tightly against the connectors 104 without interfering with the tab member 114 .
[0034] The arms 130 are similarly arranged to the arms 128 having a body portion 146 and a width 148 . In the exemplary embodiment, the width 148 is larger than the width 140 . The arms 130 also include a flange 142 that extends generally perpendicular to the body portion 146 in a direction toward the arm 132 . The arm 132 does not include a flange, but rather has a substantially uniform thickness along the length since there is no adjacent tab member that it will interfere with. In one embodiment, the arm 132 has a square profile.
[0035] Referring now to FIGS. 6-8 , the operation of the insertion tool 116 will be described. First the operator prepares the cables 102 for installation by inserting the cables 102 and connectors 104 into the bracket 108 . The insertion tool 116 is then slid on to the assembly of cables ( FIG. 6 ) with the arms 128 , 130 , 132 disposed about the cables 102 . The insertion tool 116 is moved into position with the ends of the projections 134 in contact with the bracket 108 ( FIG. 7 ) such that the flanges 142 are disposed in contact on the bottom of the connectors 104 . Using the U-shaped portion 120 as a handle, the operator may orient and align the row of cables with the drawer 110 ( FIG. 7 ) and insert the connectors 104 into the receptacles 106 ( FIG. 8 ) with the bracket 108 pushed against the drawer 110 by the projections 134 . Once the cables 102 are coupled to the drawer 110 , the insertion tool 116 may be slid in the reverse direction to remove the insertion tool from the assembly. It should be appreciated that the insertion tool 116 may be used to insert the row of cables into any of the rows within the drawer 110 even if other rows of cables have already been installed.
[0036] Referring now to FIGS. 9-11 , an exemplary removal tool 150 is shown that may be used to decouple and extract a row of cables 102 from the drawer 110 . The removal tool 150 includes a generally planar body 152 with a U-shaped handle portion 154 extending from one end. The U-shaped handle portion 154 defines an opening 156 that is sized to receive the operator's fingers. The U-shaped handle portion 154 includes a flange member 158 that increases the thickness of the handle and facilitates the grasping of the handle by the operator while allowing the body portion 152 to remain relatively thin. It should be appreciated that a relatively thin body portion 152 allows the body portion 152 to be inserted between rows of cables 102 to allow an operator to remove an internal row of cables from the drawer 110 without removing the adjacent rows.
[0037] Extending from one side 160 are a plurality of engagement members 162 that are configured to engage the tab member 114 and release the connector mechanism from the receptacle 106 . In the exemplary embodiment, each engagement member 162 is comprised of a first projection 164 and a second projection 166 that are separated by a slot 168 . The slot 168 is sized to fit around the shaft 115 ( FIG. 1 ) to allow the ends 170 , 172 of the projections 164 , 166 to engage the head portion 117 of the tab member 114 . In one embodiment, an angled surface is arranged on an end of the projections 164 , 166 distal from the side 160 of the body portion 152 .
[0038] On an opposing side 174 from the engagement member 162 , the removal tool 150 has a plurality of ribs 176 . The ribs 176 are generally tapered with a base portion being thicker than the tip to allow them to fit in between the cables 102 when the removal tool 150 is inserted into a matrix of cables. In one embodiment, the plurality of ribs 176 includes a first plurality of ribs 178 and a second plurality of ribs 180 . The ribs 180 are wider than the ribs 178 to accommodate the walls 141 in the drawer 110 . Each of the ribs 176 has a first side and a second side with the first side being positioned opposite one of the projections 164 . In one embodiment, the engagement members include a plurality of engagement members arranged opposite the ribs 176 and an engagement member arranged on the end.
[0039] Referring now to FIGS. 12-14 , the operation of the removal tool 150 is shown for extracting a row of cables 102 from the drawer 110 . First the operator identifies the row of cables 102 to be removed and slides the removal tool 150 over the row of cables 102 with the engagement members 162 facing the connectors 104 ( FIG. 13 ). The engagement members 162 are inserted onto the tab members 114 such that the shaft portion 115 is positioned within the slots 168 . In this position, the engagement member 162 is arranged between the head portion 117 and the receptacle 106 . The operator then grasps the handle portion 154 and moves the removal tool 150 in the direction away from the drawer 110 . This causes the ends 170 , 172 to contact the head portion 117 of the tab member 114 , resulting in the connector mechanism disengaging from the receptacle 106 ( FIG. 14 ). The operator then continues to move the row of cables 102 away from the drawer 110 and separates the row of cables 102 from the cable matrix ( FIG. 14 ). It should be appreciated that the removal tool 150 may be used to extract any row of cables from the matrix and that the tool may be used to extract an internal row without removing the adjacent rows.
[0040] Embodiments of the invention provide a system having the insertion tool 116 and the removal tool 150 that provides advantages in the insertion and extraction of rows of cables 102 having connectors 104 in a cable matrix coupled to a drawer. The system provides advantages in reducing the time for installation and removal. The system provides further advantages in increasing the reliability of servicing by reducing the risk of cables being installed in the wrong receptacles.
[0041] The values shown and described herein in connection with the various embodiments are illustrative. In some embodiments, values or configurations different than those explicitly described herein may be used.
[0042] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0043] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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A method and system for installing and removing a row of cables from a cable array is provided. The method includes providing an installation tool having a first body with a plurality of arms extending from one side. The plurality of arms being configured to receive a cable connector body, the plurality of arms including at least one first projection extending from one of the plurality of arms. The installation tool is moved onto a row of cables held coupled together by a bracket, each of the cables in the row of cables having a cable connector body. The connector bodies are engaged into receptacles and the bracket is moved with the at least one first projection.
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FIELD OF THE INVENTION
[0001] The present invention relates to a panel unit of controllable radiation transmissivity for the construction of walls, roofs, awnings, skylights, windows, and the like.
BACKGROUND OF THE INVENTION
[0002] Israel Patent Application No. 124,949 teaches a panel which comprises a plurality of rotatable members having an opaque surface, which members, when rotated, are adapted, in at least one angular position, to substantially block the passage of light through the panel, and, in a plurality of other, selectable angular positions, to provide a plurality of differing radiation transmissivities.
[0003] While the above-mentioned panel does indeed provide a steplessly adjustable light transmissivity, it has certain disadvantages, inasmuch as the rotatable light-blocking members are accommodated in an array of tubular cells of relatively large size and wall thickness, that add to the costs of these panels.
DISCLOSURE OF THE INVENTION
[0004] It is an object of the present invention to ameliorate the disadvantages of the prior art light-blocking panels and to provide a panel unit having controllable radiation transmissivity facilitating substantially the complete blocking of radiation.
[0005] The invention therefore provides a panel unit of controllable radiation transmissivity, comprising a housing constituted by a front, radiation-receiving panel and a rear panel, said panels being spaced apart and connected to one another by connecting means; a plurality of rotatable radiation-blocking members disposed between said front panel and said rear panel, said members being rotatable from one angular position in which said radiation-blocking members are adapted to substantially block the passage of light through said panel unit, to a selectable plurality of other angular positions in which said radiation-blocking members are adapted to provide a plurality of differing radiation transmissivities; characterized in that first guiding surfaces for said rotatable radiation-blocking members are disposed inside of, and extend across, said housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures so that it may be more fully understood.
[0007] With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0008] In the drawings:
[0009] [0009]FIG. 1 is an exploded view of the panel unit according to the present invention;
[0010] [0010]FIG. 2 is an end view of the panel unit of FIG. 1, without the drive mechanism and its housing;
[0011] [0011]FIG. 3 is a perspective view, in partial cross-section and to a larger scale, of the rotatable radiation-blocking member;
[0012] FIGS. 4 - 6 illustrate variants of the radiation-blocking member;
[0013] [0013]FIG. 7 represents the general shape and location of the lower cross-members;
[0014] [0014]FIG. 8 indicates the shape and location of the upper cross-member to a larger scale;
[0015] [0015]FIG. 9 is an exploded view of part of the drive mechanism;
[0016] [0016]FIG. 10 is a partial top view of the cross-member accommodating the drive mechanism;
[0017] [0017]FIG. 11 is a side view of the components shown in FIG. 10;
[0018] [0018]FIG. 12 illustrates the components of the gearbox of FIGS. 10 and 11;
[0019] [0019]FIG. 13 illustrates the fully encased gearbox, and
[0020] [0020]FIG. 14 is an end view of another embodiment of a panel unit according to the invention.
DETAILED DESCRIPTION
[0021] Referring now to the drawings, FIG. 1 illustrates a radiation-receiving front panel 2 , a rear panel 2 ′ and two lateral connecting members 4 , 4 ′ which, in assembly, constitute the housing of the panel unit according to the present invention. These components are seen to better effect in FIG. 2 and will be explained in detail further below.
[0022] Further seen in FIG. 1 is a battery of rotatable radiation-blocking members 6 disposed between front panel 2 and rear panel 2 ′. This central component of the panel unit is shown to a larger scale in FIGS. 2 and 3, and will be discussed in conjunction with these Figures. The radiation-blocking members 6 are supported by lower cross-members 8 of which, in the panel of FIG. 1, there are three, resting, in assembly, on rear panel 2 ′. The number of these cross-members obviously depends on the actual length of the panel unit. Also seen are upper cross-members 9 , in assembly, substantially co-planar with, but above, the lower cross-members 8 . Both the upper and lower cross-members will be discussed further below in conjunction with FIGS. 2, 4 and 5 . Cross-members 8 and 9 are shown to better effect in FIGS. 4 and 5, respectively.
[0023] [0023]FIG. 1 also illustrates the drive mechanism, which includes an electric motor 10 coupled to a reduction gear 12 that drives the radiation-blocking members 6 via gearboxes 14 , each member having its own gearbox 14 . Cross-member 16 , advantageously made of an aluminum extrusion, serves as housing for the drive mechanism and also closes off the front end of the panel unit. Cross-member 16 , as well as the drive mechanism, is covered by a cover plate 18 .
[0024] Supporting rings 20 , their purpose and the manner of their mounting, are discussed below in conjunction with FIGS. 2 and 3.
[0025] [0025]FIG. 2 is a fragmented end view of the assembled panel unit, but without the drive mechanism and its housing. There are seen front panel 2 and rear panel 2 ′, two substantially identical plastic extrusions, advantageously made of polycarbonate. Each panel consists of two spaced-apart plane sheets interconnected by ribs 22 , 22 ′, which provide mechanical strength and define air spaces for thermal and acoustic insulation. Each panel is also provided with flanges 24 on each of its lateral edges. The inside surface of each flange 24 is comprised of sawtooth-like barbs 26 , which are adapted to engage and lock against similarly shaped barbs 28 in a lateral, substantially H-shaped, connecting member 30 . The latter is advantageously made of an aluminum extrusion and connects not only the front and rear panels of a single panel unit, but also, as is clearly shown, constitutes the connecting member of adjacent panel units. Member 30 is furthermore provided with a number of rail-like ledges 32 , 34 , 36 and 32 ′, 34 ′, 36 ′, the purpose of which will become apparent further below.
[0026] It will be appreciated that, the above notwithstanding, the panels could also be single-plane sheets or even glass sheets, and that the panels could be connected at their front and rear ends, rather than laterally.
[0027] Inside the space defined by front panel 2 , rear panel 2 ′ and connecting members 30 (FIG. 2), there are located a plurality of rotatable, radiation-blocking members 6 , supporting rings 20 for members 6 , lower cross-member 8 and upper cross-member 9 .
[0028] Radiation-blocking member 6 , shown to better effect in FIG. 3, is a tubular, generally transparent, plastic extrusion with a profile advantageously reinforced by horizontal and vertical ribs 38 , 38 ′ respectively, and is approximately semi-cylindrical, subtending an angle of about 180°. The top surface of member 6 is substantially plane and is rendered opaque (hereinafter “opaque plane 40 ”) by such known means as painting, coating with an opaque film, or the provision of an opaque plastic layer applied by coextrusion. Edges 42 , 42 ′ of member 6 extend beyond the largest width of the semi-circular profile, edge 42 being coplanar with top surface 40 , while edge 42 ′ is stepped down to a depth equaling the thickness of protruding edge 42 , so that, in the blocking position represented in FIG. 2, the two edges overlap and also provide abutment surfaces.
[0029] Supporting rings 20 are made of a plastic material and are thin enough to be elastically deformable, having an inside diameter substantially identical with the outside diameter of the semi-circular profile, and are sprung into pairs of recesses 44 , 44 ′ provided in edges 42 , 42 ′ at appropriate distances, depending on the total length of the panel unit.
[0030] Rings 20 are in turn supported by lower cross-member 8 , which has the form of an extruded plastic T-profile that rests on rear panel 2 ′ and is held in position by ledges 32 , 32 ′ of connecting members 4 . The vertical web 46 of cross-member 8 is provided with preferably cylindrical recesses 48 , of a curvature slightly smaller than the outside curvature of rings 20 , so that the latter have only line contact with recesses 48 .
[0031] Further envisaged variants of radiation-blocking member 6 are illustrated in FIGS. 4 - 6 . FIG. 4 shows a first of such variants, in the form of a tubular, fully cylindrical portion 7 consisting of a transparent plastic extrusion and comprising a diametrical, substantially opaque planar partition 41 , co-extruded with the cylindrical portion 7 , but made of an opaque plastic.
[0032] [0032]FIG. 5 illustrates another cylindrical variant of radiation-blocking member 6 , in which the transparent, tubular, cylindrical portion 7 is provided with two diametrically opposite pairs of inward-pointing, short flanges 11 , 11 ′, defining between the partners of each pair a slot, into which is slid an opaque strip 43 , either of plastic or metal.
[0033] [0033]FIG. 6 illustrates a further variant of radiation-blocking member 6 , seen to consist of two transparent, substantially half-cylindrical portions 13 , 13 ′ and a substantially planar, diametrical, opaque partition 41 . The two half-cylindrical portions 13 , 13 ′ are laterally mutually offset, producing a left overhang 15 and a right overhang 17 . It is seen that the right overhang 17 is stepped down, so that in the blocking position shown in FIG. 6, overhangs 15 and 17 overlap and also constitute abutment surfaces, with all opaque surfaces being rendered co-planar.
[0034] The variants of FIGS. 4 - 6 do not require the use of rings 20 and are therefore in direct contact with recesses 48 in cross-member 8 .
[0035] Another solution could be in the form of a flat, elongated strip with a zebra-like cross-section, looking as if cross-hatched, in which transparent stripes alternate with opaque stripes. Such a strip could offer maximal transmissivity at a certain angle of incidence, and substantial opacity at another angle of incidence.
[0036] [0036]FIG. 7 illustrates the general shape and location of lower cross-member 8 with respect to lower panel 2 ′.
[0037] Upper cross-member 9 , seen in FIG. 2 and, to better effect, in the perspective drawing of FIG. 8, has the task of substantially maintaining the contact between radiation-blocking members 6 and their rings 20 with the curved recesses of lower cross-member 8 , but without causing additional friction when members 6 are rotated. This is achieved by providing a small gap a between rings 20 and the lower surface of upper cross-member 9 , as clearly seen in FIG. 2. Cross-member 9 , a U-profile advantageously produced by extrusion (see also FIG. 8) is located above rings 20 and is held in this position by ledges 34 , 36 of connecting member 4 .
[0038] As mentioned above, FIG. 2 represents the state of maximum opacity of the panel unit. Radiation transmissivity increases when, relating to FIG. 2, radiation-blocking members 6 are rotated in the clockwise sense, with transmissivity becoming maximal when the opaque plane 40 (FIG. 3) is rotated into a position where it offers the least surface area to the sun or the brightest part of the sky.
[0039] [0039]FIG. 9 represents an exploded view of part of the drive mechanism, including cross-member 16 which accommodates the entire mechanism, motor 10 , advantageously a stepping motor, manually and/or electronically controlled, depending upon light conditions sensed by a photodetector. Further seen are reduction gear 12 and slotted shaft 50 , extending over the entire width of the unit. A gear 52 , meshing with the output gear 54 of reduction gear 12 , is keyed to shaft 50 . Also seen are two posts 56 , whereby the motor-gearbox unit is attached to cross-member 16 . Partly shown is the first of cross-members 8 , which defines the respective positions of gearboxes 14 (FIG. 10).
[0040] Shown in the top view of FIG. 10 are gearboxes 14 , which, as will be seen in FIGS. 12 and 13, are in fact worm gears, all of which are keyed to and are driven by shaft 50 . The worm wheels are keyed to coupling members 58 , being the output members of gearboxes 14 . Coupling members 58 are provided with shaped projections, part of which fit the spaces created by reinforcing ribs 38 , 38 ′ of radiation-blocking members 6 , thus constituting the drivers of members 6 .
[0041] In the side view of FIG. 11, there are shown extruded cross-member 16 , reduction gear 12 , a second vertical member 60 of the extrusion, a low rail 62 that is an integral part of the extrusion, the first of the three cross-members 8 that, in the embodiment of FIG. 1, support the radiation-blocking members 6 , and coupling member 58 .
[0042] Gearbox 14 , to be discussed in greater detail below with reference to FIGS. 12 and 13, is positioned between vertical member 60 and rail 62 , but has one degree of freedom in translation in a direction perpendicular to the paper, which enables it to align itself with radiation-blocking members 6 , the positions of which are defined by the recesses in webs 46 of cross-member 8 .
[0043] [0043]FIG. 12 illustrates the components accommodated in gearbox 14 of FIGS. 10 and 11, already defined as a worm gear. Worm 64 is keyed to shaft 50 by means of key 65 , but has one degree of freedom in translation in the axial direction of shaft 50 . Worm 64 meshes with worm wheel 66 , which, in turn, is keyed to axle 68 of coupling member 58 ; thus, rotation of shaft 50 will produce a rotation (at reduced speed) of coupling member 58 .
[0044] Axle 68 ends in a flange 70 , from which project drive fingers 72 A, 72 B, 72 C and 72 D. Of these fingers, 72 A and 72 B fit, and thus can be slipped into, the two spaces produced in radiation-blocking members 6 below horizontal reinforcing rib 38 (FIG. 3), and fingers 72 C and 72 D come to rest on opaque plane 40 of member 6 .
[0045] Further seen are two elastic fingers 74 which, at their ends, carry cupped projections 76 . These projections are designed to be snapped into two holes (not shown) of appropriate size and location near the end of each radiation-blocking member 6 , thus constituting a positive link between members 6 and coupling members 58 .
[0046] [0046]FIG. 13 represents the fully encased gearbox 14 . There is also seen an annular segment 78 , integral with the casing and subtending a defined angle which is configured to cooperate with a similar segment (not shown) integral with flange 70 , which segments constitute a stop and also serve as reference points for the proper assembly of the panel unit.
[0047] [0047]FIG. 14 illustrates another embodiment of the invention which dispenses with the separate, H-shaped connecting members 30 of FIG. 2 by providing each of the panels with a relatively short, slender flange 24 , such as shown in FIG. 2, and a longer and heavier flange 80 , the lower end of which is configured to constitute a connecting member in the form of a female counterpart to flange 24 . The sawtooth-like barbs 28 of flange 24 are adapted to engage and interlock with similarly shaped barbs 82 within the end portion of flange 80 .
[0048] While it would, of course, be possible to provide one of panels 2 , 2 ′ with two flanges 24 and the other one with two flanges 80 , the advantage of the design illustrated in FIG. 14 resides in the fact that the same extruded profile can be used for front panel 2 and, simply turned around, also for rear panel 2 ′.
[0049] Cross members 8 , 9 are fixedly attached to their respective panels, e.g., by cementing.
[0050] It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes 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.
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The invention provides a panel unit of controllable radiation transmissivity, including a housing constituted by a front, radiation-receiving panel and a rear panel, the panels being spaced apart and connected to one another by connecting means; a plurality of rotatable radiation-blocking members disposed between the front panel and the rear panel, the members being rotatable from one angular position in which the radiation-blocking members are adapted to substantially block the passage of light through the panel unit, to a selectable plurality of other angular positions in which the radiation-blocking members are adapted to provide a plurality of differing radiation transmissivities; characterized in that first guiding surfaces for the rotatable radiation-blocking members are disposed inside of, and extend across, the housing.
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BACKGROUND OF THE INVENTION
[0001] The present application claims priority from Japanese Application 2010-008717, filed on Jan. 19, 2010, the entire contents of which being incorporated herein by reference.
[0002] 1. Field of the Invention
[0003] The present invention relates to a cartridge for chemical processing, the cartridge carrying out chemical processing while moving a content by deformation based on an externally applied force.
[0004] 2. Description of the Related Art
[0005] There has been known a cartridge for chemical processing, the cartridge carrying out chemical processing while moving a content by deformation based on an externally applied force. The cartridge for chemical processing has formed therein wells and channels that are shaped and arranged suitably for the procedure of desirable chemical processing. If the content is moved, for example, by sliding a roller while the roller is pressed against the cartridge, the chemical processing based on the procedure can be easily executed.
[0006] Japanese Unexamined Patent Application Publication No. 2004-226068 discloses a cartridge for chemical processing that houses a microarray chip. With this cartridge, hybridization can be performed at the microarray chip by moving a solution with application of an external force. Also, target molecules can be measured by optically measuring the microarray chip from the outside of the cartridge through a window that is formed of a silicone rubber.
[0007] However, with the cartridge of related art, bright spots caused by, for example, impurities in the silicone rubber, which is used as the window, disturb the optical measurement. In addition, the silicone rubber is deformed and hence cannot maintain uniformity of the gap between the microarray chip and the window. The flow of effluent after the hybridization is not uniform for the entire microarray chip. In some cases, the silicone rubber may even contact the chip. As the result, the effluent remains uneven, and measurement accuracy is degraded.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a cartridge for chemical processing that can increase inspection accuracy with a microarray chip.
[0009] A cartridge for chemical processing according to an aspect of the present invention carries out chemical processing while moving a content by deformation based on an externally applied force, and includes a microarray chip housed in the cartridge for chemical processing; a member having a surface that faces a surface of the microarray chip; a supporting unit for supporting the member such that a width of a gap between the member and the microarray chip is variable by the externally applied force; and a limiting unit for restricting a variable range of the gap by the supporting unit such that the width of the entire gap between the surface of the member and the surface of the microarray chip does not become smaller than a predetermined width.
[0010] With the cartridge for chemical processing, the variable range of the gap is restricted such that the width of the entire gap between the surface of the member and the surface of the microarray chip does not become smaller than a predetermined width. Accordingly, the gap between the surface of the member and the surface of the microarray chip can be properly controlled, and the inspection accuracy with the microarray chip can be increased.
[0011] The limiting unit may be provided at the member.
[0012] The limiting unit may be formed at the member and serve as a contact portion that contacts the surface of the microarray chip.
[0013] Alternatively, the limiting unit may be formed at the microarray chip and serve as a contact portion that contacts the surface of the member.
[0014] The gap between the surface of the member and the surface of the microarray chip may be uniform when the gap is restricted by the limiting unit.
[0015] The member may be transparent and the surface of the microarray chip may be optically measurable through the member from the outside of the cartridge for chemical processing.
[0016] Alternatively, the microarray chip may be transparent and the surface of the microarray chip may be optically measurable through the microarray chip from the outside of the cartridge for chemical processing.
[0017] The member may have an extending portion that pushes and eliminates a space in the cartridge for chemical processing in an area surrounding the microarray chip when the member is pressed against the microarray chip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A and 1B illustrate a configuration of a cartridge for chemical processing according to an embodiment, FIG. 1A being a cross-sectional view showing the configuration of the cartridge for chemical processing, FIG. 1B being a plan view from a direction indicated by line IB-IB in FIG. 1A ;
[0019] FIGS. 2A and 2B illustrate states during hybridization, FIGS. 2A and 2B being cross-sectional views of cartridges for chemical processing;
[0020] FIGS. 3A to 3C illustrate a portion of a cartridge having a member facing a microarray chip, FIG. 3A being a cross-sectional view of a cartridge for chemical processing having a member, FIG. 3B being an enlarged cross-sectional view of the member, FIG. 3C being a cross-sectional view of a cartridge for chemical processing showing a reinforcing method of the member;
[0021] FIGS. 4A and 4B illustrate alternative configurations of members, FIG. 4A being a cross-sectional view showing an example in which the member is provided with a bonding portion having a flange-like extending portion, FIG. 4B being a cross-sectional view showing a situation without an extending portion; and
[0022] FIGS. 5A and 5B illustrate a cartridge for chemical processing configured to read a microarray chip from a substrate according to another embodiment, FIGS. 5A and 5B being cross-sectional views of the cartridge for chemical processing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Cartridges for chemical processing according to embodiments of the present invention will now be described.
[0024] FIG. 1A is a cross-sectional view showing a configuration of a cartridge for chemical processing according to an embodiment. FIG. 1B is a plan view from a direction indicated by line IB-IB in FIG. 1A .
[0025] Referring to FIGS. 1A and 1B , the cartridge for chemical processing according to this embodiment includes a substrate 1 made of a relatively hard resin, and a sheet 2 made of a material, such as a silicone rubber, having an airtight property and elasticity. The sheet 2 is stacked on the substrate 1 .
[0026] The cartridge for chemical processing has formed therein wells (not shown) and channels (not shown) that connect the wells. The wells and channels are arranged and shaped in accordance with the procedure of predetermined chemical processing. The wells and channels are formed as unbonded regions of the substrate 1 and the sheet 2 . The substrate 1 and the sheet 2 are bonded to each other in a region surrounding the wells and channels. Accordingly, the inside of the cartridge for chemical processing is hermetic.
[0027] When a content is introduced into the cartridge, the sheet 2 is elastically deformed by the pressure of the content. The sheet 2 is separated from the substrate 1 in the region with the well or channel, and hence a gap is defined. The content is sealed in the space of the gap. If the content becomes lost, the shape of the sheet 2 is restored and closely contacts the substrate 1 . The desirable chemical processing can be performed while the content in the cartridge is moved from a well to the next well by moving a roller or the like that is pressed against the sheet 2 from the outside (for example, see Japanese Unexamined Patent Application Publication No. 2005-308504).
[0028] Referring to FIGS. 1A and 1B , the substrate 1 has a light-shielding region 11 of black color. In addition, a microarray chip 3 is attached to the substrate 1 at a position surrounded by the light-shielding region 11 , for inspecting a DNA and a RNA (mRNA, cDNA, and the like), and a biopolymer such as a protein. Sites, to which probes respectively corresponding to target molecules are fixed, are arrayed on a surface 31 of the microarray chip 3 . The target molecules are respectively coupled to the sites through hybridization. A fluorescent substance is added to each of the target molecules around the hybridization, so that the target molecules are optically detected by using the fluorescence from the sites.
[0029] Referring to FIGS. 1A and 1B , a member 5 made of a hard transparent resin is arranged at a position to face the microarray chip 3 . The member 5 is bonded to the sheet 2 . In particular, the member 5 is bonded to the sheet 2 with an adhesive polymer interposed therebetween such that the hermeticity of the cartridge for chemical processing is maintained.
[0030] The member 5 also has a recess 51 in a center portion and a flange-like bonding portion 52 in a peripheral portion. The member 5 is bonded to the sheet 2 via a bonding surface 52 a of the bonding portion 52 . Referring to FIG. 1A , the member 5 further has protrusions 53 on a bottom surface. The protrusions 53 determine a gap between the member 5 and the surface 31 of the microarray chip 3 . The bottom surface of the member 5 and the surface 31 of the microarray chip 3 are flat. The member 5 is hard enough so that the deformation of the member 5 can be substantially ignored. When the protrusions 53 are in contact with the surface 31 of the microarray chip 3 , the gap between the member 5 and the surface 31 of the microarray chip 3 is maintained uniform. For example, the gap is about 20 μm.
[0031] The wells, where the hybridization is performed, are provided in the region, to which the microarray chip 3 is attached. The space between the microarray chip 3 and the member 5 is supplied with a hybridization solution through the other wells and channels.
[0032] FIGS. 2A and 2B are cross-sectional views showing states during hybridization.
[0033] In an example of FIG. 2A , the member 5 is pinched between jigs 71 and mechanically fixed. The member 5 is vibrated by reciprocating the jigs 71 in the vertical direction in FIG. 2A , to stir the hybridization solution or a cleaning solution that is supplied between the microarray chip 3 and the member 5 . Also, at this time, the temperature in the cartridge can be controlled by pressing a thermally conductive member 81 against the recess 51 of the member 5 . Since the thickness of the member 5 is reduced in the region of the recess 51 , the change in temperature by the thermally conductive member 81 can be accelerated.
[0034] In an example of FIG. 2B , suction devices 72 are used instead of the jigs 71 , to suck and vibrate the member 5 like the example of FIG. 2A . Hybridization can be performed similarly to the example of FIG. 2A .
[0035] After the hybridization, referring to FIG. 1A , the microarray chip 3 is irradiated with laser light through an optical system 6 and fluorescence is detected while the protrusions 53 of the member 5 are in contact with the surface 31 of the microarray chip 3 . At this time, the member 5 functions as a window that allows the laser light and fluorescence to pass therethrough and to allow the microarray chip 3 to be optically read from the outside of the cartridge. Owing to this, the transparent resin for the member 5 is desirably a material with high-grade optical homogeneity, such as a polycarbonate resin or a polyolefin resin. With the cartridge for chemical processing according to this embodiment, since the optical reading is performed through the member 5 , measurement accuracy can be prevented from being degraded due to the sheet 2 . Since the member 5 is made of the hard transparent resin and is used as the window, the disadvantage provided if the silicone rubber is used as the window can be avoided.
[0036] Also, as described above, with the cartridge for chemical processing according to this embodiment, since the gap between the member 5 and the surface 31 of the microarray chip 3 is maintained uniform, the disadvantage caused by the remaining effluent is not provided, and the highly accurate reading can be performed for the entire microarray chip 3 . It is to be noted that the optical reading is performed while the gap between the member 5 and the surface 31 of the microarray chip 3 is filled with the cleaning solution or other predetermined solution.
[0037] With the cartridge for chemical processing according to this embodiment, since the light-shielding region 11 reduces background light from a rear surface of the cartridge and scattered light in the cartridge, the measurement accuracy can be increased.
[0038] Instead of the protrusions 53 of the member 5 , protrusions or spacers, which form a uniform gap between a microarray chip and a member, may be provided at the microarray chip and/or the substrate. This may be an example, in which the protrusions 53 shown in FIG. 1A are not coupled to the member 5 but are coupled to the microarray chip 3 .
[0039] FIGS. 3A to 3C illustrate a portion of a cartridge having a member facing a microarray chip.
[0040] FIG. 3A is a cross-sectional view of a cartridge for chemical processing having a member. FIG. 3B is an enlarged cross-sectional view of the member.
[0041] Referring to FIGS. 3A and 3B , a member 5 A made of a polycarbonate resin has an outer peripheral surface 50 a that is bonded to an end surface of the sheet 2 . The member 5 A has protrusions 53 A that provide a uniform gap between the member 5 A and the microarray chip 3 . When the protrusions 53 A are brought into contact with the microarray chip 3 , the gap between a bottom surface 54 of the member 5 A and the surface 31 of the microarray chip 3 is maintained uniform.
[0042] FIG. 3C is a cross-sectional view showing a reinforcing method of a member.
[0043] In an example of FIG. 3C , a ring-like reinforcing member 55 with a high rigidity is fitted to an outer peripheral portion of a member 5 B. The reinforcing member 55 is formed of a material with a higher rigidity (for example, a metal) than that of a polycarbonate resin. The reinforcing member 55 is integrally molded with the polycarbonate resin when the member 5 B is molded. As described above, since the intensity of the member 5 B is increased by the reinforcing member 55 , uniformity of the gap between the member 5 B and the microarray chip 3 can be increased.
[0044] FIG. 4A is a cross-sectional view showing a member provided with a flange-like extending portion.
[0045] Referring to FIG. 4A , a member 5 C is provided with a flange-like extending portion 52 C. The member 5 C is bonded to a sheet 2 A via a bonding surface 52 b of the member 5 C.
[0046] Referring to FIG. 4A , the member 5 C has the extending portion 52 C extending beyond the bonding surface 52 b . When the member 5 C is pressed against the microarray chip 3 , the extending portion 52 C pushes the sheet 2 A, and hence can eliminate an unneeded space in the cartridge.
[0047] In contrast, FIG. 4B illustrates a situation without an extending portion. Referring to FIG. 4B , a member 5 D does not have an extending portion extending beyond a bonding surface 52 b of a bonding portion 52 D. In this situation, the member 5 D cannot push the sheet 2 A. The sheet 2 A may be lifted in an area surrounding the member 5 D due to the pressure of the content in the cartridge. This may disturb the discharge of the effluent after the hybridization. As described above, if the member 5 C has the extending portion 52 C ( FIG. 4A ) that pushes the sheet 2 A, the discharge of the effluent after the hybridization can be promoted.
[0048] FIGS. 5A and 5B are cross-sectional views showing a cartridge for chemical processing configured to read a microarray chip from a substrate according to another embodiment.
[0049] Referring to FIGS. 5A and 5B , this cartridge for chemical processing includes a light-shielding substrate 1 A made of a relatively hard resin, and a sheet 2 B made of a material, such as a silicone rubber, having an airtight property and elasticity. The sheet 2 B is stacked on the substrate 1 A.
[0050] Referring to FIGS. 5A and 5B , a microarray chip 3 A made of a transparent material is attached to the substrate 1 A. Sites respectively corresponding to target molecules are arrayed on a surface 31 A of the microarray chip 3 A. The substrate 1 A has a through hole 12 penetrating therethrough from a bottom surface of the substrate 1 A (lower surface in FIG. 5A ) to the microarray chip 3 A.
[0051] Also, a light-shielding member 5 E is bonded to an inner surface (lower surface in FIG. 5A ). The member 5 E is made of a material with a higher rigidity than that of the sheet 2 B. The member 5 E is at a position to face the microarray chip 3 A. Referring to FIG. 5B , the member 5 E has protrusions 53 E that contact the surface 31 A of the microarray chip 3 A. While the protrusions 53 E are in contact with the surface 31 A of the microarray chip 3 A, the gap between the surface 31 A and a bottom surface 54 E of the member 5 E is maintained uniform.
[0052] Referring to FIG. 5B , the member 5 E is vibrated by reciprocating suction devices 73 sucking the sheet 2 A in the vertical direction in FIG. 5B during hybridization, to stir a hybridization solution or a cleaning solution that is supplied between the microarray chip 3 A and the member 5 E. Also, at this time, the temperature in the cartridge can be controlled by pressing a thermally conductive member 82 against the member 5 E.
[0053] After the hybridization, referring to FIG. 5A , the microarray chip 3 A is irradiated with laser light through an optical system 6 and fluorescence from the surface 31 A is detected while the protrusions 53 E of the member 5 E are in contact with the surface 31 A of the microarray chip 3 A. At this time, the microarray chip 3 A functions as a window that allows the laser light and fluorescence to pass therethrough and to allow the sites on the microarray chip 3 A to be optically read from the outside of the cartridge. The microarray chip 3 A may be, for example, a polyolefin resin. The protrusions 53 E may be alternatively provided on the surface 31 A of the microarray chip 3 A.
[0054] Also, with the cartridge for chemical processing according to this embodiment, since the gap between the member 5 E and the surface 31 A of the microarray chip 3 A is maintained uniform, nonuniformity caused by the remaining effluent does not appear, and the highly accurate reading can be performed for the entire microarray chip 3 A.
[0055] Further, with the cartridge for chemical processing according to this embodiment, since the substrate 1 A and the member 5 E shield light, these light-shielding members reduce background light from the surface of the cartridge and scattered light in the cartridge during the optical reading. Accordingly, the measurement accuracy can be increased.
[0056] As described above, with the cartridge for chemical processing according to any of the embodiments and examples of the present invention, a variable range of the gap is restricted such that the width of the entire gap between the surface of the member and the surface of the microarray chip does not become smaller than a predetermined width. Accordingly, the gap between the surface of the member and the surface of the microarray chip can be properly controlled, and the inspection accuracy with the microarray chip can be increased.
[0057] The scope and field of application of the present invention is not limited to the embodiments. The present invention can be widely applied to a cartridge for chemical processing, the cartridge carrying out chemical processing while moving a content by deformation based on an externally applied force.
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A cartridge for chemical processing carries out chemical processing while moving a content by deformation based on an externally applied force, and includes a microarray chip housed in the cartridge for chemical processing; a member having a surface that faces a surface of the microarray chip; a supporting unit for supporting the member such that a width of a gap between the member and the microarray chip is variable by the externally applied force; and a limiting unit for restricting a variable range of the gap by the supporting unit such that the width of the entire gap between the surface of the member and the surface of the microarray chip does not become smaller than a predetermined width.
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FIELD OF THE INVENTION
[0001] The present invention relates to an appliance for drying clothing articles, and, more particularly, to a dryer using microprocessor based controls for controlling dryer operation.
BACKGROUND OF THE INVENTION
[0002] It is common practice to detect the moisture level of clothes tumbling in a dryer by the use of moisture sensors located in the dryer drum. A voltage signal from the moisture sensor is used to estimate the moisture content of the articles being dried based on the actual characteristics of the load being dried. The sensors are periodically sampled to provide raw voltage values that are then filtered, or smoothed, and inputted to processor modules that determine when the clothes are dry, near dry, or at a target level of moisture content, and the drying cycle should terminate.
[0003] As can be appreciated, the voltage signal from the moisture sensor may be highly variable over time and may not accurately reflect the moisture content of the clothing articles. The articles may from time to time contact the electrodes of the moisture sensor and sometimes not come into contact with the electrodes due to generally random tumbling patterns of the clothes.
[0004] Another factor effecting the accuracy of the sensor to detect moisture content is the response time of the sensor to accurately sense the moisture content of the clothing as compared to the relatively short period of time the clothing contacts the sensors. Filtered sampled voltages tend to approximate the moisture level or target voltage level for full loads after the clothing has partially dried; however, during the initial stages of the drying cycle the sampled voltages may not accurately reflect the true moisture content of the clothes due to sensor response time. When the sensor response time is relatively long as compared to the length of time clothing contacts the sensor, the filtered sampled voltages tend not to accurately reflect the actual voltage. This problem is more pronounced for small loads that do not come into contact with the sensor as frequently as large loads. This makes it difficult for a dryer during an automatic drying cycle to accurately predict the time required to dry the clothing.
[0005] Another factor affecting the accuracy of the sensor to detect moisture content occurs when clothing articles are not evenly dried. That is some portions of the clothing may be wetter than other portions of the clothing and the wetter portions may not be accurately sensed by the circuit for short contact periods due to response time of the sensors.
[0006] Any compensation for the response time of the moisture sensor that provides a voltage reading closer to the actual voltage and moisture content of the clothing would be an improvement allowing for the microprocessor based controls to more accurately predict the drying time required for the drying cycle.
BRIEF DESCRIPTION OF THE INVENTION
[0007] The present invention relates to an appliance for drying clothing articles that comprises a signal acceleration processor coupled to receive and monitor a moisture signal from a moisture sensor. The processor determines gradients in the moisture signal and detects local extrema in the moisture signal when the gradients change sign. By local extrema it is meant one of either local maximums in the moisture signal or local minimums in the moisture signal.
[0008] It should be understood that the moisture signal may comprise a voltage signal that is linked to the resistance of the clothes by means of an electronic circuit that can be designed in many ways. In one embodiment of the present invention, the voltage signal is chosen to be proportional to the resistance of the clothes, i.e. the voltage signal has a lower value for clothes that are wet and a higher value for clothes that are dry. In this embodiment, the local extrema utilized are local minimums that occur when the moisture signal gradient changes sign from a negative gradient signal (descending raw voltage signal) to a positive gradient signal (ascending raw voltage signal). In an alternative embodiment of the present invention, the voltage signal is chosen to be inversely proportional to the resistance of the clothes, i.e. the voltage signal has a higher value for clothes that are wetter and a lower value for clothes that are dryer. In this alternative embodiment, the local extrema utilized are local maximums that occur in the moisture signal as the signal gradients change sign from an ascending signal gradient to a descending signal gradient.
[0009] The processor uses each detected local extremum and the gradient signal preceding the detected local extremum to determine a predicted moisture signal value for the clothing articles.
[0010] By determining the moisture signal gradient and detecting the local extremum, the processor uses this information to predict a moisture signal that compensates for sensor response time. The predicted moisture signal approximates the moisture value for the clothes if the clothes were to remain in contact with the sensor until the sensor signal has stabilized.
[0011] The appliance of the present invention may further include a noise-reduction filter coupled to the signal acceleration processor to receive the predicted moisture signal values from the signal acceleration processor and reduce the noise contained therein. This filtering may take many forms and in one embodiment computes a new filtered voltage using a time dependent weighted average of the predicted moisture signal values.
[0012] In accordance with the present invention there is provided an appliance for drying clothing articles. The appliance comprises a drum for receiving the clothing articles, a motor for rotating the drum about an axis, a heater for supplying heated air to the drum during a drying cycle, a sensor for providing a moisture signal indicative of the moisture content of the clothing articles, and a signal acceleration processor. The moisture signal comprises a plurality of sensed moisture values. The signal acceleration processor is coupled to receive and monitor the sensed moisture values for determining gradients from the sensed moisture values. The signal acceleration processor detects local extrema in the moisture signal when changes in sign occur between two successive gradients. The signal acceleration processor determines predicted moisture signal values for the clothing articles by extrapolating each of the local extrema utilizing each of the gradients of the moisture signal readings and the sensed moisture value occurring prior to the sign change between two successive gradients.
[0013] While gradients are preferably determined between two successive sensed moisture values for a predetermined sampling rate, the signal acceleration processor may be configured to determine gradients between every third, or higher sensed moisture values.
[0014] In one embodiment the local extrema comprise local minimums in the moisture signal and the sign change occurring between two successive gradients changes from a negative gradient to a positive gradient.
[0015] In another embodiment, the local extrema comprise local maximums in the moisture signal and the sign change occurring between two successive gradients changes from a positive gradient to a negative gradient.
[0016] In accordance with the present invention there is provided a method for drying clothing articles in a dryer appliance. The method comprises:
[0017] generating a moisture signal indicative of the moisture content of the clothing articles where the generated moisture signal comprises a plurality of sensed moisture values;
[0018] determining gradients from the sensed moisture values;
[0019] detecting local extrema in the moisture signal when changes in sign occur between two successive gradients; and
[0020] determining predicted moisture signal values for the clothing articles by extrapolating each of the local extrema utilizing the gradient of the moisture signal readings and the sensed moisture value occurring prior to the sign change between two successive gradients.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a better understanding of the nature and objects of the present invention reference may be made by way of example to the accompanying diagrammatic drawings.
[0022] FIG. 1 is a perspective view of an exemplary clothes dryer that may benefit from the present invention;
[0023] FIG. 2 is a block diagram of a controller system used in the present invention;
[0024] FIG. 3 is a plot for two load sizes of exemplary raw voltage signals received from the sensor where the sensor voltage is proportional to the resistance of the clothes;
[0025] FIG. 4 is an enlarged plot of a portion of one of the raw voltage signals of FIG. 3 ;
[0026] FIG. 5 is an exemplary flow chart for predicting the moisture content in the clothing;
[0027] FIG. 6 is a plot for an exemplary raw voltage signal received from the sensor where the sensor voltage is inversely proportional to the resistance of the clothes; and,
[0028] FIG. 7 is an enlarged plot of a portion of raw voltage signal of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1 shows a perspective view of an exemplary clothes dryer 10 that may benefit from the present invention. The clothes dryer includes a cabinet or a main housing 12 having a front panel 14 , a rear panel 16 , a pair of side panels 18 and 20 spaced apart from each other by the front and rear panels, a bottom panel 22 , and a top cover 24 . Within the housing 12 is a drum or container 26 mounted for rotation around a substantially horizontal axis. A motor 44 rotates the drum 26 about the horizontal axis through, for example, a pulley 43 and a belt 45 . The drum 26 is generally cylindrical in shape, having an imperforate outer cylindrical rear wall 28 and a front flange or wall 30 defining an opening 32 to the drum. The front wall 30 and opening 32 are normally closed by a door (not shown). Clothing articles and other fabrics are loaded into the drum 26 through the opening 32 . A plurality of tumbling ribs or baffles (not shown) are provided within the drum 26 to lift the articles and then allow them to tumble back to the bottom of the drum as the drum rotates. The rear wall 28 is rotatably supported within the main housing 12 by a suitable fixed bearing. The rear wall 28 includes a plurality of holes 36 that receive hot air that has been heated by a heater such as a combustion chamber 38 and a rear duct 40 . The combustion chamber 38 receives ambient air via an inlet 42 . Although the exemplary clothes dryer 10 shown in FIG. 1 is a gas dryer, it could just as well be an electric dryer without the combustion chamber 38 and the rear duct 40 . For an electric dryer, electrical heating elements may be located in a heater housing between the rear panel 16 and the rear wall 28 . The heated air is drawn from the drum 26 by a blower fan 48 which is also driven by the motor 44 . The air passes through a screen filter 46 which traps any lint particles. As the air passes through the screen filter 46 , it enters a trap duct 49 and is passed out of the clothes dryer through an exhaust duct 50 . After the clothing articles have been dried, they are removed from the drum 26 via the opening 32 .
[0030] In one the detailed description of this invention, a moisture sensor 52 is used-to predict the percentage of moisture content or degree of dryness of the clothing articles in the container. Moisture sensor 52 typically comprises a pair of spaced-apart rods or electrodes and further comprises circuitry for providing a voltage signal representative of the moisture content of the articles to a controller 58 based on the electrical or ohmic resistance of the articles. The moisture sensor 52 may be located on the front interior wall of the drum. Alternatively, moisture sensor 52 may be located on a rear drum 28 wall for stationary rear drum walls. In some instances the moisture sensor has been used on baffles contained in the dryer drum. By way of example and not of limitation, the sensor signal may be chosen to provide a continuous representation of the moisture content of the articles in a range suitable for processing by controller 58 . Typically, this is a range of 1 to 5 volts. The circuitry associated with the sensor 52 (not shown) may be designed to provide a higher voltage reading for wetter clothes than dryer clothes, or alternatively, be designed to provide a lower voltage reading for wetter clothes than dryer clothes.
[0031] As the clothes are tumbled in dryer drum 26 they randomly contact the spaced-apart electrodes of stationary moisture sensor 52 . Hence, the clothes are intermittently in contact with the sensor electrodes. The duration of contact between the clothes and the sensor electrodes is dependent upon several factors, such as drum rotational speed, the type of clothes, and the amount or volume of clothes in the drum. When wet clothes are in the dryer drum and in contact with the sensor electrodes, the resistance across the sensor 52 is low. Conversely, when the clothes are dry and contacting the sensor electrodes, the resistance across the sensor 52 is high and indicative of a dry load. However, there may be situations that could result in erroneous indications of the actual level of dryness of the articles. For example, in a situation when wet clothes are not contacting the sensor electrodes, the resistance across the sensor is very high (open circuit), which would be falsely-indicative of a dry load. Further, if a conductive portion of dry clothes, such as a metallic button or zipper, contacts the sensor electrodes, the resistance across the sensor 52 would be low, which would be falsely indicative of a wet load. Hence, when the clothes are wet there may be times when the sensor 52 erroneously senses a dry condition (high resistance) and, when the clothes are dry, there may be times when the sensor erroneously senses a wet condition (low resistance). Accordingly, noise-reduction and smoothing is provided by controller 58 that leads to a more accurate and reliable sensing of the actual dryness condition of the articles and this results in more accurate and reliable control of the dryer operation.
[0032] The controller 58 is responsive to the voltage signal from moisture sensor 52 and predicts a percentage of moisture content or degree of dryness of the clothing articles in the drum as a function of the resistance of the articles. As suggested above, the value of the voltage signal supplied by moisture sensor 52 is related to the moisture content of the clothes. For example, in the embodiment where the voltage is lower for wetter clothes, at the beginning of the cycle when the clothes are wetter, the voltage from the moisture sensor 52 may range between about one or two volts. As the clothes become dry, the voltage from the moisture sensor 52 may increase to a maximum of about five volts, for example. However, when the clothes touch the rods, the response time associated with the moisture sensor electrodes and circuitry to measure voltage drop across the electrodes may be greater than the contact duration of the clothes with the electrodes. Thus when the clothes contact the electrodes and the voltage across the electrodes drops towards a minimum value representative of the moisture content of the clothes, the voltage drop does not reach this minimum value due to the sensor response time. The controller 58 of the present invention compensates for this shortcoming as is described in more detail herein after.
[0033] A more detailed view of the controller 58 used in the present invention is shown in FIG. 2 . Controller 58 comprises an analog to digital (A/D) converter 60 for receiving the signal representations sent from moisture sensor 52 . It should be understood that the signal from sensor 52 is processed through circuitry (not shown). The signal is sampled by A/D converter 60 in accordance with a counter/timer 78 and the sampled values of the moisture signal are sent to a central processing unit (CPU) 66 for further signal processing which is described below in more detail. The CPU which receives power from a power supply 68 comprises one or more processors or processing modules stored in a suitable memory device, such as a read only memory (ROM) 70 , for predicting a percentage of moisture content or degree of dryness of the clothing articles in the container as a function of the electrical resistance of the articles. It will be appreciated that the memory device need not be limited to ROM memory being that any memory device that permanently stores instructions and data will work equally effective. Once it has been determined that the clothing articles have reached a desired degree of dryness, then CPU 66 sends respective signals to an input/output module 72 which in turn sends respective signals to deenergize the motor and/or heater. As the drying and cool down cycles are shut off, the controller may activate a beeper via an enable/disable beeper circuit 80 to indicate the end of the cycle to an user. An electronic interface and display panel 82 allows the user for programming operation of the dryer and further allows for monitoring progress of respective cycles of operation of the dryer.
[0034] Referring to FIG. 3 there are shown two curves 82 and 84 which are indicative of the raw voltage signal sensed by the moisture sensors or rods 52 during the drying cycle in accordance with an embodiment of the present invention where the raw voltage signal provided by sensor 52 and associated circuitry (not shown) has a lower value for clothes that are wetter and a higher value for clothes that are dryer. Curve 82 represents a situation for a curve representative of a small load whereas curve 84 represents a curve that is indicative of a large load. The curve 84 is closer to the actual moisture content of the clothes in the dryer than curve 82 due to the fact that there are more clothes in contact with the sensor rods or electrodes during the drying process. When the clothes touch the sensor electrodes, the resistance between the electrodes decreases and the voltage drops across the sensor electrodes thereby decreases to a lower value that is indicative of the moisture content of the clothing. However if the clothes do not contact the sensor electrodes for a long enough period of time to overcome the time response delay associated with the sensor electrodes, then the signal reading does not reach its steady state value.
[0035] From FIGS. 3 and 4 it can be seen that curves 82 and 84 have a series of maximums 88 and minimums 90 . For smaller loads, it is noted that the minimums 90 are further from the actual moisture level of the load as compared to the larger loads in curve 84 . However, the slope of the curve immediately preceding the minimum 90 for smaller loads is usually steeper than that for heavier loads. Accordingly, the present invention in the embodiment of FIGS. 3 and 4 provides a processor or controller 58 for detecting the minimums 90 of the voltage signal from the sensor electrodes and the gradient immediately before the minimum. The processor utilizes this information to extrapolate predicted moisture signals for each minimum as shown by points 95 forming curve 94 in FIG. 4 .
[0036] Referring to FIG. 5 , the processed flow steps stored within the memory 70 starts with the processor controller 58 reading the raw voltage signal from the sensor electrodes at step 92 . This comprises periodic sampling of the raw voltage signal by A/D converter 60 to provide the sampling points 93 shown in FIG. 4 . The controller 58 stores the raw voltage sample values, or sensed moisture values, 93 and computes the gradient between the sample values at step 96 . When the computed gradients change sign between successive computed gradients from a negative gradient, or descending signal, to a positive gradient, or ascending signal, the controller 58 detects an extremum, or minimum in this embodiment, as shown at decision box 98 . When there is no change in sign between successive gradients, no minimum is detected and the controller 58 returns the last filtered voltage at 100 to the computation of the rod gradient value. If the minimum is detected, then the accuracy of the raw voltage sampled value 93 is improved by the accelerating hardware at step 102 . The accuracy of the raw voltage sampled value 93 is improved by predicting a voltage value closer to the true moisture value of the clothing articles. This is predicted by taking the last raw voltage sampled value 93 before the changes in sign between successive gradients and extrapolating this value using the formula:
Predicted voltage value=(raw voltage sampled value at extremum×( a +( b ×last gradient/( c −last gradient))))/ d, (I)
[0037] where a, b, c and d are constants. In this embodiment, these constants are chosen as a=8; b=8; c=32 and d=8.
[0038] Formula (I) is used to extrapolate the values 95 in curve 94 . It should be understood that other formulae may be developed to extrapolate the values and that Formula (I) is a preferred formula. It should also be understood that while the minimum voltages 90 for curve 82 (smaller load). are greater than the minimum voltage 90 for curve 84 (larger load), the gradients in curve 82 are typically steeper than in curve 84 resulting in an associated curve 94 . It should be understood that predicted curve 94 is not the same sum for the values of both curves 82 and 84 . However, the predicted curve 94 for each of curves 82 and 84 is a more accurate representation of the moisture content of the clothing articles.
[0039] Next, the CPU 66 computes at step 104 a new filtered voltage value for the predicted signal voltage using a weighted average formula to reduce the effect of unwanted noise. In the preferred embodiment, the filtered voltage occurs when the number of different minimums detected is greater than 20 , since anything prior to this may be considered too soon in the sensing of the raw voltage signal to represent an accurate reading. Further, the filtered voltage using the weighted average at 104 is dependant upon the time between samples or the time between the determination of minimums. The present invention weighs the filtered voltage average in accordance with a weighted average formula:
Filtered voltage=(( e −sample count)×last filtered voltage sample+sample count×predicted voltage)/ e, (II)
[0040] where e is a constant. In this embodiment, e is chosen to equal 1024.
[0041] The sample count is used to determine the elapsed time between minimums. When the elapsed time between minimums is too great, stability conditions may need to be considered so as not to place too much weight upon the last filtered voltage sample. It should be understood that other suitable filtering algorithms may be employed to filter out unwanted noise.
[0042] Referring to FIG. 6 there is shown one curve 184 which is also indicative of the raw voltage signal sensed by the moisture sensors or rods 52 during the initial stages or time of the drying cycle in accordance with an alternative embodiment of the present invention where the raw voltage signal provided has a higher value for clothes that are wetter and a lower value for clothes that are dryer. From FIGS. 6 and 7 it can be seen that curve 184 has a series of maximums 188 and minimums 190 . The processor or controller 58 for this embodiment, detects the maximums 188 of the voltage signal from the sensor electrodes and the gradient immediately before the maximum. The processor utilizes this information to extrapolate predicted moisture signals for each maximum as shown by points 195 forming curve 194 in FIG. 4 .
[0043] The extrapolated signal may be processed in the same manner as that described in FIG. 5 for the minimums. Referring to FIG. 5 , the processed flow steps stored within the memory 70 starts with the processor controller 58 reading the raw voltage signal from the sensor electrodes at step 92 . This comprises periodic sampling of the raw voltage signal by the A/D converter 60 to provide the sampling points, or sensed moisture values, 193 shown in FIG. 7 . The controller 58 stores the raw voltage moisture values 193 and computes the gradient occurring between the values 193 at step 96 . When there is a change in sign between successive computed gradients from a positive gradient, or ascending signal, to a negative gradient, or descending signal, the controller 58 detects an extremum, or maximum in this embodiment as shown at decision box 98 . When no change in sign occurs between successive gradients, no maximum is detected and the controller 58 returns the last filtered voltage moisture value at 100 to the computation of the rod gradient value. If the maximum is detected, then the accuracy of the raw voltage moisture value is improved by the accelerating hardware at step 102 . The accuracy of the raw voltage is improved by predicting a voltage value closer to the true moisture value of the clothing articles. This is predicted by taking the last gradient, before the occurrence of a sign change between two successive gradients, the raw voltage moisture value at the extremum, and extrapolating this value using formula (I). Formula (I) is used to extrapolate the values 195 in curve 194 .
[0044] Next, the CPU 66 computes at step 104 a new filtered voltage value for the predicted signal voltage using a weighted average formula similar to that of Formula (II) to reduce the effect of unwanted noise.
[0045] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the present invention as disclosed herein.
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A clothes drying appliance has a moisture sensor and a signal acceleration processor coupled to receive and monitor a moisture signal from the moisture sensor. The processor determines signal gradients in the moisture signal and detects either minimums or maximums in the moisture signal when a sign change occurs between two successive signal gradients. The processor uses the detected local minimum or maximum information and the gradient preceding the detected local minimum or maximum to extrapolate a predicted moisture signal value for the clothing articles. The generation of the predicted moisture signal compensates for sensor response time.
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BACKGROUND
[0001] Tubular systems often employ tools that require electrical power, such as, motors and solenoids, for example, in the case of a downhole completion application. Some systems employ dynamos to supply the electrical power needed. Dynamos are electrical generators that have rotors turned by mud motors or turbines driven by fluid flow. These devices serve their function adequately. However, with the moving parts operating within extreme environments, such as those found downhole including high pressures, high temperatures, fast moving erosive and caustic fluids littered with contaminants, for example, maintenance of such devices can be difficult, time consuming and labor intensive. Devices that lessen some of the foregoing issues are well received in the art.
BRIEF DESCRIPTION
[0002] Disclosed herein is a power-generating device that includes a thermoelectric material contoured to conform to at least a portion of a tubular and at least two conductors in operable communication with the thermoelectric material.
[0003] Further disclosed is a method of making a generating device. The method includes, casting a sheet of thermoelectric material, bonding a layer of conductive material to a first surface of the thermoelectric material, and bonding a layer of conductive material to a second surface of the thermoelectric material thereby constructing a layered assembly. The layered assembly is formed to be perimetrically mountable to a tubular surface.
[0004] Further disclosed is a method of making a generating device. The method includes extruding a thermoelectric material, bonding a layer of conductive material to a first surface of the thermoelectric material, and bonding a layer of conductive material to a second surface of the thermoelectric material. The foregoing layered assembly is formed to be perimetrically mountable to a tubular surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0006] FIG. 1 depicts an end view of a power-generating device disclosed herein;
[0007] FIG. 2 depicts a cross sectioned side view of the power-generating device of FIG. 1 taken at arrows 2 - 2 ;
[0008] FIG. 3 depicts a partially sectioned perspective view of a portion of a layered assembly employed in the construction of the power-generating device of FIG. 1 ;
[0009] FIG. 4 depicts a sequential representation of steps employed during an embodiment of a construction process for the power-generating device of FIG. 1 ; and
[0010] FIG. 5 depicts a partial side view of a downhole completion application employing the power-generating device of FIG. 1 .
DETAILED DESCRIPTION
[0011] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0012] Referring to FIGS. 1-3 , an embodiment of a power-generating device is disclosed generally at 10 . The power-generating device 10 works on the principle of the Seebeck effect to convert temperature differences across a thermoelectric material directly into electricity, and uses no moving parts in the process. The power-generating device 10 includes, a layered assembly 14 , conformed to a surface 18 (an outer surface in this embodiment) of a tubular 22 . The layered assembly 14 has a core 26 of thermoelectric material 30 , with conductors 34 , 38 , shown herein as layers of conductive material, electrically bonded to opposing surfaces 44 , 48 of the thermoelectric material 30 . A protector 50 including layers 54 , 58 of electrically insulative material electrically insulates the conductors 34 , 38 while fluidically isolating the conductors 34 , 38 and the thermoelectric material 30 from an environment that the power-generating device 10 is submerged within. Terminals 64 , 68 sealably penetrate the protector 50 and are electrically connected to the conductors 34 , 38 respectively. The foregoing structure generates electrical energy in the thermoelectric material 30 when a radially oriented temperature gradient exists thereacross. Connection to the terminals 64 , 68 allow the electrical energy generated to be conducted to a load (not shown) such as, an electrical motor, solenoid, heater or battery, for example.
[0013] Referring to FIG. 3 , the layered assembly 14 is shown in a flat position with portions of each layer removed for illustrative purposes. The thermoelectric material 30 that constitutes the core 26 can be made of solid composite materials as described in the paper, “Thermoelectric Behavior of Segregated-Network Polymer Nanocomposites,” James C. Grunlan, et al.; Nano Letters, 2008 Vol. 8, No. 12, pgs. 4428-4432, incorporated herein by reference in its entirety. Although this thermoelectric material includes both polymeric particles and carbon nano-particles, alternate thermoelectric materials may be employed as long as they meet the requirements outlined herein. The thermoelectric material 30 can be processed by methods, such as, casting or extruding, for example, to form a sheet of the core 26 . After which, in this embodiment, the conductors 34 , 38 are electrically and optionally mechanically bonded to the surfaces 44 , 48 respectively. The conductors can be made of conductive materials, such as, copper, gold, silver or aluminum, for example. These materials can be bonded to the core 26 in one of several ways including, vapor deposition, soldering and brazing, for example. The insulative layers 54 , 58 are bonded to the conductors 34 , 38 respectively. The insulative layers 54 , 48 may be sheets of insulative material such as polymeric, elastomeric or glass, for example. The insulative layers 54 , 58 can be bonded to the conductors 34 , 48 through chemical and mechanical means such as bonding with an adhesive agent, for example. Portions 74 , 78 of the layers 54 , 58 that extend beyond the core 26 and the conductors 34 , 38 can be sealably attached to one another through adhesive means compatible with the material that the insulative layers 54 , 58 are constructed of. In alternate embodiments the insulative layers 54 , 58 can be applied to the core 26 and the conductors 34 , 38 by conformal coating processes, such as, by dipping or spraying, for example.
[0014] The terminals 64 , 68 can be electrically connected to the conductors 34 , 38 either before or after the insulative layers 54 , 48 are applied. Processes, such as, soldering, welding and brazing of the terminals 64 , 68 to the conductors 34 , 48 may be facilitated by doing so prior to application of the layers 54 , 58 over the conductors 34 , 38 . Electrical attachment of the terminals 64 , 68 to the conductors 34 , 38 after the layers 54 , 58 are applied can be done by insulation displacement methods. Regardless of the method of electrical attachment of the terminals 64 , 68 to the conductors 34 , 38 sealing of the terminals to the layers 54 , 58 allows the layers 54 , 58 to protect the conductors 34 , 38 and the thermoelectric material 30 from fluids and other environmental conditions within which the layered assembly 14 may be submerged.
[0015] Referring to FIG. 4 , the layered assembly 14 can be heated above a glass transition temperature of the materials employed and then rolled about a perimeter of a die 82 to a desired shape, such, as a cylinder 86 , for example, as illustrated in this embodiment. After this forming operation, the layered assembly 14 can be cooled, to a temperature below the glass transition temperature, after which the die 82 may be removed therefrom. The formed layered assembly 14 can then be assembled about the tubular 22 and attached thereto by adhesive, clamping, or wrapping with another material, for example. Alternately, the layered assembly 14 can be formed directly onto the outer surface 18 of the tubular 22 thereby employing the tubular 22 as the die 82 in the forming process directly.
[0016] Since, as mentioned above, the thermoelectric material 30 may be extruded, as opposed to being cast, for example, it can be extruded directly into a desired shape, (i.e. the cylinder 86 in the example illustrated). Consequently, the shape of the core 26 of the thermoelectric material 30 , as formed, can strongly influence which methods should be employed to bond the conductors 34 , 38 and the insulative layers 54 , 58 thereto. Regardless of the methods of assembly employed, however, the functioning of the finished power-generating device 10 should not be significantly altered.
[0017] Referring to FIG. 5 , although an embodiment of the power-generating device 10 disclosed herein is shown employed in a downhole completion application, it should be understood that the power-generating device 10 disclosed herein is not limited to such application. For example, the power-generating device 10 could be employed above ground on an oil or gas pipeline that have a temperature gradient thereacross. The downhole application illustrated herein shows two of the power-generating devices 10 positioned longitudinally displaced from one another along the tubular 22 , illustrated herein as a drill or other type of string 90 positioned within a casing 92 in a borehole 93 . The power-generating devices 10 are connected to one another through a connecting module 94 that provides electrical continuity from the terminals 64 , 68 (not shown in this view) of one of the power-generating devices 10 to the terminals 64 , 68 of the other of the power-generating devices 10 . Although only two of the power-generating devices 10 are illustrated herein any number of the power-generating devices 10 could be connected in the same fashion. The connecting module 94 can connect two of the power-generating devices 10 along a single length of drill string pipe or can be configured to connect two of the power-generating devices 10 that are located on separate pipes of the string 90 . The connecting module 94 , or similar device, could connect power-generating devices 10 that are nested one radially inside of another. Additionally, the connecting module 94 of a similar device could also connect between one of the power-generating devices 10 and a tool 98 , such as, an actuator, heater, motor, sensors, batteries or monitoring circuitry, for example, as illustrated. Since the surface area available along the string 90 for mounting a plurality of the power-generating devices 10 can be very large and the temperature differential across the power-generating devices 10 due to production fluids flowing therethrough can be significant the electrical energy generation potential is great. As such, the power-generating devices 10 disclosed herein can provide power to the tool 98 without having to be connected to surface nor having to generate the power downhole with movable componentry such as mud motors and turbines, for example.
[0018] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A power-generating device includes a thermoelectric material contoured to conform to at least a portion of a tubular and at least two conductors in operable communication with the thermoelectric material.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to German Utility Model Application DE 20 2004 016 214.8, filed on Oct. 20, 2004, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
The description relates to a residual grid cutting device for comminuting residual sheet metal grids which have been processed with sheet metal processing machines.
BACKGROUND
Specific geometric shapes are cut out by means of a laser or stamped out by stamps from large metal sheets by sheet metal processing machines. A residual sheet metal grid is left over as a waste product requiring disposal. The residual sheet metal grid can be removed from the sheet metal processing machine manually or automatically and discarded in a container in a complete or folded state. However, residual sheet metal grids of this type are generally large and unwieldy. This impairs the production operation because wide transport paths are necessary, the process reliability may suffer and the space inside the container is not fully used. Therefore, it has already been proposed to stamp or cut up the residual grids, for example, with a laser machine. Whilst the laser machine cuts up the residual sheet metal grids, it is not available for processing the sheet metal. The comminution of the residual sheet metal grids therefore impedes optimum use of the laser machine for processing sheet metal.
As an alternative, it has been proposed to break down the residual sheet metal grids into strips by means of a guillotine shears following the production of the parts. However, those strips still have the same width as the original residual sheet metal grids. Handling such strips remains difficult. Furthermore, containers are not properly used.
SUMMARY
According to one aspect, a device for cutting up residual sheet metal grids includes a cutting mechanism which has, transversely to the residual grid supply direction, a plurality of shearing teeth which are constructed and arranged in such a manner that the residual sheet metal grids are cut into pieces both in relation to the residual grid width and in relation to the residual grid length. With a residual grid cutting device of this type, planar residual sheet metal grids or residual sheet metal grids having slight deformations which are produced during processing on stamping or laser machines can be cut up into small pieces. The number of pieces relative to the residual grid width can be determined by the number of shearing teeth. The residual grid pieces obtained in this manner can be of a size that allows optimum use of the space in a container. The residual grid cutting device can be operated in isolation or can be arranged downstream of a sheet metal processing machine and consequently be linked thereto. Long transport paths can thereby be prevented and the residual sheet metal grids can be comminuted by the residual grid cutting device directly after being processed by the sheet metal processing machine.
In one embodiment, at least one cutting edge or one cutting edge portion of a shearing tooth can be orientated in such a manner that it comes into engagement with the residual sheet metal grid, during a cutting operation, first by means of a first end and then by means of a second end. This means that cutting is carried out by the shearing teeth, not stamping. The cutting edge comes into contact with the residual sheet metal grid only gradually during the cutting operation. Less force is thereby required in order to comminute the residual sheet metal grid. Consequently, the residual grid cutting device can be operated so as to optimize the forces applied. For example, a configuration of the cutting edge is also possible in which the cutting edge has two cutting edge portions which are orientated obliquely relative to the residual grid supply plane and together form a tip which comes into engagement first with the residual sheet metal grid. The ends of the cutting edge portions remote from the tip come into engagement with the residual sheet metal grid later.
It is possible to bring about engagement of the cutting edge in the residual sheet metal grid, which engagement continues with the cutting movement, if at least one cutting edge of a shearing tooth is orientated obliquely relative to the residual grid supply plane. This means that the engagement of the cutting edge in the residual sheet metal grid extends during the cutting movement from one end of the cutting edge to the other end of the cutting edge.
In one embodiment, the shearing teeth have at least one cutting edge which is orientated transversely to the residual grid supply direction. The cutting edge can form an angle α in the range 0<α≦90° relative to the residual grid supply direction. The orientation of the cutting edge determines the shape of the residual grid pieces into which the residual sheet metal grid is comminuted. If a first cutting edge of a cutting tooth is orientated perpendicularly to the residual grid supply direction, another cutting edge can be orientated parallel with the residual grid supply direction so that rectangular residual grid pieces are cut out. It is also possible to orientate a cutting edge parallel with the residual grid supply direction and to orientate a second cutting edge at an angle in the order of 0<α≦90° relative to the residual grid supply direction so that a saw-toothlike cutting edge is produced.
In some constructions, the cutting teeth have two cutting edges which are orientated transversely to the residual grid supply direction. The cutting edges preferably converge at a tip.
In such an orientation of the cutting edges, a saw-toothlike contour can be obtained. Depending on the construction of the shape of the saw teeth, lateral movement of the residual sheet metal grid or the cutting mechanism may be necessary in order to ensure that not only zig-zag-like strips, but also pieces which are actually smaller are sheared off and splitting of the residual sheet metal grid is brought about relative to the width thereof.
In a particularly preferred configuration, it may be provided that the cutting edges of a shearing tooth are of different lengths. This means that an asymmetrical saw-tooth shape is produced. With a saw-tooth shape of this type, lateral movement of the residual sheet metal grid or the cutting mechanism is not necessary in order to bring about comminution in the longitudinal and transverse direction of the residual sheet metal grid.
The cutting mechanism is preferably in the form of a step type shearing device which has, transversely to the residual grid supply direction, a plurality of shearing teeth which can be driven by at least one stroke device and which can be moved past a support face for the residual sheet metal grid.
The contour of the support face is advantageously adapted to the contour of the shearing teeth. Variable possible uses result when a stroke device is provided for each shearing tooth. This means that the cutting teeth can be moved individually, in particular individually one after the other, in the case of relatively thick residual sheet metal grids in order to comminute the residual sheet metal grid into individual pieces. By the stroke devices being controlled in a suitable manner, however, the shearing teeth can also be moved simultaneously if, for example, relatively thin metal sheets have to be comminuted. Shearing teeth of the same type can be arranged on the individual stroke devices, in particular shearing teeth which have the same dimensions.
In some embodiments, the device includes a shearing tooth holder, on which the shearing teeth are arranged and which can be driven by at least one stroke device. This means that the shearing teeth are moved together irrespective of the thickness of the residual sheet metal grid. It is advantageous for the shearing teeth to have different heights. The stroke device must therefore apply smaller forces for shearing off the residual grid pieces. The shearing teeth do not all have to be moved simultaneously through the metal sheet.
If the cutting mechanism is in the form of a step type shearing device, the residual grid is not automatically drawn in. Therefore, it is advantageous for the residual grid supply system to be in the form of a drivable residual grid transport device.
In a preferred configuration, it is provided that the residual grid cutting device is operated in a clocked manner and the advance of the residual grid transport device is adapted to the size, in particular the depth, of the shearing teeth or a stop which limits the advance is provided for the residual sheet metal grid. During clocked operation, the residual sheet metal grid is moved forwards between two strokes of the shearing teeth. The forward movement is of such a magnitude that not only are strips separated from the residual sheet metal grid, but also the strips further broken down into smaller pieces. It may be necessary for cutting edges produced in a first cutting operation to be crossed by the cutting edges of the cutting teeth in a second cutting operation. As an alternative or in addition, at least one stop may be provided for the residual sheet metal grid and determines the extent to which the residual sheet metal grid is moved under the shearing teeth.
The advance or the position of the stop can be adjusted in such a manner that an overlapping cut is produced. The at least one stop can be arranged on a shearing tooth. In particular, each shearing tooth can have a stop.
Consequently, the stop can be moved with the shearing tooth. The shearing teeth can be moved so far upwards that the residual sheet metal grid can be moved completely under the cutting teeth, if necessary. If the shearing teeth are changed in order to obtain a different cutting geometry, the stop is also automatically changed. The advance is thereby always correctly adjusted to the shearing tooth depth of the shearing tooth currently being used.
In some other implementations, the shearing teeth are arranged on mutually opposite shearing tooth holders. It is particularly preferable for the shearing tooth holders to be in the form of rotatable shafts. This means that the residual sheet metal grids can be separated into identical pieces in a rotary cutting operation. The shearing teeth can be arranged on the shearing tooth holders in such a manner that the shearing teeth draw in the residual sheet metal grid during cutting. Therefore, the residual grid supply system does not have to be drivable. It is also advantageous in this configuration for the cutting edges of the shearing teeth not to engage simultaneously in the residual sheet metal grid over the length of the cutting edges thereof. In that manner, cutting is brought about instead of the metal sheet being stamped. The shearing teeth can be arranged in such a manner that the metal sheet is not completely cut, but instead is partially deformed. The maximum force occurring is thereby reduced.
The shearing teeth are advantageously arranged on cutter wheels which are arranged on a shaft in a rotationally secure manner. The production of the cutting mechanism is thereby simplified. Individual cutter wheels with shearing teeth fitted thereto can further be readily exchanged.
The shearing teeth are preferably constructed in a triangular manner and a plurality of rows of shearing teeth are provided in a peripheral direction on a shearing tooth holder, the shearing teeth of rows which are adjacent in a peripheral direction being arranged so as to be offset relative to each other. Owing to the triangular construction of the shearing teeth, it is possible for them first to be introduced into the metal sheet by means of a shearing tip.
Consequently, the force necessary is reduced. Owing to the geometry of the shearing teeth, it is possible to adjust the cutting gap by adjusting the spacing of the axes of the shafts. The fact that the shearing teeth are arranged so as to be offset relative to each other ensures that the metal sheet is split into pieces.
It is particularly preferable for the shearing teeth of a first shearing tooth holder to delimit free spaces whose contours are adapted to the contours of the shearing teeth of a second shaft. This means that the shearing teeth of the various shearing tooth holders are offset relative to each other by a half pitch. Complete separation of the residual sheet metal grid is thereby ensured.
According to some aspects, a sheet metal processing unit includes a sheet metal processing machine and a residual grid cutting device. This means that the residual grid cutting device can be linked to a sheet metal processing machine and the comminution of the residual sheet metal grids can be brought about directly after the sheet metal is processed. The residual sheet metal grids do not have to be intermediately stored, which is possible in principle, however, if the residual grid comminution device is operated in isolation.
In a preferred configuration, there may be provision for a transport device to be provided for transporting the residual sheet metal grids from the sheet metal processing machine to the residual grid supply system. Consequently, it is ensured that the processed residual sheet metal grids are removed from the sheet metal processing machine and are correctly supplied to the residual grid cutting device.
A sorting device can be associated with, in particular integrated in, the residual grid cutting device. Consequently, sorting of the residual pieces in accordance with the type of material can be carried out and those pieces can be conveyed to separate collection containers.
The sorting is thereby effected directly after the residual sheet metal grids are cut up so that the sheet metal pieces do not have to be sorted at a later point in time.
Other features will be apparent from the description, the drawings and the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective top view of a residual grid cutting device.
FIG. 2 shows the cutting mechanism of the residual grid cutting device of FIG. 1 .
FIG. 3 is a cross-section through the residual grid cutting device.
FIG. 4 a is a schematic illustration of four shearing teeth each having a stroke device.
FIG. 4 b is a schematic illustration of four shearing teeth having a common shearing tooth holder.
FIG. 5 is a side view of a sheet metal processing unit.
FIG. 6 shows part of a cutting mechanism of a residual grid cutting device.
FIG. 7 shows a cutter wheel of the arrangement according to FIG. 6 .
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , a residual grid cutting device 1 includes a cutting mechanism 2 which has a plurality of shearing teeth 4 transversely to the residual grid supply direction 3 . A residual sheet metal grid 6 is supplied to the cutting mechanism 2 by means of a residual grid supply system 5 . The residual sheet metal grid 6 is located in the residual grid supply plane. The residual grid supply system 5 is in the form of a residual grid transport device which can be driven and consequently can move the residual sheet metal grid 6 against at least one stop 7 . The stops 7 are arranged on the shearing teeth 4 in the embodiment and are also moved therewith. When the residual sheet metal grid 6 strikes the stop 7 , the residual sheet metal grid 6 is supported on a support face 8 whose contour is adapted to the shearing teeth 4 . In some embodiments, a stroke device 9 is associated with each shearing tooth 4 in the embodiment. The stroke devices 9 are arranged in a carrier 10 which also acts as a cover. In some embodiments, the shearing teeth 4 can be caused to carry out a stroke movement by means of the stroke devices 9 and moved past the saw-toothlike edge of the support face 8 .
In the case of a stroke movement downwards, the cutting edges 11 , 12 of the teeth 4 engage in the residual sheet metal grid 6 . In this instance, it should be noted that the cutting edges 11 , 12 are arranged obliquely relative to the residual grid supply plane. This means that the cutting edges 11 , 12 first come into contact with the residual sheet metal grid 6 at one end 13 , 14 and, in the case of further stroke movement downwards, the cutting edges 11 , 12 come 11 into engagement in a continuous manner with the residual sheet metal grid 6 over the length thereof as far as the ends 15 , 16 . This means that the cutting edges 11 , 12 are constructed so as to be angled for shearing. Therefore, the shearing teeth 4 carry out a cutting movement. During the cutting movement, the shearing teeth 4 are moved past the edge of the support face 8 . The support face 8 therefore forms an abutment for the residual sheet metal grid 6 . The cutting edges 11 , 12 are constructed so as to be of different lengths, the cutting edge 11 being orientated obliquely relative to the residual grid supply direction 3 .
Owing to the arrangement of the cutting edges 11 , 12 relative to each other, parallelograms are cut out in the embodiment. Therefore, the residual sheet metal grid 6 is divided up into regular parallelograms.
FIG. 3 is a cross-section through the cutting mechanism 2 . It is clearly visible that the cutting edge 12 is also constructed so as to be angled for shearing. The shearing tooth 4 is moved downwards and raised by the stroke device 9 . A control unit 17 is arranged in the rear portion of the cutting mechanism 2 .
FIG. 4 a shows an arrangement of shearing teeth 4 with each including a respective stroke device 9 . Therefore, they can be moved individually or together. They are preferably moved individually in order to cut relatively thick residual sheet metal grids. They may be moved together in order to cut relatively thin metal sheets. The cutting edges 11 are arranged obliquely relative to the residual grid supply plane. All the shearing teeth 4 are of the same height H.
According to another embodiment depicted in FIG. 4 b , the shearing teeth 4 a to 4 d are arranged on a common cutting tooth holder 20 . The holder 20 is connected to two stroke devices 9 . Therefore, the shearing teeth 4 a to 4 d are moved together. Metal sheets of different thicknesses are still comminuted by a common movement of the shearing teeth 4 a to 4 d . In order better to distribute the force which has to be applied by the stroke devices 9 , the shearing teeth 4 a to 4 c have different heights HI to H 3 so that first the tip of the shearing tooth 4 c comes into engagement with the residual sheet metal grid, and subsequently the cutting edge lie gradually comes into engagement with the residual sheet metal grid. Subsequently, the tip of the shearing tooth 4 b and then the cutting edge lib gradually come into engagement with the residual sheet metal grid. Subsequently, the tips of the teeth 4 a and 4 d engage in the residual sheet metal grid and the cutting edges 11 a and lid subsequently cut the residual sheet metal grid.
FIG. 5 is a side view of a sheet metal processing unit 25 . The sheet metal processing unit 25 comprises a sheet metal processing machine 26 which comprises a table 27 for transporting metal sheets or residual sheet metal grids. A residual grid cutting device 1 is coupled therewith, the residual grid supply system 5 being arranged in a plane below the table 27 . A transport device 28 is provided in order to place residual sheet metal grids from the table 27 on the residual grid supply system 5 . The residual sheet metal grids are supplied to the cutting mechanism 2 by means of the residual grid supply system 5 .
An alternative configuration of a cutting mechanism 30 is illustrated in FIG. 6 . The cutting mechanism 30 comprises a plurality of shearing teeth 31 , 32 which are arranged on 13 shearing tooth holders 33 , 34 which are in the form of rotatable shafts. The rotatable shearing tooth holders 33 , 34 are coupled for movement by means of gears 35 , 36 . The shearing teeth 31 , 32 of the various shearing tooth holders 33 , 34 are constructed so as to be different. The shearing teeth 31 are constructed in a substantially triangular manner, whereas the shearing teeth 32 have a notch 37 . The shearing teeth 31 , 32 are each arranged in rows on the shearing tooth holders 33 , 34 , the shearing teeth 31 , 32 of rows which are adjacent in a peripheral direction being arranged so as to be offset relative to each other. The shearing teeth 31 of adjacent rows further overlap each other slightly.
Four shearing teeth 32 delimit a free space 38 , the contour of the free space 38 being adapted to the shearing teeth 31 . Accordingly, four shearing teeth 31 form a free space 43 which can receive a shearing tooth 32 . Since the shearing teeth 31 , 32 are arranged on rotatable shafts, the cutting edges 39 , 40 , 41 , 42 of the shearing teeth 31 , 32 come into engagement with the residual sheet metal grid not by means of the entire length thereof simultaneously, but instead gradually with a continuous cutting movement.
FIG. 7 shows a cutter wheel 45 , on which a plurality of shearing teeth 31 are arranged. In particular, they are screwed to the cutter wheel 45 . In that manner, the shearing teeth 31 can be changed relatively readily. The cutter wheel 45 has tappets 46 so that it can be arranged on a shaft in a rotationally secure manner. Since the cutter wheel 45 can be fitted to a shaft, it can readily be changed.
Other implementations are within the scope of the following claims.
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A device for comminuting a residual sheet metal grid includes a grid supply system defining a grid supply plane and supplying the grid in a longitudinal direction; and a cutting assembly including a plurality of shearing teeth extending along a transverse direction transverse to the longitudinal direction. The shearing teeth can include a cutting edge, a cutting edge portion, or both a cutting edge and a cutting edge portion. The cutting assembly can be constructed and arranged to cut the metal grid along the longitudinal direction and the transverse direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from U.S. Provisional Patent Application No. 61/559,500 filed on Nov. 14, 2011, the contents of which are hereby wholly incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a circuit for driving an ultrasonic scaling probe suitable for use in dentistry, and more specifically, to a circuit that is stable, has fine tuning and auto-shutdown mechanisms.
BACKGROUND OF THE INVENTION
[0003] Conventional dental scalers include an energizing coil enclosed within a handle where an oscillator of a drive circuit is coupled to the coil for applying an oscillatory current to the coil. Two standard magnetostrictive scaler tool sets are typically used in the dental business, one is 25 kHz and the second is 30 kHz.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to an objective of providing stable operation of a dental scaler apparatus while lowering the power range of the apparatus in order to reduce possible dental damage caused by the use of such an apparatus. In view of this objective, the present invention is directed to a novel tuning mechanism for fine tuning the operating frequency of a low power dental scaler.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a block diagram illustrating a dental scaler apparatus according to the present invention; and
[0006] FIG. 2 is a circuit diagram detailing an exemplary embodiment of the dental scaler apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0007] In order to oscillate the scaler handle, different drive circuits can be used that utilize: 1) microprocessor 2) Phase Locked Loop (PLL) 3) LC oscillator topology. It is desirable to use an LC drive for its simple design while meeting operational goals. Tuning is straight forward and incorporates the feedback transformer inductance (L) and a switchable capacitor bank (C), specifically arranged in a binary fashion, with enough bits (binary cap arrangement) to provide a smooth range of adjustment for C. The transformer is the handle feedback mechanism for the tuning arrangement.
[0008] For such an LC resonant circuit tuning follows the standard resonant formula of F=1/{2*pi*(LC)**0.5}. Specific use of the air-core feedback transformer with its secondary tuning “L” enables a temperature stable design and tight tolerance winding (and tight tolerance L). Specific use of capacitors of a tight tolerance enables a tight C with respect to value and temperature. Overall stable tuning is enabled by the unique combination of the air-core transformer, tight tolerance capacitors, and the binary capacitor arrangement—thus enabling a practical tuning mechanism for manufacturing.
[0009] By utilizing two sets of binary arranged capacitors the design can accommodate both 25 KHZ and 30 KHZ operation. The two sets of capacitors are switched by a simple relay, controlled by a slide switch. This allows use of 25 KHZ and 30 KHZ magnetostrictive insert tools. Tuning design variances can be accommodated through turns ratio changes, added resistance, and supply voltage to attain lower and higher circuit Q's.
[0010] In order to attain lower power, a greater feedback signal was necessary and this was accomplished by increasing the turns ratio from 85/9 (20 W to 40 W range) to 208/9 (˜7 W to ˜25 W range), thus supplying adequate feedback at low output levels.
[0011] The small transformer secondary L tolerance (and temperature independence—part of resonant electronics tuning) in conjunction with close tolerance capacitors (also low variation with temperature) allow tuning that is fine enough and stable with temperature, the combination being a specific design approach to allow this circuit topology to be implemented. The bank of tuning capacitors, specifically arranged in a binary fashion, with an adequate number of steps is the capacitive equivalent of a resistive potentiometer—allowing fine capacitive adjustment in tuning—this arrangement also enables the use of higher capacitive values needed to enable tuning with the inductance (L) in the circuit. This is a specific arrangement that allows smooth adjustment, tight tolerance, and cannot be done using a single variable capacitor (or a small number in a non-binary arrangement)—as they are not available in such high values (and physically small). The number of binary steps can be altered depending upon the fineness of the tuning desired. Also, capacitor tolerances can be increased or decreased as needed. The result is an LC tuning that can be made practical (would not otherwise be) for our given application (and has not been attempted via other dental scalers).
[0012] FIG. 1 illustrates an exemplary embodiment of an ultrasonic dental scaler 100 according to the present invention. As shown in FIG. 1 , the dental scaler 100 may be powered by a standard AC power source with AC power circuitry 1 connected to a footswitch 2 , which is, in turn, connected to a rectifier 3 for providing DC power to the scaler 100 . An operator may operate the footswitch 2 to connect the AC power circuitry 1 to the rectifier 3 and, thus, power to the scaler 100 .
[0013] The rectifier 3 is connected to a buck converter 4 that converts the input DC voltage from the rectifier 3 to a desirable output voltage through a current detector 5 to an output power drive 6 . The current detector 5 , which will be described in further detail, detects the output of the buck converter 4 to limit its current output. When a current from the buck converter 4 exceeds a limit, a buck shutdown from the current detector 5 is triggered to shutdown the buck converter 4 .
[0014] The output of the buck converter 4 that does not exceed the current limit is passed through to the output power drive 6 , which drives the scaler handle 14 . The operating frequency of the output power drive 6 is controlled by a tuning circuit 8 via a feedback transformer 7 . A frequency selection switch 9 is operable to select an operating frequency of the tuning circuit 8 for output via the feedback transformer 7 to the output power drive 6 to drive the scaler handle 14 at the operating frequency. Exemplary standard operating frequencies for a dental scaler are 25 kHz and 30 kHz. Accordingly, a 25 kHz bank of Tuning Adjustment Capacitors and Switches and a 30 kHz bank of Tuning Adjustment Capacitors and Switches are connected to the tuning circuit 8 for precision tuning at the respective operating frequencies.
[0015] Separately, the scaler handle 14 is supplied with water using a solenoid 12 that is controlled by the footswitch 2 via a dropping resistor 11 , whereby the solenoid 12 is turned on and off by operating the footswitch 2 . Water is supplied by the solenoid 12 , when turned on, via a manually adjustable water control 13 to the scaler handle 14 .
[0016] FIG. 2 illustrates another exemplary embodiment of the dental scaler according to the present invention in correspondence with the exemplary embodiment illustrated in FIG. 1 . As shown in FIG. 2 , a footswitch 2 is connected and controls a transformer input (K 4 ), which is an input from a 28 VAC secondary power transformer that may be comprised in a circuit corresponding to the AC power circuitry 1 illustrated in FIG. 1 . Footswitch 2 also connects to solenoid (K 1 ) corresponding to solenoid 12 illustrated in FIG. 1 via a resistor (R 37 ) corresponding to dropping resistor 11 illustrated in FIG. 1 .
[0017] A main rectifier may comprise a diode bridge (BR 1 ) and capacitor (C 1 ), and it is supplied with a 12 VDC and 22 VDC supply that may comprise a regulator (U 1 ), resistor (R 1 ), zener diode (Z 1 ), and capacitors (C 2 ) (C 3 ). The 22V supply can be adjusted so that it is higher than the buck output voltage to provide proper op-amp operation.
[0018] A buck converter may comprise a current limit having resistors (R 2 ), (R 3 ), and (R 4 ), a regulator (U 2 ), and a switching supply comprising a zener diode (Z 2 ), diode (D 1 ), transistor (Q 1 ), inductor (L 1 ), capacitors (C 6 ) (C 7 ), and a resistor (R 5 ).
[0019] A front panel power knob for controlling the buck converter may be implemented with a diode (D 2 ), resistor (R 8 ), variable resistor (R 7 ), and a turbo switch (K 5 ). The front panel may also include a LED (K 8 ) for indicating a status of the turbo switch. The buck converter may also be controlled with a lower power adjuster comprising a resistor (R 9 ) and an variable resistor (R 10 ).
[0020] A sensing resistor (R 16 ) may be used for a current detect, which may be implemented with a differential amplifier (U 3 A), resistors (R 17 )-(R 21 ), capacitor (C 11 ), diode (D 7 ). The detected current may be used for a “no-tool” current limit, which may be implemented using a flip flop (U 4 B), comparator/amplifier (U 3 B), capacitors (C 12 )-(C 15 ), resistors (R 22 )-(R 24 ), (R 26 )-(R 30 ), diode (D 8 ), and zener diode (Z 3 ). And the threshold current level may be adjusted using a variable resistor (R 25 ). A reset line to the main rectifier may be implemented using an amplifier (Q 5 ) and resistors (R 31 )-(R 32 ). And a “no-tool” LED (K 10 ) may be driven using an amplifier (Q 4 ) and resistor (R 39 ).
[0021] The buck converter and current detect circuitry cooperate to form a shutdown circuit that stops the scaler from outputting power when there is no tool inserted in the driver handle. The high line sense resistor (R 16 ) and differential amplifier (U 3 A), then feeds a comparator (U 3 B), which is used to adjust current sense level, that sets flip-flop (U 4 B), which in turn drives a transistor to shutdown the switching power supply. To re-start the power, the foot switch may be released and depressed again, which in turn re-sets the flip-flop (U 4 B) and allows power again.
[0022] A frequency selection switch (SW 1 ) switches between 25 kHz and 30 kHz operating frequencies. For each operating frequency, a bank of capacitors and switches are connected in parallel for fine tuning the scaler to the operating frequency. The switch (SW 1 ) connects to capacitors (C 20 )-(C 28 ) and switches (SW 1 B)-(SW 7 B) for 25 kHz. An extra place (C 29 ) may be included for adding an optional capacitor. The scaler may be fine tuned to 25 kHz by opening/closing the respective switches (SW 1 B)-(SW 7 B). The switch (SW 1 ) connects to capacitors (C 30 )-(C 37 ) and switches (SW 1 A)-(SW 7 A) for 30 kHz via a resistor (R 35 ). Extra places (C 38 ) and (C 39 ) may be included for adding optional capacitors. The scaler may be fine tuned to 30 kHz by opening/closing the respective switches (SW 1 A)-(SW 7 A).
[0023] In traditional engineering practice a fixed capacitor and a variable inductor are used to tune circuits, since a wide range of tunable inductors exists and very little exists for tunable capacitors in the range of our scaler need (very large values). Disadvantageously, such a variable inductor would be exposed to high enough temperature swings as to de-tune the inductor, an inherent flaw of using a variable inductor. Thus, for stable scaler tuning with respect to temperature an air-cored inductor with a low temperature coefficient (or drift) is used. Since such an inductor suffers from a low tolerance for variable operating parameters for a desired output frequency, an effective means for fine tuning the parameters of the overall circuitry is needed to operate the scaler at the respective 25 kHz and 30 kHz frequencies.
[0024] Thus, banks of capacitors having the same or variable tolerances—for example, 2.5%-10%—may be selectively switched on, in binary fashion (very effective large cap value capacitive trimpot—equivalent to resistive trimpot), to fine tune the operating frequency of the scaler. The 25 kHz bank comprises fixed capacitors C 20 and C 21 , with capacitances of 0.1 μF and 6800 pF, respectively, connected in parallel. Thus, the core operating capacitance is about 0.1068 μF. For adjustment capacitors C 22 -C 28 , C 22 is 220 pF and C 23 is 470 pF. Either value can be selected. However, if both are selected (by switches SW 1 B and SW 2 B) then the value 690 pF can be obtained. With 7 active switches 128 combinations—different capacitors—can be obtained for tuning purposes. If 6 capacitors are used, then 64 different capacitances can be obtained. Even though switched capacitors are used on occasion, they are of limited value for our application unless the binary arrangement is used and enough caps used to provide a smooth tuning range—and used in conjunction with a tight tolerance transformer, of which an air-core type is used. The combination is very effective.
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A dental scaler apparatus includes a low power transformer that is tuned to the operating frequency of a detachable scaler insert connected to the handle of the scaler apparatus by selectively connecting corresponding banks of parallel adjustment capacitors by engaging corresponding switches coupled to each of the adjustment capacitors.
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FIELD OF THE INVENTION
The present invention relates to a composite material with improved properties which can provide a molded product having excellent various properties.
BACKGROUND OF THE INVENTION
Thermoplastic composite materials have excellent mechanical and electrical properties, and investigations for use as industrial materials have recently been developed rapidly. Of polymers constituting the composite materials, polyolefins such as polyethylene, polypropylene, and so forth have characteristics such as small specific gravity, good moldability and processability, excellent chemical resistance, and so forth, and applications of the thermoplastic composite materials comprising polyolefins as a matrix will now increase.
However, since polyolefins constituting the thermoplastic composite materials are nonpolar polymers, they do not have a satisfactory affinity for glass fibers, carbon fibers, carbon black, mica, talc, alumina fibers, silicon carbide fibers, aromatic polyamide fibers, and so forth which are used as a reinforcement. Therefore, a thermoplastic composite material having a further improved reinforcing effect has been demanded.
Many investigations have been made to develop a thermoplastic composite material satisfying the above requirement.
For example, Japanese patent application (OPI) No. 74649/1977 (the term "OPI" as used herein refers to a "published unexamined Japanese patent application") describes a material prepared by adding 0.2 to 2 wt% of polyacrylic acid to a composite material composed of 50 to 95 parts by weight of a polyolefin and 5 to 50 parts by weight of an inorganic filler. However, this composite material cannot be said to possess sufficiently improved properties because the affinity of the matrix polymer for the filler has not yet been improved. Japanese patent application (OPI) No. 50041/1980 and U.S. Pat. No. 3,862,265 describe a composite material composed of a graft polyolefin and an inorganic filler which is obtained by blending an unsaturated carboxylic acid, a polyolefin, and an inorganic filler, followed by subjecting the blend to a reaction under heating and mixing in an extruder. This composite material has good affinity of the graft polyolefin for the inorganic filler but has not a sufficient flowability since it contains inorganic fibers. Therefore, a molded product prepared from this composite material has not a sufficient impact strength. Thus, composite materials having improved properties are strongly desired.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a thermoplastic composite material which can provide a molded product having excellent mechanical properties (particularly, impact strength), a small specific gravity and a good water repellency.
Another object of the present invention is to provide a composite material having a good moldability due to its excellent flowability.
The composite material of the present invention comprises a modified polyolefin (i.e., a polyolefin modified with an unsaturated carboxylic acid), a reinforcement, and at least one polyfunctional compound selected from the group consisting of a polyfunctional epoxide, a polyfunctional amino compound, and a polyfunctional polyisocyanate compound.
DETAILED DESCRIPTION OF THE INVENTION
The modified polyolefin used in the present invention can be obtained by graft-polymerizing an unsaturated carboxylic acid onto a polyolefin and has an excellent affinity for reinforcements as compared with unmodified polyolefins.
Examples of polyolefins used for preparation of the modified polyolefin include polyethylene, polypropylene, poly(4-methylpentene-1), ethylene/vinyl acetate copolymer, ethylene/ethyl acrylate copolymer, ethylene/propylene/diene copolymer, and so forth. When polypropylene is used, a composite material having particularly various excellent characteristics can be prepared.
The modifier used for preparation of the modified polyolefin is unsaturated carboxylic acids and examples thereof include acrylic acid, methacrylic acid, itaconic acid, maleic acid, and anhydrides of these acids. The amount of these modifiers used is 0.05 to 0.8 part by weight, preferably 0.1 to 0.6 part by weight, per 100 parts by weight of the polyolefin.
A modified polyolefin prepared using a small amount of the modifier has not a sufficient affinity for the reinforcement, making it difficult to prepare a composite material having excellent properties. On the other hand, when a modified polyolefin is prepared using a large amount of the modifier, modification of the polyolefin does not proceed sufficiently, and a modified polyolefin contains a large amount of unreacted modifier. Such a product tends to deteriorate with the passage of time.
The modified polyolefin can be prepared by mixing a polyolefin, a modifier, and a catalyst in predetermined proportions and reacting the resulting mixture at 150° to 280° C. for 1 to 20 minutes. When the reaction temperature and/or the reaction time exceed(s) the above-described range(s), the modified polyolefin obtained shows unfavorable coloring or unnecessary thermal decomposition.
Examples of the catalysts used for the preparation of the modified polyolefin include benzoyl peroxide, lauroyl peroxide, and ketal or dialkyl peroxides which have a decomposition temperature necessary for attaining the half life of 10 hours of at least 80° C. Specific examples of the ketal or dialkyl peroxide catalysts include 1,1-bis(t-butylperoxy)cyclohexane, n-butyl 4,4-bis(t-butylperoxy)valerate, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, 2,2-bis(t-butylperoxy)butane, 2,2-bis(t-butylperoxy)octane, dicumyl peroxide, t-butylcumyl peroxide, α,α'-bis(t-butylperoxyisopropyl)benzene, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, and 2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3.
When the modified polyolefin is prepared using ketal peroxides or dialkyl peroxides having a decomposition temperature necessary for attaining the half life of 10 hours of at least 80° C., it exhibits a more effective molecular weight-lowering effect as compared with the modified polyolefin prepared using other catalysts. Accordingly, the composite material of the present invention prepared using the modified polyolefin has excellent moldability. Further, in crystallization of the polymer in the process for molding of the composite material of the present invention, the modified polyolefin prepared by using the specified ketal peroxides or dialkyl peroxides and benzoyl peroxide in a weight ratio of 10/1 to 1/10, preferably 1/6 to 6/1, exhibits an effect of inhibiting the growth of spherulites and, as a result, a composite material having good characteristics (a spherulite size of 50μ or less, preferably 5 to 30μ) can be obtained.
The amount of the catalyst used is 0.03 to 3 parts by weight, preferably 0.05 to 1 part by weight, per 100 parts by weight of the polyolefin.
As a modification reaction of the polyolefins, a solution reaction process using a solvent as a reaction medium or a method in which the reaction is conducted in a heat-melting state can be employed. From the standpoint of prevention of unnecessary coloring of the modified polyolefin obtained, prevention of unnecessary lowering of the molecular weight of the polyolefin, and the choice of an appropriate reaction time, it is preferred to employ a heat-melting reaction using an extruder as a reactor.
Polyfunctional epoxy compounds used in the present invention are compounds having two or more epoxy groups in the molecule. Examples thereof include a bisphenol A type epoxy compound, a bisphenol F type epoxy compound, an aliphatic ether type epoxy compound, a novolak type epoxide, an isocyanurate type epoxide and so forth. Specific examples thereof include condensates between bisphenol A and epichlorohydrin; polyglycidyl ethers of polyols such as ethylene glycol, propylene glycol, polyethylene glycol, glycerol, neopentyl glycol, trimethylolpropane, and sorbitol; triglycidyl isocyanurate, N-methyl-N',N"-diglycidyl isocyanurate, and triglycidyl cyanurate. The molecular weight of these polyfunctional epoxides is, though not particularly limited, about 4,000 or less.
Polyfunctional amines used in the present invention are compounds having two or more amino groups in the molecule. Specific examples thereof include hexamethylenediamine, tetramethylenediamine, methaxylenediamine, diaminodiphenylmethane, diaminodiphenyl sulfone, 3,3'-diaminobenzidine, isophthalic acid hydrazide, diaminodiphenyl ether, nanomethylenediamine, and diethylenetetramine.
Polyfunctional isocyanates are compounds having two or more isocyanate groups in the molecule. Examples thereof include tetramethylene diisocyanate, toluidine diisocyanate, diphenylmethane diisocyanate, naphthalene diisocyanate, and their polyisocyanates obtained by extending them with a chain-extending agent. Of these polyfunctional compounds, polyepoxides having a cyanuric or isocyanuric ring have high reactivity toward the modified polyolefin in the process of preparing the composite material of the present invention and a molding product prepared from the composite material thus-obtained has more excellent impact strength as compared with other molded products.
Polyfunctional epoxides, polyfunctional amines, and polyfunctional isocyanates can be used alone or in combination, the amount thereof is each 0.03 to 5 wt% per the weight of the modified polyolefin but the total amount does not exceed 10 wt% per the weight of the modified polyolefin.
Molded products prepared from the composite material containing at least one of those polyfunctional amines, polyfunctional isocyanates, and polyfunctional epoxides of the present invention have an excellent strength characteristic as compared with molded products prepared from composite materials containing no those polyfunctional compounds.
Reinforcements used in the present invention are fibrous materials such as glass fibers, carbon fibers, graphite fibers, aromatic polyamide fibers, silicon carbide fibers, polysulfone type fibers, polyether ketone fibers, alumina fibers, potassium titanate fibers, asbestos fibers, boron fibers, metal fibers, and so forth. Fibers having the length of 5 mm or less, preferably 0.01 to 3 mm, are preferred.
As other reinforcements, powdery or flaky materials such as glass flakes, talc, mica, kaolin, clay, diatomaceous earth, calcium carbonate, calcium sulfate, magnesium oxide, carbon black, titanium oxide, metal powders, alumina, graphite, white carbon, wollastonite, molybdenum disulfide, and tungsten disulfide can be used. Those reinforcements are incorporated in the modified polyolefin alone or in combination thereof in an amount of 5 to 80 wt% per the weight of the modified polyolefin. If the amount of the reinforcement is too small, a sufficient reinforcing effect cannot be obtained. On the other hand, if the amount of the reinforcement is too large, moldability of the composite material is reduced and the mechanical properties of a molded product prepared from the composite material tend to deteriorate.
Other thermoplastic plastics, for example, engineering plastics such as polyamides, unmodified polyolefins, polyesters, polycarbonates, polyacetals, and polysulfones can be incorporated into the composite material of the present invention, if desired.
The composite material of the present invention is prepared by blending a modified polyolefin, at least one compound selected from the group consisting of polyfunctional epoxides, polyfunctional amines, and polyfunctional isocyanates, and a reinforcement in the predetermined proportions. This composite material can be molded into the desired molded product by an injection molding method or the like.
Moldability of the composite material of the present invention is superior to that of similar kinds of conventional composite materials. Thus, it is believed that a molded product prepared from the composite material of the present invention has sufficiently improved impact strength as compared with that prepared from similar kinds of conventional composite materials.
The present invention will now be explained in detail by reference to the following non-limiting examples. Unless otherwise indicated, all percents, parts, ratios and the like are by weight.
EXAMPLE 1
To 100 parts by weight of polypropylene powders having an inherent viscosity of 1.5 (measured in a tetralin solution at 135° C.) were added modifiers and peroxides with the amounts as shown in Table 1, and the mixture was blended in the Henschel mixer. The mixture was then fed into an extruder reactor of 30 φ and L/D=25, and modified in a mixed state under heat-melting at a reaction temperature of 230° C. for a reaction time of 7 minutes. The unreacted modifier was removed by reducing the pressure of the vent portion of the extruder, and then the reaction mixture was extruded into pellets to give modified polyolefins.
To 100 parts by weight of the resulting modified polyolefin pellets were each added prescribed amounts of reinforcements and polyfunctional compounds as shown in Table 1. The mixture was blended in a tumbler and melt mixed in an extruder, and extruded therefrom to give pellets of composite materials.
These composite materials were formed into 3 kinds of molded products, viz., plates of No. 1 dumbbell, 125×12.5×3.2 (mm), and 125×12.5×6.4 (mm) using a screw on-line type injection machine under molding conditions of a cylinder temperature of 220° C. and a mold temperature of 60° C.
The results obtained by measuring fabrication properties of the composite materials and mechanical properties of the molded products therefrom under the following conditions are shown in Table 1.
Melt Flow Index (molding flow index):
ASTM-D-1238, load 2.16 kg, temperature 230° C.
Izod Impact Strength: ASTM-D-256
Heat Distortion Temperature (hereinafter referred to as HDT): ASTM-D-648 ##EQU1##
TABLE 1 Experiment No. 1 2 3 4 5 6 7 8 9 10 11 12 Composition of composite material Polypropylene 100 100 100 100 100 100 100 100 100 100 100 100 Parts by weight Peroxide Kind -- Benzoyl -- Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide Parts by weight -- 0.3 -- 0.3 0.3 0.3 0.3 1.0 0.3 1.0 0.3 0.3 Modifier Kind -- Maleic -- Maleic Maleic Maleic Acrylic Acrylic Acrylic Acrylic Maleic Maleic anhydride anhydride anhydride anhydride acid acid acid acid anhydride anhydride Parts by weight -- 0.3 -- 0.3 0.3 0.3 0.3 0.7 0.3 0.7 0.3 0.3 Polyfunctional compound Kind -- -- Hexa- Hexa- Hexa- -- -- -- Hexa- Hexa- 2,4- 4,4'- methylene methylene methylene diamino methylene methylene Toluilene Diphenyl- diamine diamine diamine diphenyl diamine diaminediisocyanate methaneether diisocyanate Parts by weight -- -- 0.3 0.3 3.0 0.5 -- -- 0.3 0.3 0.3 0.3 Reinforcement Kind Carbon Carbon Carbon Carbon Carbon Carbon Carbon Carbon Carbon Carbon Carbon fiber Carbon fiber fiber fiber fiber fiber fiber fiber fiber fiber fiber fiber Parts by weight 25 25 25 25 25 25 25 25 25 25 25 25 Mechanical property of molded product Flexial strength 770 1,140 820 1,470 1,540 1,460 1,160 1,230 1,460 1,570 1,530 1,550 (kg/cm.sup.2) Flexial modulus 8.8 8.8 8.8 8.8 8.7 8.7 8.6 8.6 8.7 8.8 8.4 8.6 (× 10.sup.4 kg/cm.sup.2) Izod impact strength 15 18 16 31 33 28 17 19 29 27 34 33 (kg-cm/cm.sup.2) HDT (°C.) 145 148 145 147 143 145 148 147 147 149 146 145 Ratio of improvement in 1.0 1.5 1.1 1.9 2.0 1.9 1.5 1.6 1.9 2.0 2.0 2.0 strength (ratio) Remark Comparative " " Invention Invention Invention Comparative Comparative Invention Invention Invention Invention Example Example Example MFI Spherical size (μ) Moldability into flat plate 1 mm thick Experiment No. 13 15 16 17 18 19 20 21 22 23 24 Composition of composite material Polypropylene 100 100 100 100 100 100 100 100 100 100 100 Parts by weight Peroxide Kind Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl Benzoyl -- Benzoyl Benzoyl peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide peroxide Parts by weight 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 -- 0.3 0.3 Modifier Kind Maleic Maleic Maleic Maleic Maleic Maleic Acrylic Acrylic -- Maleic Maleic anhydride anhydride anhydride anhydride anhydride anhydride anhydride acid acid anhydride Parts by weight 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 -- 0.3 0.3 Polyfunctional compound Kind Triglycidyl Bisphenol A Neopentyl- -- Triglycidyl Hexamethylene Hexamethy lene Triglycidyl -- -- 4,4-Diphenyl- isocyanurate diglycidyl glycol di- isocyanurate diamine diamine isocyanurate methylene ether glycidyl diisocyanate ether Parts by weight 0.3 0.3 0.3 -- 0.3 0.3 0.3 0.3 -- -- 0.5 Reinforcement Kind Carbon fiber Carbon Carbon Glass Glass fiber Glass fiber Glass fiber Carbon Talc Talc Talc fiber fiber fiber fiber Parts by weight 25 25 25 25 25 25 25 25 25 25 25 Mechanical property of molded product Flexial strength 1,580 1,460 1,500 1,080 1,330 1,280 1,250 1,600 430 500 560 (kg/cm.sup.2) Flexial modulus 8.9 8.6 8.7 5.3 5.5 5.4 5.3 8.5 4.3 4.3 4.3 (× 10.sup.4 kg/cm.sup.2) Izod impact strength 32 28 30 20 25 27 28 30 10 10 19 (kg-cm/cm.sup.2) HDT (°C.) 151 150 151 145 144 145 148 149 80 80 82 Ratio of improvement in 2.1 1.9 1.9 1.2 1.5 1.5 1.4 2.1 1.0 1.0 1.3 strength (ratio) Remark Invention Invention Invention Comparative Invention Invention Invention Invention Comparative Comparative Invention Example Example Example MFI Spherical size (μ) Moldability into flat plate 1 mm thick Experiment No. 25 26 27 28 29 30 31 32 33 34 35 Composition of composite material Polypropylene 100 100 100 100 100 100 100 100 100 100 100 Parts by weight Peroxide Kind Benzoyl Benzoyl Benzoyl Benzoyl 1,1-Bis(t- 2,5-Dimethyl- Benzoyl *1 *2 *2 -- peroxide peroxide peroxide peroxide butylperoxy)- 2,5-di(t- peroxide 3,3,5- butylperoxy)- trimethyl- hexyne-3 cyclohexane Parts by weight 0.3 0.3 0.3 0.7 0.2 0.2 0. 0.2 0.2 0.2 -- Modifier Kind Maleic Maleic Maleic Maleic Maleic Maleic Maleic Maleic Maleic Maleic -- anhydride anhydride anhydride anhydride anhydride anhydride anhydride anhydride anhydride anhydride Parts by weight 0.3 0.3 0.3 0.7 0.3 0.3 0.3 0.3 0.3 0.3 -- Polyfunctional compound Kind triglycidyl Triglycidyl Triglycidyl Triglycidyl Triglyjcidyl Triglycidyl Triglycidyl Triglycidyl Triglycidyl Triglycidyl Triglycidyl isocyanurate isocyanurate isocyanurate isocyanur ate isocyanurate isocyanurate isocyanurate isocyanurate isocyanurate isocyanurte isocyanurate Parts by weight 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 Reinforcement Kind Talc Glass fiber Talc/carbon Carbon fiber Carbon fiber Carbon fiber Carbon fiber Carbon fiber Carbon fiber Carbon fiber Carbon fiber fiber = 1/1 Parts by weight 25 25 50 25 25 25 25 25 25 25 25 Mechanical property of molded product Flexial strength 540 1,320 1,530 1,640 1,480 1,450 770 1,500 1,560 1,470 750 (kg/cm.sup.2) Flexial modulus 4.5 5.4 10.1 8.2 8.7 8.7 8.4 8.6 8.7 8.6 8.3 (× 10.sup.4 kg/cm.sup.2) Izod impact strength 17 27 29 32 29 20 11 35 33 17 13 (kg-cm/cm.sup.2) HDT (°C.) 80 148 149 149 144 146 141 148 149 145 141 Ratio of improvement in 1.3 1.5 2.0 2.1 1.9 1.4 1.0 1.9 2.0 1.9 1.0 strength (ratio) Remark Invention Invention Invention Invention Invention Invention Comparative Invention Invention Invention Comparative Example Example MFI 39.9 6.1 5.6 Spherical size (μ) 100 100 100 10 10 100 100 Moldability into flat Better Best Bad Better Better Better Bad plate 1 mm thick Experiment No. 36 37 38 39 40 41 Composition of composite material Polypropylene 100 100 100 100 100 100 Parts by weight Peroxide Kind Benzoyl Benzoyl Benzoyl *1 *1 *1 peroxide peroxide peroxide Parts by weight 0.2 0.2 0.2 0.2 0.2 0.2 Modifier Kind Maleic Maleic Maleic Maleic Maleic Maleic anhydride anhydride anhydride anhydride anhydride anhydride Parts by weight 0.3 0.3 0.3 0.3 0.3 0.3 Polyfunctional compound Kind Triglycidyl Hexa- Bisphenol A Triglycidyl Hexamethylene Bisphenol A isocyanurate methylene diglycidyl isocyanurate diamine diglycidyl diamine ether ether Parts by weight 0.6 0.6 0.6 0.6 0.6 0.6 Reinforcement Kind Carbon fiber Carbon Carbon Carbon fiber Carbon fiber Carbon fiber fiber fiber Parts by weight 25 25 25 25 25 25 Mechanical property of molded product Flexial strength 1,750 1,520 1,510 1,700 1,480 1,470 (kg/cm.sup.2) Flexial modulus 8.6 8.5 8.7 8.7 8.6 8.6 (× 10.sup.4 kg/cm.sup.2) Izod impact strength 40 33 30 38 30 29 (kg-cm/cm.sup.2) HDT (°C.) 145 144 146 146 145 146 Ratio of improvement in 2.3 2.0 2.0 2.2 1.9 1.9 strength (ratio) Remark Invention Inven- Invention Invention Invention Invention tion MFI Spherical size (μ) 10 10 10 10 10 10 Moldability into flat Good Good Good Best Best Best plate 1 mm thick Notes *1: A mixture of benzoyl peroxide and 1,1bis(t-butylperoxy)-3,3,5-trimethylcyclohexane (1:1) *2: A mixture of benzoyl peroxide and 2,5dimethyl-2,5-di(t-butylperoxy)hexyne-3 (1:1)
EXAMPLE 2
To 100 parts by weight of polypropylene powders having an inherent viscosity of 2.0 (measured in a tetralin solution of 135° C.) were each added peroxides as shown in Table 2 and 0.3 part of maleic anhydride as a modifier, and the mixture was blended uniformly in the Henschel mixer. The mixture was then subjected to a heat-melting reaction under conditions of a reaction temperature of 250° C. and a reaction time period of 7 minutes.
The results obtained by measuring the inherent viscosity of modified polypropylenes thus-obtained are shown in Table 2 below.
TABLE 2______________________________________ Inherent Viscosity Amount of Peroxide Added (parts)Peroxide 0 0.05 0.1 0.3 0.4 0.8______________________________________Benzoyl peroxide 1.75 1.73 1.70 1.62 1.6 1.561,1-Bis(t-butylperoxy)- 1.75 1.45 1.3 1.00 0.95 --3,3,5-trimethylcyclohexaneDicumyl peroxide 1.75 1.08 1.32 1.08 0.98 --Benzoyl peroxide/1,1- 1.75 -- 1.31 1.09 -- --Bis(t-butylperoxy)-3,3,5-trimethyl cyclohexane(1:1 weight ratio mixture)______________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A polyolefin resin composition comprising a polyolefin modified with an unsaturated carboxylic acid, at least one member selected from the group consisting of polyepoxides, polyisocyanates, and polyamines, and a reinforcement.
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BACKGROUND
The present disclosure relates generally to the machining of composite material. In particular, this disclosure relates to machining of holes in composite material.
Composite components are being utilized in a wide variety of articles of manufacture due to their high strength and light weight. This is particularly true in the field of aircraft manufacturing. Typical materials used in the manufacture of composite components include glass or graphite fibers that are embedded in resins, such as phenolic, epoxy, and bismaleimide resins. A composite lamination can be built up by laying successive plies of fiber tows (e.g., carbon fiber tows preimpregnated with a thermoset epoxy resin) around a mandrel and then curing. As more advanced materials and a wider variety of material forms have become available, aerospace usage of composites has increased.
Certain machining applications require drilling and/or reaming a hybrid stack-up of materials. A hybrid stack-up of materials may be defined as layers of discontinuous materials such as a carbon fiber-reinforced plastic (CFRP) composite material and titanium, aluminum or steel. For example, certain aircraft require a wing made from a composite material, such as CFRP, be joined to a titanium section of an aircraft body with fasteners that pass through holes made through the mating sections. When using fasteners to attach composite skins to metal substrates, coaxial holes must be drilled in both the skin and an underlying metal substrate. High-quality holes must be produced in such materials with dimensions within narrow tolerances. The wing-to-body join task typically requires a three-step conventional drilling process comprising a pilot drill, followed by a step drill, followed by a finish diameter reamer.
Reamers are cutting tools that are typically used to perform the final cutting operation on holes, particularly holes with small tolerances. Specifically, reamers perform secondary cutting operations after a hole has been drilled close to a desired final size. Reamers therefore typically have an external diameter that is slightly larger than that of the drilled hole, and are designed to finish the hole to within a small tolerance of the desired size and to provide a relatively smooth inner wall.
Standard reamers typically include a shank, a body portion at one end of the shank, and a plurality of teeth, such as 4-8 teeth, that are spaced around the body portion and extend outwardly therefrom to form the cutting surfaces of the reamer. Each tooth includes a rake face and a cutting edge that actually engages the workpiece in the course of reaming a hole. In some cases, the teeth are uniformly spaced around the body portion. In other cases, the teeth have non-uniform or irregular spacing.
During the machining of holes in composite material, severe delamination can occur if a reaming operation is performed prior to a hole being drilled or after a hole has been only partially drilled. The repairs for this kind of damage are very expensive and production flow must be halted until the problem is resolved.
Mechanics use visual inspection and tooling pins to assure that the pre-hole is complete before they move on to the reaming operation. Visual inspection of these holes is difficult in some areas due to limited access and time consuming.
Thus there is a need for a system to inhibit or terminate (without human intervention) the performance of a reaming operation if the pre-hole is missing or other dimensional characteristics do not meet the pre-hole requirements such as depth, diameter, orientation, and location.
SUMMARY
A system is disclosed for preventing the performance of an out-of-sequence reaming operation during the machining of holes in a lamination of fiber-reinforced plastic material. The system automatically stops or inhibits a reaming operation if a sensing tip of the reamer encounters an incompletely drilled pre-hole or blank material (i.e., no pre-hole) instead of a fully drilled pre-hole. The system does not require any human intervention to inhibit the reaming operation. In one embodiment, the human or operator cannot re-start the reaming process until the machine tool or reaming equipment is reset. In some cases the reset may require manual intervention.
A rotary cutting tool is also disclosed that comprises the following elements: (a) a body comprising an internal cavity that extends from one end of the body along an axis, the internal cavity comprising a first portion having a first cross-sectional area and a second portion having a second cross-sectional area less than the first cross-sectional area; (b) a plurality of teeth extending outwardly to form cutting surfaces near another end of the body; (c) a shaft disposed in the internal cavity along the axis, the shaft being movable axially relative to the body; and (d) a sensing tip coupled to or integrally formed with one end of the shaft and disposed outside the internal cavity. A spring, fluid piston or other suitable biasing member may be arranged to resist movement of the shaft from a first position toward a second position. The shaft and the internal cavity are configured so that another end of the shaft is disposed in the first portion of the internal cavity when the shaft is in the first position and is disposed in the second portion of the internal cavity when the shaft reaches the second position.
In addition, a method for using a rotary cutting tool having a leading tip axially movable relative to a plurality of cutting edges is disclosed. The method comprises the following steps: (a) mechanically resisting relative movement of the cutting edges and the leading tip toward each other; (b) actuating a drill motor that rotates the cutting edges; (c) advancing the rotating cutting edges forward along an axis of a pre-hole; (d) monitoring a parameter to determine when the value of that parameter reaches a specified threshold corresponding to the cutting edges advancing a specified distance relative to the leading tip after the latter has stopped advancing; and (e) stopping the rotation and advancement of the cutting edges when the value of the parameter reaches the specified threshold. The leading tip is carried by a shaft that is axially movable inside a body that carries the cutting edges. In a particular embodiment, the monitored parameter may be associated with a fluid that is ported or supplied to the body at an opening proximate to one end thereof. The fluid parameter monitored may correspond to a rate of flow of fluid through the body or a pressure in the line supplying fluid to the body. Step (e) is performed when the shaft position causes the fluid parameter to reach a threshold value.
Another aspect of the disclosed subject matter is a system comprising: a source of fluid; a rotary cutting tool comprising a plurality of cutting edges, a forward tip axially movable relative to the cutting edges, an inlet, an internal cavity in fluid communication with the inlet, and means for biasing the tip and cutting edges toward moving apart, wherein the forward tip is movable between a first position where the forward tip does not reduce the flow of fluid through the internal cavity and a second position where the forward tip reduces the flow of fluid through the internal cavity; a motor coupled to the rotary cutting tool for driving rotation of the cutting edges; a shutoff device for shutting off the motor; a subsystem for guiding the flow of fluid from the fluid source to the inlet of the rotary cutting tool, the subsystem comprising a sensor capable of producing a signal when a value of a parameter of the fluid reaches a specified threshold; and a controller coupled to the sensor for receipt of the signal from the sensor, the controller being programmed to output a shutoff signal to the shutoff device in response to receipt of the signal from the sensor. For example, the sensor can be a flow sensor or a fluid pressure sensor.
A further aspect is a system comprising: a reamer comprising an axial internal cavity having first and second openings at first and second ends of the reamer and a plurality of teeth extending outwardly to form cutting surfaces near the first end of the reamer, the internal cavity comprising a first portion having a first cross-sectional area and a second portion having a second cross-sectional area less than the first cross-sectional area; a sensor capable of producing a signal when a value of a parameter reaches a specified threshold; a flow path connecting the sensor to the second opening of the reamer; a shaft disposed in the internal cavity, the shaft being movable axially relative to the reamer from a first position toward a second position; and a tip coupled to or integrally formed with another end of the shaft and disposed outside the internal cavity. The shaft and the internal cavity are configured so that another end of the shaft is disposed in the first portion of the internal cavity when the shaft is in the first position and is disposed in the second portion of the internal cavity when the shaft reaches the second position, a flow through the internal cavity being reduced when the shaft moves from the first position to the second position.
Other aspects of the invention are disclosed and claimed below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an isometric view of a sensing tip reamer in accordance with one embodiment.
FIG. 2 is a diagram showing a side view (magnified in scale) of the distal end of the sensing tip reamer depicted in FIG. 1 .
FIG. 3 is a diagram showing an isometric view of the sensing tip partly depicted in FIG. 1 .
FIG. 4 is a diagram showing an end view of the sensing tip.
FIG. 5 is a diagram showing a sectional view of a sensing tip reamer (of the type depicted in FIG. 1 ) during reaming a completed hole in a metal/composite stack-up.
FIG. 6 is a diagram showing a sectional view of a sensing tip reamer (of the type depicted in FIG. 1 ) which has been shut down in response to the sensing tip impinging on the bottom of a partially drilled pre-hole in composite material of a metal/composite stack-up.
FIG. 7 is a diagram showing a sectional view of a sensing tip reamer (of the type depicted in FIG. 1 ) which has been shut down in response to the sensing tip impinging on composite material in and at the end of a hole that is slightly short (e.g., 0.050 inch) of being completed.
FIG. 8 is a hardware block diagram showing components of a system that incorporates a sensing tip reamer of any type disclosed herein.
FIG. 9 is a logic diagram showing steps of a process for automated shutdown of a reamer if a condition indicating an incomplete hole is detected.
FIG. 10 is a diagram showing an isometric view of a sensing tip in accordance with another embodiment.
Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals.
DETAILED DESCRIPTION
The system disclosed herein is designed to prevent the running of a reaming operation prior to drilling the necessary pre-hole in CFRP material. A reaming technology is provided that will not harm the CFRP structure if a reamer were used out of sequence. A reamer having a sensing tip is installed in a powered drill motor that may be powered electrically, by pressurized air or other known means. The system shuts off the drill motor if the tip of the reamer encounters blank material. The system employs a control that shuts off the drill motor when a fluid parameter associated with a coolant or lubricant flowing through the reamer is restricted due to depression (relative to the reamer cutting edges) of the sensing tip, which is axially movable relative to the cutting edges of the reamer. The coolant or lubricant may comprise a liquid, gas, or mixture of liquid and gas such as a mist coolant or lubricant. Suitable gases may include air, inert gas or refrigerant. Depression of the sensing tip occurs when the tip meets blank material or an obstacle inside an incompletely drilled pre-hole while the cutting portion of the reamer continues to advance. If the tip is depressed by an amount sufficient to cause the magnitude of the monitored fluid parameter to reach a specified threshold, the control causes a shutoff valve to close in the case of an air-powered drive or opens a switch in the case of an electric drive, thereby stopping rotation and advancement, or advancement, of the reamer. The control may also shut down the metering pumps that provide air/coolant to the reamer. The system inhibits a reaming operation when blank or partially drilled material is encountered.
FIG. 1 shows an isometric view of a rotary cutting tool in accordance with one embodiment. The tool comprises reamer 10 and an integrally formed sensing tip/shaft comprising a sensing tip 16 and a shutoff shaft. The shutoff shaft is not visible in FIG. 1 because it is inside the reamer 10 . The reamer 10 comprises a hollow body 12 having an internal cavity (not shown in FIG. 1 ) that extends from a forward end to a rearward end along a central axis. The reamer 10 further comprises a plurality of teeth 14 extending outwardly to form cutting surfaces near the forward end of hollow body 12 . The cutting edges define an outer diameter of the reamer 10 .
FIG. 2 shows (on a magnified scale) the sensing tip 16 in its most forward position relative to reamer 10 . The sensing tip 16 comprises three contact arms 18 disposed radially outward at angles of 120 degrees. If any portion of the sensing tip 16 encounters an obstacle during reaming of a pre-hole, the sensing tip as seen in FIG. 2 will move to the right relative to the cutting teeth 14 . In one specific implementation, the diameter of a hypothetical circle around the contact arms 18 may be in the range of 0.005 to 0.100 inch smaller than the reamer outer diameter. The tip 16 is relieved to minimize any impact to chip flow. In that same implementation, the tip is made of stainless steel.
FIG. 2 also shows that each flute between cutting teeth 14 is provided with one or more vent holes 4 . As will be described in more detail below with reference to FIG. 5 , a jet spray of droplets of coolant suspended in air will flow through an internal cavity of the reamer and exit the reamer via the vent holes 4 , thereby cooling the cutting teeth 14 during the reaming operation.
The integrally formed sensing tip/shaft is shown removed from the reamer in FIG. 3 . The contact arms 18 of sensing tip 16 are machined with a tri-lobed contact surface 20 , each lobe disposed at a 135-degree angle. The integrally formed sensing tip/shaft further comprises a shutoff shaft 22 . The shutoff shaft 22 comprises a guide body 24 , a plurality of circumferentially distributed, radially projecting guide features 26 and a retention slot 28 . FIG. 4 shows an end view as seen from a vantage forward of the sensing tip 16 . The guide body 24 has an annular groove that receives a seal such as an O-ring 30 . The guide body 24 has an outer diameter greater than the outer diameter of the main portion of the shutoff shaft 22 .
FIG. 5 is a sectional view showing a sensing tip reamer (of the type depicted in FIG. 1 ) during reaming a completed hole 40 in a stack-up consisting of metal 42 and composite material 44 . In the example depicted in FIG. 5 , during advancement of the reamer 10 , the sensing tip 16 did not make contact with any obstacle inside completed pre-hole 40 , so the reaming operation did not need to be aborted. In other words, the entire pre-hole 40 was reamed completely.
FIG. 5 shows the internal structure of the reamer 10 and how shutoff shaft 22 is disposed inside the reamer internal cavity. The internal cavity comprises four circular cylindrical bores 32 a through 32 d which increase in diameter from right to left (as seen in FIG. 5 ). A jet spray of air and suspended droplets of liquid coolant enters section 32 a of the internal cavity via an opening 50 at the rear end of the hollow body 12 of reamer 10 . The air/coolant jet flows through sections 32 a , 32 b and 32 c , exiting the hollow body 12 through the aforementioned vent holes (not shown) between the cutting teeth 14 . As seen in FIG. 5 , the guide features 26 hold the shutoff shaft 22 in a central position inside section 32 c of the internal cavity of reamer 10 . The outer diameter of the guide features 26 is greater than the outer diameter of shutoff shaft 22 , creating an annular space between the outer surface of shutoff shaft 22 and the inner surface of section 32 c . The air/coolant flows through this annular space on its way to the vent holes (see items 4 in FIG. 2 ) located between the cutting teeth 14 .
To assemble the sensing tip reamer, the shutoff shaft 22 is inserted into the internal cavity of hollow body 12 and then a set screw 36 is passed through the retention slot 28 in shutoff shaft 22 , the ends of the set screw being threadably coupled in diametrally opposed threaded holes (one such hole 6 can be seen in FIG. 1 ) formed in the wall of the hollow body 12 . The set screw 36 retains the shutoff shaft 22 inside the hollow body 12 but, in cooperation with elongated axial slot 28 formed in shutoff shaft 22 , allows the shutoff shaft 22 to move axially between first and second limit positions relative to the hollow body. FIG. 5 depicts shutoff shaft 22 in the first limit position, further axial movement rearward being stopped by impingement of the rearward end of slot 28 against set screw 36 . The sensing tip/shaft 16 is urged into the relative position seen in FIG. 5 by a compression spring 38 which is placed between respective annular surfaces on the guide body 24 and on the hollow body 12 . In the absence of a force depressing the sensing tip, the sensing tip/shaft will remain in the relative position shown in FIG. 5 . In this relative axial position, the rear end 22 a of shutoff shaft 22 does not enter section 32 b of the reamer internal cavity as seen in area 8 .
In accordance with alternative embodiments, the compression spring 38 can be omitted and the shutoff shaft 22 can be pressure biased in the forward direction by the coolant flowing into the internal cavity of the reamer. The forces on the shutoff shaft 22 are unbalanced and bias the shaft to the extended position when coolant pressure is present.
In contrast, FIG. 6 shows a sectional view of the same sensing tip reamer depicted in FIG. 5 , except that the sensing tip reamer has been inserted in a partially drilled pre-hole 46 (closed at the bottom) in the metal/composite stack-up 42 / 44 . When tip 16 impinges against the blank bottom of incomplete pre-hole 46 , the sensing tip/shaft ceases to advance while the reamer 10 continues its advance. The result is that the sensing tip/shaft moves rearward relative to reamer 10 . In particular, the end 22 a of shutoff shaft 22 moves axially past position 8 and into section 32 b of the reamer internal cavity. The end portion near end 22 a which enters section 32 b has an annular groove in which an O-ring 34 is seated. Because the diameter of section 32 b is less than the diameter of section 32 c , where shutoff end 22 a previously resided, the cross-sectional area of the annular space between the shaft end 22 a and the internal cavity is reduced. In addition, the O-ring 34 further reduces the amount of air/coolant that can flow axially from section 32 b into section 32 c . The result of the rearward movement of the shaft into section 32 b of the reamer internal cavity is a reduction in the rate of air/coolant flow through the reamer (accompanied by a pressure increase in the line feeding air/coolant to the reamer). In other embodiments the O-ring 34 and the annular groove that it sits in can be omitted and a clearance fit between the rear end 22 a of shutoff shaft 22 and section 32 b can be provide which is capable of causing a suitable reduction in the rate of air/coolant flow through the reamer when rear end 22 a is engaged with section 32 b . As will be explained in more detail later, this reduction in the fluid flow rate (or increase in pressure) is detected by the system. In response to the fluid flow rate falling below a specified threshold (or the pressure increasing above a specified threshold), the supply of pressurized air to the drill motor is shut off and the reaming operation is automatically aborted. FIG. 6 shows the shutoff shaft 22 in a third position relative to the hollow body 12 , which third position is between the first and second limit positions.
FIG. 7 shows a sectional view of the same sensing tip reamer depicted in FIG. 5 , except that the sensing tip reamer has been inserted in an incompletely drilled pre-hole 46 that is only a small distance (e.g., 0.050 inch) short of a completed hole. When tip 16 impinges against the undrilled material at the exit side of the incomplete pre-hole 46 , the sensing tip/shaft again ceases to advance while the reamer 10 continues its advance. The result is that the sensing tip/shaft will again move rearward relative to reamer 10 , eventually aborting the reaming operation.
FIG. 8 is a block diagram showing components of a system providing the functionality described above. The reamer 10 is coupled to a positive feed drill 52 (e.g., a Quackenbush positive feed drill) having a pneumatic motor. The pneumatic motor of drill 52 is powered by pressurized air from a plant air source 54 via a solenoid-actuated main air shutoff valve 56 and an air valve 58 [DMFI] . The operational state of shutoff valve 56 is controlled by a microcontroller 64 which can activate/deactivate a solenoid to respectively open/close the shutoff valve 56 . The microcontroller 64 can be programmed using an external personal computer 66 . When the system is in a locked state (i.e., key switch 68 is open), the system can be activated only by using a key to close key switch 68 .
When the system is activated, the microcontroller first opens the shutoff valve 56 . Pressurized air flows through shutoff valve 56 to air valve 58 . Some of the air flow (indicated by a line labeled “P ILOT A IR ” in FIG. 8 ) is diverted to an air distribution system that distributes pilot air to solenoid-actuated valves 70 , 72 , 74 and an air pressure sensor 62 . The air pressure sensor 62 outputs a digital signal representing the pilot air pressure to the microcontroller 64 .
When the pilot air pressure reaches a first specified threshold, the microcontroller 64 is programmed to open valves 70 and 72 , thereby supplying pilot air respective air pulse generators (not shown) which are used to send pulses of air to activate pistons of respective metering pumps (also not shown) that respectively meter motor oil and coolant from respective reservoirs 78 and 80 . If the pilot air pressure reaches a second specified threshold (higher than the first specified threshold and corresponding to a pressure buildup if no air is being supplied to the drill motor), the microcontroller is programmed to open a dump valve 74 to equalize the system.
FIG. 8 depicts the delivery of motor oil via a capillary tube (labeled “A IR M OTOR L UBE ” in FIG. 8 ) to an air line 60 connected to air valve 58 . The motor oil is metered by a metering pump (not shown in FIG. 8 ) coupled to an outlet of an oil reservoir 78 . In one implementation, the metering pump is an adjustable-stroke piston pump. As previously described, pilot air from air valve 58 is provided via open valve 70 to an air pulse generator (not shown) that sends pulses of air to activate the motor oil metering pump.
The pilot air is also received by a sensor 76 . In accordance with one embodiment, sensor 76 is a flow sensor that outputs an analog signal (0 V to 5 V) representing the rate of air flow through the sensor to the microcontroller 64 . (When there is no flow, the output of the sensor is 0 V.) In accordance with an alternative embodiment, sensor 76 is a fluid pressure sensor. The air (labeled “D RILL B IT A IR ” in FIG. 8 ) flowing out of sensor 76 is supplied to the drill bit, i.e., reamer 10 , via an air line 82 . FIG. 8 also depicts the delivery of lubricant (e.g., Micro-cut 26 coolant or Boelube oil) through a capillary tube (labeled “D RILL B IT L UBE ” in FIG. 8 ) to line 82 , which feeds the air and lubricant to the reamer 10 . In one implementation, the lubricant (coolant or oil) is supplied to the reamer 10 via a ⅜-inch line for air with a ⅛-inch capillary for lubricant inside. In the implementation depicted in FIG. 8 , the lubricant is Micro-cut 26 coolant. The coolant is delivered by a metering pump (not shown in FIG. 8 ) coupled to an outlet of a coolant reservoir 80 . Again the metering pump is an adjustable-stroke piston pump. The valve 72 (under the control of microcontroller 64 ) opens pilot air from air valve 58 to an air pulse generator (not shown) that sends pulses of air to activate the coolant metering pump.
As previously described, following the actuation of the drill motor, a pre-hole in a composite/metal stackup can be reamed by the rotating cutting teeth of the advancing reamer 10 . In accordance with a flow sensor embodiment, the flow sensor output to the microcontroller is monitored to determine if the flow rate of air through the reamer has been sufficiently reduced due to obstruction of the sensing tip. The microcontroller is programmed to actuate closure of shutoff valve 56 as well as motor oil and coolant valves 70 and 72 in response to the air flow rate falling below a specified threshold. In accordance with a pressure sensor embodiment, the pressure sensor output to the microcontroller is monitored to determine if the air pressure in the supply line has increased sufficiently due to obstruction of the sensing tip. In this case, the microcontroller is programmed to actuate closure of shutoff valve 56 as well as motor oil and coolant valves 70 and 72 in response to the air pressure rising above a specified threshold.
One implementation of a method of aborting a reaming operation is depicted in the logic diagram of FIG. 9 . First, the motor air supply is turned on (step 84 ). Then the coolant valve 72 is opened. Pressurized air (90 psi) and coolant are then supplied to the reamer (step 86 ). The air flow rate is measured by the flow sensor, which outputs an analog signal representing the air flow rate to the microcontroller. The microcontroller continuously monitors whether the coolant/air flow rate has fallen below 4 cfm (step 88 ). If not, then the main air shutoff valve is not closed (step 90 ). The 3-second loop 92 is the time the system takes to detect that a drop in flow has occurred. This is an adjustable setting in the system software. The setting should be selected to avoid any momentary events that may trigger a shutoff and still stop the system in time to mitigate any damage to the workpiece to be reamed. If the coolant/air flow rate has fallen below 4 cfm, then the main air shutoff valve is switched from open to closed (step 94 ). The microcontroller then sends a message to a user screen displayed on a personal computer (step 96 ).
Referring back to FIG. 8 , the key switch 68 is a reset feature used after the system encounters an undersize or blank hole condition. It is preferred to keep this functionality away from the reamer operator so that he/she cannot not simply reset the system without removing the drill motor from the drill jig. The reset key resides with the drill motor set-up technician. This forces the operator to take a step back from the process to determine why the system tripped.
In the embodiment shown in FIGS. 3 and 4 , the sensing tip and shutoff shaft were integrally formed. In accordance with an alternative embodiment depicted in FIG. 10 , a sensing tip 100 is removable and rotatably coupled to one end of a shutoff shaft 98 . The rotating sensing tip 100 has two contact arms 18 and comprises a plug 102 having an annular groove. The plug 102 of sensing tip 100 is inserted into a socket 104 formed in a guide body 106 at one end of shutoff shaft 98 . The plug 102 is coupled to the socket 104 by inserting a slotted spring pin 108 into a radial opening in the socket wall. The radially inward end of slotted spring pin 108 sits in the annular groove 102 of the sensing tip 100 . This arrangement allows the sensing tip 100 to rotate relative to the shutoff shaft 98 while being coupled for axial movement therewith.
As in the earlier-described embodiment, the shutoff shaft 98 has a plurality of circumferentially distributed, radially projecting guide features 26 and a retention slot 28 . The guide body 106 has an annular recess that receives an O-ring 30 . The guide body 106 has an outer diameter greater than the outer diameter of the shutoff shaft 98 , providing an annular bearing surface for the spring 38 which urges the shutoff shaft and the reamer in opposite directions.
While a sensing tip reamer has been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the teachings herein. In addition, many modifications may be made to adapt a particular situation to the teachings herein without departing from the essential scope thereof. Therefore it is intended that the claims set forth hereinafter not be limited to the disclosed embodiments.
In particular, a sensing tip arranged to block the flow of an air-coolant mixture to a reamer or drill when confronted by an obstruction is not limited to use with pneumatic drilling systems, but rather could also be incorporated in electrical drilling systems. In such embodiments, instead of closing a shutoff valve, thereby shutting down the drill motor, in response to rearward relative displacement of the sensing tip, the electrical drilling system would simply be shut down by changing the state of an electrical switch.
The method claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order or in the order in which they are recited. Nor should they be construed to exclude any steps being performed concurrently.
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A system for preventing the performance of an out-of-sequence reaming operation during the machining of holes in a lamination of fiber-reinforced plastic material. The system automatically stops or inhibits a reaming operation if a sensing tip of the reamer encounters an incompletely drilled pre-hole or blank material (i.e., no pre-hole) instead of a fully drilled pre-hole. The system does not require any human intervention to inhibit the reaming operation. In one embodiment, the human or operator cannot re-start the reaming process until the machine tool or reaming equipment is reset. In some cases the reset may require manual intervention.
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TECHNICAL FIELD
[0001] The present invention relates to an encoding apparatus, decoding apparatus, and methods thereof, used in a communication system that encodes and transmits a signal.
BACKGROUND ART
[0002] When a speech or music signal is transmitted in a packet communication system typified by Internet communication, a mobile communication system, or the like, compression and encoding technologies are often used in order to increase the transmission efficiency of the speech or music signal. In recent years, while a speech or music signal is simply encoded at a low bit rate, there has been a growing need for a technology that encodes a wider-band speech or music signal.
[0003] In response to such a need, various technologies have been developed that encode a wideband speech or music signal without greatly increasing the amount of information after encoding. For example, Patent Literature 1 discloses a technology whereby a characteristic of a frequency high-band part among spectral data obtained by converting an input audio signal of a fixed time is generated as auxiliary information, and this is output together with low-band part coded information.
CITATION LIST
Patent Literature
PTL 1
[0000]
Japanese Patent Application Laid-Open No. 2003-255973
PTL 2
[0000]
WO 2007/052088
SUMMARY OF INVENTION
Technical Problem
[0006] However, with the band enhancement technology disclosed in above Patent Literature 1, a low-band part of an input signal and a high-band part generated using auxiliary information are decided beforehand in a fixed manner. Therefore, since the same coding method is used when high-band part spectral data of an input signal is minute, or conversely when high-band part spectral data has extremely high energy, or when high-band part spectral data has a complex waveform, for example, there is a problem of coding efficiency not being high. When auxiliary information is encoded at a low bit rate, in particular, the quality of decoded speech generated using calculated auxiliary information is inadequate, and in some cases there is a possibility of an allophone being generated.
[0007] It is an object of the present invention to provide an encoding apparatus, decoding apparatus, and methods thereof that enable coding of high-band part spectral data to be performed efficiently, based on low-band part spectral data, for a signal such as a wideband signal (7 kHz band) or ultrawideband signal (14 kHz band), and enable the quality of a decoded signal to be improved.
Solution to Problem
[0008] One aspect of an encoding apparatus according to the present invention performs band enhancement using a low-band side spectrum and generates a high-band side spectrum, and employs a configuration comprising: a band setting section that inputs an input signal of the frequency domain and uses a characteristic of the input signal of the frequency domain as a basis, or inputs an input signal of the frequency domain and a coding parameter and uses the coding parameter and/or a characteristic of the input signal of the frequency domain as a basis, for generating band setting information that decides a first band of a high-band side set by the band enhancement; and a high-band coding section that encodes the input signal of the first band decided based on the band setting information and generates high-band part coded information.
[0009] One aspect of a decoding apparatus according to the present invention receives and decodes coded information generated by an encoding apparatus that performs band enhancement using a low-band side spectrum of an input signal of a frequency domain and generates a high-band side spectrum, and employs a configuration comprising: a reception section that receives coded information including high-band part coded information generated by encoding an input signal of a first band that is a high-band side of the frequency domain, low-band part coded information generated by encoding the input signal of a second band of a low-band side of the frequency domain, and band setting information of the first band set based on a characteristic of an input signal of the frequency domain and/or a coding parameter included in the coded information; a low-band decoding section that generates a low-band decoded signal for the second band using the low-band part coded information; and a high-band decoding section that generates a high-band decoded signal for the first band using the high-band part coded information and the band setting information, and generates a decoded signal of the frequency domain using the low-band decoded signal and the high-band decoded signal.
[0010] One aspect of a coding method according to the present invention performs band enhancement using a low-band side spectrum and generates a high-band side spectrum, and comprises: a band setting step of inputting an input signal of the frequency domain and using a characteristic of the input signal of the frequency domain as a basis, or inputting an input signal of the frequency domain and a coding parameter and using the coding parameter and/or a characteristic of the input signal of the frequency domain as a basis, for generating band setting information that decides a first band of a high-band side set by the band enhancement; and a high-band encoding step of encoding the input signal of the first band decided based on the band setting information and generating high-band part coded information.
[0011] One aspect of a decoding method according to the present invention receives and decodes coded information generated by an encoding apparatus that performs band enhancement using a low-band side spectrum of an input signal of the frequency domain and generates a high-band side spectrum, and comprises: a receiving step of receiving coded information including high-band part coded information generated by encoding an input signal of a first band that is a high-band side of the frequency domain, low-band part coded information generated by encoding the input signal of a second band of a low-band side of the frequency domain, and band setting information of the first band set based on a characteristic of an input signal of the frequency domain and/or a coding parameter included in the coded information; a low-band decoding step of generating a low-band decoded signal for the second band using the low-band part coded information; and a high-band decoding step of generating a high-band decoded signal for the first band using the high-band part coded information and the band setting information, and generating a decoded signal of the frequency domain using the low-band decoded signal and the high-band decoded signal.
Advantageous Effects of Invention
[0012] The present invention enables coding of high-band part spectral data such as a wideband signal or an ultrawideband signal to be performed efficiently, and enables the quality of a decoded signal to be improved.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 is a block diagram showing the configuration of a communication system having an encoding apparatus and decoding apparatus according to Embodiment 1 of the present invention;
[0014] FIG. 2 is a block diagram showing the internal principal-part configuration of the encoding apparatus shown in FIG. 1 ;
[0015] FIG. 3 is a block diagram showing the internal principal-part configuration of the coding section shown in FIG. 2 ;
[0016] FIG. 4 is a block diagram showing the internal principal-part configuration of the low-band coding section shown in FIG. 3 ;
[0017] FIG. 5 is a block diagram showing the internal principal-part configuration of the high-band coding section shown in FIG. 3 ;
[0018] FIG. 6 is a drawing for explaining details of filtering processing by the filtering section shown in FIG. 5 ;
[0019] FIG. 7 is a flowchart showing the processing procedure for finding optimal pitch coefficient T p ′ for subband SB p in the search section shown in FIG. 5 ;
[0020] FIG. 8 is a block diagram showing the internal principal-part configuration of the decoding apparatus shown in FIG. 1 ;
[0021] FIG. 9 is a block diagram showing the internal principal-part configuration of the decoding section shown in FIG. 8 ;
[0022] FIG. 10 is a block diagram showing the internal principal-part configuration of the low-band decoding section shown in FIG. 9 ;
[0023] FIG. 11 is a block diagram showing the internal principal-part configuration of the high-band decoding section shown in FIG. 9 ;
[0024] FIG. 12 is a block diagram showing the internal principal-part configuration of an encoding apparatus according to Embodiment 2 of the present invention;
[0025] FIG. 13 is a block diagram showing the internal principal-part configuration of the second layer coding section shown in FIG. 12 ;
[0026] FIG. 14 is a block diagram showing the internal principal-part configuration of the low-band coding section shown in FIG. 13 ;
[0027] FIG. 15 is a block diagram showing the internal principal-part configuration of the high-band coding section shown in FIG. 13 ;
[0028] FIG. 16 is a block diagram showing the internal principal-part configuration of a decoding apparatus according to Embodiment 2 of the present invention;
[0029] FIG. 17 is a block diagram showing the internal principal-part configuration of the second layer decoding section shown in FIG. 16 ;
[0030] FIG. 18 is a block diagram showing the internal principal-part configuration of the high-band decoding section shown in FIG. 17 ;
[0031] FIG. 19 is a block diagram showing the internal principal-part configuration of an encoding apparatus according to Embodiment 3 of the present invention;
[0032] FIG. 20 is a block diagram showing the internal principal-part configuration of the second layer coding section shown in FIG. 19 ;
[0033] FIG. 21 is a block diagram showing the internal principal-part configuration of the high-band coding section shown in FIG. 20 ;
[0034] FIG. 22 is a block diagram showing the internal principal-part configuration of a decoding apparatus according to Embodiment 3 of the present invention;
[0035] FIG. 23 is a block diagram showing the internal principal-part configuration of the second layer decoding section shown in FIG. 22 ;
[0036] FIG. 24 is a block diagram showing the internal principal-part configuration of an encoding apparatus according to Embodiment 4 of the present invention;
[0037] FIG. 25 is a block diagram showing the internal principal-part configuration of the second layer coding section shown in FIG. 24 ;
[0038] FIG. 26 is a block diagram showing the internal principal-part configuration of the band enhancement coding section shown in FIG. 25 ;
[0039] FIG. 27 is a block diagram showing the internal principal-part configuration of the residual spectrum coding section shown in FIG. 25 ;
[0040] FIG. 28 is a drawing showing conceptually a correspondence relationship between an encoded/decoded spectrum band and amount of information (coding bit rate) in each layer;
[0041] FIG. 29 is a block diagram showing the internal principal-part configuration of a decoding apparatus according to Embodiment 4 of the present invention;
[0042] FIG. 30 is a block diagram showing the internal principal-part configuration of the second layer decoding section shown in FIG. 29 ;
[0043] FIG. 31 is a block diagram showing the internal principal-part configuration of the residual spectrum decoding section shown in FIG. 30 ;
[0044] FIG. 32 is a block diagram showing the internal principal-part configuration of the band enhancement decoding section shown in FIG. 30 ; and
[0045] FIG. 33 is a drawing showing conceptually another correspondence relationship between an encoded/decoded spectrum band and amount of information (coding bit rate) in each layer;
DESCRIPTION OF EMBODIMENTS
[0046] Now, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following descriptions, a speech encoding apparatus and speech decoding apparatus are taken as examples of an encoding apparatus and decoding apparatus according to the present invention.
Embodiment 1
[0047] FIG. 1 is a block diagram showing the configuration of a communication system having an encoding apparatus and decoding apparatus according to Embodiment 1 of the present invention. In FIG. 1 , the communication system is provided with encoding apparatus 101 and decoding apparatus 103 , which are able to communicate via channel 102 . Both encoding apparatus 101 and channel 102 are normally used and installed in a base station apparatus, communication terminal apparatus, or the like.
[0048] Encoding apparatus 101 divides an input signal into N samples at a time (where N is a natural number), takes N samples as one frame, and performs coding on a frame-by-frame basis. Here, an input signal subject to coding will be expressed as x n (n=0, . . . , N−1). Here, n indicates the (n+1)th signal element in a signal divided into N samples at a time. Encoding apparatus 101 transmits encoded input information (hereinafter referred to as “coded information”) to decoding apparatus 103 via channel 102 .
[0049] Decoding apparatus 103 receives coded information transmitted from encoding apparatus 101 via channel 102 , decodes this coded information, and obtains an output signal.
[0050] FIG. 2 is a block diagram showing the internal principal-part configuration of encoding apparatus 101 shown in FIG. 1 . Encoding apparatus 101 mainly comprises orthogonal transform processing section 201 and coding section 202 .
[0051] Orthogonal transform processing section 201 has internal buffers buf 1 n (n=0, . . . , N−1), and performs a Modified Discrete Cosine Transform (MDCT) on input signal x n .
[0052] Next, orthogonal transform processing by orthogonal transform processing section 201 will be described in relation to its computational procedure and data output to an internal buffer.
[0053] First, orthogonal transform processing section 201 initializes buffer buf 1 n with “ 0 ” as an initial value by means of equation 1 below.
[0000] [1]
[0000] buf1 n =0( n= 0, . . . N− 1) (Equation 1)
[0054] Then, orthogonal transform processing section 201 performs a modified discrete cosine transform (MDCT) on input signal x n , and finds input signal MDCT coefficient (hereinafter referred to as input spectrum) X(k), in accordance with equation 2 below.
[0000]
(
Equation
2
)
X
(
k
)
=
2
N
∑
n
=
0
2
N
-
1
x
n
′
cos
[
(
2
n
+
1
+
N
)
(
2
k
+
1
)
π
4
N
]
(
k
=
0
,
…
,
N
-
1
)
[
2
]
[0055] Here, k indicates an index of each sample in one frame. Orthogonal transform processing section 201 finds vector x n ′ linking input signal x n and buffer buf 1 n by means of equation 3 below.
[0000]
(
Equation
3
)
x
n
′
{
buf
1
n
(
n
=
0
,
…
N
-
1
)
x
n
-
N
(
n
=
N
,
…
2
N
-
1
)
[
3
]
[0056] Orthogonal transform processing section 201 then updates buffer buf 1 n by means of equation 4.
[0000] [4]
[0000] buf1 n =x n ( n= 0, . . . N− 1) (Equation 4)
[0057] Then orthogonal transform processing section 201 outputs input spectrum X(k) to coding section 202 .
[0058] Input spectrum X(k) is input to coding section 202 from orthogonal transform processing section 201 . Coding section 202 encodes input spectrum X(k), and generates coded information. Then coding section 202 transmits the generated coded information to decoding apparatus 103 via channel 102 .
[0059] FIG. 3 is a block diagram showing the internal principal-part configuration of coding section 202 shown in FIG. 2 . Details of the processing performed by coding section 202 will now be described with reference to FIG. 3 . Coding section 202 mainly comprises band setting section 301 , low-band coding section 302 , high-band coding section (band enhancement section) 303 , and multiplexing section 304 . These sections perform the following operations.
[0060] Input spectrum X(k) is input to band setting section 301 from orthogonal transform processing section 201 . Band setting section 301 analyzes the spectral characteristics of input spectrum X(k), and sets bands subject to coding by low-band coding section 302 and high-band coding section (band enhancement section) 303 respectively according to the analysis results. Then, band setting section 301 outputs band setting information indicating the set bands to low-band coding section 302 , high-band coding section 303 , and multiplexing section 304 .
[0061] The band setting information calculation method used by band setting section 301 will now be described.
[0062] Band setting section 301 first calculates, for input spectrum X(k), energy (low-band energy) E Low of a part for which the band is less than or equal to TH Low in accordance with equation 5-1, and energy (high-band energy) E High of a part for which the band is greater than or equal to TH High in accordance with equation 5-2, where TH Low and TH High are predetermined threshold values, and TH Low <TH High . In equation 5-2, F max is the maximum band value (maximum frequency value).
[0000]
(
Equation
5
-
1
)
E
Low
=
∑
k
=
0
TH
Low
X
(
k
)
2
[
5
]
(
Equation
5
-
2
)
E
High
=
∑
k
=
TH
High
Fmax
X
(
k
)
2
[0063] Next, band setting section 301 compares the magnitude of low-band energy E Low calculated by means of equation 5-1 with the magnitude of high-band energy E High calculated by means of equation 5-2, and decides band setting information Band_Setting in accordance with equation 6 below. That is to say, based on input spectrum energy characteristics, band setting section 301 generates band setting information for dividing the input spectrum band and setting a band on the low-band side (low-band part) and the high-band side (high-band part). Here, γ in equation 6 is a predetermined constant.
[0000]
(
Equation
6
)
Band_setting
=
{
0
if
E
Low
≥
γ
·
E
High
1
(
else
)
[
6
]
[0064] That is to say, band setting section 301 sets the band setting information Band_Setting value to 0 if low-band energy E Low is somewhat greater than high-band energy E High , and sets the band setting information Band_Setting value to 1 otherwise. Band setting section 301 outputs decided band setting information Band_Setting to low-band coding section 302 , high-band coding section 303 , and multiplexing section 304 .
[0065] Input spectrum X(k) is input to low-band coding section 302 from orthogonal transform processing section 201 . Also, band setting information Band_Setting is input to low-band coding section 302 from band setting section 301 . Based on band setting information Band_Setting, low-band coding section 302 encodes input spectrum X(k) and generates low-band part coded information. Then low-band coding section 302 outputs the low-band part coded information to multiplexing section 304 . Details of the processing performed by low-band coding section 302 will be given later herein.
[0066] Input spectrum X(k) is input to high-band coding section 303 from orthogonal transform processing section 201 . Also, band setting information Band_Setting is input to high-band coding section 303 from band setting section 301 . Based on band setting information Band_Setting, high-band coding section 303 encodes input spectrum X(k) and generates high-band part coded information (band enhancement information). Then high-band coding section 303 outputs the high-band part coded information to multiplexing section 304 . Details of the processing performed by high-band coding section 303 will be given later herein.
[0067] Multiplexing section 304 multiplexes band setting information, low-band part coded information, and high-band part coded information input from band setting section 301 , low-band coding section 302 , and high-band coding section 303 respectively, and outputs the multiplexed information to channel 102 as coded information.
[0068] FIG. 4 is a block diagram showing the internal configuration of low-band coding section 302 . Low-band coding section 302 mainly comprises coding target spectrum calculation section 401 , shape coding section 402 , gain coding section 403 , and multiplexing section 404 . These sections perform the following operations.
[0069] Band setting information Band_Setting is input to coding target spectrum calculation section 401 from band setting section 301 . Also, input spectrum X(k) is input to coding target spectrum calculation section 401 from orthogonal transform processing section 201 . Based on the band setting information Band_Setting value, coding target spectrum calculation section 401 decides a band that is to be an coding target, and outputs only the spectrum of the corresponding band within input spectrum X(k) to shape coding section 402 .
[0070] Specifically, if the band setting information Band_Setting value is 0, coding target spectrum calculation section 401 outputs a spectrum for which the band is less than or equal to Max 1 (k≦Max 1 ) within input spectrum X(k) to shape coding section 402 as coding target spectrum X′(k). Also, if the band setting information Band_Setting value is 1, coding target spectrum calculation section 401 outputs a spectrum for which the band is less than or equal to Max 2 (k≦Max 2 ) within input spectrum X(k) to shape coding section 402 as coding target spectrum X′(k).
[0071] Here, the relationship between Max 1 and Max 2 is assumed to be Max 1 <Max 2 . That is to say, if the band setting information Band_Setting value is 0, coding target spectrum calculation section 401 selects a spectrum on the lower-band side within input spectrum X(k) as coding target spectrum X′(k). On the other hand, if the band setting information Band_Setting value is 1, coding target spectrum calculation section 401 selects a spectrum of a part for which the bandwidth is greater than when the band setting information Band_Setting value is 0 within input spectrum X(k) as coding target spectrum X′(k).
[0072] Shape coding section 402 performs shape quantization on a subband-by-subband basis on coding target spectrum X′(k) input from coding target spectrum calculation section 401 . Specifically, shape coding section 402 first divides coding target spectrum X′(k) into L subbands. Then, for each of the L subbands, shape coding section 402 searches an internal shape codebook comprising SQ shape code vectors, and finds an index of a shape code vector for which evaluation measure Shape_q(i) in equation 7 below is maximal.
[0000]
(
Equation
7
)
Shape_q
(
i
)
=
{
∑
k
=
0
BW
(
j
)
(
X
′
(
k
+
BS
(
j
)
)
·
SC
k
i
)
}
2
∑
k
=
0
BW
(
j
)
SC
k
i
·
SC
k
i
(
j
=
0
,
…
,
L
-
1
,
i
=
0
,
…
,
SQ
-
1
)
[
7
]
[0073] In this equation, SC i k indicates a shape code vector configuring a shape codebook, i indicates a shape code vector index, and k indicates a shape code vector element index. Also, BW(j) represents the bandwidth of a band for which the band index is j, and BS(j) represents the minimum index of a spectrum configuring a band for which the band index is j.
[0074] Shape coding section 402 outputs shape code vector index S_max for which evaluation measure Shape_q(i) in equation 7 above is maximal to multiplexing section 404 as shape coded information. Also, shape coding section 402 calculates ideal gain Gain_i(j) in accordance with equation 8 below, and outputs this to gain coding section 403 .
[0000]
(
Equation
8
)
Gain_i
(
j
)
=
{
∑
k
=
0
BW
(
j
)
(
X
′
(
k
+
BS
(
j
)
)
·
SC
k
S
_
max
)
}
∑
k
=
0
BW
(
j
)
SC
k
S
_
max
·
SC
k
S
_
max
(
j
=
0
,
…
,
L
-
1
)
[
8
]
[0075] Gain coding section 403 directly quantizes ideal gain Gain_i(j) input from shape coding section 402 in accordance with equation 9 below. Here too, gain coding section 403 treats an ideal gain as an L-dimensional vector, searches an internal gain codebook comprising GQ gain code vectors, and performs vector quantization.
[0000]
(
Equation
9
)
Gain_q
(
i
)
=
{
∑
j
=
0
L
-
1
{
Gain_i
(
j
)
-
GC
j
i
}
}
2
(
i
=
0
,
…
,
GQ
-
1
)
[
9
]
[0076] Gain coding section 403 finds gain code vector index G_min that minimizes square error Gain_q(i) in equation 9 above. Gain coding section 403 outputs G_min to multiplexing section 404 as gain coded information.
[0077] Multiplexing section 404 multiplexes shape coded information S_max input from shape coding section 402 and gain coded information G_min input from gain coding section 403 , and outputs the multiplexed information to multiplexing section 304 as low-band part coded information. Shape coded information and gain coded information may also be directly input to multiplexing section 304 , and multiplexed with high-band part coded information by multiplexing section 304 .
[0078] This concludes a description of the configuration of low-band coding section 302 .
[0079] FIG. 5 is a block diagram showing the internal configuration of high-band coding section 303 . High-band coding section 303 is provided with band division section 501 , filter state setting section 502 , filtering section 503 , search section 505 , pitch coefficient setting section 504 , gain coding section 506 , and multiplexing section 507 . These sections perform the following operations.
[0080] Input spectrum X(k) is input to band division section 501 from orthogonal transform processing section 201 . Also, band setting information Band_Setting is input to band division section 501 from band setting section 301 . Band division section 501 divides a high-band part of input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1) according to the band setting information Band_Setting value.
[0081] Then, band division section 501 outputs bandwidth BW p (p=0, 1, . . . , P−1) and initial index BS p (p=0, 1, . . . , P−1) of each subband to filtering section 503 , search section 505 , and multiplexing section 507 as band division information.
[0082] Specifically, if the band setting information Band_Setting value is 0, band division section 501 divides a part for which the band is greater than or equal to Max 1 (Max 1 ≦k<Fmax) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). Also, if the band setting information Band_Setting value is 1, band division section 501 divides a part for which the band is greater than or equal to Max 2 (Max 2 ≦k<Fmax) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). Here, Fmax is the maximum band value. Also, below, a part in subband SB p within input spectrum X(k) is denoted as subband spectrum X p (k) (BS p ≦k<BS p +BW p ).
[0083] Filter state setting section 502 sets input spectrum X(k) input from orthogonal transform processing section 201 as a filter state used by filtering section 503 . Input spectrum X(k) is stored as a filter internal state (filter state) in an entire frequency band 0≦k<Fmax spectrum S(k) (0≦k<Max 1 ) or (0≦k<Max 2 ) band in filtering section 503 . Filter state setting section 502 outputs the set filter state to filtering section 503 .
[0084] Filtering section 503 is provided with a multi-tap pitch filter (that is, the number of taps is greater than 1). Filtering section 503 calculates input spectrum estimated value S′(k) (FL≦k≦FH) (hereinafter referred to as estimated spectrum) by filtering input spectrum X(k) based on the filter state set by filter state setting section 502 and pitch coefficient T input from pitch coefficient setting section 504 . Filtering section 503 outputs estimated spectrum S′(k) to search section 505 . Details of the filtering processing performed by filtering section 503 will be given later herein.
[0085] Search section 505 calculates similarity of a high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) divided by band division section 501 for input spectrum X(k) input from orthogonal transform processing section 201 and estimated spectrum S′(k) input from filtering section 503 . This similarity calculation is performed by means of a correlation computation or the like, for example.
[0086] The processing of filtering section 503 , search section 505 , and pitch coefficient setting section 504 forms a closed loop. In this closed loop, search section 505 calculates similarity corresponding to each pitch coefficient by variously changing pitch coefficient T input to filtering section 503 from pitch coefficient setting section 504 . Then, of the calculated similarities, search section 505 outputs the pitch coefficient for which similarity is maximal to multiplexing section 507 as optimum pitch coefficient T′. Also, search section 505 outputs estimated spectrum S′(k) to gain coding section 506 .
[0087] Under the control of search section 505 , pitch coefficient setting section 504 gradually changes pitch coefficient T within the search range (Tmin≦T≦Tmax), and successively outputs post-change pitch coefficient T to filtering section 503 .
[0088] Gain coding section 506 calculates gain information of a high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) divided by band division section 501 for input spectrum X(k) input from orthogonal transform processing section 201 . Specifically, gain coding section 506 divides a high-band part frequency band ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) into J samples, and finds the spectral power of each subband of input spectrum X(k). In this case, spectral power B(j) of the j'th subband is expressed by equation 10 below.
[0000]
(
Equation
10
)
B
(
j
)
=
∑
k
=
BL
j
BH
j
X
(
k
)
2
(
j
=
0
,
…
,
J
-
1
)
[
10
]
[0089] In equation 10, BL j represents the minimum frequency of the j'th subband, and BM j represents the maximum frequency of the j'th subband. Also, gain coding section 506 similarly calculates spectral power B′(j) of each subband of estimated spectrum S′(k) input from search section 505 in accordance with equation 11 below.
[0000]
(
Equation
11
)
B
′
(
j
)
=
∑
k
=
BL
j
BH
j
S
′
(
k
)
2
(
j
=
0
,
…
,
J
-
1
)
[
11
]
[0090] Gain coding section 506 then calculates variation V(j) of each subband for input spectrum X(k) in accordance with equation 12 below.
[0000]
(
Equation
12
)
V
(
j
)
=
B
(
j
)
B
′
(
j
)
(
j
=
0
,
…
,
J
-
1
)
[
12
]
[0091] Then, using an internal gain encoding codebook, gain coding section 506 encodes variation V(j), and outputs an index corresponding to post-coding variation V q (j) to multiplexing section 507 .
[0092] Multiplexing section 507 multiplexes optimum pitch coefficient T′ input from search section 505 and an index of variation V(j) input from gain coding section 506 as high-band part coded information, and outputs the multiplexed information to multiplexing section 304 . Optimum pitch coefficient T′ and a variation V(j) index may also be directly input to multiplexing section 304 , and multiplexed with low-band part coded information by multiplexing section 304 .
[0093] Details of the filtering processing performed by filtering section 503 will now be described with reference to FIG. 6 .
[0094] Filtering section 503 generates spectrum S(k) of a ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) band using pitch coefficient T input from pitch coefficient setting section 504 according to band division by band division section 501 . Filtering section 503 transfer function F(z) is expressed by equation 13 below.
[0000]
(
Equation
13
)
F
(
z
)
=
1
1
-
∑
i
=
-
M
M
β
i
z
-
T
+
i
[
13
]
[0095] In equation 13, T represents a pitch coefficient provided by pitch coefficient setting section 504 , and β i represents a filter coefficient stored internally beforehand. Also, in equation 13, M is an indicator relating to the number of taps, with M=1 being set, for example, when the number of taps is 3. When the number of taps is 3, (β -1 , β 0 , β 1 )=(0.1, 0.8, 0.1) may be given as an example of filter coefficient candidates. Other values, such as (β -1 , β 0 , β 1 )=(0.2, 0.6, 0.2), (0.3, 0.4, 0.3), are also applicable.
[0096] First, input spectrum X(k) is stored as a filter internal state (filter state) in a (0≦k<Max 1 ) or (0≦k<Max 2 ) band of spectrum S(k) of the entire frequency band in filtering section 503 .
[0097] Also, estimated spectrum S′(k) is stored in a spectrum S(k) high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) by means of the following filtering processing procedure. In estimated spectrum S′(k), spectrum S(k−T) of a frequency that is T lower than this k is basically assigned to estimated spectrum S′(k). Actually, however, in order to increase spectrum smoothness, spectrum β i ·S(k−T+i) obtained by multiplying nearby spectrum S(k−T+i) demultiplexed by i from spectrum S(k−T) by predetermined filter coefficient β i is added for all i's and the obtained spectrum is assigned to S′(k). This processing is expressed by equation 14 below.
[0000]
(
Equation
14
)
S
′
(
k
)
∑
i
=
-
1
1
β
i
·
S
(
k
-
T
+
i
)
2
[
14
]
[0098] Filtering section 503 calculates estimated spectrum S′(k) in a high-band part frequency band ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) by performing the above computation while changing k in the band Max 1 ≦k<Fmax or band Max 2 ≦k<Fmax range in order from low-frequency k=Max 1 or k=Max 2 .
[0099] The above filtering processing is performed after zeroizing spectrum S(k) in the high-band part frequency band ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) range each time pitch coefficient T is provided from pitch coefficient setting section 504 . That is to say, each time pitch coefficient T changes, spectrum S(k) is calculated and is output to search section 505 .
[0100] FIG. 7 is a flowchart showing the processing procedure for finding optimal pitch coefficient T p ′ for subband SB p in search section 505 . By repeating the procedure shown in FIG. 7 , search section 505 finds optimal pitch coefficient T p ′ (p=0, 1, . . . , P−1) corresponding to each subband SB p (p=0, 1, . . . , P−1).
[0101] First, search section 505 initializes minimum similarity D min , which is a variable for saving a minimum similarity value, to “+∞” (ST 2010 ). Then search section 505 calculates similarity D between an input spectrum X(k) high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) and estimated spectrum S′(k) for a certain pitch coefficient in accordance with equation 15 below (ST 2020 ).
[0000]
(
Equation
15
)
D
=
∑
k
=
0
M
′
X
(
BS
p
+
k
)
·
X
(
BS
p
+
k
)
-
(
∑
k
=
0
M
′
X
(
BS
p
+
k
)
·
S
′
(
BS
p
+
k
)
)
2
∑
k
=
0
M
′
S
′
(
BS
p
+
k
)
·
S
′
(
BS
p
+
k
)
(
0
<
M
′
≤
BW
p
)
[
15
]
[0102] In equation 15, M′ indicates the number of samples when calculating similarity D, and may be any value less than or equal to the bandwidth of each subband.
[0103] Next, search section 505 determines whether or not calculated similarity D is smaller than minimum similarity D min , (ST 2030 ). If similarity D calculated in ST 2020 is smaller than minimum similarity D min (ST 2030 : “YES”), search section 505 assigns similarity D to minimum similarity D min (ST 2040 ). On the other hand, if similarity D calculated in ST 2020 is greater than or equal to minimum similarity (ST 2030 : “NO”), search section 505 determines whether or not the search range has ended (ST 2050 ). That is to say, search section 505 determines whether or not similarity D has been calculated in accordance with equation 15 above in ST 2020 for all pitch coefficients within the search range. If the search range has not ended (ST 2050 : “NO”), search section 505 returns to ST 2020 again. Then search section 505 calculates similarity D in accordance with equation 15 for a different pitch coefficient from that when similarity D was calculated in accordance with equation 15 in the previous ST 2020 procedure. On the other hand, if the search range has ended (ST 2050 : “YES”), search section 505 outputs pitch coefficient T corresponding to minimum similarity D min to multiplexing section 507 as optimum pitch coefficient T p ′ (ST 2060 ).
[0104] This concludes a description of the processing performed by high-band coding section 303 .
[0105] This concludes a description of the configuration of encoding apparatus 101 .
[0106] Decoding apparatus 103 shown in FIG. 1 will now be described.
[0107] FIG. 8 is a block diagram showing the internal principal-part configuration of decoding apparatus 103 . Decoding apparatus 103 mainly comprises decoding section 801 and orthogonal transform processing section 802 . These sections perform the following operations.
[0108] Coded information transmitted from encoding apparatus 101 via channel 102 is input to decoding section 801 . Decoding section 801 decodes the input coded information, and outputs spectral data obtained by decoding (a decoded spectrum) to orthogonal transform processing section 802 . Details of the processing performed by decoding section 801 will be given later herein.
[0109] The spectral data (decoded spectrum) is input to orthogonal transform processing section 802 from decoding section 801 . Orthogonal transform processing section 802 executes an orthogonal transform on the spectral data (decoded spectrum), and converts it to a time-domain signal. Orthogonal transform processing section 802 outputs the obtained signal as an output signal. Details of the processing performed by orthogonal transform processing section 802 will be given later herein.
[0110] FIG. 9 is a block diagram showing the internal configuration of decoding section 801 shown in FIG. 8 . Decoding section 801 mainly comprises demultiplexing section 901 , low-band decoding section 902 , and high-band decoding section (band enhancement section) 903 .
[0111] Coded information transmitted from encoding apparatus 101 via channel 102 is input to demultiplexing section 901 . Demultiplexing section 901 demultiplexes the coded information into low-band part coded information, high-band part coded information, and band setting information. Then demultiplexing section 901 outputs the low-band part coded information to low-band decoding section 902 , outputs the high-band part coded information (band enhancement information) to high-band decoding section 903 , and outputs the band setting information to low-band decoding section 902 and high-band decoding section 903 .
[0112] Low-band part coded information and band setting information are input to low-band decoding section 902 from demultiplexing section 901 . Low-band decoding section 902 generates a low-band part decoded spectrum from the input low-band part coded information and band setting information, and outputs the generated low-band part decoded spectrum to high-band decoding section 903 . Details of the processing performed by low-band decoding section 902 will be given later herein.
[0113] High-band part coded information and band setting information are input to high-band decoding section 903 from demultiplexing section 901 . Also, a low-band part decoded spectrum is input to high-band decoding section 903 from low-band decoding section 902 . High-band decoding section 903 generates a decoded spectrum from the input low-band part decoded spectrum, high-band part coded information, and band setting information, and outputs the generated decoded spectrum to orthogonal transform processing section 802 . Details of the processing performed by high-band decoding section 903 will be given later herein.
[0114] FIG. 10 is a block diagram showing the internal configuration of low-band decoding section 902 . Low-band decoding section 902 mainly comprises demultiplexing section 911 , shape decoding section 912 , and gain decoding section 913 . These sections perform the following operations.
[0115] Demultiplexing section 911 demultiplexes low-band part coded information input from demultiplexing section 901 into shape coded information S_max and gain coded information G_min, and outputs post-demultiplexing shape coded information S_max to shape decoding section 912 , and outputs gain coded information G_min to gain decoding section 913 . Provision may also be made for shape coded information and gain coded information to be demultiplexed from coded information directly by demultiplexing section 901 .
[0116] Shape decoding section 912 incorporates a shape codebook of the same kind as the shape codebook with which shape coding section 402 of low-band coding section 302 is provided, and searches the shape codebook with shape coded information S_max input from demultiplexing section 911 as an index. Shape decoding section 912 outputs a found shape code vector to gain decoding section 913 as a shape value of an coding target band spectrum indicated by band setting information Band_Setting input from demultiplexing section 901 . Here, a shape code vector found as a shape value is denoted as Shape_q′(k).
[0117] Gain decoding section 913 incorporates a gain codebook of the same kind as the gain codebook with which gain coding section 403 of low-band coding section 302 is provided, and uses this gain codebook to perform inverse quantization of a gain value from gain coded information in accordance with equation 16 below. Here too, a gain value is treated as an L-dimensional vector, and vector inverse quantization is performed. That is to say, gain code vector GC j G — min corresponding to gain coded information G_min is taken directly as gain value Gain_q′(j).
[0000] [16]
[0000] Gain — q′ ( j )=GC j G — min ( j= 0 , . . . , L− 1) (Equation 16)
[0118] Then, using a gain value obtained by inverse quantization and a shape value input from shape decoding section 912 , gain decoding section 913 calculates low-band part decoded spectrum S 1 ( k ) in accordance with equation 17 below, and outputs calculated low-band part decoded spectrum S 1 ( k ) to high-band decoding section 903 . In spectrum (MDCT coefficient) inverse quantization, if k is present in B(j″) through B(j″+1)−1, gain value Gain_q′(j) has the value of Gain_q′(j″).
[0000]
(
Equation
17
)
S
1
(
k
)
=
Gain_q
′
(
j
)
·
Shape_q
′
(
k
)
(
k
=
BL
j
,
…
,
BH
j
j
=
0
,
…
,
L
-
1
)
[
17
]
[0119] FIG. 11 is a block diagram showing the internal configuration of high-band decoding section 903 . High-band decoding section 903 mainly comprises demultiplexing section 921 , filter state setting section 922 , filtering section 923 , gain decoding section 924 , and spectrum adjustment section 925 . These sections perform the following operations.
[0120] Demultiplexing section 921 demultiplexes high-band part coded information input from demultiplexing section 901 into optimum pitch coefficient T′, which is filtering related information, and a post-coding variation V q (j) index, which is gain related information. Then demultiplexing section 921 outputs optimum pitch coefficient T′ to filtering section 923 , and outputs the post-coding variation V q (j) index to gain decoding section 924 . If demultiplexing into optimum pitch coefficient T′ and a post-coding variation V q (j) index has been performed in demultiplexing section 901 , demultiplexing section 921 need not be provided.
[0121] Based on band setting information Band_Setting input from demultiplexing section 901 , filter state setting section 922 sets low-band part decoded spectrum S 1 ( k ) input from low-band decoding section 902 as a filter state used by filtering section 923 . Here, if an entire frequency band 0≦k<Fmax spectrum in filtering section 923 is called S(k) for convenience, of spectrum S(k), low-band part decoded spectrum S 1 ( k ) is stored in a low-band part ((0≦k<Max 1 ) or (0≦k<Max 2 )) band indicated by band setting information Band_Setting as a filter internal state (filter state). The configuration and operation of filter state setting section 922 are similar to those of filter state setting section 502 shown in FIG. 5 , and therefore a detailed description thereof is omitted here.
[0122] Filtering section 923 is provided with a multi-tap pitch filter (that is, the number of taps is greater than 1). Filtering section 923 filters low-band part decoded spectrum S 1 ( k ) based on a filter state set by filter state setting section 922 , pitch coefficient T′ input from demultiplexing section 921 , a filter coefficient stored internally beforehand, and band setting information Band_Setting input from demultiplexing section 901 . Then filtering section 923 calculates estimated spectrum S′(k) of input spectrum S(k) as shown in equation 18 below.
[0000]
(
Equation
18
)
S
′
(
k
)
=
∑
i
=
-
1
1
β
i
·
S
1
(
k
-
T
+
i
)
2
[
18
]
[0123] The transfer function shown in equation 13 above is also used by filtering section 923 . Filtering section 923 outputs estimated spectrum S′(k) obtained by filtering to spectrum adjustment section 925 .
[0124] Gain decoding section 924 decodes a post-coding variation V q (j) index input from demultiplexing section 921 based on band setting information Band_Setting input from demultiplexing section 901 , and finds post-coding variation V q (j), which is a variation V(j) quantization value. Here, the gain codebook used for post-coding variation V q (j) index decoding is incorporated in gain decoding section 924 , and is similar to the gain codebook used by gain coding section 506 shown in FIG. 5 . Gain decoding section 924 outputs post-coding variation V q (j) obtained by decoding to spectrum adjustment section 925 .
[0125] Spectrum adjustment section 925 multiplies estimated spectrum S′(k) input from filtering section 923 by post-coding variation V q (j) of each subband input from gain decoding section 924 for a high-band part specified by band setting information Band_Setting input from demultiplexing section 901 in accordance with equation 19 below. By this means, spectrum adjustment section 925 adjusts the spectrum shape in a high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) of estimated spectrum S′(k), generates decoded spectrum S 2 ( k ), and outputs this to orthogonal transform processing section 802 .
[0000]
(
Equation
19
)
S
2
(
k
)
=
S
′
(
k
)
·
V
q
(
j
)
(
Max
1
≤
k
<
F
max
or
Max
2
≤
k
<
F
max
j
=
0
,
…
,
J
-
1
)
[
19
]
[0126] In equation 19, j indicates a subband index when gain is encoded, and is set according to spectrum index k. That is to say, for spectrum index k included in a subband for which the subband index is j″, estimated spectrum S′(k) is multiplied by V q (j″).
[0127] Here, a low-band part ((0≦k<Max 1 ) or (0≦k<Max 2 )) of decoded spectrum S 2 ( k ) comprises first layer decoded spectrum S 1 ( k ), and a high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax)) of decoded spectrum S 2 ( k ) comprises post-spectrum-shape-adjustment estimated spectrum S′(k).
[0128] The actual processing performed by orthogonal transform processing section 802 will now be described.
[0129] Orthogonal transform processing section 802 has internal buffers buf 2 ( k ), which are initialized as shown in equation 20 below.
[0000] [20]
[0000] buf2( k )=0( k= 0, . . . , N− 1) (Equation 20)
[0130] Also, orthogonal transform processing section 802 finds decoded signal y n in accordance with equation 21 below using decoded spectrum S 2 ( k ) input from spectrum adjustment section 925 , and outputs decoded signal y n .
[0000]
(
Equation
21
)
y
n
=
2
N
∑
n
=
0
2
N
-
1
Z
(
k
)
cos
[
(
2
n
+
1
+
N
)
(
2
k
+
1
)
π
4
N
]
(
n
=
0
,
…
,
N
-
1
)
[
21
]
[0131] In equation 21, Z(k) is a vector that links decoded spectrum S 2 ( k ) and buffer buf 2 ( k ) as shown in equation 22 below.
[0000]
(
Equation
22
)
Z
(
k
)
=
{
buf
2
(
k
)
(
k
=
0
,
…
N
-
1
)
S
2
(
k
)
(
k
=
N
,
…
2
N
-
1
)
[
22
]
[0132] Next, orthogonal transform processing section 802 updates buffer buf 2 ( k ) in accordance with equation 23 below.
[0000] [23]
[0000] buf2( k )= S 2( k )( k= 0, . . . , N− 1) (Equation 23)
[0133] Orthogonal transform processing section 802 then outputs decoded signal y n as an output signal.
[0134] This concludes a description of the internal configuration of decoding apparatus 103 .
[0135] Thus, according to this embodiment, in a coding/decoding method that performs band enhancement using a low-band part spectrum and generates/estimates a high-band part spectrum, an encoding apparatus/decoding apparatus decides band setting—that is, which bands a low-band part and high-band part are—adaptively according to an input signal characteristic. By this means, high-band part spectral data such as a wideband signal or an ultrawideband signal can be encoded efficiently, and the quality of a decoded signal can be improved.
[0136] Specifically, band setting section 301 compares low-band part energy and high-band part energy of input signal spectral data, and if the low-band part energy is significantly greater than the high-band part energy, sets a narrower low-band part and a wider high-band part. By this means, low-band part spectral data that greatly influences the quality of a decoded signal when an input signal is speech can be encoded intensively by means of a shape-gain coding method, and the quality of a decoded signal can be increased. On the other hand, if low-band part energy is not that much greater than high-band part energy, band setting section 301 sets a wider low-band part and a narrower high-band part. By this means, encoding distortion can be reduced with a shape-gain coding method up to a higher band part, and bandwidth limitation that greatly influences the quality of a decoded signal when an input signal is audio can be improved.
[0137] In this embodiment, a configuration has been described whereby division into different subband configurations is performed by band division section 501 and gain coding section 506 in high-band coding section 303 , but the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby division is performed into identical subband configurations.
[0138] In this embodiment, a configuration has been described whereby a high-band part spectrum is divided into P parts by band division section 501 in high-band coding section 303 irrespective of the value of band setting information Band_Setting. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby a subband is divided into different numbers according to the value of band setting information Band_Setting. For example, when band setting information Band_Setting is 0, a high-band part spectrum bandwidth is wider than when band setting information Band_Setting is 1, and therefore in this case division is performed into a number greater than P. By this means, it is possible to prevent degradation of coding performance due to a subband width being too great.
[0139] Also, in this embodiment, a configuration has been described whereby an input spectrum low-band part is set as a filter state in high-band coding section 303 , and a search is performed for a spectrum position that is similar to an input spectrum high-band part. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby a search is performed for a spectrum position that is similar to an input spectrum high-band part for a low-band part decoded spectrum obtained by decoding low-band part coded information output from a low-band coding section. When the above configuration is employed, a low-band part decoded spectrum obtained on the decoding apparatus side can also be used, enabling operation on the decoding apparatus side to be ensured.
[0140] Also, when the above configuration is employed, it is necessary for a low-band part decoding section that performs local decoding for calculating a low-band part decoded spectrum to be newly provided in coding section 202 , and for a low-band part decoded spectrum to be output from the low-band decoding section to high-band coding section 303.
Embodiment 2
[0141] Embodiment 2 describes a configuration in which a first layer coding section that encodes a low-band part of spectral data is newly provided, and the coding method described in Embodiment 1 is applied to difference data between input signal spectral data and a first layer coding section coding result. Below, a coding layer in which the coding method described in Embodiment 1 is applied is described as a second layer coding section.
[0142] A communication system according to Embodiment 2 (not shown) is basically similar to the communication system shown in FIG. 1 , and differs from encoding apparatus 101 and decoding apparatus 103 of the communication system in FIG. 1 only in parts of the configuration and operation of the encoding apparatus and decoding apparatus. In the following description, reference codes “ 111 ” and “ 113 ” are assigned respectively to an encoding apparatus and decoding apparatus of a communication system according to this embodiment.
[0143] FIG. 12 is a block diagram showing the internal principal-part configuration of encoding apparatus 111 according to this embodiment. Encoding apparatus 111 according to this embodiment mainly comprises down-sampling processing section 1001 , first layer coding section 1002 , first layer decoding section 1003 , up-sampling processing section 1004 , orthogonal transform processing section 1005 , second layer coding section 1006 , and coded information integration section 1007 . These sections perform the following operations.
[0144] If the sampling frequency of input signal x n is designated SR input , down-sampling processing section 1001 performs down-sampling of input signal sampling frequency from SR Input to SR base (where SR base <SR input ), and outputs a down-sampled input signal to first layer coding section 1002 as a post-down-sampling input signal.
[0145] First layer coding section 1002 performs encoding on a post-down-sampling input signal input from down-sampling processing section 1001 using, for example, a CELP (Code Excited Linear Prediction) type speech coding method, and generates first layer coded information. Then first layer coding section 1002 outputs the generated first layer coded information to first layer decoding section 1003 and coded information integration section 1007 .
[0146] First layer decoding section 1003 performs decoding on first layer coded information input from first layer coding section 1002 using, for example, a CELP speech decoding method, and generates a first layer decoded signal. Then first layer decoding section 1003 outputs the generated first layer decoded signal to up-sampling processing section 1004 .
[0147] Up-sampling processing section 1004 performs up-sampling of the sampling frequency of a first layer decoded signal input from first layer decoding section 1003 from SR base to SR input . Then up-sampling processing section 1004 outputs an up-sampled first layer decoded signal to orthogonal transform processing section 1005 as post-up-sampling first layer decoded signal c 1 n .
[0148] Orthogonal transform processing section 1005 has internal buffers buf 1 n and buf 2 n (n=0, . . . , N−1). Orthogonal transform processing section 1005 performs a Modified Discrete Cosine Transform (MDCT) on input signal x n and post-up-sampling first layer decoded signal c 1 n input from up-sampling processing section 1004 . Orthogonal transform processing section 1005 performs orthogonal transform processing of input signal x n and post-up-sampling first layer decoded signal c 1 n , and calculates input spectrum X(k) and first layer decoded spectrum C(k). The processing performed by orthogonal transform processing section 1005 is similar to the processing described in Embodiment 1, and therefore a description thereof is omitted here. Orthogonal transform processing section 1005 outputs obtained input spectrum X(k) and first layer decoded spectrum C(k) to second layer coding section 1006 .
[0149] Second layer coding section 1006 generates second layer coded information using input spectrum X(k) and first layer decoded spectrum C(k) input from orthogonal transform processing section 1005 , and outputs the generated second layer coded information to coded information integration section 1007 . Details of second layer coding section 1006 will be given later herein.
[0150] Coded information integration section 1007 integrates first layer coded information input from first layer coding section 1002 and second layer coded information input from second layer coding section 1006 . Then coded information integration section 1007 adds a transmission error code or the like to the integrated information source code if necessary, and then outputs this to channel 102 as coded information.
[0151] The internal principal-part configuration of second layer coding section 1006 shown in FIG. 12 will now be described with reference to FIG. 13 .
[0152] Second layer coding section 1006 mainly comprises band setting section 1101 , low-band coding section 1102 , high-band coding section (band enhancement section) 1103 , and multiplexing section 1104 .
[0153] Input spectrum X(k) and first layer decoded spectrum C(k) are input to band setting section 1101 from orthogonal transform processing section 1005 . Band setting section 1101 analyzes the spectral characteristics of input spectrum X(k) and first layer decoded spectrum C(k), and sets bands subject to coding by low-band coding section 1102 and high-band coding section (band enhancement section) 1103 respectively according to the analysis results. Then band setting section 1101 outputs this information as band setting information to low-band coding section 1102 , high-band coding section 1103 , and multiplexing section 1104 .
[0154] The band setting information calculation method used by band setting section 1101 will now be described.
[0155] Band setting section 1101 first calculates difference spectrum C sub (k) between input spectrum X(k) and first layer decoded spectrum C(k) by means of equation 24. In equation 24, Fmax is the maximum band value (maximum frequency value).
[0000] [24]
[0000] C sub ( k )= X ( k )− S 1( k )( k= 0, . . . , F max) (Equation 24)
[0156] Then band setting section 1101 calculates, for difference spectrum C sub (k), energy (low-band energy) E Low of a part for which the band is less than or equal to TH Low in accordance with equation 25-1, and energy (high-band energy) E High of a part for which the band is greater than or equal to TH High in accordance with equation 25-2, where TH Low and TH High are predetermined threshold values, and TH Low <TH High .
[0000]
(
Equation
25
-
1
)
E
Low
=
∑
k
=
0
TH
Low
C
sub
(
k
)
2
[
25
]
(
Equation
25
-
2
)
E
High
=
∑
k
=
TH
High
Fmax
C
sub
(
k
)
2
[0157] Next, band setting section 1101 compares the magnitude of low-band energy E Low and the magnitude of high-band energy E High calculated by means of equations 25, and decides band setting information Band_Setting in accordance with equation 26. Here, γ in equation 26 is a predetermined constant.
[0000]
(
Equation
26
)
Band_Setting
=
{
0
(
if
E
Low
≥
γ
·
E
High
)
1
(
else
)
[
26
]
[0158] That is to say, band setting section 1101 sets the band setting information Band_Setting value to 0 if low-band energy E Low is somewhat greater than high-band energy E High , and sets the band setting information Band_Setting value to 1 otherwise. Band setting section 1101 outputs decided band setting information Band_Setting to low-band coding section 1102 , high-band coding section 1103 , and multiplexing section 1104 .
[0159] Input spectrum X(k) and first layer decoded spectrum C(k) are input to low-band coding section 1102 from orthogonal transform processing section 1005 . Also, band setting information Band_Setting is input to low-band coding section 1102 from band setting section 1101 . Based on band setting information Band_Setting, low-band coding section 1102 encodes difference spectrum C sub (k) between input spectrum X(k) and first layer decoded spectrum C(k), and generates low-band part coded information. Then low-band coding section 1102 outputs the low-band part coded information to multiplexing section 1104 . Details of the processing performed by low-band coding section 1102 will be given later herein.
[0160] Input spectrum X(k) and first layer decoded spectrum C(k) are input to high-band coding section 1103 from orthogonal transform processing section 1005 . Also, band setting information Band_Setting is input to high-band coding section 1103 from band setting section 1101 . Based on band setting information Band_Setting, high-band coding section 1103 encodes input spectrum X(k) and generates high-band part coded information (band enhancement information). Then, high-band coding section 1103 outputs the high-band part coded information to multiplexing section 1104 . Details of the processing performed by high-band coding section 1103 will be given later herein.
[0161] Multiplexing section 1104 multiplexes band setting information Band_Setting, low-band part coded information, and high-band part coded information input from band setting section 1101 , low-band coding section 1102 , and high-band coding section 1103 respectively, and generates second layer coded information. Then multiplexing section 1104 outputs the obtained second layer coded information to coded information integration section 1007 . Band setting information, low-band part coded information, and high-band part coded information may also be input directly to coded information integration section 1007 , and multiplexed by coded information integration section 1007 .
[0162] FIG. 14 is a block diagram showing the internal configuration of low-band coding section 1102 . Low-band coding section 1102 mainly comprises difference spectrum calculation section 1201 , shape coding section 1202 , gain coding section 1203 , and multiplexing section 1204 . These sections perform the following operations.
[0163] Difference spectrum calculation section 1201 calculates difference spectrum C sub (k) between input spectrum X(k) and first layer decoded spectrum C(k), and outputs calculated difference spectrum C sub (k) to shape coding section 1202 .
[0164] Difference spectrum C sub (k) is input to shape coding section 1202 from difference spectrum calculation section 1201 . Shape coding section 1202 encodes difference spectrum C sub (k) shape information, and outputs this to multiplexing section 1204 as shape coded information. Also, shape coding section 1202 calculates an ideal gain at the time of shape information coding, and outputs the calculated ideal gain to gain coding section 1203 . The processing performed by shape coding section 1202 is similar to that of shape coding section 402 shown in FIG. 4 , and therefore a description thereof is omitted here.
[0165] Ideal gain is input to gain coding section 1203 from shape coding section 1202 . Gain coding section 1203 encodes the ideal gain, and outputs this to multiplexing section 1204 as gain coded information. The processing performed by gain coding section 1203 is similar to that of gain coding section 403 shown in FIG. 4 , and therefore a description thereof is omitted here.
[0166] FIG. 15 is a block diagram showing the internal configuration of high-band coding section 1103 . High-band coding section 1103 is provided with band division section 1301 , filter state setting section 1302 , filtering section 1303 , search section 1305 , pitch coefficient setting section 1304 , gain coding section 1306 , and multiplexing section 1307 , which perform the operations described below. With the exception of filter state setting section 1302 , the above configuration elements perform similar processing to that of identically named configuration elements shown in FIG. 5 , and therefore descriptions thereof are omitted here.
[0167] Filter state setting section 1302 sets first layer decoded spectrum C(k) input from orthogonal transform processing section 1005 as a filter state used by filtering section 1303 . First layer decoded spectrum C(k) is stored as a filter internal state (filter state) in an entire frequency band 0≦k<Fmax spectrum S(k) ((0≦k<Max 1 ) or (0≦k<Max 2 )) band in filtering section 1303 .
[0168] This concludes a description of the processing performed by high-band coding section 1103 .
[0169] This concludes a description of the configuration of encoding apparatus 111 .
[0170] Decoding apparatus 113 according to this embodiment will now be described.
[0171] FIG. 16 is a block diagram showing the internal principal-part configuration of decoding apparatus 113 . Decoding apparatus 113 mainly comprises coded information demultiplexing section 1401 , first layer decoding section 1402 , up-sampling processing section 1403 , orthogonal transform processing section 1404 , second layer decoding section 1405 , and orthogonal transform processing section 1406 . These sections perform the following operations.
[0172] Coded information transmitted from encoding apparatus 111 via channel 102 is input to coded information demultiplexing section 1401 . Coded information demultiplexing section 1401 demultiplexes the input coded information into first layer coded information and second layer coded information, outputs the first layer coded information to first layer decoding section 1402 , and outputs the second layer coded information to second layer decoding section 1405 .
[0173] First layer decoding section 1402 decodes the first layer coded information input from coded information demultiplexing section 1401 and generates a first layer decoded signal, and outputs the generated first layer decoded signal to up-sampling processing section 1403 . The operation of first layer decoding section 1402 is similar to that of first layer decoding section 1003 shown in FIG. 12 , and therefore a detailed description thereof is omitted here.
[0174] Up-sampling processing section 1403 performs up-sampling of the sampling frequency of a first layer decoded signal input from first layer decoding section 1402 from SR base to SR input , and outputs an obtained post-up-sampling first layer decoded signal to orthogonal transform processing section 1404 .
[0175] Orthogonal transform processing section 1404 performs orthogonal transform processing (MDCT) on a post-up-sampling first layer decoded signal input from up-sampling processing section 1403 . Then orthogonal transform processing section 1404 outputs obtained post-up-sampling first layer decoded signal MDCT coefficient (hereinafter referred to as first layer decoded spectrum) C(k) to second layer decoding section 1405 . The operation of orthogonal transform processing section 1404 is similar to the processing on a post-up-sampling first layer decoded signal by orthogonal transform processing section 1005 shown in FIG. 12 , and therefore a detailed description thereof is omitted here.
[0176] Second layer decoding section 1405 generates second layer decoded spectrum S 2 ( k ) including a high-band component using first layer decoded spectrum C(k) input from orthogonal transform processing section 1404 and second layer coded information input from coded information demultiplexing section 1401 . Then second layer decoding section 1405 outputs generated second layer decoded spectrum S 2 ( k ) to orthogonal transform processing section 1406 . Details of the processing performed by second layer decoding section 1405 will be given later herein.
[0177] Orthogonal transform processing section 1406 executes an orthogonal transform on second layer decoded spectrum S 2 ( k ) input from second layer decoding section 1405 , and converts it to a time-domain signal. Orthogonal transform processing section 1406 outputs the obtained signal as an output signal. The operation of orthogonal transform processing section 1406 is similar to the processing by orthogonal transform processing section 802 shown in FIG. 8 , and therefore a detailed description thereof is omitted here.
[0178] FIG. 17 is a block diagram showing the internal configuration of second layer decoding section 1405 shown in FIG. 16 . Second layer decoding section 1405 mainly comprises demultiplexing section 1501 , low-band decoding section 1502 , high-band decoding section (band enhancement section) 1503 , and spectrum synthesis section 1504 .
[0179] Second layer coded information is input to demultiplexing section 1501 from coded information demultiplexing section 1401 . Demultiplexing section 1501 demultiplexer the coded information into low-band part coded information, high-band part coded information, and band setting information. Then demultiplexing section 1501 outputs the low-band part coded information to low-band decoding section 1502 , outputs the high-band part coded information (band enhancement information) to high-band decoding section 1503 , and outputs the band setting information to low-band decoding section 1502 and high-band decoding section 1503 .
[0180] Low-band part coded information and band setting information are input to low-band decoding section 1502 from demultiplexing section 1501 . Low-band decoding section 1502 generates a low-band part decoded spectrum from the input low-band part coded information and band setting information, and outputs the generated low-band part decoded spectrum to spectrum synthesis section 1504 . The processing performed by low-band decoding section 1502 is similar to that of low-band decoding section 902 shown in FIG. 10 , and therefore a description thereof is omitted here.
[0181] High-band part coded information and band setting information are input to high-band decoding section 1503 from demultiplexing section 1501 . First layer decoded spectrum C(k) is input to high-band decoding section 1503 from orthogonal transform processing section 1404 . High-band decoding section 1503 generates a high-band part decoded spectrum from input first layer decoded spectrum C(k) and high-band part coded information, and outputs the generated high-band part decoded spectrum to spectrum synthesis section 1504 .
[0182] FIG. 18 is a block diagram showing the internal configuration of high-band decoding section 1503 . High-band decoding section 1503 mainly comprises demultiplexing section 1601 , filter state setting section 1602 , filtering section 1603 , gain decoding section 1604 , and spectrum adjustment section 1605 , which perform the operations described below. With the exception of filter state setting section 1602 , the above configuration elements perform similar processing to that of identically named configuration elements shown in FIG. 11 , and therefore descriptions thereof are omitted here.
[0183] Based on band setting information Band_Setting input from demultiplexing section 1501 , filter state setting section 1602 sets first layer decoded spectrum C(k) input from orthogonal transform processing section 1404 as a filter state used by filtering section 1603 . Here, an entire frequency band 0≦k<Fmax spectrum in filtering section 1603 is called S(k) for convenience. In this case, of spectrum S(k), first layer decoded spectrum C(k) is stored in a low-band part ((0≦k<Max 1 ) or (0≦k<Max 2 )) band indicated by band setting information Band_Setting as a filter internal state (filter state). The configuration and operation of filter state setting section 1602 are similar to those of filter state setting section 502 shown in FIG. 5 , and therefore a detailed description thereof is omitted here.
[0184] This concludes a description of the processing performed by high-band decoding section 1503 .
[0185] Low-band part decoded spectrum S 1 ( k ) is input to spectrum synthesis section 1504 from low-band decoding section 1502 . Also, high-band part decoded spectrum S 2 ( k ) is input to spectrum synthesis section 1504 from high-band decoding section 1503 . Spectrum synthesis section 1504 adds input low-band part decoded spectrum S 1 ( k ) and high-band part decoded spectrum S 2 ( k ) in the frequency domain by means of equation 27, and calculates addition spectrum S add (k). Spectrum synthesis section 1504 outputs calculated addition spectrum S add (k) to orthogonal transform processing section 1406 .
[0000] [27]
[0000] S add ( k )= S 1( k )+ S 2( k )( k= 0, . . . , F max) (Equation 27)
[0186] This concludes a description of the internal configuration of decoding apparatus 113 .
[0187] Thus, according to this embodiment, even in a configuration using a coding/decoding method that performs band enhancement using a low-band part spectrum and generates/estimates a high-band part spectrum, and in which there is a coding layer (core layer) that encodes a low band, an encoding apparatus/decoding apparatus decides band setting—that is, which bands a low-band part and high-band part are—adaptively according to an input signal characteristic. By this means, high-band part spectral data such as a wideband signal or an ultrawideband signal can be encoded efficiently, and the quality of a decoded signal can be improved.
[0188] Specifically, band setting section 1101 compares low-band part energy and high-band part energy of difference data between input signal spectral data and spectral data encoded by the core layer. Then, if the low-band part energy is significantly greater than the high-band part energy, band setting section 1101 sets a narrower low-band part narrower and a wider high-band part. By this means, low-band part spectral data that greatly influences the quality of a decoded signal when an input signal is speech can be encoded intensively by means of a shape-gain coding method, and the quality of a decoded signal can be increased. Also, if low-band part energy is not that much greater than high-band part energy, band setting section 1101 sets a wider low-band part and a narrower high-band part. By this means, coding distortion can be reduced with a shape-gain coding method up to a higher band part, and bandwidth limitation that greatly influences the quality of a decoded signal when an input signal is audio can be improved.
[0189] In this embodiment, band setting section 1101 decides band setting information Band_Setting based on an energy ratio of a low-band part and high-band part of a difference spectrum between an input spectrum and first layer decoded spectrum. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby band setting section 1101 decides band setting information Band_Setting based on an energy ratio of a low-band part and high-band part of an input spectrum.
[0190] Also, a configuration has been described whereby a first layer decoded spectrum is set as a filter state in high-band decoding section 1503 in a decoding apparatus according to this embodiment. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby a low-band part of a spectrum obtained by adding a first layer decoded spectrum and low-band part decoded spectrum in the frequency domain is set as a filter state. By this means, a low-band part spectrum used in band enhancement is more similar to an input spectrum, so that the precision of a low-band part used in band enhancement is improved, and as a result, the quality of a decoded signal can be further improved. In the above configuration, it is necessary for a low-band part decoded spectrum to be output to high-band decoding section 1503 from low-band decoding section 1502 .
Embodiment 3
[0191] In Embodiment 3 of the present invention, a configuration is described in which a first layer coding section that encodes a low-band part of spectral data is newly provided in the same way as in Embodiment 2, and the coding method described in Embodiment 1 is applied to difference data between input signal spectral data and a first layer coding section coding result. Below, a coding layer in which the coding method described in Embodiment 1 is applied is described as a second layer coding section. However, in this embodiment, a configuration is described whereby a band other than a band encoded by the first layer coding section is encoded by the second layer coding section. That is to say, a second layer coding section of Embodiment 2 has a configuration in which only a high-band coding section (band enhancement section) is present.
[0192] A communication system according to Embodiment 3 (not shown) is basically similar to the communication system shown in FIG. 1 , and differs from encoding apparatus 101 and decoding apparatus 103 of the communication system in FIG. 1 only in parts of the configuration and operation of the encoding apparatus and decoding apparatus. In the following description, reference codes “ 121 ” and “ 123 ” are assigned respectively to an encoding apparatus and decoding apparatus of a communication system according to this embodiment. encoding apparatus 121
[0193] FIG. 19 is a block diagram showing the internal principal-part configuration of encoding apparatus 121 according to this embodiment. Encoding apparatus 121 according to this embodiment mainly comprises down-sampling processing section 1001 , first layer coding section 1002 , first layer decoding section 1003 , up-sampling processing section 1004 , orthogonal transform processing section 1005 , second layer coding section 1701 , and coded information integration section 1007 . These sections perform the following operations. With the exception of second layer coding section 1701 , the above configuration elements perform the same processing as configuration elements in encoding apparatus 111 described in Embodiment 2, and are therefore assigned the same reference codes, and descriptions thereof are omitted here.
[0194] Second layer coding section 1701 generates second layer coded information using input spectrum X(k) and first layer decoded spectrum C(k) input from orthogonal transform processing section 1005 , and outputs the generated second layer coded information to coded information integration section 1007 .
[0195] The internal principal-part configuration of second layer coding section 1701 shown in FIG. 19 will now be described with reference to FIG. 20 .
[0196] Second layer coding section 1701 mainly comprises band setting section 1801 , high-band coding section (band enhancement section) 1802 , and multiplexing section 1803 . These sections perform the following operations.
[0197] Input spectrum X(k) and first layer decoded spectrum C(k) are input to band setting section 1801 from orthogonal transform processing section 1005 . Band setting section 1801 analyzes the spectral characteristics of input spectrum X(k) and first layer decoded spectrum C(k). Band setting section 1801 sets a band subject to coding by high-band coding section (band enhancement section) 1802 according to the analysis results, and outputs this as band setting information to high-band coding section 1802 and multiplexing section 1803 .
[0198] The band setting information calculation method used by band setting section 1801 will now be described.
[0199] Band setting section 1801 first calculates difference spectrum C sub (k) between input spectrum X(k) and first layer decoded spectrum C(k) by means of equation 28. In equation 28, Fmax is the maximum band value (maximum frequency value).
[0000] C sub ( k )= X ( k )− C ( k )=0, . . . F max) (Equation 28)
[0200] Then band setting section 1801 calculates, for difference spectrum C sub (k), energy (first band energy) E 1 of a part for which the band is TH 1 Low to TH 1 High and energy (second band energy) E 2 of a part for which the band is TH 2 Low to TH 2 High in accordance with equations 29-1 and 29-2. Here, TH 1 Low , TH 1 High , TH 2 Low , and TH 2 High are predetermined threshold values, TH 1 Low <TH 2 Low , and TH 1 High <TH 2 High .
[0000]
(
Equation
29
-
1
)
E
1
=
∑
k
=
TH
1
Low
TH
1
High
C
sub
(
k
)
2
[
29
]
(
Equation
29
-
2
)
E
2
=
∑
k
=
TH
2
Low
TH
2
High
C
sub
(
k
)
2
[0201] Next, band setting section 1801 compares the magnitude of first band energy E 1 calculated by means of equation 29-1 and the magnitude of second band energy E 2 calculated by means of equation 29-2, and decides band setting information Band_Setting in accordance with equation 30. Here, γ 2 in equation 30 is a predetermined constant.
[0000]
(
Equation
30
)
Band_Setting
=
{
0
(
if
E
1
≥
γ2
·
E
2
)
1
(
else
)
[
30
]
[0202] That is to say, band setting section 1801 sets the band setting information Band_Setting value to 0 if first band energy E 1 is somewhat greater than second band energy E 2 , and sets the band setting information Band_Setting value to 1 otherwise. Band setting section 1801 outputs decided band setting information Band_Setting to high-band coding section 1802 and multiplexing section 1803 .
[0203] Input spectrum X(k) and first layer decoded spectrum C(k) are input to high-band coding section 1802 from orthogonal transform processing section 1005 . Also, band setting information Band_Setting is input to high-band coding section 1802 from band setting section 1801 . Based on band setting information Band_Setting, high-band coding section 1802 encodes input spectrum X(k) and generates high-band part coded information (band enhancement information). Then high-band coding section 1802 outputs the high-band part coded information to multiplexing section 1803 . Details of the processing performed by high-band coding section 1802 will be given later herein.
[0204] Multiplexing section 1803 multiplexes band setting information and high-band part coded information input from band setting section 1801 and high-band coding section 1802 respectively, and outputs the multiplexed information to coded information integration section 1007 as second layer coded information. Band setting information and high-band part coded information may also be input directly to coded information integration section 1007 , and multiplexed by coded information integration section 1007 .
[0205] FIG. 21 is a block diagram showing the internal configuration of high-band coding section 1802 . High-band coding section 1802 is provided with band division section 1311 , filter state setting section 1302 , filtering section 1303 , search section 1305 , pitch coefficient setting section 1304 , gain coding section 1306 , and multiplexing section 1307 , which perform the operations described below. With the exception of band division section 1311 , the above configuration elements perform the same processing as configuration elements shown in FIG. 15 , and are therefore assigned the same reference codes, and descriptions thereof are omitted here.
[0206] Input spectrum X(k) is input to band division section 1311 from orthogonal transform processing section 1005 . Also, band setting information Band_Setting is input to band division section 1311 from band setting section 1801 . Band division section 1311 divides a high-band part of input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1) according to the band setting information Band_Setting value. Band division section 1311 outputs bandwidth BW p (p=0, 1, . . . , P−1) and initial index BS p (p=0, 1, . . . , P−1) of each subband to filtering section 1303 , search section 1305 , and multiplexing section 1307 as band division information.
[0207] Specifically, if the band setting information Band_Setting value is 0, band division section 1311 divides a part for which the band is less than or equal to Max 3 (Flow≦k<Max 3 ) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). Also, if the band setting information Band_Setting value is 1, band division section 1311 divides a part for which the band is less than or equal to Max 4 (Flow≦k<Max 4 ) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). Here, Max 3 and Max 4 are predetermined constants, and Max 3 <Max 4 . Also, Flow is a maximum frequency band value corresponding to a sampling frequency of a signal down-sampled by down-sampling processing section 1001 . That is to say, it is the maximum usable frequency index of a first layer decoded spectrum. Also, below, a part in subband SB p within input spectrum X(k) is denoted as subband spectrum X p (k) (BS p ≦k<B S p +BW p ).
[0208] The effect of the above-described kind of band division method will now be described. Band setting information Band_Setting is set by comparing energy (first band energy) E 1 of a part for which the band is TH 1 Low to TH 1 High and energy (second band energy) E 2 of a part for which the band is TH 2 Low to TH 2 High . If this band setting information Band_Setting value is 0, this means that low-band side energy is greater than high-band side energy. In this case, a band encoded by high-band coding section 1802 is given a narrow setting (Flow≦k<Max 3 ) by band division section 1311 , and there is an effect of improving the quality of a decoded signal by focusing coding on a lower band with high energy. Also, if the band setting information Band_Setting value is 1, this means that high-band side energy is greater than low-band side energy. In this case, a band encoded by high-band coding section 1802 is given a wider and higher-band setting (Flow≦k<Max 4 ) by band division section 1311 , and there is an effect of improving the quality of a decoded signal by performing encoding up to a band on the high-band side with high energy.
[0209] This concludes a description of the processing performed by high-band coding section 1802 .
[0210] This concludes a description of the configuration of encoding apparatus 121 .
[0211] Decoding apparatus 123 according to this embodiment will now be described.
[0212] FIG. 22 is a block diagram showing the internal principal-part configuration of decoding apparatus 123 . Decoding apparatus 123 mainly comprises coded information demultiplexing section 1401 , first layer decoding section 1402 , up-sampling processing section 1403 , orthogonal transform processing section 1404 , second layer decoding section 1901 , and orthogonal transform processing section 1406 . With the exception of second layer decoding section 1901 , the above configuration elements perform the same processing as configuration elements in decoding apparatus 113 of Embodiment 2, and are therefore assigned the same reference codes, and descriptions thereof are omitted here.
[0213] Second layer decoding section 1901 generates second layer decoded spectrum S 2 ( k ) including a high-band component using first layer decoded spectrum C(k) input from orthogonal transform processing section 1404 and second layer coded information input from coded information demultiplexing section 1401 . Second layer decoding section 1901 outputs generated second layer decoded spectrum S 2 ( k ) to orthogonal transform processing section 1406 .
[0214] FIG. 23 is a block diagram showing the internal configuration of second layer decoding section 1901 shown in FIG. 22 . Second layer decoding section 1901 mainly comprises demultiplexing section 2001 and high-band decoding section (band enhancement section) 2002 .
[0215] Second layer coded information is input to demultiplexing section 2001 from coded information demultiplexing section 1401 . Demultiplexing section 2001 demultiplexes the coded information into high-band part coded information and band setting information, and outputs these to high-band decoding section 2002 .
[0216] High-band part coded information and band setting information are input to high-band decoding section 2002 from demultiplexing section 2001 . High-band decoding section 2002 generates a decoded spectrum from the input high-band part coded information and band setting information, and outputs the generated decoded spectrum to orthogonal transform processing section 1406 .
[0217] Apart from input information being a first layer decoded spectrum rather than a low-band part decoded spectrum, the processing performed by high-band decoding section 2002 is similar to that of high-band decoding section 903 shown in FIG. 9 , and therefore a description thereof is omitted here.
[0218] This concludes a description of the internal configuration of decoding apparatus 123 .
[0219] Thus, according to this embodiment, even in a configuration using a coding/decoding method that performs band enhancement using a low-band part spectrum and generates/estimates a high-band part spectrum, and in which there is a coding layer (core layer) that encodes a low band, an encoding apparatus/decoding apparatus decides band setting to be enhanced—that is, a spectrum of up to which band is generated by means of band enhancement—adaptively according to an input signal characteristic. By this means, high-band part spectral data such as a wideband signal or an ultrawideband signal can be encoded efficiently, and the quality of a decoded signal can be improved.
[0220] Specifically, band setting section 1801 compares low-band part energy (first band energy) and high-band part energy (second band energy) of difference data between input signal spectral data and spectral data encoded by the core layer. Then, if the first band energy is significantly greater than the second band energy, band setting section 1801 makes a narrower setting for a high-band part generated by band enhancement. By this means, middle-band part spectral data that greatly influences the quality of a decoded signal when an input signal is speech can be encoded intensively, and the quality of a decoded signal can be increased. Here, a middle-band part denotes a band on the low-band side even within a high-band part when a band is divided into a low-band part and high-band part. Also, if first band energy is not that much greater than second band energy, band setting section 1801 makes a wider setting for a high-band part generated by band enhancement. By this means, bandwidth limitation that greatly influences the quality of a decoded signal when an input signal is audio can be improved by performing band enhancement up to a higher-band part.
[0221] In this embodiment, a configuration has been described by way of example in which band setting section 1801 adjusts the upper limit of a band of a spectrum generated by high-band coding section 1802 . However, the present invention is not limited to this, and can also be applied in a similar way to a configuration in which high-band coding section 1802 adjusts other than a band upper limit (for example, a band lower limit or the like) of a spectrum generated by high-band coding section 1802 .
[0222] As described above, according to this embodiment, when generating high-band part spectral data of a signal subject to coding based on low-band part spectral data, an encoding apparatus decides band setting—that is, which bands a low-band part and high-band part are—adaptively according to an input signal characteristic. By this means, high-band part spectral data such as a wideband signal or an ultrawideband signal can be encoded efficiently, and the quality of a decoded signal in a decoding apparatus can be improved.
Embodiment 4
[0223] With the band enhancement methods disclosed in Patent Literature 1 and Patent Literature 2, band setting is fixed irrespective of input signal characteristics such as described in Embodiment 1, Embodiment 2, and Embodiment 3. Here, an input signal characteristic is an energy ratio between a low-band spectrum and a high-band spectrum, tonality, or the like. Similarly, with the band enhancement methods disclosed in Patent Literature 1 and Patent Literature 2, band setting is fixed irrespective of conditions at the time of coding.
[0224] Band enhancement technology is essentially a technology that generates spectral data of a high-band part of a signal subject to coding in a pseudo fashion with very little information (very few bits) using a low-band part spectral data obtained by decoding high-band part spectral data. Consequently, if the coding bit rate is extremely high, using a spectrum coding method other than a band enhancement method will often enable the quality of a decoded signal to be improved. However, since the band enhancement methods disclosed in Patent Literature 1 and Patent Literature 2 always perform band enhancement using a fixed band setting irrespective of conditions at the time of coding, there is a problem of coding efficiency not being high.
[0225] In Embodiment 4 of the present invention, a configuration is described whereby band setting is switched adaptively in a band enhancement method according to conditions at the time of coding. Below, a case in which a coding bit rate is used as an example of conditions at the time of coding is taken by way of example. Here, a case is described by way of example in which three bit rates—BR 1 , BR 2 , and BR 3 —are used as coding bit rates. The relationship of the coding bit rates is assumed to be BR 1 <BR 2 <BR 3 .
[0226] A communication system according to Embodiment 4 (not shown) is basically similar to the communication system shown in FIG. 1 , and differs from encoding apparatus 101 and decoding apparatus 103 of the communication system in FIG. 1 only in parts of the configuration and operation of the encoding apparatus and decoding apparatus. In the following description, reference codes “ 131 ” and “ 133 ” are assigned respectively to an encoding apparatus and decoding apparatus of a communication system according to this embodiment.
[0227] FIG. 24 is a block diagram showing the internal principal-part configuration of encoding apparatus 131 according to this embodiment. Encoding apparatus 131 according to this embodiment mainly comprises down-sampling processing section 2401 , first layer coding section 2402 , first layer decoding section 2403 , up-sampling processing section 2404 , orthogonal transform processing section 2405 , second layer coding section 2406 , and coded information integration section 2407 . These sections perform the following operations.
[0228] If the sampling frequency of input signal x n is designated SR input , down-sampling processing section 2401 performs input signal sampling frequency down-sampling from SR input to SR base (where SR base <SR input ), and outputs a down-sampled input signal to first layer coding section 2402 as a post-down-sampling input signal.
[0229] First layer coding section 2402 performs coding on a post-down-sampling input signal input from down-sampling processing section 2401 using, for example, a CELP (Code Excited Linear Prediction) type speech coding method, and generates first layer coded information. Then first layer coding section 2402 outputs the generated first layer coded information to first layer decoding section 2403 and coded information integration section 2407 .
[0230] First layer decoding section 2403 performs decoding on first layer coded information input from first layer coding section 2402 using, for example, a CELP speech decoding method, and generates a first layer decoded signal. Then first layer decoding section 2403 outputs the generated first layer decoded signal to up-sampling processing section 2404 .
[0231] Up-sampling processing section 2404 performs up-sampling of the sampling frequency of a first layer decoded signal input from first layer decoding section 2403 from SR base to SR input . Then up-sampling processing section 2404 outputs an up-sampled first layer decoded signal to orthogonal transform processing section 2405 as post-up-sampling first layer decoded signal c 1 n .
[0232] Orthogonal transform processing section 2405 has internal buffers buf 1 n and buf 2 n (n=0, . . . , N−1). Orthogonal transform processing section 2405 performs a Modified Discrete Cosine Transform (MDCT) on input signal x n and post-up-sampling first layer decoded signal c 1 n input from up-sampling processing section 2404 . Orthogonal transform processing section 2405 performs orthogonal transform processing of input signal x n and post-up-sampling first layer decoded signal c 1 n , and calculates input spectrum X(k) and first layer decoded spectrum C 1 ( k ). The processing performed by orthogonal transform processing section 2405 is similar to the processing described in Embodiment 1, and therefore a description thereof is omitted here. Orthogonal transform processing section 2405 outputs obtained input spectrum X(k) and first layer decoded spectrum C 1 ( k ) to second layer coding section 2406 .
[0233] Second layer coding section 2406 generates second layer coded information using input spectrum X(k) and first layer decoded spectrum C 1 ( k ) input from orthogonal transform processing section 2405 based on coding bit rate information (hereinafter referred to as “bit rate information”) input to encoding apparatus 131 from outside, and outputs the generated second layer coded information to coded information integration section 2407 . Details of second layer coding section 2406 will be given later herein. In this embodiment, a case will be described by way of example in which encoding apparatus 131 uses three bit rates—BR 1 , BR 2 , and BR 3 —as coding bit rates, and the relationship of the coding bit rates is BR 1 <BR 2 <BR 3 .
[0234] Coded information integration section 2407 integrates first layer coded information input from first layer coding section 2402 , second layer coded information input from second layer coding section 2406 , and bit rate information. Then coded information integration section 2407 adds a transmission error code or the like to the integrated information source code if necessary, and then outputs this to channel 102 as coded information.
[0235] The internal principal-part configuration of second layer coding section 2406 shown in FIG. 24 will now be described with reference to FIG. 25 .
[0236] Second layer coding section 2406 mainly comprises band enhancement coding section 2501 , residual spectrum coding section 2502 , and multiplexing section 2503 . These sections perform the following operations.
[0237] First layer decoded spectrum C 1 ( k ) and input spectrum X(k) are input to band enhancement coding section 2501 from orthogonal transform processing section 2405 . Also, bit rate information is input to band enhancement coding section 2501 from outside. Furthermore, decoded residual spectrum D 1 ( k ) is input to band enhancement coding section 2501 from residual spectrum coding section 2502 . Band enhancement coding section 2501 calculates band enhancement coded information from input first layer decoded spectrum C 1 ( k ), input spectrum X(k), bit rate information, and decoded residual spectrum D 1 ( k ), and outputs this band enhancement coded information to multiplexing section 2503 . Details of the processing performed by band enhancement coding section 2501 will be given later herein.
[0238] First layer decoded spectrum C 1 ( k ) and input spectrum X(k) are input to residual spectrum coding section 2502 from orthogonal transform processing section 2405 . Also, bit rate information is input to residual spectrum coding section 2502 from outside. Residual spectrum coding section 2502 calculates residual spectrum coded information from input first layer decoded spectrum C 1 ( k ), input spectrum X(k), and bit rate information, and outputs this residual spectrum coded information to multiplexing section 2503 . Also, residual spectrum coding section 2502 outputs decoded residual spectrum D 1 ( k ) obtained by decoding the residual spectrum coded information to band enhancement coding section 2501 . Details of the processing performed by residual spectrum coding section 2502 and residual spectrum coded information will be given later herein.
[0239] Multiplexing section 2503 multiplexes band enhancement coded information and residual spectrum coded information input from band enhancement coding section 2501 and residual spectrum coding section 2502 respectively, and generates second layer coded information. Then multiplexing section 2503 outputs the obtained second layer coded information to coded information integration section 2407 . Band enhancement coded information and residual spectrum coded information may also be input directly to coded information integration section 2407 , and multiplexed by coded information integration section 2407 .
[0240] FIG. 26 is a block diagram showing the internal configuration of band enhancement coding section 2501 . Band enhancement coding section 2501 is provided with band division section 2601 , addition spectrum calculation section 2602 , filter state setting section 1302 , filtering section 1303 , search section 1305 , pitch coefficient setting section 1304 , gain coding section 1306 , and multiplexing section 1307 , which perform the operations described below. With the exception of band division section 2601 and addition spectrum calculation section 2602 , the above configuration elements perform similar processing to that of identically named configuration elements shown in FIG. 15 , and therefore descriptions thereof are omitted here. However, for filter state setting section 1302 only, processing differs from that of the identically named configuration element shown in FIG. 15 in terms of the name of an input spectrum and the input source configuration element name.
[0241] Input spectrum X(k) is input to band division section 2601 from orthogonal transform processing section 2405 . Also, bit rate information is input to band division section 2601 from outside. Band division section 2601 divides a high-band part of input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1) according to the bit rate information.
[0242] Specifically, if the bit rate information indicates that the coding bit rate is BR 1 , band division section 2601 divides a part for which the band is greater than or equal to Max 1 (Max 1 ≦k<Fmax) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). Also, if the bit rate information indicates that the coding bit rate is BR 2 , band division section 2601 divides a part for which the band is greater than or equal to Max 2 (Max 2 ≦k<Fmax) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1). And if the bit rate information indicates that the coding bit rate is BR 3 , band division section 2601 divides a part for which the band is greater than or equal to Max 3 (Max 3 ≦k<Fmax) within input spectrum X(k) into P subbands SB p (p=0, 1, . . . , P−1).
[0243] Here, Fmax is the maximum band value, and the relationship of Max 1 , Max 2 , and Max 3 is Max 1 <Max 2 <Max 3 .
[0244] That is to say, if bit rate information indicates that the coding bit rate is BR 1 , a wide setting is made for a high-band part of an input spectrum subject to band enhancement coded information calculation by band enhancement coding section 2501 . Also, if bit rate information indicates that the coding bit rate is BR 3 , a narrow setting is made for a high-band part of an input spectrum subject to band enhancement coded information calculation by band enhancement coding section 2501 . And if bit rate information indicates that the coding bit rate is BR 2 , a setting between the above two(wide setting and narrow setting) is made for a high-band part of an input spectrum subject to band enhancement coded information calculation.
[0245] Then band division section 2601 outputs bandwidth BW p (p=0, 1, . . . , P−1) and initial index BS p (p=0, 1, . . . , P−1) of each subband to filtering section 1303 , search section 1305 , and multiplexing section 1307 as band division information. Below, a part in subband SB p within input spectrum X(k) is denoted as subband spectrum X p (k) (BS p ≦k<BS p +BW p ).
[0246] First layer decoded spectrum C 1 ( k ) is input to addition spectrum calculation section 2602 from orthogonal transform processing section 2405 . Also, decoded residual spectrum D 1 ( k ) is input to addition spectrum calculation section 2602 from residual spectrum coding section 2502 . Addition spectrum calculation section 2602 adds these two spectra in the frequency domain as shown in equation 31, and calculates addition spectrum A(k). Then addition spectrum calculation section 2602 outputs addition spectrum A(k) to filter state setting section 1302 .
[0000] [31]
[0000] A ( k )= C 1( k )+ D 1( k )( k= 0, . . . F max) (Equation 31)
[0247] Thereafter, in the same way as in Embodiment 2, band enhancement coded information is generated by means of filter state setting section 1302 , filtering section 1303 , search section 1305 , pitch coefficient setting section 1304 , gain coding section 1306 , and multiplexing section 1307 , and the band enhancement coded information is output to multiplexing section 2503 .
[0248] In Embodiment 2, filter state setting section 1302 set first layer decoded spectrum C(k) input from orthogonal transform processing section 1005 as a filter state used by filtering section 1303 . In contrast, in this embodiment, filter state setting section 1302 sets addition spectrum A(k) input from addition spectrum calculation section 2602 as a filter state used by filtering section 1303 . Then addition spectrum A(k) is stored as a filter internal state (filter state) in an entire frequency band 0≦k<Fmax spectrum S(k) low-band part ((0≦k<Max 1 ) or (0≦k<Max 2 )) band in filtering section 1303 .
[0249] FIG. 27 is a block diagram showing the internal configuration of residual spectrum coding section 2502 . Residual spectrum coding section 2502 mainly comprises coding target spectrum calculation section 2701 , shape coding section 2702 , gain coding section 2703 , and multiplexing section 2704 . These sections perform the following operations.
[0250] Input spectrum X(k) and first layer decoded spectrum C 1 ( k ) are input to coding target spectrum calculation section 2701 from orthogonal transform processing section 2405 . Also, bit rate information is input to coding target spectrum calculation section 2701 from outside. Coding target spectrum calculation section 2701 first calculates difference spectrum B(k) between input spectrum X(k) and first layer decoded spectrum C 1 ( k ). Below, a part in subband SB p within difference spectrum B(k) is denoted as subband spectrum B p (k) (BS p ≦k<BS p +BW p ).
[0000] [32]
[0000] B ( k )= X ( k )− C 1( k )( k= 0, . . . , F max) (Equation 32)
[0251] Then, coding target spectrum calculation section 2701 sets a partial band spectrum within difference spectrum B(k) obtained by means of equation 32 as an coding target spectrum according to the bit rate information.
[0252] Specifically, if the bit rate information indicates that the coding bit rate is BR 1 , coding target spectrum calculation section 2701 sets a part for which the band is less than or equal to Max 1 (0≦k<Max 1 ) within difference spectrum B(k) as coding target spectrum D(k). Also, if the bit rate information indicates that the coding bit rate is BR 2 , band division section 2601 sets a part for which the band is less than or equal to Max 2 (0≦k<Max 2 ) within difference spectrum B(k) as coding target spectrum D(k). And if the bit rate information indicates that the coding bit rate is BR 3 , band division section 2601 sets a part for which the band is less than or equal to Max 3 (0≦k<Max 3 ) within difference spectrum B(k) as coding target spectrum D(k).
[0253] As stated above, the relationship of Max 1 , Max 2 , and Max 3 is Max 1 ≦Max 2 <Max 3 .
[0254] That is to say, if bit rate information indicates that the coding bit rate is BR 1 , coding target spectrum calculation section 2701 makes a narrow bandwidth setting for spectrum (coding target spectrum) D(k) subject to coding by residual spectrum coding section 2502 . Also, if bit rate information indicates that the coding bit rate is BR 3 , coding target spectrum calculation section 2701 makes a wide coding target spectrum bandwidth setting. And if bit rate information indicates that the coding bit rate is BR 2 , coding target spectrum calculation section 2701 sets a coding target spectrum bandwidth between the above two (between wide setting and narrow setting).
[0255] Then coding target spectrum calculation section 2701 outputs set coding target spectrum D(k) to shape coding section 2702 .
[0256] Shape coding section 2702 performs quantization on a subband-by-subband basis on coding target spectrum D(k) input from coding target spectrum calculation section 2701 . Specifically, shape coding section 2702 first divides coding target spectrum D(k) into L subbands. Then, for each of the L subbands, shape coding section 2702 searches an internal shape codebook comprising SQ shape code vectors, and finds an index of a shape code vector for which evaluation measure Shape_q(i) in equation 33 below is maximal.
[0000]
(
Equation
33
)
Shape_q
(
i
)
=
{
∑
k
=
0
BW
(
j
)
(
D
(
k
+
BS
(
j
)
)
·
SC
k
i
)
}
2
∑
k
=
0
BW
(
j
)
SC
k
i
·
SC
k
i
(
j
=
0
,
…
,
L
-
1
,
i
=
0
,
…
,
SQ
-
1
)
[
33
]
[0257] In this equation, SC i k indicates a shape code vector configuring a shape codebook, i indicates a shape code vector index, and k indicates a shape code vector element index. Also, BW(j) represents the bandwidth of a band for which the band index is j, and BS(j) represents the minimum index of a spectrum configuring a band for which the band index is j.
[0258] Shape coding section 2702 outputs shape code vector index S_max for which evaluation measure Shape_q(i) in equation 33 above is maximal to multiplexing section 2704 as shape coded information. Also, shape coding section 2702 calculates ideal gain Gain_i(j) in accordance with equation 34 below, and outputs this to gain coding section 2703 .
[0000]
(
Equation
34
)
Gain_i
(
j
)
=
{
∑
k
=
0
BW
(
j
)
(
D
(
k
+
BS
(
j
)
)
·
SC
k
S
_
max
)
}
∑
k
=
0
BW
(
j
)
SC
k
S
_
max
·
SC
k
S
_
max
(
j
=
0
,
…
,
L
-
1
)
[
34
]
[0259] Also, shape coding section 2702 outputs a shape information decoded value obtained by performing inverse quantization (local decoding) of shape coded information to gain coding section 2703 . Here, a shape information decoded value found as a shape value is denoted as Shape_q′(k).
[0260] Gain coding section 2703 directly quantizes ideal gain Gain_i(j) input from shape coding section 2702 in accordance with equation 9. Here too, gain coding section 2703 treats ideal gain as an L-dimensional vector, searches an internal gain codebook comprising GQ gain code vectors, and performs vector quantization.
[0261] Gain coding section 2703 finds gain code vector index G_min that minimizes square error Gain_q(i) in equation 9. Gain coding section 2703 outputs G_min to multiplexing section 2704 as gain coded information.
[0262] Also, gain coding section 2703 applies a gain information decoded value obtained by performing inverse quantization (local decoding) on gain coded information to a shape information decoded value input from shape coding section 2702 , and calculates a residual spectrum decoded value (hereinafter referred to as decoded residual spectrum D 1 ( k )) as shown in equation 35. Here, in equation 35, Shape_q′(k) is a decoded shape value and Gain_q′(k) indicates a decoded gain.
[0000]
(
Equation
35
)
D
1
(
k
)
=
Gain_q
′
(
j
)
·
Shape_q
′
(
k
)
(
k
=
BL
j
,
…
,
BH
j
j
=
0
,
…
,
L
-
1
)
[
35
]
[0263] Then gain coding section 2703 outputs decoded residual spectrum D 1 ( k ) to band enhancement coding section 2501 .
[0264] Multiplexing section 2704 multiplexes shape coded information and gain coded information input from shape coding section 2702 and gain coding section 2703 respectively, and outputs the multiplexed information to multiplexing section 2503 as residual spectrum coded information.
[0265] This concludes a description of the configuration of encoding apparatus 131 .
[0266] A conceptual diagram of coding processing with an above-described configuration and decoding processing with a configuration described later herein is shown in FIG. 28 . FIG. 28 is a drawing showing conceptually a correspondence relationship between an encoded/decoded spectrum band and amount of information (coding bit rate) in a coding section/decoding section of each layer.
[0267] In FIG. 28 , part “A” indicates a band of a spectrum encoded/decoded by first layer coding section 2402 and first layer decoding section 2403 . Also, part “B” indicates a band of a spectrum encoded/decoded by residual spectrum coding section 2502 and residual spectrum decoding section 2902 described later herein within a band of a spectrum encoded/decoded by second layer coding section 2406 and second layer decoding section 2805 described later herein. And part “C” indicates a band of a spectrum encoded/decoded by band enhancement coding section 2501 and band enhancement decoding section 2903 described later herein within a band of a spectrum encoded/decoded by second layer coding section 2406 and second layer decoding section 2805 described later herein.
[0268] If bit rate information indicates that the coding bit rate is a low bit rate (BR 1 ), band enhancement coding section 2501 and band enhancement decoding section 2903 make corresponding part “C” wide, and residual spectrum coding section 2502 and residual spectrum decoding section 2902 make corresponding part “B” narrow (see FIG. 28( a )). On the other hand, if bit rate information indicates that the coding bit rate is a high bit rate (BR 3 ), band enhancement coding section 2501 and band enhancement decoding section 2903 make corresponding part “C” narrow, and residual spectrum coding section 2502 and residual spectrum decoding section 2902 make corresponding part “B” wide (see FIG. 28( c )). And if bit rate information indicates that the coding bit rate is BR 2 , band enhancement coding section 2501 and band enhancement decoding section 2903 make a corresponding part “C” setting approximately midway between that when the coding bit rate is BR 1 and that when the coding bit rate is BR 3 (see FIG. 28( b )).
[0269] Thus, in this embodiment, a band of a spectrum that is encoded/decoded by a coding section/decoding section is set adaptively according to a coding bit rate indicated by bit rate information. By this means, an input signal can be encoded/decoded efficiently even if the coding bit rate changes.
[0270] Decoding apparatus 133 according to this embodiment will now be described.
[0271] FIG. 29 is a block diagram showing the internal principal-part configuration of decoding apparatus 133 . Decoding apparatus 133 mainly comprises coded information demultiplexing section 2801 , first layer decoding section 2802 , up-sampling processing section 2803 , orthogonal transform processing section 2804 , second layer decoding section 2805 , and orthogonal transform processing section 2806 . These sections perform the following operations.
[0272] Coded information transmitted from encoding apparatus 131 via channel 102 is input to coded information demultiplexing section 2801 . Coded information demultiplexing section 2801 demultiplexes the input coded information into first layer coded information, second layer coded information, and bit rate information, outputs the first layer coded information to first layer decoding section 2802 , and outputs the second layer coded information and bit rate information to second layer decoding section 2805 .
[0273] First layer decoding section 2802 decodes the first layer coded information input from coded information demultiplexing section 2801 and generates a first layer decoded signal, and outputs the generated first layer decoded signal to up-sampling processing section 2803 . The operation of first layer decoding section 2802 is similar to that of first layer decoding section 2403 shown in FIG. 24 , and therefore a detailed description thereof is omitted here.
[0274] Up-sampling processing section 2803 performs up-sampling of the sampling frequency of a first layer decoded signal input from first layer decoding section 2802 from SR base to SR input , and outputs an obtained post-up-sampling first layer decoded signal to orthogonal transform processing section 2804 .
[0275] Orthogonal transform processing section 2804 performs orthogonal transform processing (MDCT) on a post-up-sampling first layer decoded signal input from up-sampling processing section 2803 . Then orthogonal transform processing section 2804 outputs obtained post-up-sampling first layer decoded signal MDCT coefficient (hereinafter referred to as first layer decoded spectrum) C 1 ( k ) to second layer decoding section 2805 . The operation of orthogonal transform processing section 2804 is similar to the processing on a post-up-sampling first layer decoded signal by orthogonal transform processing section 2405 shown in FIG. 24 , and therefore a detailed description thereof is omitted here.
[0276] Second layer decoding section 2805 generates output spectrum C 2 ( k ) using a high-band component using first layer decoded spectrum C 1 ( k ) input from orthogonal transform processing section 2804 and second layer coded information and bit rate information input from coded information demultiplexing section 2801 . Then second layer decoding section 2805 outputs generated output spectrum C 2 ( k ) to orthogonal transform processing section 2806 . Details of the processing performed by second layer decoding section 2805 will be given later herein.
[0277] Orthogonal transform processing section 2806 executes an orthogonal transform on output spectrum C 2 ( k ) input from second layer decoding section 2805 , and converts it to a time-domain signal. Orthogonal transform processing section 2806 outputs the obtained signal as an output signal. The operation of orthogonal transform processing section 2806 is similar to the processing by orthogonal transform processing section 802 shown in FIG. 8 , and therefore a detailed description thereof is omitted here.
[0278] FIG. 30 is a block diagram showing the internal configuration of second layer decoding section 2805 shown in FIG. 29 . Second layer decoding section 2805 mainly comprises demultiplexing section 2901 , residual spectrum decoding section 2902 , and band enhancement decoding section 2903 .
[0279] Second layer coded information is input to demultiplexing section 2901 from coded information demultiplexing section 2801 . Demultiplexing section 2901 demultiplexes the second layer coded information into residual spectrum coded information and band enhancement coded information. Demultiplexing section 2901 outputs the residual spectrum coded information to residual spectrum decoding section 2902 , and outputs the band enhancement coded information to band enhancement decoding section 2903 . If demultiplexing into residual spectrum coded information and band enhancement coded information has been performed in coded information demultiplexing section 2801 , demultiplexing section 2901 need not be provided.
[0280] Residual spectrum decoding section 2902 decodes residual spectrum coded information input from demultiplexing section 2901 , and calculates decoded residual spectrum D 1 ( k ). Then residual spectrum decoding section 2902 outputs obtained decoded residual spectrum D 1 ( k ) to band enhancement decoding section 2903 . Details of the processing performed by residual spectrum decoding section 2902 will be given later herein.
[0281] Band enhancement coded information is input to band enhancement decoding section 2903 from demultiplexing section 2901 . Also, first layer decoded spectrum C 1 ( k ) is input to band enhancement decoding section 2903 from orthogonal transform processing section 2804 . Furthermore, bit rate information is input to band enhancement decoding section 2903 from coded information demultiplexing section 2801 . In addition, decoded residual spectrum D 1 ( k ) is input to band enhancement decoding section 2903 from residual spectrum decoding section 2902 . Band enhancement decoding section 2903 calculates output spectrum C 2 ( k ) from these items of information, and outputs this to orthogonal transform processing section 2806 . Details of the processing performed by band enhancement decoding section 2903 will be given later herein.
[0282] FIG. 31 is a block diagram showing the internal configuration of residual spectrum decoding section 2902 . Residual spectrum decoding section 2902 mainly comprises demultiplexing section 3001 , shape decoding section 3002 , and gain decoding section 3003 .
[0283] Residual spectrum coded information is input to demultiplexing section 3001 from demultiplexing section 2901 . Demultiplexing section 3001 demultiplexer the residual spectrum coded information into shape coded information and gain coded information, outputs the shape coded information to shape decoding section 3002 , and outputs the gain coded information to gain decoding section 3003 .
[0284] Shape coded information is input to shape decoding section 3002 from demultiplexing section 3001 . Also, bit rate information is input to shape decoding section 3002 from coded information demultiplexing section 2801 . Shape decoding section 3002 incorporates a shape codebook of the same kind as the shape codebook with which shape coding section 2702 is provided, and searches the shape codebook with shape coded information S_max input from demultiplexing section 3001 as an index. Shape decoding section 3002 outputs a found shape code vector to gain decoding section 3003 as a shape value of a band spectrum corresponding to bit rate information input from coded information demultiplexing section 2801 . Here, a shape code vector found as a shape value is denoted as Shape_q′(k).
[0285] Here, shape decoding section 3002 calculates a band corresponding to bit rate information by means of the same kind of method as described for coding target spectrum calculation section 2701 .
[0286] Gain decoding section 3003 incorporates a gain codebook of the same kind as the gain codebook with which gain coding section 2703 is provided, and uses this gain codebook to perform inverse quantization of a gain value from gain coded information in accordance with equation 16. Here too, a gain value is treated as an L-dimensional vector, and vector inverse quantization is performed. That is to say, gain code vector GC j G — min corresponding to gain coded information G_min is taken directly as gain value Gain_q′(j).
[0287] Then, using a gain value obtained by inverse quantization and a shape value input from shape decoding section 3002 , gain decoding section 3003 calculates decoded residual spectrum D 1 ( k ) for a band corresponding to bit rate information input from coded information demultiplexing section 2801 in accordance with equation 35, and outputs calculated decoded residual spectrum D 1 ( k ) to band enhancement decoding section 2903 . In spectrum (MDCT coefficient) inverse quantization, if k is present in B(j″) through B(j″+1)−1, gain value Gain_q′(j) has the value of Gain_q′(j″).
[0288] As with shape decoding section 3002 , gain decoding section 3003 calculates a band corresponding to bit rate information by means of the same kind of method as described for coding target spectrum calculation section 2701 .
[0289] FIG. 32 is a block diagram showing the internal configuration of band enhancement decoding section 2903 shown in FIG. 30 . Band enhancement decoding section 2903 mainly comprises demultiplexing section 3101 , filter state setting section 3102 , filtering section 3103 , gain decoding section 3104 , spectrum adjustment section 3105 , and addition spectrum calculation section 3106 .
[0290] Demultiplexing section 3101 demultiplexes band enhancement coded information input from demultiplexing section 2901 into optimum pitch coefficient T′, which is filtering related information, and a post-coding variation V q (j) index, which is gain related information. Then demultiplexing section 3101 outputs optimum pitch coefficient T′ to filtering section 3103 , and outputs the post-coding variation V q (j) index to gain decoding section 3104 . If demultiplexing into optimum pitch coefficient T′ and a post-coding variation V q (j) index has been performed in coded information demultiplexing section 2801 or demultiplexing section 2901 , demultiplexing section 3101 need not be provided.
[0291] First layer decoded spectrum C 1 ( k ) is input to addition spectrum calculation section 3106 from orthogonal transform processing section 2804 . Also, decoded residual spectrum D 1 ( k ) is input to addition spectrum calculation section 3106 from residual spectrum decoding section 2902 . Addition spectrum calculation section 3106 adds these two spectra in the frequency domain as shown in equation 31, and calculates addition spectrum A(k). Then addition spectrum calculation section 3106 outputs addition spectrum A(k) to filter state setting section 3102 .
[0292] Filter state setting section 3102 sets addition spectrum A(k) input from addition spectrum calculation section 3106 as a filter state used by filtering section 3103 . Here, if an entire frequency band 0≦k<Fmax spectrum in filtering section 3103 is called Z(k) for convenience, of spectrum Z(k), addition spectrum A(k) is stored in a band corresponding to bit rate information as a filter internal state (filter state). The configuration and operation of filter state setting section 3102 are similar to those of filter state setting section 502 shown in FIG. 5 , and therefore a detailed description thereof is omitted here.
[0293] Filtering section 3103 is provided with a multi-tap pitch filter (that is, the number of taps is greater than 1). Filtering section 3103 filters addition spectrum A(k) for a band corresponding to bit rate information input from coded information demultiplexing section 2801 based on a filter state set by filter state setting section 3102 , pitch coefficient T′ input from demultiplexing section 3101 , and a filter coefficient stored internally beforehand. Then filtering section 3103 calculates estimated spectrum X′(k) of input spectrum X(k) as shown in equation 36.
[0000]
(
Equation
36
)
X
′
(
k
)
=
∑
i
=
-
1
1
β
i
·
Z
(
k
-
T
+
i
)
2
[
36
]
[0294] Here, filter state setting section 3102 and filtering section 3103 use a high-band part of a spectrum calculated by means of the same kind of method as described for band division section 2601 as a band corresponding to bit rate information.
[0295] The transfer function shown in equation 13 is also used by filtering section 3103 . Filtering section 3103 outputs estimated spectrum X′(k) obtained by filtering to spectrum adjustment section 3105 .
[0296] Gain decoding section 3104 decodes a post-coding variation V q (j) index input from demultiplexing section 3101 for a band corresponding to bit rate information input from coded information demultiplexing section 2801 , and finds post-coding variation V q (j), which is a variation V(j) quantization value. Here, the gain codebook used for decoding an index of post-coding variation V q (j) is incorporated in gain decoding section 3104 , and is similar to the gain codebook used by gain coding section 506 shown in FIG. 5 . Gain decoding section 3104 outputs post-coding variation V q (j) obtained by decoding to spectrum adjustment section 3105 .
[0297] Here, gain decoding section 3104 uses a high-band part of a spectrum calculated by means of the same kind of method as described for band division section 2601 as a band corresponding to bit rate information.
[0298] Spectrum adjustment section 3105 multiplies estimated spectrum X′(k) input from filtering section 3103 by post-coding variation V q (j) of each subband input from gain decoding section 3104 for a high-band part specified by bit rate information input from coded information demultiplexing section 2801 in accordance with equation 37.
[0299] Here, spectrum adjustment section 3105 uses a high-band part of a spectrum calculated by means of the same kind of method as described for band division section 2601 as a band corresponding to bit rate information. By this means, spectrum adjustment section 3105 adjusts the spectrum shape in an estimated spectrum high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax) or (Max 3 ≦k<Fmax)), generates output spectrum C 2 ( k ), and outputs this to orthogonal transform processing section 2806 .
[0000]
(
Equation
37
)
C
2
(
k
)
=
X
′
(
k
)
·
V
q
(
j
)
[
37
]
(
Max
1
≤
k
<
F
max
or
Max
2
≤
k
<
F
max
or
Max
3
≤
k
<
F
max
j
=
0
,
…
,
J
-
1
)
[0300] In equation 37, j indicates a subband index when gain is encoded, and is set according to spectrum index k. That is to say, for spectrum index k included in a subband for which the subband index is j″, estimated spectrum X′(k) is multiplied by V q (j″).
[0301] Here, a low-band part ((0≦k<Max 1 ) or (0≦k<Max 2 ) or (Max 3 ≦k<Fmax)) of output spectrum C 2 ( k ) comprises addition spectrum A(k) obtained by adding first layer decoded spectrum C 1 ( k ) and decoded residual spectrum D 1 ( k ), and a high-band part ((Max 1 ≦k<Fmax) or (Max 2 ≦k<Fmax) or (Max 3 ≦k<Fmax)) of output spectrum C 2 ( k ) comprises post-spectrum-shape-adjustment estimated spectrum X′(k).
[0302] This concludes a description of the internal configuration of decoding apparatus 113 .
[0303] Thus, according to this embodiment, an encoding apparatus/decoding apparatus employs a configuration whereby band setting according to a band enhancement method is switched adaptively according to conditions at the time of coding (for example, the coding bit rate). By this means, coding efficiency can be improved in line with conditions at the time of coding.
[0304] Specifically, for example, if the bit rate at the time of coding is a low bit rate, band division section 2601 makes a wide setting for a band generated by means of a band enhancement technology that is more effective with a low bit rate, and makes a narrow setting for a band quantized by means of a spectrum coding technology other than a band enhancement technology. Also, if the bit rate at the time of coding is a high bit rate, band division section 2601 makes a narrow setting for a band generated by means of a band enhancement technology, and makes a wide setting for a band quantized by means of a spectrum coding technology (a technology other than a band enhancement technology) that encodes a spectrum shape more precisely.
[0305] When performing band enhancement coding/decoding, an encoding apparatus/decoding apparatus can improve the coding efficiency of band enhancement coding by using a high-precision spectrum that can be obtained at the time of coding/decoding (an addition spectrum resulting from addition of a first layer decoded spectrum and decoded residual spectrum) as a low-band part decoded spectrum. In this way, the quality of a decoded signal can be greatly improved by means of the method described in this embodiment.
[0306] In this embodiment, a configuration has been described whereby a narrow setting is made for a band of a spectrum that is encoded/decoded by band enhancement coding section 2501 and band enhancement decoding section 2903 when bit rate information indicates that the coding bit rate is the highest bit rate, but the present invention is not limited to this. For example, the present invention can be applied in a similar way to a configuration whereby a band of a spectrum encoded/decoded by band enhancement coding section 2501 and band enhancement decoding section 2903 is eliminated. In this case, band enhancement coding section 2501 and band enhancement decoding section 2903 are unnecessary in second layer coding section 2406 and second layer decoding section 2805 respectively, and a spectrum of all bands becomes subject to quantization in residual spectrum coding section 2502 and residual spectrum decoding section 2902 . Also, at this time, the entire amount of information (bits) that can be used by second layer coding section 2406 and second layer decoding section 2805 is assigned to residual spectrum coding section 2502 and residual spectrum decoding section 2902 . A configuration such as described above in which a band encoded/decoded by a band enhancement coding section and band enhancement decoding section is eliminated has been confirmed by experimentation to be particularly effective when the coding bit rate is extremely high.
[0307] In this embodiment, a case such as shown in FIG. 28 in which band “C” subject to coding by band enhancement coding section 2501 and band “B” subject to coding by residual spectrum coding section 2502 do not overlap in the frequency domain has been described as an example. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration other than that shown in FIG. 28 . For example, a conceptual diagram of another configuration is shown in FIG. 33 . FIG. 33 is a drawing showing conceptually another correspondence relationship between an encoded/decoded spectrum band and amount of information (coding bit rate) in a coding section/decoding section of each layer.
[0308] In the case of a configuration such as shown in FIG. 33 , processing that is partially different from the kind of coding processing described in this embodiment is performed. Specifically, in second layer coding section 2406 , coding is first performed by residual spectrum coding section 2502 , and then coding is performed by band enhancement coding section 2501 using a decoded residual spectrum. However, in the case of the configuration shown in FIG. 33 , coding is first performed by band enhancement coding section 2501 , and an obtained residual spectrum of a high-band spectrum and input spectrum is encoded by residual spectrum coding section 2502 .
[0309] In this embodiment, a configuration whereby a low-band part is encoded/decoded by first layer coding section 2402 and first layer decoding section 2403 has been described as an example, but the present invention is not limited to this, and can also be applied in a similar way to a configuration in which first layer coding section 2402 and first layer decoding section 2403 are not present. At this time, a configuration is used in which residual spectrum coding section 2502 and residual spectrum decoding section 2902 encode/decode a band set for an input spectrum itself based on bit rate information.
[0310] In this embodiment, no particular explanation has been given of what kind of bit assignment is performed for band enhancement coding section 2501 and residual spectrum coding section 2502 according to bit rate information at the time of coding. An example of a possible bit assignment method is the use of a configuration whereby bits assigned to band enhancement coding section 2501 are always fixed, and bits assigned to residual spectrum coding section 2502 are variable. However, the present invention is not limited to a bit assignment method for band enhancement coding section 2501 and residual spectrum coding section 2502 , and can also be applied in a similar way to a configuration that employs a bit assignment method other than the above. An example of a method other than the above is the use of a configuration whereby, as a coding bit rate indicated by bit rate information increases for band enhancement coding section 2501 and residual spectrum coding section 2502 , the number of bits assigned to them both is increased. Another option is a configuration whereby, as a coding bit rate indicated by bit rate information increases, the number of bits assigned to band enhancement coding section 2501 is reduced, and the number of bits assigned to residual spectrum coding section 2502 is increased.
[0311] In the above description, a case in which a coding bit rate is used as an example of conditions at the time of coding has been taken as an example, and a case in which band setting is performed according to the coding bit rate has been described, but provision may also be made for the input signal sampling frequency or a coding parameter such as a quantization gain to be used instead of the coding bit rate. If band setting is performed according to the input signal sampling frequency, a possible configuration example is one whereby processing when the coding bit rate is a low bit rate in this embodiment is used if the sampling frequency is greater than or equal to a predetermined threshold value, and processing when the coding bit rate is a high bit rate in this embodiment is used if the sampling frequency is less than the threshold value. Also, with regard to a coding parameter such as quantization gain, a possible configuration example is one whereby processing when the coding bit rate is a low bit rate in this embodiment is used if, for example, gain sampled by the first layer coding section (adaptive excitation gain, fixed excitation gain, or the like) is greater than or equal to a predetermined threshold value, and processing when the coding bit rate is a high bit rate in this embodiment is used if this gain is less than the threshold value.
[0312] This concludes a description of embodiments of the present invention.
[0313] In the above embodiments, a band setting section decides band setting information according to an energy ratio of a low-band part and high-band part of an input spectrum or a difference spectrum between an input spectrum and first layer decoded spectrum. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration in which band setting information is decided using other information. One example of such a configuration is one whereby tonality analysis is performed on an input spectrum or a difference spectrum between an input spectrum and first layer decoded spectrum, and the band setting section decides band setting information by the degree of tonality. In this case, it is necessary for a configuration element that calculates tonality to be newly provided. A tonality calculation method (detection method) used in this case is disclosed in detail in Patent Literature 2 and so forth.
[0314] Specifically, if input signal tonality is low—that is, if an input signal has a marked tendency toward being speech—the band setting section makes a narrower setting for a low-band part and a wider setting for a high-band part. This corresponds to a case in which the value of band setting information Band_Setting is 0 in these embodiments. By this means, low-band part spectral data that greatly influences the quality of a decoded signal when an input signal is speech can be encoded intensively by means of a shape-gain coding method, and the quality of a decoded signal can be increased.
[0315] Also, if input signal tonality is high—that is, if an input signal has a marked tendency toward being audio (music)—the band setting section makes a wider setting for a low-band part and a narrower setting for a high-band part. This corresponds to a case in which the value of band setting information Band_Setting is 1 in these embodiments. By this means, coding distortion can be reduced with a shape-gain coding method up to a higher band part, and bandwidth limitation that greatly influences the quality of a decoded signal when an input signal is audio can be improved.
[0316] Also, when tonality is used to decide band setting information, if tonality is calculated by a configuration element other than the band setting section, the amount of computation necessary for tonality calculation can be reduced by using a configuration whereby calculated tonality is input to the band setting section. In this case, it is sufficient to input tonality to the band setting section, and it is not necessary to input an input spectrum or difference spectrum.
[0317] In the above embodiments, a case in which the value of band setting information is one of two values, 0 or 1, has been given as an example, but the present invention is not limited to this, and can also be applied in a similar way to a configuration in which band setting information can have two or more values. Although the number of bits (amount of information) necessary for band setting information increases, increasing the possible values of band setting information and increasing the number of band setting patterns enables band setting to be performed that is more appropriate for an input signal. For example, by providing for four possible band setting values—0, 1, 2, and 3—and setting one of these four values according to the energy ratio of a low-band part and high-band part, a band quantized by a coding section of each layer can be set more finely according to the input signal.
[0318] In the above embodiments, a configuration in which a band setting section performs band adjustment for each processed frame has been described as an example. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby band adjustment is performed in units of processing of several frames, for example. By means of a configuration of this kind, the amount of processing computation by the band setting section can be reduced, and input signal discontinuity that may occur due to band adjustment for each processed frame can be alleviated.
[0319] In the above embodiments, a configuration in which a band setting section performs band adjustment independently for each processed frame has been described as an example. However, the present invention is not limited to this, and can also be applied in a similar way to a configuration whereby a band of a current frame is adjusted (set) based on band setting information for a past processed frame. One possible configuration example is one whereby band setting information for several frames back is used to smooth parameters (first band energy, second band energy, and so forth) at the time of current frame band setting on a time axis, and decide current frame band setting information. Another possible configuration example is one whereby band setting information itself is smoothed after delaying band setting information for several frames so that band setting information itself does not fluctuate rapidly. By means of a configuration of this kind, rapid fluctuation of band setting information for each processed frame can be prevented, and decoded signal discontinuity that may occur due to band adjustment for each processed frame can be alleviated.
[0320] In above Embodiment 1 through Embodiment 3, an encoding apparatus has been described as adaptively deciding an extension band setting according to an input signal characteristic, and in above Embodiment 4, an encoding apparatus has been described as adaptively deciding an extension band setting according to a coding parameter indicating conditions at the time of coding. However, it is also possible for an encoding apparatus to input both an input signal and a coding parameter, and decide an extension band setting based on both an input signal characteristic and a coding parameter. For example, one possible actual method is first to set an extension band to some extent by means of a coding parameter (such as a coding bit rate), and then to perform finer extension band setting adjustment using an input signal characteristic (such as a high-band/low-band energy ratio). By this means, more appropriate band setting can be performed, enabling more efficient encoding to be performed, and also enabling the quality of a decoded signal in a decoding apparatus to be improved. Alternatively, it is also possible for an encoding apparatus to input both an input signal and a coding parameter, to select either the input signal characteristic or the coding parameter by determining which of these parameters is suitable for use, and to decide an extension band setting based on the selected parameter.
[0321] An encoding apparatus and decoding apparatus according to the present invention are not limited to the above embodiments, and it is possible for such apparatus to be implemented with various modifications. For example, the embodiments may be combined to be implemented as appropriate.
[0322] A decoding apparatus according to each of the above embodiments has been assumed to perform processing using coded information transmitted from an encoding apparatus according to each of the above embodiments. However, the present invention is not limited to this, and as long as coded information includes a necessary parameter and data, it is possible for processing to be performed with coded information that is not necessarily from an encoding apparatus according to an above embodiment.
[0323] The present invention can also be applied to, and the same kind of operation and effects as in these embodiments can also be obtained in, a case in which recording and writing of a signal processing program is performed in/on/to a machine-readable recording medium such as memory or a disk, tape, CD, or DVD, and operation thereof is performed.
[0324] In the above embodiments, a case has been described by way of example in which the present invention is configured as hardware, but it is also possible for the present invention to be implemented by software.
[0325] The function blocks used in the above embodiments are implemented as LSIs typically comprising integrated circuitry. These may be implemented individually as single chips, or a single chip may incorporate some or all of them. Here, the term LSI has been used, but the terms IC, system LSI, super LSI, and ultra LSI may also be used according to differences in the degree of integration.
[0326] Implementation of integrated circuitry is not limited to an LSI method, and implementation by means of dedicated circuitry or a general-purpose processor may also be used. An FPGA (Field Programmable Gate Array) for which programming is possible after LSI fabrication, or a reconfigurable processor allowing reconfiguration of circuit cell connections and settings within an LSI, may also be used.
[0327] Furthermore, in the event of the introduction of an integrated circuit implementation technology whereby LSI technology is replaced by a different technology as an advance in, or derivation from, semiconductor technology, integration of the function blocks may of course be performed using that technology. The application of biotechnology or the like is also a possibility.
[0328] The disclosures of Japanese Patent Application No. 2009-244838, filed on Oct. 23, 2009, and Japanese Patent Application No. 2009-272194, filed on Nov. 30, 2009, including the specifications, drawings and abstracts, are incorporated herein by reference in their entirety.
INDUSTRIAL APPLICABILITY
[0329] An encoding apparatus, decoding apparatus, and methods thereof according to the present invention enable the quality of a decoded signal to be improved when performing band enhancement using a low-band part spectrum and estimating a high-band part spectrum, and are suitable for use in a packet communication system, mobile communication system, or the like, for example.
REFERENCE SIGNS LIST
[0000]
101 , 111 , 121 , 131 Encoding apparatus
102 Channel
103 , 113 , 123 , 133 Decoding apparatus
201 , 802 , 1005 , 1404 , 1406 , 2405 , 2804 , 2806 Orthogonal transform processing section
202 Coding section
301 , 1101 , 1801 Band setting section
302 , 1102 Low-band coding section
303 , 1103 , 1802 High-band coding section
902 , 1502 Low-band decoding section
903 , 1503 , 2002 High-band decoding section
304 , 404 , 507 , 1104 , 1204 , 1307 , 1803 , 2503 , 2704 Multiplexing section
401 , 2701 Coding target spectrum calculation section
402 , 1202 , 2702 Shape coding section
403 , 506 , 1203 , 1306 , 2703 Gain coding section
501 , 1301 , 1311 , 2601 Band division section
502 , 922 , 1302 , 1602 , 3102 Filter state setting section
503 , 923 , 1303 , 1603 , 3103 Filtering section
505 , 1305 Search section
504 , 1304 Pitch coefficient setting section
801 Decoding section
901 , 911 , 921 , 1501 , 1601 , 2001 , 2901 , 3001 , 3101 Demultiplexing section
1504 Spectrum synthesis section
912 , 3002 Shape decoding section
913 , 924 , 1604 , 3003 , 3104 Gain decoding section
925 , 1605 , 3105 Spectrum adjustment section
1001 , 2401 Down-sampling processing section
1002 , 2403 First layer coding section
1003 , 1402 , 2403 , 2802 First layer decoding section
1004 , 1403 , 2404 , 2803 Up-sampling processing section
1006 , 1701 , 2406 Second layer coding section
1007 , 2407 Coded information integration section
1201 Difference spectrum calculation section
1401 , 2801 Coded information demultiplexing section
1405 , 1901 , 2805 Second layer decoding section
2501 Band enhancement coding section
2502 Residual spectrum coding section
2602 , 3106 Addition spectrum calculation section
2902 Residual spectrum decoding section
2903 Band enhancement decoding section
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Disclosed is an encoding apparatus that can efficiently encode a signal that is a broad or extra-broad band signal or the like, thereby improving the quality of a decoded signal. This encoding apparatus includes a band establishing unit ( 301 ) that generate, based on the characteristic of the input signal, band establishment information to be used for dividing the band of the input signal to establish a first band part of lower frequency side and a second band part of higher frequency side; a lower frequency encoding unit ( 302 ) for encoding, based on the band establishment information, the input signal of the first band part to generate encoded lower frequency part information; and a higher frequency encoding unit ( 303 ) for encoding, based on the band establishment information, the input signal of the second band part to generate encoded higher frequency part information.
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BACKGROUND OF THE INVENTION
This invention relates to enameling compositions used as an insulating coating material for transformer wire. One of the problems involved with current methods and materials used in manufacturing and applying transformer wire coatings is the need for a suitable solvent for dissolving the coating constituents and providing a low viscosity solution. Since the solvents currently utilize expensive hydrocarbon and cresols, other materials are continuously being evaluated in an attempt to reduce the quantity of solvents employed. Over the past 15 years for example, an insulating coating composition consisting of a mixture of polyvinyl acetal and phenolic were reduced in solvent content from 85 weight percent down to 75 percent. This reduction was realized by variations in the polyvinyl acetal and phenolic materials as well as a selected combination of hydrocarbon and cresol solvents. Besides the expense involved in utilizing liquid solvents in the wire coating industry, requirements are now being made by the Environmental Protection Agency to reduce solvent usage by a substantial amount in order to reduce the overall concentration of solvents existing in the atmosphere.
U.S. Pat. application Ser. No. 595,034 filed July 11, 1975, now abandoned, discloses a three component wire insulating composition which includes an epoxy resin in combination with polyvinyl acetal and phenolic resins. The three component composition further reduced the solvent content down to 70 weight percent by taking advantage of the good filmforming properties of the epoxy resin. The use of an epoxy wire coating per se has not heretofore proven feasible due to the poor hydrolytic stability existing with known epoxy compounds. When transformer wires are coated for electrical insulating purposes, and are subjected to long exposure times in the presence of heat and moisture, it is essential that the coating remain electrically stable. Hydrolytic stability therefore is an important parameter for evaluating efficient transformer wire insulating materials. In order to determine hydrolytic stability, the transformer wire coatings are subjected to moisture and temperature for a prescribed period of time and are subsequently measured to determine whether the electrical insulating properties have deteriorated. Wires coated with epoxy compounds per se become hydrolytically unstable and are infeasible for long term transformer wire coatings.
Another requirement for transformer wire coating materials is a low dissipation factor. Since the electrical properties of the coating depend to a large extent upon the transformer operating temperature, the wire coating materials must be able to withstand the high temperatures involved, under short circuit load conditions. In order for the transformer wire coating to be electrically and thermally stable, the dissipation factor, which is a fairly good indication of the ability of the coating to dissipate heat, must be determined at various operating temperatures. If the transformer wire coating has too high a dissipation factor, thermal runaway can occur causing insulation to decrease to an inoperable value.
Formulations intended for use as insulating coatings must be carefully evaluated for temperature, moisture and overall electrical stability for long periods of time in order to ensure that short circuits do not occur due to electrical insulation failure. The polyvinyl acetal and phenolic composition disclosed within the aforementioned U.S. Patent application contains approximately phenolic resin in a ratio of one part to two parts polyvinyl acetal. Attempts to increase the polyvinyl acetal concentration resulted in wire coatings having too high a dissipation factor along with hydrolytic instability. Attempts on the other hand to increase the phenolic content seriously interfered with the flexibility of the coating. As described earlier, various epoxy resin compositions provided good flexible and pin hole free insulating coatings but were hydrolytically unstable and unsuitable per se as wire coatings. Attempts to combine epoxy resins, phenolic resins, and polyvinyl acetal such as suggested within U.S. Pat. No. Re 25,625 have not proven successful when evaluated for transformer wire coatings. Coatings prepared from the aforementioned re-issued patent disclosure were too inflexible to withstand the transformer winding operation. Wire coatings prepared from the adhesive composition disclosed within U.S. Pat. No. 3,239,598 resulted in wire coatings having an excessive dissipation factor and poor flexibility.
The three component coating composition disclosed within aforementioned U.S. Patent application Ser. No. 595,034 resulted in wire coatings having good flexibility, low dissipation factor and hydrolytic stability. The addition of epoxy resin to the polyvinyl acetal and phenolic resins substantially improved the flow properties of the coating during the coating process. With ratios of polyvinyl acetal to phenolic from about 2 to 1, additions of about 11 to 25% epoxy resin can be employed. It has since been discovered that even better coatings can be obtained with further increases in the amount of epoxy added to the coating composition. The higher epoxy compositions allow the coating to flow more evenly over the wire surface when applied by dry electrostatic techniques and, is a valuable feature in transformer wire coating operations. These higher epoxy compositions permit the formulation of higher solids enamels which greatly reduce the solvent required.
The purpose of this invention therefore is to provide three component wire coating composition having a high concentration of epoxy resin.
SUMMARY OF THE INVENTION
Improved transformer wire insulating compositions are disclosed having increased amounts of epoxy resin. The increased epoxy constituent substantially improves the coating flow properties and provides for wider variations in the coating application process. Proportionately decreasing the phenolic and polyvinyl acetal resins allows for the increased epoxy constituent without affecting the coating electrical properties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a transformer wire coated with an enamel composition according to the invention;
FIG. 2 is a triaxial diagram of some state of the art wire coating compositions;
FIG. 3 is a graphic representation of the relationship between dissipation factor and PVA to phenolic ratio for constant epoxy concentrations;
FIG. 4 is a graphic representation of the relationship between the ratio of PVA to phenolic for operable concentrations of epoxy resin; and
FIG. 5 is a triaxial diagram of the improved coating composition of the invention.
GENERAL DESCRIPTION OF THE INVENTION
The aforementioned U.S. Patent application discloses the combination of the reaction product of a mixture of polyvinyl acetal resin, phenol aldehyde resin and epoxy resin in a particular range of proportions for electrically insulating coatings for transformer wires. Transformer wire coatings to be subjected to the high temperatures and moisture conditions existing within a transformer enclosure must have a low dissipation factor, good flexibility and be hydrolytically stable for the reasons discussed earlier. The aforementioned U.S. Patent application limited the ranges of the three constituents to ensure that no problem in flexibility, dissipation factor or hydrolytic stability would occur. The phenol aldehyde resin was kept at less than 40% in order not to reduce the flexibility and at least 20% in order to avoid an excessively high dissipation factor. The polyvinyl acetal resin was kept at less than 65% in order not to create an excessively high dissipation factor while at least 40 percent was required to provide satisfactory flexibility. The epoxy concentration was kept at less than 30 percent to avoid both high dissipation factor problems as well as hydrolytic instability. Seven percent of the epoxy was required however to promote adequate fusion of the powder particles and to impart uniformity to the coating. Since the epoxy constituent is an extremely beneficial contributor to the amount of solids remaining on the wire, after the fusion process, attempts to increase the epoxy content above 30 percent were heretofore infeasible because of the high dissipation factor and hydrolytic instability inherent within the epoxy material.
Since the aforementioned three component wire coating composition is applied to transformer wire, by a wet die process, as well as by a dry electrostatic coating process, tests were undertaken to determine the theoretical maximum solids content of coating material that can be operably applied by both methods to transformer wire. The wet die technique was chosen as the test method of application for purposes of convenience in applying to the wire. After dissolving samples containing increasing amounts of epoxy resin, plastic films were case from the samples. Hydrolytic stability and dissipation factor measurements were also taken in order to determine whether increases in the amount of epoxy within the coating could be tolerated without seriously interfering with the electrical characteristics. Using the resins and solvents disclosed within the aforementioned U.S. Patent application it was then discovered that for very high epoxy coatings containing approximately the same amount of phenolic resin as described within the teachings of the aforementioned U.S. Patent application and substantially less polyvinyl acetal resin, strong, flexible and hydrolytically stable coatings resulted having satisfactory low dissipation factors.
FIG. 1 shows the insulation coating 2 on the transformer wire 1 containing ingredients described within the aforementioned U.S. Patent Application in amounts ranging from low to high epoxy resin content.
FIG. 2 shows the preferred range of compositions B as disclosed therein along with the operational range A. It is to be noted that high concentrations of polyvinyl acetal increases the dissipation factor to an excessive and inoperable value as indicated and that high concentrations of phenol aldehyde produce coatings having poor flexibility. The high ranges of epoxy are known to produce problems with hydrolytic stability. The compositional range disclosed within the aforementioned U.S. re-issue patent is shown at C and can be seen to encompass high dissipation problems at the high polyvinyl acetal end of the range and problems with hydrolytic stability at the high epoxy end. The composition disclosed within the aforementioned U.S. patent is shown at D to exhibit poor flexibility when evaluated as a wire coating material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the increasing epoxy compositions described earlier and evaluated for dissipation factor, hydrolytic stability, and flexibility, it was discovered that the dissipation factor increased with increasing ratios of polyvinyl acetal to phenolic as well as increasing amounts of epoxy resin. When the epoxy content was kept constant and the amount of polyvinyl acetal was increased relative to the phenolic resin the dissipation factor also increased in proportion to the polyvinyl acetal to phenolic ratio. The relationship between dissipation factor and polyvinyl acetal to phenolic ratio (P.V.A./phenolic) is shown at E in FIG. 3. Since the low ratio values exhibited low dissipation for the same epoxy content of 35 percent, an attempt was made to increase the epoxy content in excess of 35% to determine whether low dissipation could be realized within the same range of ratios. In order to determine operability as an insulating coating the increased epoxy resins were also evaluated for flexibility and hydrolytic stability using standard techniques. The samples which showed good hydrolytic stability and good flexibility as well as a dissipation factor of less than 25 percent at 170° C. were considered to pass the evaluation. Coatings having dissipation factors in excess of 25 percent at 170° C. and/or having poor electrolytic stability and poor flexibility failed the evaluation.
The results of the large series of evaluations for increasing epoxy mixes within the ratio of P.V.A. to phenolic range of 1.0 to 2.0 is shown in FIG. 4.
The samples which failed any of the aforementioned parameters are indicated by crosses and the samples which passed all the parameters are indicated by circles to show the effective range of both the epoxy content and the P.V.A. to phenolic ratios. An approximate compositional range of epoxy mixes is designated at F where the epoxy content varies from as low as 10 percent to as high as 60 percent within a range in P.V.A. to phenolic ratios of from 1.10 to 1.90. It is to be noted that both low and high epoxy compositions failed within the range of ratios and that low and high ratios failed for the same epoxy compositions.
FIG. 5 shows the effective compositional range G for concentrations of epoxy, phenol aldehyde and polyvinyl acetal as measured in weight percent for the samples from FIG. 4 that possessed the necessary requirements for operable insulating wire coatings. The increase in the overall amounts of the epoxy constituent expands the manufacturing tolerances for the process of preparing and applying the coating composition and greatly improves over the low epoxy composition shown earlier in FIG. 2. The increased epoxy content should exhibit anticipated problems in hydrolytic stability since the ranges now indicated at G in FIG. 5 extend within the area of the diagram within FIG. 2 where hydrolytic instability occurs.
The improved compositions within the region designated as F having the configuration of an inverted truncated cone, however, do not exhibit poor flexibility, hydrolytic instability or high dissipation as anticipated from the teachings of the prior art. Since the improved compositional range now comprises: Polyvinyl acetal 20-46% by weight; phenolic resin 14-34% by weight; and epoxy resin 30-60% by weight, insufficient polyvinyl acetal should therefore result in wire coatings having poor flexibility as indicated in FIG. 2. The excellent hydrolytic stability and low dissipation factor for the high epoxy-low polyvinyl to acetal composition implies a coaction between the epoxy resin and the polyvinyl acetal resin since the phenolic resin composition remains relatively unchanged. Since the epoxy material is hydrolytically unstable per se it is surprising, therefore, that by decreasing the particular component of the composition that improves the necessary property of hydrolitic stability (polyvinyl acetal) and increasing the component which has high inherent dissipation (epoxy) can result in a wire coating possessing superior electrical insulating properties.
Compositions were prepared using the resin materials described within the forementioned U.S. patent application but having the improved ranges shown in FIG. 5 and were applied to transformer wires by a wet floating die process in one case and by a dry electrostatic process in another. In both methods of application the resulting coatings exhibited dissipation factors less than 25 percent at 170° C. with good continuous and flexible coatings that were also hydrolytically stable. In the solvent application system, the solvent represented approximately 60 percent by weight of the total solution whereas the composition applied by entraining the dry powder in a fluidized bed gas stream and applying a high voltage electrostatic DC field between the powder and the transformer wire equally adhered without any solvents at all. The wire was heated to a first temperature to fuse the coating and then to a second higher temperature to cause the resins to react.
Besides providing good rheological flow properties to the coating by decreasing the polyvinyl acetal and increasing the epoxy resin content impressive costs savings can also be realized since the polyvinyl acetal is the most expensive ingredient in the composition. Combining the compositional range of the prior art with that of the improved coating formulation provides a large range of manufacturing latitude and greatly improves the overall transformer manufacturing efficiency. Extending the range from 20 to 65 parts by weight polyvinyl acetal; 14 to 40 percent by weight phenol aldehyde resin; and 7 to 60 weight percent epoxy resin greatly expands the overall manufacturing tolerances. In the transformer wire coating field the range in materials composition determine the manufacturing "window". It can be readily understood, therefore, the wider the range of materials used in preparing the wire coating composition the larger the manufacturing window and, ultimately, the lower the manufacturing costs.
Although the improved wire enamel composition of the invention is disclosed for use within power transformers this is by way of example only. The improved wire coating composition of the invention and the methods of application thereof find application wherever electrically insulating wire coatings may be required having good flexibility, low dissipation and good hydrolitic stability.
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Improved three component insulating coatings for both wet solvent and dry electrostatic application to transformer wires contain an increased epoxy resin concentration and a decreased amount of polyvinyl acetal and phenol aldehyde resins. The increased epoxy content gives substantially improved coatings with no adverse dissipation and hydrolytic effects. The epoxy constituent can range from 30-60 percent by weight providing the ratio of the polyvinyl acetal to phenol aldehyde is kept within the range of from 1 to 1 to 2 to 1.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/569,613, which is the National Stage of International Application No. PCT/US2004/001217, filed Sep. 9, 2004, which application is fully incorporated herein expressly by reference.
FIELD OF THE INVENTION
The present invention relates generally to the field of semiconductor device fabrication and, in particular, the invention provides an improved processing step for use in a method of forming metal contacts and other structures in thin film semiconductor devices. A new device structure for thin film photovoltaic devices is also provided.
BACKGROUND
A major advantage of thin-film photovoltaic (PV) modules over conventional wafer-based modules is the potential for low cost of production. However, in practice, cost savings have been difficult to achieve as a major component of cost is the number and complexity of process steps involved in the manufacturing sequence and can quickly outweigh savings in material costs. In particular, the number of steps that require precise alignment, or the speed of the equipment used to perform a step, can have a strong bearing on cost, as can the robustness of a process, which might in some cases lead to additional remedial steps being required or result in lower performance of the end product because of material degradation. Therefore, process improvements that reduce alignment requirement, reduce the number of steps, reduce damage to the device, or allow a step to be performed more quickly provide significant advantages.
SUMMARY
According to a first aspect, the present invention provides a method of modifying a hole pattern in an organic resin masking material formed over a structure as a step in performing a process on the structure, the method comprising the steps of:
(a) forming a mask by applying a thin layer of the organic resin (e.g., 0.1 to 10 μm) over the structure;
(b) forming openings in the mask to provide the hole pattern;
(c) performing a processing step on the surface areas of the structure exposed through the openings in the mask;
(d) placing the structure into an atmosphere of solvent vapor of a solvent of the mask material whereby the mask material softens and re-flows to reduce the size of the openings in the mask causing edges of the surface areas on which the processing step was performed to be covered by the mask for subsequent processing steps.
In preferred embodiments of the first aspect, the opening step is followed by a further processing step such as an etch, a doping step, or a coating step, and the re-flow step is performed after the further processing to modify the mask before still further processing. For example, in one embodiment, the mask is opened, an etching step is performed through the mask, the openings in the mask are reduced by re-flowing, and a contact layer is applied over the mask, which contacts the regions left uncovered by the re-flowing step but is isolated from the edges of the hole-formed by the etch.
According to a second aspect, the present invention provides a method of forming a photovoltaic device structure in a silicon film deposited on a glass substrate, the film comprising an n + type region closest the glass, a lightly doped region over the n + type region, and a p + type region over the lightly doped region, the method comprising the steps of:
1. dividing the silicon film into a plurality of cell regions by forming isolation grooves;
2. forming a mask of organic resin in a thin layer (e.g., 0.1 to 10 μm) over the silicon film;
3. forming a first set of openings in the mask in locations where n type contacts are required;
4. etching the silicon film in the first set of openings to expose at least some of the n + type silicon;
5. placing the substrate into an atmosphere of solvent vapor of a solvent of the mask material whereby the mask material softens and re-flows to reduce the size of the first openings in the mask;
6. forming a second set of openings in the mask in locations where p type contacts are required;
7. forming a metal layer over the surface of the mask and extending the metal into the first and second openings to contact the n + type and p + type silicon;
8. forming isolation grooves in the metal to separate the contacts to the p type and n type silicon within each cell.
Preferably, the method of the second aspect further includes the step of etching the silicon film in the second set of openings to remove damaged material from the surface of the p + type silicon before formation of the metal layer.
Preferably, also before forming the mask of organic resin material over the silicon film in the second aspect, a tough, thin, cap layer of silicon nitride is formed on the silicon surface.
Further in the second aspect, an anti-reflection layer is preferably formed on the glass substrate before the silicon film is deposited.
The organic resin is preferably novolac, but other similar resins are also suitable such as commonly available photoresists. The openings in the resin layer can be formed by chemical removal using solutions of caustic substances such as potassium hydroxide (KOH) or sodium hydroxide (NaOH). In a preferred method according to the invention, droplets of dilute (15%) potassium hydroxide are dispensed at locations intended for opening the mask. The KOH solution is preferably deposited using ink-jet print technology. Other methods of making openings in the mask layer include laser ablation and photographic techniques (using photoresist).
In a preferred embodiment, the re-flow step is performed by passing the supporting structure or substrate through a zone containing the vapor of the solvent at room temperatures (e.g., 21° C.). This causes the organic resin to re-flow, shrinking the size of the openings. As the samples exit this zone, they are preferably heated to drive out the remaining solvent.
The rate of re-flow will vary with the aggressiveness of the solvent used, the concentration, and temperature. There are many suitable volatile solvents that will dissolve organic resins such as novolac, including substances such as acetone. Acetone is a suitable solvent for the process but acts quite aggressively, requiring only a few seconds to achieve significant re-flow. Greater accuracy can be achieved by using a less aggressive solvent and, where the resin is novolac, the preferred solvent is propylene glycol monomethyl ether acetate (PGMEA). In the preferred arrangement, the supporting structure or substrate is introduced into an atmosphere containing a saturated vapor of PGMEA for 4 minutes until a slight shrinkage of the holes in the resin is observed.
In the case of PGMEA, the heating step is under heat lamps at a temperature of 90° C.
The re-flowing step may also be used-to close pin holes existing in the mask to prevent them from interfering with a further step or a device operation of a finished device. The re-flowing step may also be used to totally close the openings made in the opening step following the further processing.
The preferred method of forming the openings in the mask layer comprises the method of depositing a reactive material onto the surface of the mask layer in a predetermined pattern, the method comprising:
(a) placing the structure on a stage;
(b) locating an ink-jet print device over the structure and in close proximity thereto, the ink-jet device and stage being moveable relative to one another;
(c) supplying the ink-jet device with the reactive material;
(d) moving the structure and the ink-jet device relative to one another under control of control means; and
(e) controlling the ink-jet device to deposit predetermined amounts of the reactive material onto a surface of the mask in the predetermined pattern as the structure and the ink-jet device move relative to one another.
Preferably, the stage is an X-Y stage and the ink-jet device is fixed, such that relative motion of the structure and the print head is achieved by moving the stage under the ink-jet device.
In embodiments where the organic resin is novolac or a similar resin, such as commonly available photoresists, the caustic solution is preferably a solution such as potassium hydroxide (KOH) or sodium hydroxide (NaOH). In a preferred method according to the invention, the solution is a 15% potassium hydroxide solution. Preferably, also glycerol is added to the solution in a suitable amount to provide the correct viscosity for the ink-jet device.
The ink-jet device may be, for example, an ink-jet print head model 128ID, 64ID2, or 64-30 manufactured by Ink Jet Technology Inc. These heads require solution viscosities of 5 to 20 centipoise.
Preferably, the steps of etching silicon through the mask comprise the method of applying a dilute solution of hydrofluoric acid (HF) and potassium permanganate (KMnO4) to the silicon surface exposed through the mask to thereby etch the silicon to a desired depth. This solution is chosen because it etches silicon without damaging novolac resin.
Preferably, the area of silicon to be etched has a width and length that are significantly greater (say by at least an order of magnitude) than the depth to be etched. In preferred embodiments, the silicon to be etched is a thin film of silicon on a foreign substrate and the etch is limited by the silicon being etched substantially down to the substrate. However, the process can also be made to progress at a rate, which allows depth of etch to be controlled by timing of the etch.
Preferably, the dilute solution of HF and KMnO4 comprises a solution of 1% HF and 0.1% KMnO4. With this solution, 1.5 μm of silicon will substantially etch away in 12 minutes at room temperature (21° C.).
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a diagram of a section through a semiconductor device after initial steps of applying an anti-reflection coating over a glass substrate and depositing a doped semiconductor film over the anti-reflection coating;
FIG. 2 is the sectional view seen in FIG. 1 after a scribing step has been completed to form a cell separating groove dividing separate cell areas and insulating layers have been applied over the semiconductor layer;
FIG. 3 is a schematic diagram of an X-Y table with an ink-jet print head fitted for directly applying the insulation etchant, using ink-jet technology;
FIG. 4 is the sectional view seen in FIG. 2 (shifted slightly to the left) after a pattern of etchant has been directly deposited onto the insulating layer to open the insulating layer in areas where contacts to an underlying n + type region of the semiconductor layer are required;
FIG. 5 is the sectional view seen in FIG. 4 after the insulation layer has been opened in the areas where contacts to the underlying n + type region of the semiconductor layer are required;
FIG. 6 is the sectional view seen in FIG. 5 after further etching steps have been performed to remove some of the doped semiconductor film in the area where the contact to the underlying n + type region of the semiconductor layer is required;
FIG. 7 is the sectional view seen in FIG. 6 after a re-flow step to flow some of the insulating layer into the hole formed by removal of some of the doped semiconductor film in the area where a contact to the underlying n + type region of the semiconductor layer are required. A pattern of caustic solution has been directly deposited onto the insulating layer to open the insulating layer in an area where a contact to an upper p + type region of the semiconductor layer is required;
FIG. 8 is the sectional view seen in FIG. 7 after the caustic has opened the insulation layer in the areas where the contact to the upper p + type region of the semiconductor layer is required;
FIG. 9 is the sectional view seen in FIG. 8 after further etching steps have been performed to clean the surface of the doped semiconductor film of damaged material in the areas where the contact to the upper p + type region of the semiconductor layer is required;
FIG. 10 is the sectional view seen in FIG. 9 after a metal layer has been applied to contact the p + and n + type regions of the semiconductor material and to interconnect adjacent cells;
FIG. 11 is the sectional view seen in FIG. 10 after the metal layer has been interrupted to separate the contacts to the p + and n + type regions from each other within each cell;
FIG. 12 is a back view (silicon side) of part of the device of FIG. 11 ; and
FIG. 13 is a diagram of a part of a completed device, illustrating the interconnection between adjacent cells.
DETAILED DESCRIPTION
Referring to the drawings, FIG. 1 illustrates a part of a semiconductor structure 11 , which is a precursor to the photovoltaic device fabrication process described below. The semiconductor structure 11 is formed as a thin semiconductor film applied to a substrate 22 in the form of a glass sheet to which a thin silicon nitride anti-reflection coating 71 has been applied. The anti-reflection coating 71 has a thickness of 80 nm. For optimal performance, the thin semiconductor film comprises a thin polycrystalline silicon film 12 formed with a total thickness in the range of 1 to 2 μm and, preferably, 1.6 μm. The polycrystalline silicon film 12 has an upper p + type region 13 , which is 60 nm thick, a lower n + type region 15 , which is 40 nm thick, and a 1.5 μm thick intrinsic or lightly p type doped region 14 separating the p + and n + type regions. The sheet resistance in both n + type and p + type layers is preferably between 400 and 2500Ω/□, with no more than 2×10 14 cm −2 boron in total. Typical values are around 750Ω/□ for n + type material and 1500Ω/□ for p + type material. The thickness of the n + type and p + type layers is typically between 20 and 100 nm. The glass surface is preferably textured to promote light trapping, but this is not shown in the drawings for sake of clarity.
Division into Cells
As seen in FIG. 2 , the silicon film 12 is separated into cells by scribed isolation grooves 16 . This is achieved by scanning a laser over the substrate in areas where isolation grooves 16 are required to define the boundaries of each photovoltaic cell. To scribe the grooves 16 , the structure 11 is transferred to an X-Y stage (not shown) located under a laser operating at 1064 nm to produce focused laser beam 73 , which cuts the isolation grooves through the silicon. The laser beam is focused to minimize the width of the groove, which is lost active area. Typically, a pulse energy of 0.11 mJ is required to fully ablate the silicon film and gives a groove width of 50 μm. To ensure a continuous groove, successive pulses are overlapped by 50%. The optimum cell width is in the range of 5 to 8 mm and cell widths of 6 mm are typical.
As seen in FIG. 2 , two layers of insulation are preferably used on the surface of the silicon and are added after the laser scribing step described above. The first insulation layer is an optional thin but tough cap nitride 72 . This layer protects the exposed silicon along the edges of the cell definition grooves 16 after laser scribing and passivates the surface of the silicon. The cap nitride 72 is preferably capable of being etched completely in a few minutes to allow access to the silicon at n type and p type contact locations and typically comprises 60 μm of silicon nitride deposited by PECVD at a temperature of 300° to 320° C.
Before the cap layer 72 is applied, the structure 11 is transferred to a tank containing a 5% solution of hydrofluoric acid for one minute. This removes any remaining debris and any surface oxides that may have formed. The structure is rinsed in de-ionized water and dried.
The second insulation layer 17 is a thin layer of organic resin. The insulating resin is resistant to dilute solutions of hydrofluoric acid (HF) and potassium permanganate (KMnO4) and is preferably vacuum compatible to 10-6 mbar. The insulation material most often used is novolac resin (AZ P150) similar to that used in photoresist (but without any photoactive compounds). The novolac resin is preferably loaded with 20 to 30% white titania pigment (titanium dioxide), which improves coverage and gives it a white color that improves its optical reflectivity to help trap light within the silicon. The resin layer 17 serves as an etch mask for etching steps described below and also covers over the rough jagged surface that is formed along the edges of the cell definition grooves 16 , an area that is prone to pinholes in the cap nitride layer 72 . The organic resin layer 17 also thermally and optically isolates the metal layer from the silicon to facilitate laser patterning of a metal layer in contact forming process steps described below.
The novolac resin is applied to each module to a thickness of 4 to 5 μm using a spray coater. After the structure 11 is coated, it is passed under heat lamps to heat it to 90° C. to cure. As seen in FIG. 2 , the insulation layer 17 is applied over the cap layer 72 and extends into the cell separation groves 16 .
Opening Mask and Etching N Type Contact Openings
In order to make electrical contact to the buried n + type layer and the upper p + type layer with a metal layer, which will be subsequently formed, holes must be made through the novolac resin layer 17 and the cap nitride layer 72 in the locations where the n type “crater” contacts and the p type “dimple” contacts are required. Firstly, with regard to the “crater” contacts to the buried n + type silicon layer, as well as opening the novolac resin layer 17 and the cap nitride layer 72 , most of the silicon film 12 must be removed from areas beneath what will later become the n type metal pads to form the n type contact openings 32 . Referring to FIGS. 3 , 4 , and 5 , ink-jet technology is used to open holes in the novolac resin layer 17 at the crater locations. To achieve this, the structure 11 is loaded onto an X-Y stage equipped with an ink-jet head 91 having multiple nozzles with a nozzle spacing of 0.5 mm and controlled by controller 92 . The glass is held down with a vacuum chuck and initially scanned to ensure that no point is deformed more than 1 mm above the stage. The glass is then scanned beneath the head 91 at a table speed of typically 400 mm/s. Droplets 76 of dilute (15%) potassium hydroxide (KOH) (see FIG. 4 ) are dispensed at locations intended for n type “crater” contacts. The odd numbered nozzles fire in the odd-numbered cells, and the even-numbered nozzles fire in the even-numbered cells, so that within a given cell, the spacing between lines of droplets is 1 mm. The spacing between droplets within each line is 400 μm, hence the rate of droplet release at a table speed of 400 mm/s is 1 kHz. The droplets are sized to etch circular openings in the resin layer that are about 100 μm in diameter. The KOH solution removes the resin insulation 17 in the area-of the droplet 76 after a few minutes to form the hole 32 seen in FIG. 5 .
The openings 32 are spaced holes so that lateral continuity is maintained in the semiconductor layer after contact formation. The ink-jet printing presses applies a droplet 76 of the caustic solution in a controlled manner to remove the insulation only where the n type contacts are to be formed. The caustic solution preferably contains potassium hydroxide (KOH) but can also use sodium hydroxide (NaOH) and includes glycerol for viscosity control. The print head used for this purpose is a model 1281D, 64ID2 or 64-30 manufactured by Ink Jet Technologies Inc., and will print substances having a viscosity in the range 5 to 20 centipoise. The droplet size deposited by the print head is in the range of 20 to 240 picolitre corresponding to a deposited droplet diameter range of 50 to 150 μm. In the preferred embodiment the droplets are printed at a diameter of 100 μm. It should be noted that novolac is an organic resin closely related to the resins used in photo-resist material and the etchant printing process described above will apply equally to the patterning of other such materials.
To extend the opening 32 into the silicon layer 12 as seen in FIG. 6 , the structure 11 is rinsed in water to remove residual KOH from the ink-jet printing process, and it is then immersed in a tank containing a 5 solution of hydrofluoric acid for 1 minute to remove the silicon nitride from the n type contact openings 32 . The sheet is then directly transferred to a tank containing 1% hydrofluoric acid (HF) and 0.1% potassium permanganate (KMnO 4 ) for 4 minutes. This time is long enough to remove all of the p + type layer and etch down along grain boundaries to expose some of the n + type layer for the silicon thicknesses stated above, however the time should be adjusted for different silicon layer thicknesses, silicon crystal quality, and extent of surface texturing. The structure 11 is then rinsed in de-ionized water and dried.
The resulting opening 32 in the silicon 12 has a rough bottom surface 82 , in which some points may be etched through to the anti-reflection layer 71 and some ridges 83 extend into the lightly doped p type region 14 , as seen in FIG. 6 . However, as long as some of the n + type region is exposed, good contact can be made to the n + type region. Because the p type region is very lightly doped in the area near the n + type region, there is insufficient lateral conductivity to cause shorting if some p type material is also left in the bottom of the hole 32 .
Re-Flow of Mask
Because the side walls of the hole 32 are passing through the p + type region 13 and the lightly doped region 14 , the walls need to be insulated to prevent shorting of the p-n junction. This is achieved by causing the insulation layer 17 to re-flow, whereby a portion of the insulation layer 78 in the vicinity of the edge of the opening 32 flows into the hole to form a covering 79 over the walls as seen in FIG. 7 . To achieve this, the sheet is passed through a zone containing a vapor of a suitable solvent. This causes the novolac resin of the insulating layer 17 to re-flow, shrinking the size of the crater openings 32 . As the samples exit this zone, they are heated under heat lamps to a temperature of 90° C. to drive out the remaining solvent.
The rate of re-flow will vary with the aggressiveness of the solvent used, the concentration and temperature. There are many suitable, volatile solvents that will dissolve organic resins such as novolac, including substances such as acetone. Acetone is a suitable solvent for the process, but acts quite aggressively, requiring only a few seconds to cover the walls of the hole 32 with resin, and making it difficult to control the process accurately. The preferred solvent is propylene glycol monomethyl ether acetate (PGMEA) and the device is introduced into an atmosphere containing a saturated vapor of PGMEA at room temperature (e.g., 21° C.) for 4 minutes until a slight shrinkage of the holes in the insulation is observed.
Opening Mask and Cleaning P Type Contact Openings
A further set of holes 19 (see FIG. 8 ) are then formed in the insulation layer 17 , again using the printing and etching process described above with reference to FIGS. 3 , 4 , and 5 . These openings are formed by printing droplets 81 of caustic solution onto the insulation (see FIG. 7 ) in the locations where p type contact “dimples” are required. Following the removal of the insulation layer 17 by the caustic solution to form the openings 19 (see FIG. 8 ), any residual caustic solution is washed off with water and the cap layer 72 removed in the openings 19 with an etch of 5% hydrofluoric acid (HF) for 1 minute (note times of from 10 seconds to 10 minutes may be required to remove the nitride layer depending on its stoichiometry). Optionally, any damaged silicon material on the surface of the p + type region 13 is then removed to allow good contact using an etch in 1% hydrofluoric acid (HF) and 0.1% potassium permanganate (KMnO 4 ) for ten seconds followed by a rinse in de-ionized water to provide the slightly recessed contact “dimple” 85 seen in FIG. 9 . This length of etch is long enough to remove surface plasma damage without etching all the way through the p + type layer 13 . It is also short enough to have negligible impact on the n type contacts.
Formation of Metal Contacts
The final stage of device fabrication involves depositing a metal layer and slicing it up so that it form a a plurality of independent electrical connections, each one collecting current from one line of p type dimple contacts and delivering it to a line of n type crater contacts in the adjacent cell. In this manner, monolithic series interconnection of the cells is achieved.
Before the metal layer is applied, the structure 11 is immersed into a tank containing a 0.2% solution of hydrofluoric acid for 20 seconds. This acid removes the surface oxide from both the crater and dimple contacts. There is wide latitude for the strength and duration of this etch. The structure is then rinsed in de-ionized water and dried.
Turning to FIG. 10 , the contact metal for the n type and p type contacts is applied simultaneously by depositing a thin metal layer 28 over the insulation layer 17 and extending into the holes 32 and 19 to contact the surfaces 82 and 85 of the n + type region 15 and p + type region 13 . The metal layer is preferably a thin layer of pure aluminum, which makes good electrical contact to both n + type and p + type silicon, provides good lateral conductivity, and has high optical reflectance. The aluminum thickness is typically 100 nm.
Isolation of N and P Type Contacts
The isolation of the n type and p type contacts is achieved by using a laser 86 (see FIG. 10 ) to melt and/or evaporate the metal layer 28 to thereby form an isolation groove 31 , as seen in FIG. 11 . When the laser is pulsed on, a small amount of metal is ablated directly under the beam creating a hole 31 .
The structure 11 is processed using a laser operating at 1064 nm to scribe the isolation grooves in the metal layer 28 . The laser is adjusted so that it scribes through the metal layer 28 without damaging the silicon 12 . These scribes 31 separate the n type contacts 32 from the p type contacts 19 within each cell, while retaining the series connection of each cell to its neighbors. Preferred laser conditions are a pulse energy of 0.12 mJ with the beam defocused to a diameter of about 100 μm. The pulse overlap is 50% and the scribes are spaced 0.5 mm apart. In addition, there are discontinuous scribes 34 along each cell definition groove 16 (see FIG. 12 ).
FIG. 12 illustrates a rear view of a part of a device made by the process described above, from which it can be seen that each of the cells of the device 11 comprises an elongate photovoltaic element 35 a , 35 b , 35 c , 35 d divided across its long axis by a plurality of transverse metal isolation scribes 31 , which isolate alternate sets of holes 19 and holes 32 respectively providing contacts to the p + type and n + type regions of the cell. The transverse scribes 31 are made as long substantially straight scribes extending over the length of the device, such that each scribe crosses each elongate cell.
Following the formation of the first set of scribes 31 , a further set of metal isolation scribes 34 are formed over the cell separation scribes 16 between adjacent cells 11 to isolate every second pair of cells. The metal isolation scribes 34 extending to either side of any one of the elongate transverse scribes 31 are offset by one cell with respect to those on the other side of the same transverse scribe 31 , such that the cells become series connected by a matrix of connection links 36 with alternating offsets, connecting one set of p type contacts 19 of one cell 35 to a set of n type contacts 32 of an adjacent cell 35 , as shown in FIG. 12 .
The metal isolation scribes 31 comprises a first set of long scribes transverse to the cells 35 from 50 to 200 μm wide, preferably about 100 μm wide. The scribes are typically spaced on centers of 0.2.2.0 mm and preferably about 0.5 mm to form conducting strips about 0.2-1.9 mm and preferably about 0.4 mm wide. The isolation scribes 34 comprises a second set of interrupted scribes parallel to the long direction of the cells 35 and substantially coincident with the cell isolation grooves 16 in the silicon. The isolation scribes 34 are also from 50 to 200 μm wide, preferably about 100 μm wide. It is equally possible to form the isolation scribes 34 before forming the transverse isolation scribes 31 . The scribed areas are illustrated in FIG. 12 with cross-hatching.
A portion of the completed structure is illustrated in FIG. 13 , which shows the connection of an n type contact of one cell to the p type contact of an adjacent cell to provide a series connections of cells. In practice there may be several n type contacts grouped together and several p type contacts grouped together; however, for the sake of clarity only one of each is shown in each cell. The arrangement shown is FIG. 13 is also schematic as the isolation grooves 16 in the silicon and the isolation grooves 31 in the metal run perpendicularly to one another in practice as is shown in FIG. 12 .
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative, and not restrictive.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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As a step in performing a process on a structure, a hole pattern is provided in a thin layer of organic resin masking material formed over the structure to provide a process mask. A processing step is then performed through the openings in the mask, and after a processing step is completed the mask is adjusted by a re-flow process in which the structure is placed into an atmosphere of solvent vapor of a solvent of the mask material. By way of the re-flow process, the mask material softens and re-flows to reduce the size of the openings in the mask causing edges of the surface areas on which the processing step was performed to be covered by the mask for subsequent processing steps.
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This application is a continuation of application Ser. No. 07/707,703, filed May 30, 1991.
BACKGROUND OF THE INVENTION
This invention relates to precision hydrodynamic bearings.
As part of the continuing advances in computer technology, greater and greater amounts of data are sought to be stored in smaller and smaller areal densities on magnetic disks. Magnetic disk drives typically include both a plurality of spinning magnetic disks suspended on a common precision spindle bearing assembly and also at least one magnetic read/write head which "flies" in close proximity to and at selected locations over an assigned one of the plurality of disks. The head reads or writes streams of data from or to "tracks" of magnetic interactions in the magnetic layer of a selected disk. The width of the tracks determines the number of tracks which can be defined on a given disk. The greater the number of tracks the greater the storage density. A magnetic disk drive assembly whose spindle bearing has low runout can accommodate higher track densities, and this results in increased storage density per disk.
Hydrodynamic spindle bearings are known in which the shaft part and the housing part have respective bearing surfaces which support relative rotary motion therebetween. By means of the bearing surfaces, one part rides on a film of liquid lubricant, e.g., oil, against the other part. These bearings generally have low runout, but require a continuously circulating lubrication supply. These bearings can be characterized by their means of lubrication, i.e., a lubrication system which is self-contained or which relies on an external supply.
Within the development of the self-contained lubrication type hydrodynamic spindle bearings comes the nettlesome problem of preventing lubricant leakage out of the bearing. In a magnetic disk drive, these losses can degrade bearing performance and thus cause read/write errors. As well, leakage of lubricant can lead to contamination of the magnetic disk surface, which can cause malfunction of the read/write process or even catastrophic failure of the flying head assembly.
In one known commercially successful product, the Phillips Video 2000 videocassette recorder, lubrication losses are minimized by using grease lubrication. The useful life of such bearings, of course, is limited by the stability of the grease. As well, rotational velocity is effected by the grease viscosity. No known disk drive spindle bearings utilize this technology.
Clearance type lubricant seals are required in disk drive applications to satisfy desired longevity. Clearance seal hydrodynamic spindle bearings, e.g., the ferromagnetic fluid type and the capillary seal type, are well known. However, they are strained by the centrifugal effects of the rotating part (especially a rotating housing), and are vulnerable to leakage of lubricant as may be initiated by trapped bubbles. Associated with the concern about trapped bubbles and lubricant blowout, use of o-ring static seals for assembly is often avoided, and then the lubricant filling requires a relatively elaborate vacuum impregnation procedure. Nevertheless, oil-lubricated bearings with clearance seals are of interest.
It is therefore an object of the present invention to provide a hydrodynamic spindle bearing of the clearance seal type which is self-lubricating and essentially leak-free by utilizing the centrifugal acceleration of rotation to keep the lubricant inside the housing. Risk of leakage through the clearance seals is minimal when the spindle is running due to the tendency of the centrifugal acceleration of rotation to keep the lubricant inside the housing.
It is another object of the present invention to provide a hydrodynamic spindle bearing of the clearance seal type which is not likely to suffer from seal blowout.
SUMMARY OF THE INVENTION
The present invention provides a self-lubricating hydrodynamic spindle bearing for support of a spindle of a disk drive assembly in a high track density magnetic recording system. In one aspect of the invention, the lubricant retention function associated with the crankcase of an automotive engine is utilized to avoid seal blowout due to gaseous ingestion. Risk of lubricant leakage thus is practically nil when the spindle is running. In particular, the crankcase design provides large reservoirs for oil storage with an air cover in communication with the ambient environment through an air vent provided by a clearance seal.
In one embodiment of the invention, removable endcaps are mated with the bearing housing over the bearing shaft, creating a crankcase therein. This design defines a copious reservoir volume for holding the lubricant when the spindle is not operating, such that the lubricant level is unlikely to reach the clearance seal for various orientations of the spindle axis. The unfilled space of the reservoir is vented to the external atmosphere during operation. Because the atmosphere of the interior communicates freely with the outside, use of o-ring type static seals to seal the endcaps to the housing is without the risk of "blow-out" caused by expansion of trapped bubbles. Use of removable endcaps also facilitates loading of the lubricant into the bearing.
The crankcase reservoir volume is defined within the bearing so that natural body force effects cause the lubricant to be fed into the hydrodynamic bearing, i.e., the endcap cross-section is such that the centrifugal field effectively feeds the entrance edge of the hydrodynamic bearing lubrication circuit when the housing is rotating about the fixed shaft.
In another aspect of the invention, a leak-preventing capillary trap of minimal continuous axial length is provided at the clearance seal for passive capture of wandering lubricant when the bearing is at rest. The capillary trap, if employed, prevents leakage of the lubricating oil when the system is at rest. This trap has a central minimum gap such that the oil meniscus is stabilized statically. Full evacuation of lubricant trapped at the clearance seal is achieved toward the interior of the housing by centrifugal pumping, i.e., the inboard side of the rotating part of the seal is coned and fluted such that the rotating centrifugal field will throw all statically trapped oil into the lubricant reservoir.
In yet another aspect of the invention, a three way restrictive valve is provided to assure balanced feeding of lubricant to both ends of the spindle for either vertical or horizontal spindle orientation.
In a preferred embodiment of the invention, a disk drive spindle bearing assembly includes a housing and a shaft having cooperating bearing surfaces which define at least one transverse bearing gap therebetween. The bearing surfaces further define a lubricant entrance end and a lubricant exit end of the gap. The bearing housing includes a flow control valve and at least one axial passage coupling the valve to the lubricant entrance end of the gap. The housing has at least one radial passage for delivery of lubricant from the lubricant exit end of the gap to the lubricant valve, and the lubricant valve delivers lubricant to the lubricant entrance end of the gap via the axial passage. The housing and shaft, along with housing endcaps mated over the shaft, form a lubricant storage reservoir therebetween, and further form a feed means for centrifugally feeding of stored lubricant from the reservoir into the entrance end of the gap. The cooperating bearing surfaces further define an inwardly directed viscous pumping means (which may include helically scored surfaces of the housing bearing surfaces) for pumping of lubricant from the entrance end to the exit end of the gaps, and which may further include the housing radial passage, for pressurizing and circulating the lubricant therein.
The bearing assembly also has a crankcase means for venting the bearing interior to the ambient environment. The crankcase means includes at least one of the housing endcaps having a central bore and being concentrically mated over the shaft for defining a clearance seal thereat. The clearance seal includes a capillary trap for defining the air/lubricant interface within the clearance seal. This assembly includes crankcase vent clearing means for drawing lubricant from the clearance seal into the bearing by centrifugal action, clearing open the clearance seal so as to be able to act as a crankcase vent thereby.
In still another aspect of the invention, a bladder may be attached to the bearing to supply a volume of lubricant to the bearing on demand. The bladder responds to a rotation-actuated differential pressure to cause the lubricant to flow out of the bladder into the lubrication circuit when the spindle speed exceeds a predetermined value. The lubricant returns to the bladder when the spindle speed falls below this value. The lubricant thus is entrained within the bearing when operating at speed or within the bladder when not up to speed, thus virtually eliminating the possibility of lubricant leakage out of the bearing.
A particularly preferred embodiment of the invention includes a compliant bladder means for delivery of lubricant to the bearing from a bladder reservoir. The shaft is provided with a central axial passage which delivers lubricant from the bladder reservoir through a central radial passage of the shaft to the housing flow control valve via a housing central radial passage, when the housing is in rotation.
The shaft central radial passage communicates with the housing central radial passage at a connection zone within the bearing, defining a radial lubricant flow path to the valve. Conical bearing surfaces at each end of the device form a tightly toleranced gap therebetween distal to the connection zone, wherein each such gap communicates with the connection zone via a relatively loosely toleranced axial passage between the shaft and housing. Each such passage terminates at the connection zone via a tightly toleranced axial capillary seal. The central radial passage of the housing is also tightly toleranced, forming a shaft capillary seal adjacent to the connection zone. The capillary seals seal the bearing at rest, and enable lubricant feed to the bearing as the housing rotates about the fixed shaft. However, other bearing configurations, such as plate and journal, are also within the scope of the present invention.
In this rotating housing design, an important physical parameter to be considered is the centrifugal force which is imparted to the liquid lubricant if it adheres to the bearing surface of the rotating housing and assumes its angular speed. This can be expressed in terms of the centrifugal head which is more than five times the overall length of the bearing of typical dimensions. In other words, if the spindle is vertical, the bearing can be more than five times the typical height of the bearing and the lubricant would not be driven out of the bearing cavity through the shaft clearance at the lower end by gravity.
It is further noted that while the centrifugal head might be a potential burden for clearance-type seals, it is a salient feature of the present invention in that the centrifugal head is utilized to retain the lubricant. As well, the general centrifugal effect is to drive the lubricant to the largest diameter of the bearing cavity away from the clearance seals on the rotating axis. Hence, as seen in the illustrated configurations, the lubricant is always driven toward the outer peripheries of the conical bearings. This condition particularly favors an inward-pumping grooved bearing arrangement for which the outer periphery is the feeding edge of the lubricating film. It will thus be appreciated that a special feature of the invention is the utilization of the natural centrifugal acceleration field for fluid retention and flow regulation. Since the level of centrifugal field in a typical disk drive spindle (based on 3,600 rpm and 5 mm radius) is over 70 g's, this provides a very powerful control mechanism.
The details of the crankcase configuration may depend on whether the housing or the shaft rotates during operation but the basic concept as explained above is applicable in either case. The present crankcase design thus will be understood to maintain and contain the lubricant supply for the dormant device, employing a clearance seal with an optional capillary trap, and to centrifugally clear the seal and feed lubricant into the bearing as the bearing goes into operation. With the seal cleared, now the crankcase can vent entrained gases without loss of lubricant. The optional bladder provides further security against lubricant leakage.
As a result of the foregoing, the lubricating oil is fully contained within the bearing housing in spite of a variety of field environments which would otherwise induce leakage of the lubricant. A typical bearing according to the invention can range in diameter from about 5 mm to about 2 cm, operating at a speed ranging from about 1800 to about 10,000 rpm. Nevertheless, other sizes and speeds are also within the scope and teaching of the present invention.
The lubricant type and volume must be selected such that adequate lubrication is achieved during operation, and the lubricant reservoirs must be sized accordingly. The lubricant is preferably a viscous oil, such as a vacuum oil which is chemically compatible with head/disk interface requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawing in which like reference numerals refer to like elements and in which:
FIG. 1 is a cut-away side view of a magnetic disk drive assembly incorporating the present invention.
FIG. 2 is a partial side cross-section of an embodiment of the invention, and FIG. 2A is an inset showing a capillary trap seal of the invention.
FIG. 3 is a partial side cross-section of an alternative embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An illustrative disk drive assembly 10 is shown in FIG. 1 where shaft 11 is fixedly mounted in drive assembly frame 13. At least one and normally a plurality of magnetic disks 14 are mounted concentrically to the spindle shaft 11 over and supported by a rotating spindle housing 15. A motor 16 also mounted to frame 13 drives the rotating housing 15 and causes the disks 14 to rotate. Typically the exterior of the spindle housing 15 receives a hub with spacers for receipt of disks 14. The housing ends are capped by endcaps 18. Access to the data stored on a given spinning disk is obtained by servoed placement of a magnetic head (not shown) adjacent to the data track to be read. A self-pumping hydrodynamic spindle bearing assembly 19 according to the present invention is formed by internal cooperation of endcaps 18, housing 15 and shaft 11, as more fully set forth below.
One embodiment of bearing assembly 19 is shown in FIG. 2, where housing 15 mounted on shaft 11 forms a pair of conical bearings 20, 21 with their apexes directed toward each other. Specifically, shaft 11 includes conical portions 22, 23 which mate with inclined wall portions 24, 26 of housing 15, separated by bearing gaps, g,g', respectively. The housing wall portions 24, 26 are internally grooved, such as with inward-pumping spiral grooves 32, 34, substantially over their bearing surfaces. Wall portions 24, 26 flare radially inwardly from cylindrical surfaces 25, 27 to cylindrical surfaces 31, 29, respectively.
The shaft conical portions 22, 23 taper radially inwardly from cylindrical surfaces 36, 38 to truncated ends 40, 42. These ends 40, 42 define a connection zone 44 therebetween. At least one of the conical portions 22, 23 is an insert which is mated over and affixed to shaft 11 so as to become a part thereof, thus to facilitate assembly of bearing assembly 19. In FIG. 2, conical portion 23 is formed by such an added insert, with portion 22 being an integral part of shaft 11.
Housing 15 includes at least one radial passage 46 which extends from connection zone 44 to a three-way valve assembly 48. T-shaped valve assembly 48 includes passages 50, 52 which extend axially from valve control center 49 out to radially inwardly directed discharge ports 56, 58, adjacent to cylindrical surfaces 36, 38, respectively, and also includes a float 51. Float 51 assumes a position within valve control center 49 depending upon the orientation of the bearing at rest, with float 51 reacting to gravity accordingly. With the valve vertical, end A up, float 51 falls toward end B and nestles in seat "a" of valve 48; in the reversed vertical orientation, float 51 falls toward end a and nestles into seat "b" of valve 48. In either case, with the bearing spinning, float 51 only partially obstructs fluid flow where it lies such that the lower passage 50 or 52 has a higher flow resistance than the upper passage 52 or 50, so as to balance the effect of gravity draining lubricant away from the upper passage toward the lower passage. With the spinning bearing horizontally oriented, float 51 is thrown into seat "c" , such that fluid flow is balanced between passages 50, 52.
The endcaps 18 of FIG. 1 are shown in FIG. 2 in greater detail as endcaps 60, 62. These endcaps are concentrically engaged over shaft 11 at their respective passages 64, 66, forming clearance seals thereat. Preferably each of the passages 64, 66 flares open into bearing assembly 19. As shown in FIG. 2, passages 64, 66 are defined by cylindrical walls 76, 78 nominally at a first diameter D1 and opening out along cylindrical walls 80, 82 to a larger second diameter D2, which assists in clearing the seals inwardly into the bearing as the housing begins rotation.
The endcaps also define lubricant reservoirs 87, 89 between axially extending walls 90, 92, transverse walls 83, 85, and cone end walls 63, 65, respectively. As seen in cross-section, these transverse walls are preferably arcuate, providing an autofeed feature by centrifugally directing the lubricant from the reservoirs into the bearing infeeds 97, 99 during spindle rotation. The endcaps are sealingly mated against static o-rings 63, 65 at housing annular ends 68, 70.
Shaft 11 is graduated at its ends from a smaller first outer diameter D1, D1 to a larger second outer diameter D2, D2 by means of tapered shaft portions 72, 74, respectively. A narrowed throat 86, 88 is formed by the endcap cylindrical wall 76, 78 and the adjacent shaft, and enables formation of a respective capillary trap seal 94, 96 thereat. The menisci formed by lubricant trapped in capillary trap seal 96 are shown in the inset of FIG. 2A. Generally, the trap seal and the menisci are formed as taught in U.S. Pat. No. 4,795,275, which is incorporated herein by reference.
The crankcase function of the invention is significant during operation of the bearing, when the centrifugal field clears the capillary seals 94, 96, opening throats 86, 88, such that these throats can then act as crankcase breather vents. This venting prevents pressure-induced seal, i.e., lubricant, blowouts. In particular, the crankcase fluid reservoirs 87, 89 are provided an air cover in communication with the ambient environment via the thus opened throats 86, 88, thus automatically equalizing pressure gradients which may develop within the bearing.
In operation, the lubricant flow begins with radially outwardly driving of the lubricant in reservoir 87 and/or 89, depending upon orientation of the bearing, up to and into the bearing entrance edges, i.e., infeeds 97, 99, adjacent the cone flat surfaces 36, 38, as the spindle housing rotates up to speed, and then along inward-pumping spiral grooves 32, 34 to connection zone 44. The lubricant then is thrown outward along radial passage 46 into valve assembly 48, which builds a head in valve 48 and which in turn drives the lubricant along passages 50, 52 axially from valve control center 49 out to the radially inwardly directed discharge ports 56, 58, adjacent to flat surfaces 36, 38, respectively, where the flow circuit begins again. The lubricant falls back according to gravity into one or both of the reservoirs when the bearing is at rest.
The capillary type clearance seal functions as a fluid trap when the spindle is not operating. In various embodiments, the fluid trapping function is enhanced by: providing a nonwetting treatment on the reservoir faces; providing tapered shaft clearance to stabilize trapped fluid at the minimum clearance location of the capillary seal; and/or providing tapered radial slots inboard of this minimum clearance location to function as centrifugal pump impellers to draw trapped fluid into the bearing interior as soon as the spindle rotates. While use of ferromagnetic sealing is also possible within the invention, the effective sealing of the present invention essentially obviates the need for use of ferromagnetic lubricant.
The installation orientation of the spindle affects details of various features cited in this application. Generally speaking, the principles for fluid retention as described for either fully vertical or fully horizontal orientation remain valid for an inclined orientation.
While either or both of the reservoirs themselves can be factory-loaded with lubricant, as in the embodiment of FIG. 2, a bladder may be provided to carry a factory-loaded supply of lubricant during product shipment, reducing the risk of leakage, but where the lubricant is delivered to the bearing as the housing rotates up to speed. Return of the lubricant to the bladder as the bearing comes to rest provides further secure storage of the lubricant, but is not essential unless further transport of the product is expected. The bladder may also be used to provide an additional supply of lubricant as the system demands.
As shown in FIG. 3, in an alternative embodiment of the invention, bearing assembly 100 is provided with a compliant bladder 101, such as a bag, bellows or diaphragm, for example, for automatic lubricant storage and delivery. Shaft 102 defines an annular chamber 103 and at least one radial passage 104 which couples chamber 103 via a central axial passage 105 to connection zone 109. Bladder 101 is sealingly engaged at shaft shoulder 106 in chamber 103 such that a lubricant flow path is defined between the interior 107 of bladder 101 through passage 105 and passage 104 to connection zone 109 for feeding of fluid into valve 48 via housing central radial passage 110. (Fluid flow is indicated by arrows 137.)
Cooperating conical bearing surfaces 112, 114 and 116, 118 at respective ends of device 100 form a respective tightly toleranced gap G,G' therebetween distal to connection zone 109. Each such gap forms a relatively high pressure capillary seal, and communicates with the connection zone via a relatively loosely toleranced and lower pressure axial passage 120, 122 defined between the shaft and housing. Each such passage 120, 122 terminates at the connection zone via a tightly toleranced axial capillary seal 124, 126. Preferably capillary seals 124, 126 are formed by a relatively long tapered surface of the housing or the shaft cooperating with an adjacent surface of the shaft or housing. The central radial passage 110 of the housing is also tightly toleranced, and also forms a capillary seal 128 similarly adjacent to the connection zone.
The bladder seals chamber 103 from the ambient environment, such that fluid flow is induced from the bladder to the connection zone when the pressure at connection zone 109 falls below the ambient, as centrifugally induced by rotation of the housing. Alternatively, chamber 103 is closed to the ambient environment and the bladder is exposed to a high pressure source as may be actuated by the spindle rotation. As well, the bearing is dimensional such that a liquid environment is maintained at least in capillary seals 124, 126, 128 and in passage 104, at rest.
Generally speaking, when the shaft rotates, the centrifugal force imposed upon the lubricant in housing radial passage 110 draws lubricant from connection zone 109 into valve 48, lowering the pressure at the connection zone. Therefore with the pressure behind the bladder being relatively high, lubricant in the bladder interior 107 is drawn via shaft central axial passage 105 through shaft central radial passage 104 to valve 48 via housing central radial passage 110 in response to the gradient.
More specifically, maintenance of the proper relationship of the capillary seals, in dimension and the pressure established thereat, relative to the ambient environment, is essential to operation of this embodiment. At rest, the pressure in passages 120, 122 is nearly ambient Pa, and the pressures P124, P126 and P128 at capillary seals 124, 126, 128, respectively, are essentially related as: Pa>P126=P128=P124. Also, the pressure P104 in shaft radial passage 104 is nearly equal to P128.
In operation, as the housing rotates, the centrifugal force applied to the lubricant at seal 128 causes P124, P126 and P104 to fall below Pa, and lubricant is thus drawn into the bearing from bladder 101 as it adjusts to the pressure change, as well as being drawn from passages 120, 122.
Thus it will be appreciated that the capillary seals 124, 126, 128 seal the bearing at rest, enable lubricant to be drawn out of the bladder to feed the bearing in use, and then are reestablished as the housing slows to a halt while the bladder expands and withdraws the lubricant supply.
Passages 120, 122 are provided with a circumferential groove 133, 134 defined in the shaft or housing. The function of these grooves depends upon orientation of the bearing. For example, if the bearing is operating vertically with end a up, the lower capillary seal 126 terminates at or above groove 134. The lower groove thus acts as a stabilizer for the meniscus of the lower seal, while the meniscus of the upper seal will be located below groove 133 and above the central connection zone 109.
As will now be appreciated, the invention provides a bearing which may be operated either vertically or horizontally. However, if the equipment orientation is always vertical, e.g., with end A up, then the lower passage 52 may be made narrower than passage 50 to naturally balance the fluid flow in view of gravitational effects, thus eliminating float 51 and substantially simplifying the configuration of three-way valve 48. Similarly, for constantly horizontal operation, like-sized passages 50, 52 may be provided, again eliminating float 51 and substantially simplifying valve 48.
An additional benefit of the present invention is that it securely holds the shaft within the housing with minimal canting of the shaft, as required in precision applications. This stability is provided by close tolerances maintained within the bearing and also by the shaft cones having a common apex with their bases being maximally separated. This arrangement provides a broad fulcrum over which the shaft must cant, making canting less likely.
It will be understood that the above description pertains to only several embodiments of the present invention. Hence, the description is provided by way of illustration and not by way of limitation. The invention, therefore, is to be limited only according to the following claims.
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A self-lubricating hydrodynamic spindle bearing for support of a spindle of a magnetic disk drive assembly includes a crankcase design which provides large reservoirs for oil storage with an air cover in communication with the ambient environment through an air vents provided by clearance seals formed between respective central passages of housing-sealing endcaps and the shaft. The crankcase reservoir volume is defined within the bearing so that natural body force effects cause the lubricant to be fed into the hydrodynamic bearing. A leak-preventing capillary trap of minimal continuous axial length may be provided at the clearance seal for passive capture of wandering lubricant when the bearing is at rest. Full evacuation of lubricant trapped at the clearance seal is achieved toward the interior of the housing by centrifugal pumping, e.g., the inboard side of the rotating part of the seal is coned and fluted such that the rotating centrifugal field will throw all statically trapped oil into the lubricant reservoir. A three way restrictive valve is provided to assure balanced feeding of lubricant to both ends of the spindle for either vertical or horizontal spindle orientation. A pressure-actuated bladder may be attached to the bearing to deliver a volume of lubricant to the bearing on demand.
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BACKGROUND TO THE INVENTION
This invention relates to a hydraulic control arrangement for a roof support unit of a longwall mineral mining installation having a conveyor and a plurality of roof support units positioned side-by-side along the goaf side of the conveyor, and in particular to hydraulic control means for controlling the advance of roof bar extensions of the roof bars of the roof support units.
The roof bar extensions of such an installation are advanced towards the face being won by hydraulic rams associated with the corresponding roof bars. The roof bar extensions support the roof of the mineral mining working in the critical region adjacent to the face. It is important, therefore, to advance the roof bar extensions as soon as possible after the conveyor has been advanced following a winning run of the plough (or other winning machine) along the face side of the conveyor. Known systems for advancing the roof bar extensions incorporate either manual control means or automatic control means.
A known hydraulic control arrangement is effective to advance the roof bar extension of a roof support unit by the same distance as that through which the advance ram of that unit advances the associated conveyor section. The hydraulic ram which advances the roof bar extension is actuated by the movement of the advance ram which advances said conveyor section. The resulting synchronisation of the roof bar extension ram and the advance ram enables the roof of the working to be supported reliably, at all times, even in the critical region adjacent to the face. The roof bar extension ram is controlled by a metering ram having a metering chamber which communicates with the working chamber of the advance ram that diminishes in volume as the associated conveyor section is advanced. Thus, the hydraulic fluid displaced from this working chamber of the advance ram passes into the metering chamber. Then, by pressurising the metering piston of the metering ram, a metered amount of hydraulic fluid is forced out of the metering chamber into the appropriate working chamber of the roof bar extension ram, so that the roof bar extension is advanced towards the mineral face (see British Pat. No. 2 068 050).
A form of hydraulic control arrangement of this type has the metering ram formed within the advance ram. In this case, the metering chamber is formed within the piston rod (which is hollow) of the advance ram, the metering piston being guided in the hollow piston rod and being braced against the end wall of the cylinder. When the conveyor is advanced, the metering piston forces pressurised hydraulic fluid out of the metering chamber and into the appropriate working chamber of the roof bar extension ram, so that the roof bar extension is advanced towards the mineral face in synchronism with the advance of the conveyor. The metering chamber is arranged to have a cross-section which corresponds to that of said working chamber of the roof bar extension, so that the roof bar extension is advanced by the same distance as the conveyor (See DE-OS No. 3 217 822).
The aim of the invention is to provide an improved hydraulic control arrangement of this type. In particular, the hydraulic control arrangement should achieve reliable synchronous control without the need for matching the cross-sectional area of the roof bar extension ram absolutely to the cross-sectional area of the metering ram.
SUMMARY OF THE INVENTION
The present invention provides a hydraulic control arrangement comprising a first hydraulic ram, a second hydraulic ram, and a hydraulic control circuit associated with the first and second hydraulic rams, each of the hydraulic rams having a cylinder, a piston reciprocable within the cylinder, and a piston rod fixed to the piston, and each of the hydraulic rams having a cylindrical working chamber and an annular working chamber positioned on opposite sides of its piston, wherein the piston rod of each hydraulic ram constitutes the cylinder of a respective metering ram, a respective metering piston being reciprocable within the cylinder of each metering ram to define a metering chamber therewithin, wherein the hydraulic control circuit includes a line, which interconnects the two metering chambers, and a hydraulic valve positioned in a hydraulic fluid supply line leading to one of the working chambers of the second hydraulic ram, and wherein the metering piston of the second hydraulic ram controls the hydraulic valve, thereby controlling the flow of hydraulic fluid to said one working chamber of the second hydraulic ram.
Thus, the metering piston of the first hydraulic ram is used to load the metering piston of the second hydraulic ram, which, in turn, opens the hydraulic valve through which the second hydraulic ram is charged with pressurised hydraulic fluid during extension. The hydraulic valve is kept open by the metering piston of the second hydraulic ram for a period which depends upon the working stroke of the metering piston of the first hydraulic ram. Consequently, the working stroke of the second hydraulic ram is dependent upon the working stroke of the first hydraulic ram, so that synchronised control takes place.
Advantageously, the arrangement further comprises a high-pressure hydraulic fluid supply line and a hydraulic return line, the high-pressure line and the return line being connectible to the working chambers of the first and second hydraulic rams. Preferably, the metering piston of the first hydraulic ram extends through the piston of that ram, and is fixed to the internal end wall of the cylinder of that ram.
In a preferred embodiment, the hydraulic valve is positioned in the end wall of the cylinder of the second hydraulic ram that defines part of said one working chamber. Conveniently, the hydraulic valve is a mechanically-actuated, spring-loaded, non-return valve. In order to achieve synchronised control with working strokes of the same length, the metering chambers may have the same cross-sectional area.
Advantageously, the metering piston of the second hydraulic ram extends through the piston of the second hydraulic ram, said metering piston being movable relative to both the piston rod and the cylinder of the second hydraulic ram. The metering piston may control the hydraulic valve indirectly by means of an actuating member. Preferably, the actuating member is a rod which is slidably mounted in a bore in said end wall of the cylinder of the second hydraulic ram.
The line which interconnects the two metering chambers may be connected to the return line by a hydraulic line which incorporates a non-return valve. In this way, the metering chamber of the first hydraulic ram is filled with hydraulic fluid during extension of that ram. It is further recommended that the metering chambers are protected by pressure-relief valves.
In a preferred embodiment, a first hydraulic control valve is arranged in the hydraulic fluid supply line upstream of the hydraulic valve, the first hydraulic control valve being arranged to control the flow of hydraulic fluid from the high-pressure line along the hydraulic fluid supply line to the hydraulic valve, and being opened and closed in dependence upon the pressure of the hydraulic fluid in the metering chamber of the second hydraulic ram. This valve prevents unrequired extension of the second hydraulic ram if the hydraulic valve were to fail. Thus, the provision of the first hydraulic control valve further increases the functional reliability of the hydraulic control arrangement, and ensures that, when the second hydraulic ram is the advance ram of a roof bar extension, the roof bar extension cannot be extended so far that collision with a winning machine can occur. Advantageously, the first hydraulic control valve is a hydraulically-operated valve which has a hydraulic control line connected to the line which interconnects the two metering chambers. Thus, the first hydraulic control valve is opened only when the pressure of hydraulic fluid in the hydraulic system constituted by the interconnected metering chambers has reached a predetermined level.
Advantageously, a second hydraulic control valve is arranged in the hydraulic fluid supply line, the second hydraulic control valve being a mechanically-operated control valve, and being effective to open and close the hydraulic fluid supply line to the flow of hydraulic fluid from the high-pressure line.
Preferably, the arrangement further comprises a manually-actuated hydraulic control valve for controlling the extension and retraction of the second hydraulic ram. Advantageously, the manually-actuated hydraulic control valve controls the flow of hydraulic fluid between the high-pressure and return lines and hydraulic lines leading to the two working chambers of the second hydraulic ram. In this case, the arrangement may further comprise a control device for controlling the first hydraulic control valve. Conveniently, the control device includes a non-return valve which is connected to the line which interconnects the two metering chambers so that, when said non-return valve is open, the line interconnecting the two metering chambers (and hence the hydraulic control line associated with the first hydraulic control valve) is connected to the return line, whereby the first hydraulic control valve is closed to block the flow of hydraulic fluid from the high pressure line along the hydraulic fluid supply line. The control device may be provided with a manually-actuated switching member by means of which the control device is actuated, and the hydraulic lines connecting the working chambers of the second hydraulic ram to the manually-actuated hydraulic control valve may include respective hydraulically-operated, non-return valves.
There may be a plurality of second hydraulic rams, the metering chamber of each of which is connected to the metering chamber of the first hydraulic ram. Advantageously, the volume of the annular working chamber of the first hydraulic ram is at least equal to the volume of the annular working chamber of the second hydraulic ram(s).
In a preferred embodiment, the arrangement further comprises a third hydraulic ram, the third hydraulic ram having cylindrical and annular working chambers which are pressurisable in dependence upon the pressurisation of one of the working chambers of the first hydraulic ram.
Advantageously, the arrangement further comprises a low-pressure hydraulic fluid supply line, the cylindrical working chamber of the third hydraulic ram being connected to the low-pressure line via a hydraulic line which includes a hydraulically-actuated control valve, said control valve being provided with a hydraulic control line which is connected to the cylindrical working chamber of the first hydraulic ram. Conveniently, the cylindrical working chamber of the third hydraulic ram is connected to the high-pressure line via a hydraulic line containing a pilot-operated control valve. Preferably, the pilot-operated control valve is a 3/3-way control valve whose input side is connected to the high-pressure line and to the return line.
The invention also provides a roof support unit for a mineral mining installation, the roof support unit comprising a floor sill, a roof bar supported above the floor sill, a roof bar extension associated with the roof bar, and a hydraulic control arrangement as defined above, the first hydraulic ram of the hydraulic control arrangement being arranged to advance a conveyor section relative to the roof support unit, and the second hydraulic ram of the hydraulic control arrangement being arranged to advance the roof bar extension with respect to the roof bar.
Advantageously, the third hydraulic ram is arranged to brace the roof bar extension against the roof of a mine working.
Preferably, the second hydraulic control valve is arranged to close the hydraulic fluid supply line when the roof bar extension is inclined to the roof bar at a predetermined angle. This contributes to the functional reliability of the hydraulic control arrangement, since the automatic advance of the roof bar extension is immediately inhibited if, because of, for example, material breaking away from the roof, the roof bar extension asumes an angle of inclination at which there is a risk of collision with a winning machine moving along the mineral face.
The invention further provides a mineral mining installation comprising a conveyor, and a plurality of roof support units positioned side-by-side along the goaf side of the conveyor, wherein each of the roof support units is as defined above.
The invention also provides a hydraulic ram comprising a cylinder, a piston reciprocable within the cylinder, and a piston rod fixed to the piston, the hydraulic ram having a cylindrical working chamber and an annular working chamber positioned on opposite sides of the piston, and the piston rod constituting the cylinder of a metering ram, a metering piston being reciprocable within the cylinder of the metering ram to define a metering chamber therewithin, wherein a hydraulic valve is positioned in the end wall of the cylinder that defines part of the cylindrical working chamber, the hydraulic valve controlling the supply of pressurised hydraulic fluid to the cylindrical working chamber, and the hydraulic valve being actuated by movement of the metering piston towards said end wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic representation of the advance ram of a mine roof support unit, a ram for advancing an extension of a mine roof support unit roof bar, and a simplified hydraulic circuit diagram; and
FIG. 2 is a view similar to FIG. 1, but showing a more advanced hydraulic circuit diagram.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows a hydraulic advance ram 1 of a mine roof support unit (not shown), and a hydraulic ram 2 which is used for advancing a forward extension (not shown) of the roof bar of that roof support unit. The forward extension is slidably supported by the roof bar, which in turn is supported above a floor sill by means of hydraulic props. The roof support unit is positioned side-by-side with other roof support units on the goaf side of a longwall conveyor (such as a scraper-chain conveyor) in a longwall mine working.
In the illustrated arrangement, the advance ram 1 forms part of a known type of advance mechanism which includes relay rods connected between the roof support unit and the conveyor. Retraction of the advance ram 1 advances the conveyor towards the face of the longwall working by way of the relay rods; and extension of the advance ram advances the roof support unit in a follow-up step, the conveyor being used as an abutment for the advance of the roof support unit.
The advance ram is constituted by a cylinder 3, a piston 4 which is slidably guided within the cylinder, and a piston rod 5 fixed to the piston. The piston rod 5 has an axially-extending bore, and so constitutes the cylinder of a metering ram. The metering ram has a metering piston 7, which acts within the bore of the piston rod 5 to define a metering chamber 6. The metering piston 7 extends through, and is sealed off from the piston 4. The metering piston 7 is fixed to the base 8 of the advance ram 1. The metering chamber 6 is connected to the free end of the piston rod 5 by an axially-extending bore 9. The bore 9 has a smaller diameter than the bore defining the metering chamber 6, and is connected to a hydraulic line 10. The line 10 is connected to a hydraulic return line 12 by way of a non-return valve 11. A pressure-relief valve 13 is also connected to the line 10.
The ram 2 is constituted by a cylinder 14, a piston 15 which is slidably guided within the cylinder, and a piston rod 16 which is connected to the roof bar extension. The piston rod 16 has an axially-extending bore, and so constitutes the cylinder of a metering ram. The metering ram has a metering piston 18 which acts within the bore of the piston rod 16 to define a metering chamber 17. The metering piston 18 extends through, and is sealed off from, the piston 15. The metering piston 18 passes through the cylindrical working chamber 19 of the ram 2 towards the base 21 of this ram. The metering chamber 17 is connected to the free end of the piston rod 16 by an axially-extending bore 20. The bore 20 has a smaller diameter than the bore defining the metering chamber 17, and is connected to the line 10. The metering chamber 6 of the advance ram 1 is, therefore, in continuous hydraulic communication with the metering chamber 17 of the ram 2, by way of the line 10.
A mechanically-actuated, spring-loaded, non-return valve 22 is arranged in a bore in the base 21 of the ram 2, the bore leading to the working chamber 19 of the ram 2. A hydraulic line 23 leads away from the mouth of this bore. The valve 22 has a closure member in the form of a ball. The valve 22 is normally held in the closed position by the pressure of hydraulic fluid in the line 23. In order to open the valve 22, its ball is lifted from its seat, in opposition to this pressure, by the piston rod 18 via a rod 24 (or other actuating member) which projects into the working chamber 19. Thus, the working chamber 19 of the ram 2 can be charged with hydraulic fluid from the line 23, so as to extend the ram 2, and so advance the roof bar extension towards the face.
The advance ram 1 is provided with a hydraulic control valve 25, which can be actuated either manually or automatically. The input side of the control valve 25 is connected to a hydraulic pressure line P and to a hydraulic return line R. The output side of the control valve 25 is connected to the cylindrical working chamber 28 and the annular working chamber 29 of the advance ram 1 by lines 26 and 27 respectively. A similar hydraulic control valve 30 is associated with the ram 2, the input side of the control valve 30 being connected to the pressure line P and the return line R; and the output side being connected, via respective lines 31 and 32, to the cylindrical working chamber 19 and the annular working chamber 33 of the ram 2.
In order to advance the longwall conveyor, the annular working chamber 29 of the advance ram 1 is charged with the pressurised hydraulic fluid, via the control valve 25, so that the piston 4 moves into the cylinder 3. As this happens, the metering piston 7 displaces a certain quantity of hydraulic fluid from the metering chamber 6 into the metering chamber 17 of the ram 2, and thus forces the metering piston 18 towards the base 21 of the ram 2. The metering piston 18 applies thrust to the rod 24 of the valve 22. This opens the valve 22 and establishes communication with the line 23. As a result, the piston 15, together with the piston rod 16, is moved out of the cylinder 14 to advance the roof bar extension towards the face. As the piston 15 moves out, the volume of the metering chamber 17 increases, so that the metering piston 18 moves away from the rod 24 of the valve 22. Consequently, the valve 22 closes again, under the pressure of the hydraulic fluid in the line 23. The metering chamber 17 of the ram 2 has a cross-section coresponding to that of the metering chamber 6 of the advance ram 1. The working stroke of the metering piston 18 is, therefore, equal to the working stroke of the metering piston 7. This ensures that, when the advance ram 1 is retracted (that is to say when the longwall conveyor is advanced), the metering piston 18 of the ram 2 executes the same working stroke as the metering piston 7.
The metering piston 18 thus holds the valve 22 in the open position over a distance of travel that coresponds to the retraction stroke of the advance ram 1. This ensures that the ram 2 executes the same working stroke as the advance ram 1.
In order to advance the roof support unit, in a follow-up step, after the longwall conveyor has been advanced, the cylindrical working chamber 28 of the advance ram 1 is charged with pressurised hydraulic fluid via the control valve 25, so tht the piston 4 moves out of the cylinder 3. As this happens, the metering chamber 6 is filled with pressurised hydraulic fluid from the return line 12, via the non-return valve 11 which is now open. The ram 2 is extended in a similar manner with the aid of its control valve 30. The pressure relief valve 13 is effective to bleed off excess pressure from both the metering chambers 6 and 17.
The more advanced hydraulic circuit diagram shown in FIG. 2 represents a preferred form of hydraulic control means. The hydraulic circuit of FIG. 2 is basically a more complex version of the circuit of FIG. 1, so corresponding parts have been given the same reference symbols.
Referring now to FIG. 2, the input side of a multiway contol valve 25, which is a manually-operable control valve, is connected to a high-pressure line P, a return line R and a low-pressure line ND. The low-pressure line ND is used to retract the advance ram 1 in order to advance the conveyor, whereas the high-pressure line P is used to extend the advance ram in order to advance the roof support unit in a follow-up step. A manually-operable, multi-way control valve 30 is associated with the ram 2, the input side of the control valve 30 being connected only to the high-pressure line P and the return line R. The valve 22, which is fitted in the base 21 of the ram 2, is provided with a spring 34 which biasses the closure member (ball) against its valve seat. In order to open the valve 22, an actuating member (rod) 24, which projects into the working chamber 19 of the ram 2, is again provided, and this is actuated by the metering piston 18 of the ram 2. Control valves 35 and 36 are arranged in series in the line 23 connecting the valve 22 to the high-pressure line P. The control valve 35 is a hydraulically-operated control valve, which is normally closed (see FIG. 2) by the biassing force of a spring. In this position, (position o), the control valve 35 prevents the flow of pressurised hydraulic fluid along the line 23. The control valve 35 can be opened (to position a) by the pressure of hydraulic fluid in a control line 38. The control line 38 connects the control valve 35 to the line 10 which connects the metering chamber 6 of the advance ram 1 to the metering chamber 17 of the ram 2.
The control valve 36 is a mechanially-operated control valve, which is biassed towards a closed position by the force of a spring 40. The control valve 36 is normally held open by a plunger 39, so as to permit flow of pressurised hydraulic fluid along the line 23 (see FIG. 2). The plunger 39 is operated by a component 41 of the roof support unit. For example, the component 41 could be the goaf shield or the roof bar of the roof support unit. The arrangement is such that hydraulic fluid flows through the control valve 36 as long as the roof bar extension associated with the ram 2 does not exceed a predetermined angle of inclination relative to the floor of the mine working. If the roof bar extension did assume an excessive angle of inclination, there could arise the danger of a winning machine (such as a coal plough) colliding with the roof bar extension as it moved along the mineral face. When the angle of inclination of the roof bar extension exceeds the predetermined angle, the plunger 39 is arranged to contact a narrow cam portion 42 of the component 41. This releases the plunger 39, so that the control valve 36 is closed by the force of the spring 40. The control valve 36 then blocks the flow of hydraulic fluid along the line 23, and so prevents the extension of the ram 2, and the advance of the associated roof bar extension.
The control valve 25 is a 5/3-way valve having switching positions o, a and b. If the control valve 25 is switched from the illustrated position o into the position a, the annular working chamber 29 of the advance ram 1 is connected to the low-pressure line ND, and the cylindrical working chamber 28 of the advance ram is connected to the return line R. Consequently, the advance ram 1 is retracted, and the conveyor is thereby advanced towards the mineral face. As the advance ram 1 is retracted, pressurised hydraulic fluid is forced out of the metering chamber 6 and into the metering chamber 17 of the ram 2, via the line 10. This causes the metering piston 18 to move towards the rod 24 and, in so doing, opens the valve 22 against the biassing force of the spring 34. As this happens, hydraulic pressure builds up in this system, and this is applied, via the control line 38, to the control valve 35. When this pressure reaches a predetermined level, the control valve 35 is switched from the illustrated position o (in which it prevents flow of pressurised hydraulic fluid along the line 23) into the position a, so that hydraulic fluid can flow to the valve 22 of the ram 2. Consequently, as the valve 22 is open, pressurised hydraulic fluid can pass from the highpressure line P, through the line 23 and the open control valves 35 and 36, and into the working chamber 19 of the ram 2. While the advance ram 1 is in the extended position, the hydraulic pressure is maintained in the metering chambers 6 and 17 and the line 10, so that the valve 22 remains open. Consequently, the piston rod 16 of the ram 2 moves out of the cylinder 14 to the same extent as the piston rod 5 of the advance ram 1 moves into the cylinder 3. As soon as the pressure in the metering chambers 6 and 17 (and hence also in the line 10 and the control line 38) diminishes, the control valve 35 is automatically switched into the position o by the biassing force of the spring 37, and so the supply of pressurised hydraulic fluid to the valve 22 is interrupted. The control valve 35 thus provides additional safety in the event of the valve 22 failing to operate. In such a case, the control valve 35 prevents undesirable extension of the roof bar extension associated with the ram 2.
As the ram 2 is extended, pressurised hydraulic fluid is forced out of its annular working chamber 33 and into the return line R, via the line 32, a valve device 43 and the open control valve 30. The valve device 43 is incorporated in both the lines 31 and 32, which lead to the output side of the control valve 30. The valve device 43 comprises two hydraulically-actuated, spring-loaded non-return valves 44 and 45; the valve 44 being contained in the line 32, and the valve 45 being contained in the line 31. The non-return valve 44 can be opened by the pressure of hydraulic fluid in either the hydraulic control line 38 or the line 31. Similarly, the non-return valve 45 can be opened by the pressure of hydraulic fluid in either the line 32 or a hydraulic control line 46. The control line 46 is connected to the line 26 which connects the output side of the control valve 25 to the working chamber 28 of the advance ram 1. As long as the pressure in the control line 38 holds the control valve 35 in the position a, the non-return valve 44 is also held open, so that the pressurised hydraulic fluid displaced from the ram 2 can flow away through the line 32. If the pressure in the control line 38 drops, the valve 44 closes, and so shuts off the discharge of hydraulic fluid from the annular working chamber 33 of the ram 2.
The control arrangement described above ensures that the ram 2 is extended automatically once the advance ram 1 is retracted. However, the contorl valve 30 and the lines 31 and 32 can also be used to extend or retract the ram 2 manually. For this purpose, a control device 47 is provided. The device 47 includes a mechanically-operated, spring-loaded, non-return valve 48 which is connected to the control line 38, via a line 49. The valve 48 is also connected to the line 26, via a line 49. The valve 48 is also connected to the line 26, via a line 50. The valve 48 is normally in the closed position, and it can be opened by means of a manually-operable switching member 51, for example a button, or a lever. When the switching member 51 is actuated, the valve 48 opens, so that the control line 38 communicates, via the lines 49 and 50 with the line 26 which establishes connection with the return line R in the switching position o of the control valve 25. Actuation of the switching member 51, therefore, causes the control line 38 (and the hyraulic system 6, 10 and 17 connected thereto) to be depressurised, so that the control valve 35 is switched into the position o, and the flow of pressurised hydraulic fluid along the line 23 is blocked. If the control valve 30 is then moved into the position a, communication between the high-pressure line P and the working chamber 19 of the ram 2 is established by way of the line 31, so tht the ram 2 can be extended manually. Pressurised hydraulic fluid is then discharged from the annular working chamber 33, and into the return line R via the ine 32, the open valve 44 and the control valve 30. The valve 44 is opened by the hydraulic pressure in the line 31. Similarly, by manually moving the control valve 30 to the position b, the ram 2 can be retracted by pressurised hydraulic fluid flowing to the working chamber 33 along the line 32; and the valve 45 is opened, by the hydraulic pressure in the line 32, to permit hydraulic fluid discharged from the working chamber 19 to flow to the return line R.
If the valve 48 is then closed, with the aid of the actuating member 51, the automatic synchronised control arrangement is switched in again.
The control device 47 also includes pressure-relief valves 13 as well as a pair of opposed non-return valves 52a and 52b. The non-return valves 52a, and 52b open and close in opposite directions, and are incorporated in a line 52 connecting the lines 27 and 32. During extension of the advance ram 1, the non-return valve 52a is hydraulically actuated by way of the line 50. Consequently, hydraulic fluid flows out of the annular working chamber 29 of the advance ram 1, along the lines and 27 and 32, and into the annular working chamber 33 of the ram 2, so that the latter is retracted in synchronism with the extension of the advance ram 1.
It will be apparent that the movements of the advance ram 1 and the ram 2 can be synchronised in a reliable manner with the aid of the control means described above. Moreover, the arrangement may be modified in such a manner that a plurality of (for example, two) rams 2 are associated with a common advance ram 1. In this case, the metering pistons 18 of the rams 2 are actuated in the manner described, by the metering piston 7 of the common advance ram 1. The volume of the annular working chamber 29 of the advance ram 1 is equal to, or greater than, the volume of the annular working chamber(s) 33 of the associated ram(s) 2. Accordingly, the volume of the cylindrical working chamber 28 of the advance ram 2 is greater than the volume of the annular working chamber(s) 33. Furthermore, the plunger-operated valve 22 could be replaced by, for example, a magnetically-operated valve.
At least one hydraulic pivot ram may be provided for the roof bar extension associated with the ram 2, the pivot ram(s) enabling the roof bar extension to be swung upwards towards, and braced against, the roof of the working. A pivot ram of this kind is designated by the numeral 53 in FIG. 2. The ram 53 has a cylindrical working chamber 57, which is connected, via a hydraulic line 58, to the low-pressure line ND; the annular working chamber 59 of the ram 53 being connected to the return line R. A hydraulically-operated, spring-loaded, nonreturn valve 54 is provided in the line 58. The valve 54 is normally closed, and may be opened by the pressure of hydraulic fluid in a control line 55, which is connected to the line 26 leading to the working chamber 28 of the advance ram 1. A pilot-operated control valve 56 is associated with the ram 53. This valve 56 is a 3/3-way valve, whose input side is connected to the return line R and to the high-pressure line P, and whose output side communicates, via a line 60, with the line 58 downstream of the valve 54.
The arrangement is such that, during the follow-up advance movement of the roof support unit (that is to say during extension of the advance ram following pressurisation of the working chamber 28), the value 54 is opened by the pressure of hydraulic fluid in the control line 55, so that the working chamber 57 of the ram 53 is connected to the low-pressure pipe ND. The result of this is that the roof bar extension of the roof support unit remains braced against the roof of the working. The roof bar itself, however, is slightly retracted by relaxing the pressurisation of the props of the unit. Consequently, as the roof support unit is advanced, its roof bar is guided into the roof bar extension, which is braced against the roof. On completion of the follow-up advance step, and after the props of the roof support unit have been repressurised, the ram 53 can again be charged, via the pilot valve 56, with hydraulic fluid from the high-pressure line P.
The arrangement described above could be modified by replacing the pilot-operated control valve 56 by a hydraulically-operated control valve. In this case, the roof bar extension would be pressed against the roof by the ram 53, normally by a high force corresponding to the pressurised hydraulic fluid in the high-pressure line P. This high force would be reduced by connecting the working chamber 57 of the ram 53 to the low-pressure line ND, when the roof bar extension is to be extended: or, when the roof support unit is advanced, the roof bar extension is retracted.
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A hydraulic control arrangement comprises a first hydraulic ram, a second hydraulic ram, and a hydraulic control circuit associated with the first and second hydraulic rams. Each of the hydraulic rams has a cylinder, a piston reciprocable within the cylinder, and a piston rod fixed to the piston. Each of the hydraulic rams has a cylindrical working chamber and an annular working chamber positioned on opposite sides of its piston. The piston rod of each hydraulic ram constitutes the cylinder of a respective metering ram, a respective metering piston being reciprocable within the cylinder of each metering ram to define a metering chamber therewithin. The hydraulic control circuit includes a line, which interconnects the two metering chambers, and a hydraulic valve positioned in a hydraulic fluid supply line leading to the cylindrical working chamber of the second hydraulic ram. The metering piston of the second hydraulic ram controls the hydraulic valve, thereby controlling the flow of hydraulic fluid to the cylindrical working chamber of the second hydraulic ram.
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FIELD OF THE INVENTION
[0001] The invention relates to a control system for controlling safety-critical processes in general and to a control system with communication via a fieldbus specifically.
BACKGROUND OF THE INVENTION
[0002] For several years, fieldbus systems have been used more and more frequently in the field of automation, said fieldbus systems being connected to input/output appliances and to a superordinate control device. One example of this is the interbus based on the EN 50254 standard.
[0003] Such fieldbus systems typically comprise a multiplicity of signal units or bus users, connected to the processes which are to be controlled, and a bus master which controls frame-based communication using “fieldbus messages” via the fieldbus.
[0004] Such fieldbus systems allow the cabling complexity to be significantly reduced, since copper lines can be saved. However, one problem is that of designing serial fieldbus systems such that they meet safety-related demands. Such safety-related functions may be, by way of example, a stop function or an emergency-off function which allows the fieldbus system to be put into a safe state.
[0005] In earlier fieldbus systems, the control signals required for this purpose are respectively transmitted between controllers and bus users via separate lines, i.e. not via the fieldbus itself.
[0006] Other known approaches involve all those devices which are intended to perform safety functions being designed with an appropriate level of redundancy. In this regard, DE 40 32 033 A1 may be mentioned, for example, which discloses an electrical automation system (for a technical installation) which is of redundant design at least in part. In this system, safety-related signals are triggered in duplicate and are transmitted on at least two mutually independent signal paths to at least partially redundant users which evaluate the safety-related signals.
[0007] DE 37 06 325 C2 describes a control and data network in which safety-related devices are connected to a separate emergency-stop control line in order to be able to communicate with one another.
[0008] These known techniques have the attendant drawback that either a large number of redundant components is required or parallel single lines are needed in order to transmit the additional control signals.
[0009] The patent DE 197 42 716 C2 now discloses a control and data transmission installation in which safety-related devices can communicate with one another via the fieldbus and each output is connected via a switch to a bus interface device and directly to the safety-related device of the respective bus user and/or of a master control device.
[0010] Although this installation already has the advantage that safe control is effected using the fieldbus, the invention described below is intended to improve it further.
[0011] A further control system for controlling safety-critical processes is proposed in the patent DE 199 28 517 C2, in which a safe control unit is connected to the fieldbus. This system has drawbacks in a variety of respects, however.
[0012] Message data which are addressed to a signal unit must first be produced and must then be replaced with failsafe message data again by the safe control unit. This procedure appears inefficient.
[0013] In addition, data can be transmitted between the bus master and the safe control unit only via the active fieldbus so that the control unit can perform processing. This is considered to be disadvantageous, since this communication is possible only when the fieldbus is active.
[0014] Furthermore, transmission via the fieldbus is relatively slow and diagnosis options are disadvantageously available under very great restrictions, if at all.
GENERAL DESCRIPTION OF THE INVENTION
[0015] The invention is therefore based on the object of improving a control system for safety-critical processes such that efficient communication between the safe control units and the bus master is achieved.
[0016] A further object of the invention is to provide a control system of this type which opens up improved diagnosis and reaction options, particularly in the event of error.
[0017] Another object of the invention is to provide a control system of this type which ensures a high level of safety.
[0018] Yet a further object of the invention is to provide a control system of this type which avoids the aforementioned drawbacks, the flexibility of the system being able to be increased by the ability to integrate safety-related devices into the system easily and inexpensively.
[0019] The object of the invention is achieved in surprisingly simple fashion merely by the subject matter of the independent claims. Advantageous developments of the invention are defined in the subclaims.
[0020] In line with the invention, the control and data transmission system is set up to control safety-critical processes and comprises a fieldbus, particularly a serial fieldbus, and a bus master connected to the fieldbus for the purpose of controlling the communication via the fieldbus.
[0021] The system also comprises at least one safe signal unit or a safe bus user which, during operation, is linked to or connected to at least one of the safety-critical processes via I/O channels.
[0022] Preferably, the system comprises a plurality of signal units, particularly safe and non-safe signal units, the safe signal units being linked to the safety-critical processes, and the non-safe signal units being linked to non-safe processes.
[0023] In addition, the bus master and the signal units are connected to one another, particularly in series, via the fieldbus, and the fieldbus is used to effect circulating communication or message traffic between the bus master and the signal units.
[0024] Also, a safe first control unit, particularly with an integrated safe controller, is included which is used to control the safety-critical processes. For this purpose, the safe signal units and the safe control unit each have safety-related devices.
[0025] This makes provision for failsafe communication in order to control the safety-critical processes. It is obvious to a person skilled in the art that absolute failsafety cannot be achieved, and therefore failsafe communication is understood to mean communication which ensures increased failsafety as compared with non-safe communication.
[0026] In line with the invention, the safe control unit or safe control device, particularly the safety-related device in the safe control unit, is connected to the bus master independently of the fieldbus or not via the fieldbus and communicates with said bus master independently of the fieldbus, in particular bidirectionally.
[0027] Since the first control unit is not connected directly to the fieldbus, but rather is connected to the bus master, preferably directly by means of a first interface, the failsafe data can be sent from the first control unit to the bus master via the first interface, preferably a “multiport memory interface” which is present anyway. This interface may comprise one or more ethernet interfaces, in particular fast-ethernet interfaces as well.
[0028] Next, the bus master now inserts the failsafe data just into the fieldbus messages or the summed frame of the fieldbus communication in order to send the data to the signal units. Accordingly, the safety-related data are sent to the appropriate signal units at data level and hence the originally non-safe bus protocol is made “safe” at data level.
[0029] The communication between the safe control unit and the bus master via the parallel or non-serial multiport memory interface is considerably more efficient and affords, by way of example, more diagnosis options than communication via the fieldbus.
[0030] In other words, the safe control unit produces the safety-oriented protocol and sends it to the bus master. The communication on the fieldbus is then handled, in particular, such that the safety-oriented protocol is inserted as user data into the fieldbus messages by the bus master directly and/or without dedicated safety-related functionality and is transmitted to the safe signal units.
[0031] Hence, in comparison with the solution proposed in the document DE 199 28 517 C2, exactly the opposite course is taken, namely connecting the safe control unit to the bus master directly and not via the fieldbus. The invention thus avoids drawbacks which were accepted by this system.
[0032] The present invention admittedly does not allow an existing control system to be retrofitted as easily as is achieved by connecting the safe control unit to the fieldbus in line with DE 199 28 517 C2, which means that at first glance the impression of a backward step in comparison therewith might be obtained.
[0033] However, it may seem surprising to a person skilled in the art that other substantial advantages over this solution can be obtained which possibly far outweigh existing drawbacks.
[0034] In particular, much tighter and faster communication between the safe control unit and the bus master is made possible.
[0035] So, according to one embodiment of the invention, a connection between the safe control unit and the bus master is established by means of an ethernet connection, particularly also a fast-ethernet-connection with accordant interfaces.
[0036] In addition, the actual communication between the control unit and the bus master is safe.
[0037] Furthermore, flexible reaction to errors is made possible to the extent that not every error needs to result directly in the system being switched off, but rather the system can continue to be operated using an emergency program in the event of predetermined errors.
[0038] This method which is independent of the fieldbus or network thus makes the safety engineering system more efficient and much safer than in the previously known control systems.
[0039] In the case of frame-based transmission via the fieldbus, the bus master inserts, by way of example, the failsafe data from the safe control unit into the fieldbus frame in order to send the data to the signal unit.
[0040] This field-bus-independent communication between the safe control unit and the bus master has a number of advantages at the same time.
[0041] Firstly, it is advantageous that data interchange between the safe control unit and the bus master can also take place when the communication via the fieldbus is not active. This may be used, by way of example, to the effect that the safe control unit controls the bus master such that the latter is only (and only then) put into operation when a predetermined functionality, e.g. a safe operating condition, of the safe control unit is a certainty.
[0042] By way of example, the bus master is not put into operation until the safe control unit has successfully completed a self-test. The self-test is performed, in particular automatically, whenever the safe control unit has been turned on (“powerup”). Preferably, the bus master is deactivated by the safe control unit during the self-test or is switched to an inoperable state, e.g. to a reset state.
[0043] Alternatively, or in addition, the bus master may likewise perform a self-test after turn-on, that is to say particularly after the self-test in the control unit, which means that the safety of the system is increased further.
[0044] In other words, the bus master is not switched to an operating condition until after the successful self-test in the first control unit and/or in the bus master. The effect which may be achieved thereby is that the communication via the fieldbus is not actually started at all if there is a malfunction in the bus master or in the safe control unit. A further advantage is if the bus master is active only for as long as the first control unit is active.
[0045] Preferably, the bus master and the first control unit are separate components which are connected to one another via the first field-bus-independent interface. In accordance with an advantageous embodiment, the bus master and the first control unit communicate via an ethernet-protocol. Inter alia, an ethernet—oder fast-ethernet-connection makes it possible to integrate the first control unit and/or the bus master into a further present or to be established network. As well, the communication via an ethernet protocol, particularly by means of fast ethernet may be considerably faster compared to a common fieldbus.
[0046] The serial fieldbus is preferably an interbus, and the bus master is preferably a standard G4 bus master, that is to say a non-safe bus master based on the EN 50254 standard.
[0047] As already mentioned above, a G4 bus master of this type has a “multiport memory interface” which is used to connect the safe control unit to the bus master. Accordingly, the data transmission between the bus master and the safe control unit takes place via the multiport memory interface, which may also comprise an ethernet interface, and not via the fieldbus.
[0048] In this case, particularly the first control unit provides safe control data and a safety protocol for the safe communication and sends the safe control data and a safety protocol to the bus master. The bus master in turn puts the safe control data and the safety protocol, particularly without changing this information, into the correct fieldbus messages as user data. For the purpose of connection to the fieldbus, the bus master has a second interface which is used to send data via the fieldbus, the first and second interfaces preferably being isolated from one another.
[0049] The features of the system which are described above advantageously allow a standard, generally non-safe bus master to be used for various safety-related controllers.
[0050] According to a further advantageous embodiment of the invention, the fieldbus is designed as an ethernet bus, particularly advantageous also as a fast-ethernet bus. Using such a bus, very high data transmission rates—approximately 100 Mbit/s are possible by fast ethernet transmission—may be achieved. A further advantage, inter alia, is the facile integration into existent networks.
[0051] A further preference is an embodiment in which the safe control unit is connected to the bus master upstream of the fieldbus connection, which means that safety-related data are processed in advance.
[0052] With particular preference, the bus master and the safe control unit are integrated in a common interface module. In other words, the safety engineering system provided by the safe control unit is integrated into the bus master interface. This allows, inter alia, the safe control unit to test the software in the interface module which contains the bus master and to start the safe control unit or control of the safety-critical processes only if the test result is positive. For this purpose, the bus master can be controlled by the safe control unit.
[0053] The interbus executes communication via the fieldbus cyclically. Preferably, this involves each cycle having been divided into a processing cycle in the safe control unit and a bus cycle in which data are transferred to the signal unit via the fieldbus. A further preference is that the processing cycle and the bus cycle are executed continuously and in sync.
[0054] Since many applications involve controlling a multiplicity of processes, and the processes also include non-safety-critical processes, the system preferably comprises not only the safe control unit but also at least one second non-safe control unit for the non-safe control of non-safety-critical processes. This non-safe control also preferably takes place in sync.
[0055] In this case, the bus master uses a third interface, for example, to communicate with the second control unit, the first, second and/or third interfaces being respectively isolated from one another. In this context, provision may be made for the first and second control units to interchange data with one another, specifically even, if appropriate, when the bus master has been deactivated. The third interface may as well comprise an ethernet interface, which ma as well, e.g., be a fast-ethernet interface for communication of the bus-master with the second control unit by means of an ethernet protocol. Further, the second control unit and the first control unit may intercommunicate by means of an ethernet connection if the first control unit is equipped with an ethernet interface, too.
[0056] The reason for one particular advantage of the invention is that the system may, under certain prerequisites, continue to be operated even when a malfunction arises. By way of example, preferably at least two operating conditions are defined, namely a first safe operating condition and a second operating condition, whose safety level is lower than that of the first operating condition. This second operating condition is an emergency operation program, for example. It involves the system being transferred to the second operating condition by the safe control unit when predetermined safety information is provided.
[0057] On the one hand, the predetermined safety information may be sent by the safe signal units via the fieldbus and evaluated by the safe control unit. If the safe control unit establishes that there has been a malfunction, it transfers the system to the second operating condition.
[0058] On the other hand, the predetermined safety information may alternatively be generated in the safe control unit itself.
[0059] By way of example, the safe control unit has at least two processors (CPUs) which are regularly aligned with one another in order to increase the level of safety. If one of the two processors fails, the system is still able to continue operation at a lower safety level, i.e. in the second operating condition. This allows the system to use an emergency operation mode, particularly one which has a time limit, so that the system can be run down under control or a faulty component can be replaced the first time that there is a change of shift, for example.
[0060] To prevent permanent operation in the second operating condition, the control system is automatically deactivated or switched to an inoperable state by the first control unit, preferably after a predetermined period of time has elapsed.
[0061] The invention also relates to the safe control unit and the interface module with the bus master and the safe control unit, set up for use in the inventive control system.
[0062] The invention is explained in more detail below using exemplary embodiments and with reference to the drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0063] In the drawing:
[0064] FIG. 1 shows a schematic overview of the inventive control system,
[0065] FIG. 2 shows a block diagram of the inventive control system,
[0066] FIG. 3 shows a schematic illustration of a plurality of cycles in the transmission via the interbus and
[0067] FIG. 4 shows a more detailed illustration of an interbus cycle as shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0068] FIG. 1 shows a control system 1 having a bus master 2 which controls the communication with a multiplicity of signal units, also called bus users, via a fieldbus 4 .
[0069] The signal units include both safe and non-safe signal units 5 , 7 , the safe signal units 5 being controlled by a control unit with a safety function 8 (safe control unit 8 for short), and the non-safe signal units 7 being controlled by a control unit without a safety function 10 (non-safe control unit 10 for short).
[0070] The safe and non-safe control units are not connected directly to the fieldbus 4 , but rather directly to the bus master 2 by means of interfaces 12 , 14 which are separate from the fieldbus.
[0071] FIG. 2 shows a more detailed illustration of the control system 1 with three illustrative signal units.
[0072] The bus master 2 is a standard G4 bus master and is integrated together with the safe control unit 8 in an interface module 16 , which is in the form of a push-in module. In this example, the interface module 16 is an interbus interface module IBS S7 400 ETH S DSC/I-T. The serial fieldbus is thus in the form of an interbus based on the EN 50254 standard or based on DIN 19258. The safety engineering system is thus organized as an integral component of the interbus interface. According to another embodiment of the control system shown in FIG. 2 , the fieldbus 4 is designed as an ethernet bus. The ethernet bus may in particular be a fast-ethernet bus as well.
[0073] The G4 bus master 2 has a multiport memory interface which is functionally divided into the interface 12 for the control unit with a safety function 8 and the interface 14 for the control unit without a safety function 10 . These interfaces 12 , 14 permit respective bidirectional communication 18 , 20 between the safe control unit 8 and the bus master 2 , on the one hand, and between the non-safe control unit 10 and the bus master 2 , on the other. According to a development of this embodiment, the communication may be carried out via an ethernet protocol, whereby the interfaces 12 , 14 in this case are ethernet interfaces, accordingly.
[0074] In line with the invention, the processing by the control units 8 , 10 is initially independent of the fieldbus and in advance, since the control units 8 , 10 are connected to the fieldbus master 2 upstream of the fieldbus connection 22 .
[0075] With further reference to FIG. 2 , the bus master 2 has an interbus protocol master chip (IPMS) 24 . The IPMS protocol chip 24 has an RS422 driver 28 for the fieldbus signals connected to it by means of DC isolation, e.g. an optocoupler 26 .
[0076] The interface module 16 also has two connecting points for the circulating serial fieldbus 4 in the form of a remote interbus interface 22 , which in this case is in the form of a DSUB plug connector.
[0077] There is also a parameterizable bypass or a connection between the safe control unit 8 and the non-safe control unit 10 (not shown in the figure).
[0078] The bypass allows the non-safe control unit 10 and the safe control unit 8 to interchange data even without functionality of the IPMS protocol chip 24 .
[0079] In an emergency or in the event of a malfunction, the safe control unit may thus use the bypass to undertake the tasks of the non-safe control unit or control of the non-safe processes. A safe disconnection strategy (stop Kat 1 or 2) or an emergency operation functionality may also be implemented using this system.
[0080] This tighter synchronization of the components comprising the fieldbus master 2 , the safe control unit 8 and the non-safe control unit 10 advantageously allows more efficient execution and a higher level of diagnosis.
[0081] The safe signal unit 6 , a further safe signal unit 32 and a non-safe signal unit 34 are connected to the fieldbus 4 in series. The signal units 6 , 32 and 34 are also linked to processes 40 , 42 and 44 which are controlled and monitored by the control units 8 and 10 via the fieldbus 4 and the corresponding signal units 6 , 32 and 34 .
[0082] In this context, the processes 40 and 42 are safety-critical processes and the process 44 is a non-safety-critical process. The safe signal units 6 , 32 are, by way of example, safe slave modules SDIO 4 / 4 which respectively have a safety-related device 46 , 48 for handling the safe control of the safety-critical processes 40 , 42 .
[0083] A safety-critical process may be an emergency-off function or the monitoring of a safety cage, for example. It goes without saying that further signal units and processes may be connected to the fieldbus.
[0084] Again with reference to the interface module 16 , the latter is provided with the following mechanisms.
[0085] Starting up the fieldbus 4 and the safe controller 8 involves a reciprocal check being performed according to the following sequence:
The safe control unit 8 performs a self-test after powerup and, during this time, keeps the bus master 2 in the reset condition using the communication 18 taking place by the interface 12 , e.g. using a reset line. Only when the safe control unit 8 has been tested successfully is the bus master 2 put into operation. Hence, if the safe control unit 8 is removed or if it has a fault, the bus master 2 is prevented from starting up. When the safe control unit 8 has been tested successfully, the bus master 2 itself undergoes a self-test. Following a successful self-test in the bus master 2 , the latter sends its version identifier to the safe control unit. The output stage of the firmware in the interface module 16 is then tested by appropriate test means in the safe control unit 8 .
[0089] In addition, the safe control unit 8 is set up such that it takes on the activity only of bus masters which may contain functionalities with a safety capability.
[0090] Furthermore, the fieldbus 4 is activated only for as long as the safe control unit 8 is active.
[0091] This alone achieves a considerable safety gain, since multiple checking of the safety function is ensured.
[0092] With reference to FIGS. 3 and 4 , an additional increase in the safety and in the reaction speed attained in line with the invention is explained.
[0093] The reason for this is that during the system's runtime the fieldbus cycle and the safe control cycle are executed in sync. This means that the fieldbus 4 cannot run without permanent or continuous synchronization with the safe control unit 8 .
[0094] FIG. 3 shows a plurality of fieldbus cycles 50 for this. Each fieldbus cycle is divided into a processing cycle 52 for the safe control unit and an interbus I/O cycle 54 . In the interbus I/O cycle 54 , the data are transferred to the signal units 6 , 32 , 34 .
[0095] FIG. 4 shows a fieldbus cycle 50 or more precisely an interbus cycle in detail. In this context, the processing cycle 52 contains fields 106 , 132 and 134 , each field being respectively associated with one of the signal units 6 , 32 and 34 and containing the control or user data for the respective signal unit. Each field or user data field is in turn constructed from a plurality of bus messages, e.g. from three respective bus messages of one byte each.
[0096] The safe control unit 8 therefore provides user data and safety-protocol-related data at data level, the safety-protocol-related data being transported as user data via the fieldbus from the point of view of the bus master 2 . Hence, in particular, there is no safety-related interpretation by the bus master 2 itself. This has the advantage that a “non-safe” standard G4 bus master can be used.
[0097] In terms of the sequence and design of the fields, reference is made to the patent specification DE 197 42 716 C1 from the same applicant, the full scope of which hereby becomes the subject matter of this disclosure by way of reference.
[0098] In line with the invention, similar synchronization to that for the safe controller 8 may also be effected for the non-safe controller 10 . This function may be performed using a “dead man” signal (e.g. toggle bit) from the non-safe controller to the safe controller. This type of concatenation increases the transfer speed and the deterministics in the system 1 .
[0099] In addition, there may be provision for individual reprogramming of the safe controller 8 during the run time. With the direct integration and the connection to the non-safe controller 10 or a superposed network structure, it is possible to reach and take action on the safe controller 8 in all operating phases, particularly when the fieldbus 4 is not capable of running. Hence, simplified access to diagnosis data through to reprogramming are possible during the run time or while the network is stopped. In line with the system proposed in document DE 199 28 517 C2, this is possible only when the fieldbus is capable of running or possibly using an additional network connection on the safe controller.
[0100] In addition, the invention allows the organization of further safety-technical functionalities, which are possible only to a limited extent using a safety engineering system which is decoupled from the interface module 16 , through the concatenation of network or bus master 2 and the safe controller 8 .
[0101] Again with reference to FIG. 2 , the safe controller has two processors or CPUs 62 and 64 , each processor being associated with a particular safety-critical process. In this case, the processor 62 controls the processes 40 and 42 and the processor 64 likewise controls the processes 40 and 42 . If one of the two processors 62 or 64 on the safe controller 8 now fails or if the safety engineering system is disturbed, the safe controller 8 is set up such that it can continue to operate the control of the safety-critical processes 40 , 42 , possibly in interaction with the bus master, in an operating condition with a lower safety level, a “emergency operation program”.
[0102] In particular, reciprocal alignment takes place between the processors 62 and 64 and possibly further processors, the system 1 continuing to run in an emergency operation program if one of the processors 62 or 64 fails.
[0103] To this end, by way of example, parameterization is used in order to allow the safe control unit 8 to react to errors in the system. The text below illustrates three possible errors and the system reaction or function by way of example in this regard.
[0104] Error A: the non-safe controller 10 fails or malfunctions.
[0105] The system 1 reacts to the error A by virtue of the safe controller 8 undertaking at least part of the control function of the non-safe controller 10 .
[0106] To this end, information about the error or fault is sent to the safe control unit 8 from the non-safe control unit 10 . A reaction program then undertakes the desired activity.
[0107] Error B: the CPU 62 in the safe control unit 8 fails.
[0108] The safe control unit 8 is switched from the first to the second operating condition and continues to operate at a lower safety level.
[0109] In addition, information is sent to the safety-critical process 42 , which is controlled by the operational CPU 64 , indicating that an error has occurred. A reaction program then undertakes the desired activity, for example for a predetermined time.
[0110] Error C: the CPU 64 in the safe control unit 8 fails.
[0111] The safe control unit 8 is switched from the first to the second operating condition and continues to operate at a lower safety level.
[0112] The operation of the control system 1 is equivalent to that for error B.
[0113] Accordingly, in the event of part of the safety engineering system failing, the bus master 2 and the remaining partial operation of the safety engineering system can continue to operate the system 1 . The system 1 can thus continue to be operated even when the safety engineering system is operational only at a lower safety level.
[0114] The text below uses a practical example to explain the advantage of the safe control using such an emergency program or using operation with two operating conditions having different safety levels.
[0115] The system 1 is used to control an aerial cableway.
[0116] To date, failure of the safety engineering system has resulted in the cablecar gondola or transport stopping. The people being transported have then had to be rescued from the gondola from the ground or from the air. The risk created by the rescue, e.g. frostbite when the weather is adverse and long periods of waiting, danger caused by rescue attempts by the helicopter, is disproportionately high in this case.
[0117] The inventive solution reduces the likelihood of total failure. This is because the inventive system with the interface module 16 or network card with the two operating conditions described above permits continued operation at a lower safety level in the second operating condition, which means that it is at least possible to unload the cablecar. For this, provision may be made for operation at a lower safety level to have a time limit.
[0118] It is obvious to a person skilled in the art that the embodiments described above are to be understood by way of example, and that the invention is not limited thereto, but rather can be varied in diverse ways without departing from the spirit of the invention.
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There is provided a control system for controlling safety-critical processes that includes a fieldbus, a bus master for controlling a communication via the fieldbus, at least one signal unit for linking to at least one of the safety-critical processes, and a first control unit for controlling at least one of the safety-critical processes. The bus master and the at least one signal unit are connected to one another via the fieldbus to provide communication between at least one signal unit and the bus master. The at least one signal unit and the first control unit have safety-related devices. Failsafe communication is provided to control at least one of the safety-critical processes, and the first control unit is connected to the bus master independently of the fieldbus.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to provisional patent Application No. 60/717,715, entitled, “System and Methods for Initiating Communication between IM Clients and Mobile Clients” filed on Sep. 16, 2005, and to provisional patent Application No. 60/728,232, entitled, “System and Methods for Initiating Communication between IM Clients and Mobile Clients” filed on Oct. 19, 2005, each of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to computer-to-mobile communications, and more particularly to a systems and methods for initiating multimedia calls between Instant Messaging (IM) clients and mobile (wireless) communication clients.
BACKGROUND OF THE INVENTION
IM-to-mobile phone call services allow IM clients on various computer hardware and software platforms (e.g., ICQ™, Microsoft Network (MSN) Messenger™, Yahoo Messenger™, Skype™) to communicate with mobile systems on cellular (wireless) networks. Such services have been implemented, for example, by Skype Limited, under the SkypeOut™ brand name. However, any connection enabled by such services raises billing problems. Particularly, it raises the question of who should bear the cost of the communication—whether it should be the initiator of the call; the recipient; or both of them. In the case of both the initiator and the recipient bearing the cost, a further question is what portions of the cost should be borne by each.
Conventionally, billing of IM-to-mobile calls is achieved in a number of different ways. Under the MSN Messenger™ model, the IM client can send instant messages to cellular devices for free. The instant messages are then translated into Short Message Service (SMS) messages. In this case, the service costs are typically borne by the cellular operator, but the responses by the mobile client are always subject to payment. In other words, only one party to the communication is required to pay for its share. Under a second model, the cellular customer may also be subject to payment for incoming SMS messages. This service is for message exchange only.
Yet another billing model is provided by the Skype™ software. Using the software, a user of the SkypeOut™ service can initiate Public Switched Telephone Network (PSTN) voice calls or mobile (or cellular) voice calls to a standard handset in certain countries from his IM client. Unlike computer-to-computer IM communication services, users do have to pay for this kind of service. In addition, the IM users are required to register in advance and to provide credit card numbers as a condition for using the system.
Conventional billing solutions described above have certain drawbacks. Having the recipient of the call bear the costs of the communication under the MSN Messenger™ model may expose the recipient for payment for unsolicited calls, which may negatively affect the number of users wishing to connect to the service.
Having the initiator of the call bear the costs of the communication, fully or partially, is equally problematic. IM services are usually provided on the Internet for free, and hence users may be reluctant to bear the cost of such communication. Additionally, billing IM users requires registration and provision of billing methods (such as credit card details), which may negatively affect the number of users willing to join such service. Therefore, it is desirable to provide IM-to-mobile phone services without burdening the users with pre-registration requirements and/or costs on unsolicited messages or calls.
Another problem with conventional technology is that a mobile phone user is prevented from initiating IM communication with an IM user. More particularly, mobile phones do not include any mechanism through which a user can enter the IM address of the IM user. For example, mobile phones typically utilize E.164-based numbering mechanisms (i.e., using digits, * symbol, and # symbol) to setup a conversation (typically using the Q.931 protocol). Addressing in the IM space, and in the Internet in general, is done using Uniform Resource Identifier (URI) and/or Uniform Resource Locator (URL) types of addresses and/or email addresses (which use both letters and digits). This makes it impossible to enter an IM address in typical mobile phones. Moreover, even if E.164-based numbering mechanisms could be used to identify IM address, the volume of IM addresses would require very long E.164 addresses. Therefore, it is desirable to provide IM-to-mobile phone services where both the IM user and the mobile phone user can initiate calls. Embodiments of the present invention are directed to these and other important objectives.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide systems and methods for initiating communication between IM clients and mobile phones. Using various embodiments of the present invention, IM-to-mobile phone services can be provided without requiring an IM user to pre-register and without burdening the mobile phone users with unsolicited messages or calls. Various embodiments of the present invention also enable mobile phone users to initiate communication with IM users.
In some embodiments, methods for initiating communication between an Instant Messaging (IM) client and a mobile phone are provided, the methods comprising: receiving a communication request from the IM client using a first server; delivering the received communication request to the mobile phone using the first server; recording information regarding the communication request; receiving a communication response from the mobile phone; associating the received response from the mobile phone with the communication request from the IM client based on the recorded information; and sending the received communication response to the IM client.
In some embodiments, systems for initiating communication between an IM client and a mobile phone are provided, the systems comprising: a first server coupled with a computer network and a telephone network, wherein the IM client is coupled with the computer network and the mobile phone is coupled with the telephone network; wherein, the first server is configured to receive a communication request from the IM client, deliver the received communication request to the mobile phone, record information regarding the communication request, receive a communication response from the mobile phone, associate the received response from the mobile phone with the communication request from the IM client based on the recorded information, and send the received communication response to the IM client.
In some embodiments, methods for initiating communication between an IM client and a mobile phone are provided, the methods comprising: receiving a call from a mobile phone at a first server, wherein the call is made by dialing a number from the mobile phone, the number indicating that an IM client is an intended recipient of the call and identifying the IM client; sending a communication request to the IM client based on the received call using the first server.
In some embodiments, systems for initiating communication between an IM client and a mobile phone are provided, the systems comprising: a first server coupled with a computer network and a telephone network, wherein the IM client is coupled with the computer network and the mobile phone is coupled with the telephone network; wherein the first server is configured to receive a call from a mobile phone, the call being made by dialing a number from the mobile phone, the number indicating that an IM client is an intended recipient of the call and identifying the IM client; wherein the first server is configured to send a communication request to the IM client based on the received call.
BRIEF DESCRIPTION OF THE DRAWINGS
The Detailed Description of the Invention, including the description of various embodiments of the invention, will be best understood when read in reference to the accompanying figures wherein:
FIG. 1 is a flow diagram illustrating the initiation of IM communication from an IM client to a mobile phone, according to various embodiments of the present invention;
FIG. 2 is a flow diagram illustrating the initiation of IM communication from a mobile phone to an IM client, according to various embodiments of the present invention;
FIG. 3 is a diagram illustrating a system including an (Intelligent Network) IN server according to various embodiments of the present invention;
FIG. 4 is a diagram illustrating a system including a multimedia gateway and a Short Message Service (SMS) gateway, according to various embodiments of the present invention; and
FIG. 5 is a diagram illustrating a system including an IN server and a multimedia gateway, according to various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention provide systems and methods for initiating communication between IM clients and mobile clients. In accordance with the present invention, an IM user at an IM client may initiate a call with a mobile user at a mobile client by sending the mobile client a sign or message (e.g., such as an SMS message) asking the mobile user to call-back the IM client and thereby initiate an IM-mobile call automatically.
More particularly, as illustrated in the flow diagram of FIG. 1 , an IM user (not shown) at an IM client 10 may desire to communicate via IM with a mobile user (not shown) at a mobile phone 16 . Communicating via IM may include simple text IM, voice IM, video IM, or any combination of the same. In order to initiate communication, IM client 10 may send a suitable IM message 20 to IM server 12 . IM server 12 may then send a special message 22 based on IM message 20 to an intelligent network (IN) server 14 in a mobile network. IM server 12 may be any suitable server for implementing instant messaging, or may be omitted when appropriate (in which case IM message 20 may be sent directly to IN server 14 ). Special message 22 may be a proprietary message, a non-propriety message, a suitable IM message (and may be the same as IM message 20 ), etc., for setting up an IM conversation between IM server 12 and IN server 14 . IN server 14 may then send an SMS message 24 to mobile phone 16 . SMS message 24 is based on special message 22 and may be associated with an identification number (e.g., a phone number). The identification number can be used for identifying the IM user at IM client 10 , for identifying the desired IM conversation, for indicating a generic acceptance of an incoming IM conversation request, and/or for performing any other suitable function.
Upon receiving the SMS message 24 , the mobile user may decide to accept the IM conversation request and press a suitable button (e.g., a “send” button) on mobile phone 16 . In response to this, mobile phone 16 may initiate a call 26 to IN server 14 . This call may be placed to the identification number associated with SMS message 24 . IN server 14 may then recognize call 26 as corresponding to the IM conversation request based upon the identification number called. Alternatively, IN server 14 may recognize the call as corresponding to the IM conversation request based upon the relative time between SMS message 24 and call 26 , based upon the absence of an intermediate call, and/or based upon any other suitable factor(s). IN server 14 may then send a suitable IM message 28 to IM server 12 . For example, IM message 28 may be a message indicating that the mobile user is accepting the IM conversation request. The IM message 28 may alternatively be any suitable special message. Finally, IM server 12 may send an IM message 30 to IM client 10 and thereby initiate the IM conversation.
To facilitate the IM conversation, IN server 14 may convert call 26 to any suitable format depending on the capabilities of mobile phone 16 . For example, call 26 may be converted to a multi-media call, a voice only call, a web browsing call, etc.
In addition, embodiments of the present invention provide systems and methods that enable a mobile phone user to initiate IM communication with an IM user. According to various embodiments as illustrated in the flow diagram of FIG. 2 , a mechanism is provided to convert calls to special phone numbers to IM addresses. As illustrated in FIG. 2 , this may be accomplished by a mobile user (not shown) at mobile phone 16 calling a special number such as “*55501”. Within this number “*555” represents any suitable prefix to designate that the mobile user would like to make an IM call and “01” represents a number corresponding to a suitable “buddy.” To enable each user to have multiple stored “buddies,” a range of addresses, such as “*55501”-“*55599,” may be provide to each user. The same set of numbers may be used by different users. In addition to this example, any other suitable numbering scheme could be implemented.
In response to the call initiated by the mobile user from mobile phone 16 , IN server 14 may send a suitable IM message 34 to IM server 12 . IM server 12 may then send a suitable IM message 36 to IM client 10 . The IM user at IM client 10 may then respond to the IM message 36 by sending an IM message 38 to IM server 12 . An IM conversation may then be established and IM messages 40 can be relayed between IM server 12 and IN server 14 in any suitable fashion. IM messages 40 may be transferred to mobile phone 16 as part of a call 42 , which may be converted to any suitable form by IN server 14 depending on the capabilities of mobile phone 16 . For example, call 42 may be converted to a multi-media call, a voice only call, a web browsing call, etc.
Although this example is illustrated in the context of making an IM call from a mobile phone, this technique could also be applied to sending an email from a mobile phone, or for any other suitable purpose.
FIG. 3 is a block diagram illustrating one example of a system for implementing various embodiments of the present invention. As shown, the system includes an IM client 10 and an IM server 12 connected to network 44 . IM client 10 can be any type of device that implements IM. For example, IM client 10 can be a personal computer (PC) with IM software installed. Computer network 44 could be any suitable computer network or combination of networks, and may include the Internet, local area networks, wide area networks, dial-up connections, wireless connection, DSL connection, cable connections, satellite connections, etc. Computer network 44 may be in communication with IN server 14 , which may be in connection with telephone network 46 .
Telephone network 46 may be any suitable telephone network or combination of networks, and may include a PSTN network, a private network, a wireless network, a satellite network, the Internet, etc. Telephone network 46 may also be connected to, integrated with, or part of a mobile network 48 that communicates with mobile phone 16 . Mobile network 48 may be any suitable mobile communication network including, but not limited to, cellular networks, GSM networks, and/or satellite networks. As should be apparent to a person of ordinary skill in the art, embodiments of the present invention can be implemented using any other suitable system.
If desired, certain functions of IM server 12 and IN server 14 described above may be performed by the other of IN server 14 and IM server 12 , by IM client 10 , and/or by mobile phone 16 . For example, IM server functions may be implemented in IN server 14 , and/or vice versa. As should be apparent to a person of ordinary skill in the art, many modifications to the invention can be made without departing from the spirit and scope of the invention.
FIG. 4 is a diagram depicting a system of various embodiments of the present invention. In FIG. 4 , an IM user 411 at an IM client 410 may desire to initiate communication (e.g., a multimedia call) from IM client 410 with a mobile user 413 at a mobile phone 416 . Communicating via IM may include text, voice, video (which may be still or moving), and/or any combination of the same.
To initiate communication, user 411 at IM client 410 may select the mobile user 413 (e.g., using a “buddy” list or any other suitable mechanism) and thus cause client 410 to send a message to IM server 412 via computer network (e.g., Internet) 427 . IM server 412 may be any suitable server for implementing IM. IM server 412 may be omitted when appropriate, e.g., in a peer-to-peer IM environment. In this case, messages from IM client 410 may be sent directly to SMS gateway 414 or mobile phone 416 , as set forth below).
After receiving the message from client 410 , IM Server 412 may determine if mobile user 413 (or mobile phone 416 ) is online. If IM server 412 determines that mobile phone 416 is online, the IM server may send a suitable IM message to user 413 prompting him of the incoming IM conversation request. Otherwise, if IM server 412 determines that user 413 is not online, IM server 412 may then send a message to SMS gateway 414 requesting it to notify mobile phone 416 of the IM conversation request. SMS gateway 414 may be any suitable gateway for connecting an IM environment to an SMS environment, and may be located on the border of, or may be otherwise be connected to, a mobile network (e.g., network 428 ).
In addition to the function described above, SMS gateway 414 may translate audio/video codecs and other communication characteristics that differ between the networks (e.g., converting the AMR codec in a 324M network to/from iLBC/G.723 audio or other codecs used in the IM network), translate other audio and video characteristics (e.g., perform video rate matching), insert information into the conversation (e.g., such as advertisements (e.g., to keep costs low), call information, or emergency bulletins), and/or perform any other suitable functions. Alternatively, SMS gateway 414 may be omitted when appropriate (in which case IM server 412 (in a client-server configuration) or IM client 410 (in a peer-to-peer configuration) may send a message to an IM client (not shown) that resides on mobile phone 416 ).
Upon receiving a communication request, SMS gateway 414 may send an SMS message to mobile phone 416 via mobile telephone network 428 . Telephone network 428 can be, e.g., a Universal Mobile Telecommunication System (UMTS) network. The SMS message may include information that identifies to what telephone number (e.g., call back number) mobile phone 416 may call in order to initiate communication (e.g., a multimedia call) between mobile phone 416 and IM client 410 . The SMS message may also include information identifying the IM user 411 at IM client 410 , indicating the cost for initiating the conversation, or indicating any other suitable information. SMS gateway 414 may store suitable information in a database 417 to subsequently complete initiation of the IM conversation should user 413 respond to the SMS message.
Upon receiving the SMS message, user 413 may decide to continue initiation of the IM conversation. This may be accomplished by calling multimedia gateway 415 at the call back number indicated in the SMS message (for example, by pressing the “send” button on mobile phone 416 in response to the displayed message).
Multimedia gateway 415 may then determine the identity of the IM conversation. This determination may be based on the phone number of mobile phone 416 (as indicated by caller-id), and/or the number called, and/or any other suitable information. Gateway 415 may also access data previously stored in database 417 (such as which IM conversation(s) corresponds to a particular mobile phone 416 ). For example, gateway 415 may query database 417 to translate the called number to a valid URI. After identifying the IM conversation, multimedia gateway 415 may connect the call of mobile phone 416 to the IM conversation, and hence IM client 410 , either directly or via IM server 412 .
A variety of protocols may be used to establish the IM conversation as set forth above. For example, communication links 420 , 421 , 422 , 423 between IM client 410 , IM server 412 , SMS gateway 414 , and multimedia gateway 415 can be based on Session Initiation Protocol (SIP) or any suitable proprietary protocol. Communication link 425 between SMS gateway 414 and network 428 may be based on Signaling System 7 (SS7) protocol. Communication link 426 between network 428 and mobile phone 416 may be based on 3G-324M/radio protocol. The communication link between network 428 and multimedia gateway 415 may be based on 3G-324M/E1 protocol. Any other suitable protocols may additionally or alternatively be used in accordance with the present invention. The messages exchanged as described above may be any suitable messages. For example, the messages may be proprietary messages, non-propriety messages, suitable IM messages, etc.
Network 427 may be any suitable computer network or combinations of the same. For example, network 427 may include the Internet, an intranet, a local area network, a wide area network, a wired network, a wireless network, etc. As shown in FIG. 4 , any suitable firewall 419 may also be present to protect SMS gateway 414 and multimedia gateway 415 from unauthorized activity.
FIG. 5 is a diagram illustrating another system that enables a mobile phone user to initiate IM communication with an IM user, according to various embodiments of the present invention. To initiate the IM communication, mobile user 413 at mobile phone 416 can call a special number indicating that the user would like to make an IM call and indicating the recipient of the call. While an example has been given in connection to FIG. 2 , any suitable numbering scheme could be implemented. These special numbers may be associated with IM addresses using any suitable mechanism. For example, a Web page interface that can be accessed using a browser on a mobile phone or computer can be used to allow users to enter numbers and corresponding IM addresses. In addition, SMS messages, Interactive Voice Response (IVR) systems, and/or any other suitable mechanism can be used for the same purpose.
This call made by dialing the special number may be routed by mobile telephone network 428 to IN server 430 . Network 428 can be a UMTS mobile telephone network. IN server 430 may then forward the call to a suitable multimedia gateway 432 . Multimedia gateway 432 may then access database 434 to determine what IM address to use. This determination may be based, for example, on the telephone number of mobile phone 416 , the number dialed, and/or on any other suitable information. For example, if mobile phone 416 has a telephone number of (555) 123-4567, and mobile user 413 calls “*55501,” the database may be used to determine that “*55501” for number (555) 123-4567 corresponds to an IM address “johnsmith” on AOL's Instant Messenger service. Database 434 may be any suitable database and may be connected to multimedia gateway 432 and may include any suitable mechanism for loading addresses into the database (e.g., such as a Web server).
After determining what IM address to use, multimedia gateway 432 may send a suitable message to IM server 412 via network 427 . IM server 412 may then send a suitable IM message to IM client 410 also via computer network 427 to initiate the IM conversation. IM user 411 at IM client 410 may then accept the IM conversation and proceed as known in the art. Although this example is illustrated in the context of making an IM call, this technique could also be applied to sending an email from a mobile phone, or for any other suitable purpose.
A variety of protocols may be used to establish the IM conversation as set forth above. For example, communication link 436 between mobile phone 416 and network 428 can be based on 3G-324M/radio protocol. Communication link 438 between network 428 and multimedia gateway 432 may be based on 3G-324M/E1 protocol. Communication links 440 , 444 , 446 between multimedia gateway 432 , IM server 412 and IM client 410 can be based on SIP or any suitable proprietary protocol. Any other suitable protocol or combinations of protocols could additionally or alternatively be used in accordance with the invention. Any suitable firewall 419 may also be present to protect server 430 and/or multimedia gateway 432 from unauthorized activity.
Other embodiments, extensions, and modifications of the ideas presented above are comprehended and within the reach of one skilled in the art upon reviewing the present disclosure. Accordingly, the scope of the present invention in its various aspects should not be limited by the examples and embodiments presented above. The individual aspects of the present invention, and the entirety of the invention should be regarded so as to allow for modifications and future developments within the scope of the present disclosure. The present invention is limited only by the claims that follow.
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In some embodiments, methods comprise: receiving a communication request from the IM client using a first server; delivering the received communication request to the mobile phone using the first server; recording information regarding the communication request; receiving a communication response from the mobile phone; associating the received response from the mobile phone with the communication request from the IM client based on the recorded information; and sending the received communication response to the IM client. In some embodiments, methods comprise: receiving a call from a mobile phone at a first server, wherein the call is made by dialing a number from the mobile phone, the number indicating that an IM client is an intended recipient of the call and identifying the IM client; sending a communication request to the IM client based on the received call using the first server.
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FIELD OF THE INVENTION
The invention relates to a process to evaluate signals of a sensor, in particular of a microwave sensor to detect thickness, mass, density and/or moisture of at least one fiber sliver moving in relation to the sensor on drafting equipment, whereby a high-frequency device assigned to the sensor produces a number of first signals in digital form concerning the current state of the (at least one) fiber sliver, as well as to a device for the evaluation of the signals of such a sensor. In addition, the invention relates to a textile machine with such a device.
BACKGROUND OF THE INVENTION
In the textile industry, fiber slivers with a cross section consisting of a plurality of individual fibers are often measured for thickness, mass, density and/or moisture. This is necessary, e.g., in the area of drafting equipment in order to draft one or several fiber slivers to reduce the number or mass of their fibers in the cross-section of fiber slivers. It is then often the goal to produce an especially uniform fiber sliver, i.e., as much as possible, a fiber sliver with the same number of fibers or mass in the cross-section over its entire length. Drafting equipment of this type is used, for example, at the output of cards, in draw frames or spinning machines. In order to be able to level the sliver mass fluctuations of the fiber slivers, sliver sensors are provided, for example, on draw frames to measure sliver thickness or sliver mass and its fluctuations and to transmit this information to a control unit. At least one of the drafting elements of the draw frame is actuated by the control unit. In addition, an inspection is conducted frequently at the output of the drafting equipment to check whether the drafting process has taken place as desired, i.e., whether the mass of the fiber sliver has been leveled out.
To measure the sliver thickness fluctuation, mechanical scanning in particular is known. This mechanical scanning is at a disadvantage at extremely high delivery speeds of over 1,000 meters per minute, as is common in modern high-performance draw frames. Furthermore, the intensive mechanical compression required with mechanical sensors has a negative effect on the subsequent drafting process.
In addition to mechanical scanning of the sliver thickness fluctuations, scanning systems such as optical rays that penetrate the sliver thickness without contact, capacitive or pneumatic measuring methods, X-rays or similar methods have become known. These methods have however individual disadvantages that made them seem unsuited until now for continuous industrial application in the textile industry.
A microwave sensor has found to be an especially advantageous sensor to measure fiber sliver quality. The thickness, mass, density and/or moisture of one or several fiber slivers moving in relation to the sensor can be ascertained very reliably by means of microwave sensors. The sensor supplies a large number of signals per time unit, providing information on the current state of the (at least one) fiber sliver. The signals are transmitted in digital form and per time unit by the microwave sensor, or more precisely, by the microwave resonator, to a downstream high-frequency installation. In such a case, the fact that as the time-dependent signals are assigned to the proper location in the fiber sliver, a great computing expenditure is disadvantageously required because of the great quantity of data supplied. Furthermore, the assignment of the signals to the point on the (at least one) fiber sliver must take place exactly at the point in time at which it is in the drafting equipment. This is difficult to achieve by means of a microwave sensor and at reasonable cost, especially with very rapidly running fiber slivers.
Furthermore, if a microwave sensor such as is known for the measuring of moisture of cigarette paper is used in a conventional textile machine, e.g., a draw frame of model RSB-D 35 of the Rieter company, the first digital signals delivered by the output of the high-frequency device are analyzed for frequency shift and half-intensity width, and the corresponding values are converted by means of a D/A converter into analog signals, and these analog signals are then switched to the leveling computer of the draw frame which is provided at its input with an A/D converter. The digital output data of the leveling computer is then in turn converted into analog signals by means of a D/A converter, and are locked on to the analog input of the servo leveler which controls the lower input and central rollers. This expensive procedure is costly and subject to errors, because of the occurrence of the undesirable phase shift and quantization errors.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore a principal object of the present invention to create a precise and economical evaluation method and a corresponding device by which the microwave technology can be used in the evaluation of the fiber sliver state. Additional objects and advantages of the invention will be set forth in part in the following description or may be obvious from the description, or may be learned through practice of the invention.
According to the invention, the microwave sensor or its assigned high-frequency device supplies a number of first signals in digital form per time unit, from which second digital signals are formed according to a predetermined algorithm, and these indicate the current sliver thickness or sliver mass of the (at least one) fiber sliver. The first signals, representing the evolution of the resonance curve, contain information regarding phase shift and half-intensity width of the resonance signals of the microwave sensor. From these signals and based on mathematical correlations, the appertaining sliver thicknesses or sliver masses can be calculated in the form of second digital signals.
By contrast with the state of the art, no individual parameters for frequency shift and half-intensity width are thereby transmitted in analog form. Instead, a second digital signal indicating the current sliver mass or sliver thickness is transmitted. These second digital signals are subsequently used to level the drafting equipment and/or to judge the fiber sliver quality at the inlet or outlet of the drafting equipment. Hereby, the second digital signals are used in an especially preferred embodiment without interim D/A conversion to calculate leveling values, designated as third signals in this terminology, to adjust the controllable drafting equipment. This calculation can be made for reasons of cost with the same processors that also clocks the high-frequency device and/or produces the second digital signals. In an alternative embodiment, a separate processor is used to produce the third digital signals.
The term “second digital signals” (for values of sliver thickness or sliver mass) and “third digital signals”for leveling values must of course be understood in the sense that digital intermediate signals can be produced between the first and the second or the second and the third signal.
Between the first and the second digital signals as well as, preferably, between the second and the third digital signals, only a purely digital processing of the signals supplied by the sensor takes place, thus no conversion into analog signals takes place. The predetermined algorithm for conversion of the first set into the second digital signals and possibly the algorithm for conversion of the second into the third digital signals is selected depending on the fiber state analysis requirements, the speed of the passage of the fiber sliver through the sensor and the processing speed of the computers using the algorithm.
With the method according to the invention, the number of first digital signals can be reduced to a few second digital signals. In general, the number of the second signals is therefore considerably lower than the number of the first signals, e.g., {fraction (1/50)} of the first signals. As a result, a smaller flow of data has to be handled by the computer's microprocessor. The evaluated second signals can thus be transmitted more rapidly to the leveling system. In addition, the fiber sliver leveling system can react with greater precision if the number of the signals to be processed is lower.
The number of data can also be reduced in case of quality monitoring at the outlet of the textile machine. It is, however, advantageous in forming the second digital signals from the first digital signals not to effect such a great reduction, or not to effect any reduction at all, but to process more information, or all of the information so that, at a scanning rate of, e.g., 10 kHz, highly precise CV value calculations and spectrograms in the short-wave wavelength range can be obtained.
With the economical utilization of only one processor to calculate the second digital signals from the data of a sensor on the inlet side on the one hand (with data reduction) and a sensor on the outlet side on the other hand (without data reduction), a relatively great computing capacity is available for quality control of the data of the sensor on the outlet side. In this manner, thick and thin spots can be detected precisely at the outlet.
The algorithm for the formation of the second signals is advantageously a function of the fiber sliver speed. This means, e.g., in case of the fiber sliver running past the sensor at a higher speed, that a greater number of second signals per time unit is needed than when the fiber sliver is produced at a lower delivery speed.
For some specific applications, it is advantageous if the algorithm for the formation of the second signals is dependent upon the material of the fiber sliver. Viscose, cotton, polyester or other materials react very differently to the drafting forces in the drafting equipment. The difference in processing the first digital signals can provide compensation regarding speed of signal processing or magnitude of the signals.
It is especially advantageous if a predetermined number of first signals are skipped while taking into account material speed, and if the signal thus selected serves as the second signal. This means that only single signals are selected from the large number of first digital signals available. This reduces the number of signals and thereby the expense for further processing. If, for instance, only every 50 th first signal is selected, the cost of further processing is correspondingly lower. With a great number of applications, this nevertheless leads to very good results and information on the state of the (at least one) fiber sliver.
In another advantageous embodiment, the mean value is formed from a predetermined number of first digital signals that represents the second digital signal. Brief fluctuations in the state of the (at least one) fiber sliver that may be disregarded for further processing or evaluation of the fiber sliver(s) are averaged in this manner and provide sufficient description of the state of the fiber sliver.
Based on the skipped first signals or on those constituting the mean value of a predetermined length of the (at least one) fiber sliver, it can be assumed that a measured value for the characterization of the fiber sliver state is produced for this predetermined length. A length from 1 to 10 mm of the (at least one) fiber sliver within which at least one state signal is to be produced has been shown to be advantageous.
A reduction of data is also possible alternatively or in addition in the transition from the second to the third digital signals. The above explanations for the transition from the first digital signals to second digital signals can be applied to the transition from the second digital signals to the third digital signals.
In suitably designed systems that must process the second or the third signal, it may be advisable to convert the second or third digital signal into an analog signal before its further utilization. In the case of a third digital signal, it can be transmitted following analog conversion, e.g., to a servo controller that drives individual drafting rollers of the drafting equipment at varying speed via a differential motion gear. In an alternative embodiment, individual drives, located in corresponding control circuits where the leveling controls receive the signals, are provided for the drafting rolls.
Instead of being converted into an analog signal, the third signal can be further processed as a digital signal in an advantageous embodiment, preferably, with a controller having digital inputs serving to adjust at least one drafting roller. The controller can again be a servo controller in this case, or a controller for an individual drive.
In the device to evaluate signals of a sensor according to the invention, its resonator is assigned the mentioned high-frequency equipment for the production of a first digital signal from high-frequency signals of the microwave sensor. A microwave card in particular represents such a high-frequency device. In addition, the device according to the invention is provided with a processor unit for the production of the second and possibly the third digital signal, whereby the second digital signal represents the current sliver thickness or sliver mass. The sensor can be located at the inlet and/or at the outlet of the drafting equipment. If it is located at the inlet of the drafting equipment, it serves in particular for the measuring of the (at least one) entering fiber sliver and for the control of the speed of drafting rollers of the drafting equipment. At the outlet, the sensor is used to check the quality of the drafted fiber sliver. In addition, the signal can be used to control the drafting equipment.
If the high-frequency device is located in immediate proximity of the sensor, it is possible to use an especially short cable connection between the sensor and the high-frequency device. The cable transmitting the high-frequency signals acts as an antenna and could corrupt the signals if it is too long. This would affect the precision of fiber sliver measuring. Since modern drafting equipment functions with great precision, this would lead to unreliable measuring results, in particular on the high-precision leveling draw frames. In case of an outlet sensor, the immediate proximity of the sensor and the high-frequency device provides, furthermore, considerable advantages regarding precision of quality information on the outgoing fiber sliver when the first digital signals produced by the high-frequency device are processed into second digital signals without any data reduction.
It has been shown to be especially advantageous to keep the distance between the high-frequency device and the sensor, in particular the cable length between high-frequency device and sensor as short as possible, but not longer than 1.5 m. With the shorter the cable, the analog microwave resonance signals can be transmitted to the high-frequency device more precisely and with less transmission errors, thus producing a correspondingly precise measurement of the fiber sliver.
It is especially advantageous if the high-frequency devices and/or the processor units are connected to each other via communication lines for inlet and outlet sensor. The respective results of the evaluation of the fiber sliver states upstream of the drafting equipment and downstream of the drafting equipment can be compared and, if necessary, can be corrected. This also provides the possibility of forming a closed control circuit in order to achieve precise leveling of the fiber sliver.
It is especially economical if the high-frequency devices and/or processor units for inlet and outlet sensor are combined into one component. Since the resonators of the microwave sensors, contrary to conventional sensors, can be located very close to the drafting equipment, it is possible to use correspondingly short cable lengths, so that no interference signals take effect or are produced. For this reason, it is possible to combine the high-frequency devices and the processor units of the inlet and outlet sensors into one component. Reaction speeds based on processing times and production costs are thereby influenced favorably.
By using a correspondingly advanced technology, it is also possible, and in individual cases advantageous, if one single high-frequency device or one single processor unit is used for both the inlet and outlet sensors. If the high-frequency device and the processor unit are designed so that they are able to process the input signals with sufficient speed, it may suffice to use only one device and unit that would serve the inlet sensor as well as the outlet sensor. With a rational division of the computing and memory capacity for the data of the inlet sensor on the one hand and the outlet sensor on the other hand, the costs of additional high-frequency devices and processor units can thus be saved.
An efficient division of the memory and computing capacity is also advisable in case that one processor unit is assigned to the production of the second as well as of the third signals (as well as, if necessary, the clocking of the high-frequency device) originating in the signals of an inlet sensor. If, for example, only every fifth signal of the first digital signals is produced to produce the second digital signal, as a rule sufficient computing capacity is left to calculate the third digital signals, i.e., the leveling values.
The inlet sensor serves advantageously to produce signals used for the control of the drafting equipment. The outlet sensor serves in general to produce signals for quality monitoring of the drafted fiber sliver. These signals can be used in addition to control the drafting equipment.
The digital data transfer is advantageously realized at least in part by means of bus systems, e.g., by means of CAN bus connections.
Additional advantages of the invention are described through the following examples of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a simplified block diagram of drafting equipment with microwave sensors;
FIG. 2 shows an elementary diagram of an electronic circuit with microwave sensors at the inlet and at the outlet of drafting equipment;
FIG. 3 shows an elementary diagram of a combined electronic circuit for an inlet sensor and an outlet sensor;
FIG. 4 shows an elementary diagram of one single processing apparatus for an inlet sensor and an outlet sensor,
FIG. 5 shows an elementary diagram of an electronic circuit, in part separate, for an inlet sensor and an outlet sensor; and
FIG. 6 shows an elementary diagram of an electronic circuit, in part separate, for an inlet sensor and an outlet sensor with an additional processor unit.
DETAILED DESCRIPTION
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the figures. Each example is provided to explain the invention, and not as a limitation of the invention. In fact, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
FIG. 1 shows a simplified block diagram of drafting equipment 1 with microwave sensors. A fiber sliver 2 runs into the drafting equipment 1 in the direction of the arrow and comes out in the form of drafted fiber sliver 2 ′. Normally several fiber slivers 2 are at the input of the drafting equipment 1 and are united into one fiber sliver 2 ′ by the drafting equipment at its outlet.
At the inlet of the drafting equipment 1 , an inlet sensor 3 is installed. The inlet sensor 3 functions with microwave technology and determines the state of the entering fiber sliver or slivers 2 . The signal produced by the processing unit 12 downstream of the inlet sensor 3 is transmitted to the controls 5 of the machine. In the block diagram shown here, the signal of a processing unit 12 ′ downstream of the one outlet sensor 4 is also transmitted to the controls 5 . The optional outlet sensor 4 is in this case located at the outlet of the drafting equipment 1 . It is not necessary in every case that an inlet sensor 3 as well as an outlet sensor 4 be installed on the drafting equipment 1 . Normally, the outlet sensor 4 is required only where the drafting result of the drafting equipment 1 is to be checked and evaluated or is to be used to control the drafting equipment 1 .
The signal digitally processed in the processing unit 12 is transmitted from its output to the controls 5 of a leveling system 6 . If the controls 5 have an analog input, the signal is either converted accordingly already in the processing unit 12 or only in the controls 5 . This analog signal of the leveling system 6 is transmitted to a servo amplifier or servo regulator 8 and thereby to a connected servomotor 9 . The servomotor 9 drives parts of the drafting equipment 1 via a differential motion gear 10 at varying speeds in order to level out different states of the fiber slivers 2 at the inlet of the drafting equipment 1 .
The signal of the processing unit 12 ′ of the microwave outlet sensor 4 is transmitted to a quality monitor 7 that can be integrated in a not shown embodiment also in the processing unit 12 ′. Here, statistical evaluations or visual displays of the obtained drafting result can be produced. Alternatively or in addition, these results can flow into the leveling system 6 or into a control of the drafting equipment 1 .
The servicing and/or visualization of the desired and obtained drafting results as well as the entering of different parameters is effected via an operator interface 11 connected to the controls 5 .
FIG. 2 shows the basic diagram of an electronic circuit for an inlet sensor 3 and an outlet sensor 4 of which only the resonators are indicated in all figures. The usual equipment (microwave generators) needed for the production of microwaves, as well as coupling and uncoupling elements, circulators, etc. are not shown for the sake of clarity. A processing unit 12 is connected to the inlet sensor 3 . In the processing unit 12 , a high-frequency unit 13 in form of a microwave card, a processor card 14 of a microprocessor, a power supply 15 and possibly other evaluation or supply devices or interfaces are provided. The analog signals produced with the inlet sensor 3 are transmitted to the microwave card 13 . The microwave card 13 functions with high-frequency technology. A short distance between the sensor 3 and the microwave card 13 is important, since possible interference signals and transmission errors can be avoided thanks to the short cable length. The first digital signals are produced by means of the microwave card 13 . These first digital signals are processed in the following processor card 14 into second digital signals. These second digital signals that are produced according to a predetermined algorithm represent the current sliver thickness or sliver mass of the (at least one) fiber sliver 2 . From the second digital signals, the third digital signals serving to control the drafting equipment 1 are calculated, whereby the actual regulating signals either remain in digital form or can also be converted into analog signals. A conversion into analog signals can be effected with the processor card 14 or in the leveling system 6 of FIG. 1 .
The outlet sensor 4 functions with a similar design as the inlet sensor 3 . The signals of the outlet sensor 4 are transmitted to the microwave card 13 ′ which produce the first digital signals. These first digital signals are finally further processed in the processor card 14 ′ into second digital signals in accordance with an algorithm that is predetermined here too, and may possibly deviate from the inlet sensor 3 . These further processed second signals serve to monitor the quality of the delivered fiber sliver 2 ′ and also represent the sliver thickness or sliver mass. Power supply and possibly additional inputs and outputs are indicated by box 15 ′.
The algorithm for the production of the second digital signals are preferably designed for data reduction of the first digital signals, whereby, e.g., individual first digital signals are skipped or averaged. Thereby, computer capacities can be saved or can be used for other tasks, e.g., the calculation of third digital signals and/or the clocking of the microwave card(s), 13 . The formation of the third digital signals from the second digital signals can also make use of data reduction.
Furthermore, the algorithm can be a function of the speed of the (at least one) fiber sliver 2 and be independent of its material for the formation of the second signal and/or the third signal.
FIG. 3 shows another embodiment in the form of an elementary diagram. The evaluation units 13 , 13 ′ and 14 , 14 ′ are located in a common processing unit 12 ″. The microwave card 13 of the inlet sensor and the microwave card 13 ′ of the outlet sensor 4 communicate with each other and can thus exchange results and possibly use them for their own evaluation. This also applies to the processor card 14 of the inlet sensor 3 and the processor card 14 ′ of the outlet sensor 4 . These too communicate with each other and can, if necessary, use the quality data of the delivered fiber sliver 2 ′ for the control signals. With such an interconnection of the processor cards 14 , 14 ′, it is also possible, if necessary, to make better use of their computing capacity. With this type of construction, a rapid exchange of data and, in addition, an economic structure can be achieved. In most cases, it suffices to provide a common power supply and data interface 15 ″.
FIG. 4 shows another combination in form of the processing unit 12 ′″. With a correspondingly high-capacity technology, it suffices to use merely one microwave card 13 ″ and one processor card 14 ″ for the inlet sensor 3 and the outlet sensor 4 . The corresponding signals of the sensors 3 and 4 can be processed in one single microwave card 13 ″ and can be transmitted to the processor card 14 ″. The processor card 14 ″ can process simultaneously the signals of the microwave card 13 ″ and convert then, on the one hand, into sliver thickness signals and then into control signals, and, on the other hand, into quality monitoring signals (therefore, also into sliver thickness signals). The evaluation of the signals of the inlet and outlet sensor 3 , 4 can be effected in this manner especially rapidly. Such a solution requires, however, sufficiently capable microwave and processor cards which are advantageous mainly for very demanding applications.
FIG. 5 shows another example of an embodiment of the design of a microwave sensor at the inlet and at the outlet, in combination with the further processing of the signals. At the inlet sensor 3 only the microwave card 13 is provided. Similarly, outlet sensor 4 is provided with only the microwave card 13 ′. The cable lengths needed from the sensor 3 , 4 to the respective microwave card 13 or 13 ′ can thus be kept very short. The signal produced in the microwave card 13 or 13 ′ is transmitted to a common processor card 14 ″ in a processing unit 12 ″″. The common processor card 14 ″ processes the signals thus obtained and transmits them in the form of control signals that were calculated first from sliver thickness signals, or in the form of quality monitoring signals (see arrow). With this embodiment of the invention only one high-capacity microprocessor capable of rapidly processing both signals, those from the inlet sensor 3 and those from the outlet sensor 4 is needed. It is possible to provide one single power supply 15 ″ that supplies the sensors 3 , 4 and the corresponding microwave cards 13 , 13 ′ via connection lines.
FIG. 6 shows an alternative embodiment. Here, the common processor card 14 ″ only calculates the sliver thickness values, at least of the signals of the inlet sensor 3 . These sliver thickness values represent either the second digital signals produced by the processor card 14 ″, or they are calculated from these second digital signals. The sliver thickness values are then transmitted in digital form to a further processor unit 24 in order to calculate leveling values that represent the third digital signals in the chosen terminology, for the adjustment of the autoleveling drafting equipment (see arrow). Among these leveling values are, in particular, values regarding the starting point of leveling and/or the leveling intensity. The signals of the outlet sensor 4 are either processed exclusively in the common processor card 14 ″ or in the processor unit 24 . A display (not shown) is advantageously connected to the processor card 14 ″ and/or the processor unit 24 in order to provide visualization to an operator and, if needed, with the added possibility, to enter machine parameter values via an operator interface (see FIG. 1 ).
In the embodiments shown in the figures, the clocking of the microwave card is preferably also assumed by one of the processor units or processor cards shown.
It is possible, for example, with the present invention, to effect automatic machine adjustments in a pre-operational phase, in particular to pre-set at least roughly the starting point for leveling and the leveling intensity on an autoleveling drafting equipment.
The present invention is not limited to the examples of embodiments shown. In particular, devices other than microwave sensors can be operated according to the process of the invention. Also other combinations that are not described here are covered by the subclaims of the present invention. The invention can be applied in particular with cards, draw frames and combing machines with drafting equipment. It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.
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A method and device for the evaluation of signals of a sensor, in particular of a microwave sensor, is proposed for the detection of the thickness, mass, density and/or moisture of at least one fiber sliver moving relative to the sensor on drafting equipment. A high-frequency unit assigned to the sensor produces a number of first digital signals in digital form of the current state of the (at least one) fiber sliver. The method according to the invention is characterized in that a second digital signal, representing the current sliver thickness or sliver mass of the (at least one) fiber sliver and which is then used to control the drafting equipment and/or to judge the fiber sliver quality, is formed according to an algorithm from the first digital signals made available. In addition a suitable device for the evaluation of the signals of a sensor is proposed.
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[0001] In accordance with 35 U.S.C. § 119, the applicants claim the priority of Austrian patent application No. A 1609/2007 of 10 Oct. 2007.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method of producing a friction lining, whereby a friction paper is displaced with a latex based on an elastomer and fibers of the friction paper are then bonded to one another due to precipitation of the elastomer out of the latex, a friction lining, in particular a friction lining for wet operation, comprising at least one friction paper with fibers which are bonded to at least one elastomer, as well as a friction unit, in particular a motorcycle clutch, comprising a friction lining on a support and a counter plate which co-operates with the friction lining.
[0004] 2. Prior art
[0005] For specific use in the friction metals industry, such as motorcycle clutches or in applications using counter plates made from light metal or light metal alloys which are susceptible to wear, it is standard practice to use friction linings with a higher degree of elasticity than the friction linings used for other applications. The reason for this resides in the wear-sensitive counter plate because it is made from light metal or light metal alloys associated with a corresponding reduction in weight as required by the automotive industry. By reducing the weight of the clutch directly, it is possible to achieve an increase in power, especially in the case of smaller engines.
[0006] These days, latexes in powdered format are predominantly used to produce such friction paper with a higher elasticity. However, the problem with this is that they are disposed loosely between the fibers of the friction paper as spacers and an adequate bonding is not produced between the individual elements.
[0007] Problems also occur when it comes to producing friction linings with high latex contents economically, for example on a paper machine, because when using higher quantities of latex, it can no longer be kept stable and a specifically controlled precipitation of the latex on the fiber surface or in the fiber matrix no longer takes place. In the event of uncontrolled precipitation of the latex, it no longer interacts with the components of the friction paper but tends by preference towards the surfaces of the paper machine. In other words, after only a short production time, large quantities of latex deposits are left on vat walls, stirrers and in pipes. These problems occur with effect from a latex content above 20%. Production becomes impossible due to filling and clogging pipes. The paper machine clogs regularly and becomes uncontrollable. Occasionally, these latex deposits then detach and precipitate in the paper causing faulty areas and irregularities.
[0008] So far, attempts to solve this problem by using dispersing agents have failed because it has not been possible to improve the tendency of the latex to deposit or has not been so to a sufficient degree. Since these dispersing agents have a base of surface active agent and are therefore active at the boundary surface, they reduce the surface tension of aqueous solutions, thereby creating an additional and not inconsiderable foam problem.
[0009] Friction linings bonded with and containing latex are already described in the prior art. For example, JP 2000-213578 A describes a clutch for wet operation, comprising an annular core element made from a steel plate or an aluminum alloy, which is lined with a friction material on both sides. This wet friction material is produced by impregnating a paper base material with a heat-curable resin. The paper base material is made from normal paper with fibers of an organic or inorganic nature, a filler and latex. The latex content in the paper base material in this instance is in the range of between 0.4% by weight and 25% by weight.
[0010] JP 60-139933 A describes a friction element for brakes or clutches of an automotive vehicle or a motorcycle. The friction element is made from paper which contains between 1 and 30% by weight of rubber latex. An NBR or SBR latex is used by preference. This imparts a corresponding elasticity to the friction element and the coefficient of friction of thin paper can be improved. This also reduces resistance to abrasion.
OBJECTIVES AND ADVANTAGES OF THE INVENTION
[0011] The objective of this invention is to produce a friction element and friction material which has a high elasticity so that it can also be used for wear-susceptible counter plates made from light metals or their alloys.
[0012] This objective is achieved by the invention, independently in each case, firstly by means of a method of the type outlined above, whereby a non-surface active protective colloid is added to the latex as a suspension agent before applying it to the friction paper, by means of the friction lining in which the elastomer forms a two- or three-dimensional network, and by means of the friction unit, which incorporates the friction lining proposed by the invention. The advantage of this is that using a non-surface active protective colloid as a suspension agent makes it possible to use and apply higher latex contents to friction paper, as a result of which the latex generates a stable bond with the surface of the fibrous components of the friction paper on the one hand and an elastic bond between the individual fibers of the friction paper on the other hand. Since it is possible to use a higher proportion of latex in or on the friction paper, a two-dimensional or three-dimensional network is created which, on the one hand, permits a high porosity to enable the oil incorporated in the friction lining to be dispensed more easily and also possesses good wear properties even in the event of poor oiling. On the other hand, a corresponding elasticity of the friction lining is obtained because not only does the latex lie loosely between the individual fibers of the friction paper, the individual fibers bond with one another which assists and improves dispensing of the oil from the friction lining accordingly. By stabilizing the latex in this way, it is possible to apply it directly to the surface of the individual phases and only then is the dispersion or emulsion broken down by shifting the pH value, thereby initiating or causing the elastomer to precipitate out of the latex. Due to the higher latex content and elastomer content in the friction lining and the associated higher elasticity of the friction lining, the tendency of these units to fail due to wear can be reduced or prevented, as a result of which these friction linings can be used, in particular these clutches and wear-susceptible friction units made from light metals or light metal alloys.
[0013] In particular, the protective colloid is an anionically acting naphthalene sulfonic acid condensation product because it enables a correspondingly good stabilization of aqueous latex dispersions and emulsions to be achieved. In particular, in another embodiment of the invention, the naphthalene sulfonic acid condensation products used are condensation products from naphthalene sulfonic acid produced with at least one compound selected from a group comprising formaldehyde and alkanes, in particular C1 to C4. These condensation products have proved to be particularly suitable during tests conducted within the scope of the invention. In particular, sodium salts of naphthalene sulfonic acid/formaldehyde condensates may be used.
[0014] Such naphthalene sulfonic acid condensation products may be obtained from the ACAT company (Applied Chemicals Advanced Technologies) for example.
[0015] The naphthalene sulfonic acid condensation product is preferably added to the latex in a concentration selected from a range with a lower limit of 0.1% and an upper limit of 10%, by reference to the latex. Below 0.1% adequate stabilization of the latex was no longer observed, especially if this latex contained a higher proportion of elastomer. Above 10%, the reaction kinetics were found to be detrimentally affected during subsequent precipitation of the elastomer from the latex. This is associated with a longer production time and irregularities in the friction lining itself. In particular, it was found that with too high a proportion of protective colloid, the porosity of the friction lining exhibited significant irregularities, thereby resulting in areas with too low a porosity.
[0016] In particular, the naphthalene sulfonic acid condensation product is added to the latex in a concentration selected from a range with a lower limit of 1% and an upper limit of 8%, preferably from a range with a lower limit of 3% and an upper limit of 6%, by reference to the latex.
[0017] The latex preferably has an elastomer content of 40% by weight to 70% by weight, which means that for higher elastomer contents in the friction lining lower quantities of latex have to be applied and the precipitation of the elastomer from the latex is made easier, as well as shortening the production time.
[0018] The latex content may also be selected from a range with a lower limit of 45% by weight and an upper limit of 65% by weight, or selected from a range with a lower limit of 50% by weight and an upper limit of 55% by weight.
[0019] The friction paper may be displaced with a proportion of latex selected from a range with a lower limit of 15%, in particular 30%, and an upper limit of 40%, by reference to the friction paper with the latex. Below 15%, the friction lining no longer exhibits the desired elasticity. Above 40%, a further increase in the proportion of latex or elastomer causes an increase in the wear of the friction material so that it fails prematurely.
[0020] The friction lining is preferably produced on a paper machine, thereby enabling a higher degree of automation and a correspondingly straightforward production process.
[0021] The elastomer may be selected from a group comprising SBR (styrene-butadiene rubber), NBR (nitrile butadiene rubber), IR (isoprene rubber), NR (natural rubber), ABS-rubber (acrylonitrile-butadiene-styrene) and all blends thereof. With these elastomers, a very good resistance to wear of the friction lining was achieved and at the same time a high elasticity.
[0022] The porosity of the friction lining on the plate may be selected from a range with a lower limit of 35% and an upper limit of 55% of the solid density, i.e. the density of the solid material, thereby improving the wet operation capability of the friction lining, in particular the capacity of this friction lining to store oil, and further improving the dispensing of oil.
[0023] The porosity may also be selected from a range with a lower limit of 40% and an upper limit of 50%.
[0024] By preference, the friction lining has a modulus of elasticity selected from a range with a lower limit of 80 N/mm 2 and an upper limit of 160 N/mm 2 , which is even more gentle on counter plates made from light metals or light metal alloys in terms of their wear on the one hand and, on the other hand, imparts a sufficiently high wear resistance to the friction lining itself.
[0025] The modulus of elasticity of the friction lining may also be selected from a range with a lower limit of 90 N/mm 2 and an upper limit of 140 N/mm 2 .
[0026] The counter plate of the friction unit specifically has a Brinell hardness (test load 32.25 kg, ball diameter 2.5 mm, steel ball) selected from a range with a lower limit of HB 60 and an upper limit of HB 95, which permits a corresponding reduction in the weight of this friction unit as well as enabling better adjustment of the friction lining on the one hand and the counter plate on the other hand with respect to wear.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] To provide a clearer understanding of the invention, it will be explained in more detail below on the basis of examples and the appended drawing.
[0028] The drawing is a schematically simplified drawing illustrating the following:
[0029] FIG. 1 wear rate as a function of the latex content of a friction lining proposed by the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] Firstly, it should be pointed out that the same parts described in the different embodiments are denoted by the same reference numbers and the same component names and the disclosures made throughout the description can be transposed in terms of meaning to same parts bearing the same reference numbers or same component names. Furthermore, the positions chosen for the purposes of the description, such as top, bottom, side, etc., relate to the drawing specifically being described and can be transposed in terms of meaning to a new position when another position is being described. Individual features or combinations of features from the different embodiments illustrated and described may be construed as independent inventive solutions or solutions proposed by the invention in their own right.
[0031] All the figures relating to ranges of values in the description should be construed as meaning that they include any and all part-ranges, in which case, for example, the range of 1 to 10 should be understood as including all part-ranges starting from the lower limit of 1 to the upper limit of 10, i.e. all part-ranges starting with a lower limit of 1 or more and ending with an upper limit of 10 or less, e.g. 1 to 1.7, or 3.2 to 8.1 or 5.5 to 10.
[0032] By way of introduction, it should also be pointed out that within the context of the invention, the term latex should be construed as meaning by definition a colloidal dispersion or emulsion of an elastomer in an aqueous medium.
[0033] The paper used for such friction linings is a standard paper, for example a paper with a grammage of 290 g/m 2 . This paper is produced in the standard manner on a paper machine and a latex based on an elastomer is applied to the paper during the production process by means of a coating unit. The proportion of latex in the paper lies within the range specified above. It is also possible to add the latex to the fiber pulp used to produce the paper.
[0034] If necessary, other auxiliary agents may be added to the latex or to the overall mixture, such as for example solidifiers, such as polyamide resins or polyamidoamine-epichlorohydrin resins and fillers or friction particles, e.g. SiO 2 . The latex preferably has a viscosity of between 9 and 25 cps. As a result, the latex is able to penetrate the fiber matrix of the paper so that there is not just a superficial coating of latex on the paper. Once the latex has been applied to the paper, the elastomer is made to precipitate by reducing the pH value to a range of between 4.0 and 5.0. This is done by adding acids, for example.
[0035] Instead of using a paper machine, the friction lining may also be produced manually for example, in which case the latex is manually applied to the paper.
[0036] If necessary, it is also possible to apply the latex by a spraying process instead of applying a coating to the paper.
[0037] Within the scope of the invention, the following embodiments were prepared as examples.
[0038] A paper with a grammage of 300 g/m 2 was used. A latex based on the following composition was then applied to this paper.
[0000] Elastomer content: 50% by weight
Naphthalene sulfonic acid formaldehyde condensate: 0.3% by weight to 0.5% by weight (by reference to the total mixture)
Rest: water
[0039] This latex was added to the paper fiber pulp and the paper was produced with a standard paper machine.
[0040] After applying the latex, the pH value was reduced to 4.5 with an acid, preferably Al 2 (SO 4 ) 3 , to cause the elastomer molecules and elastomer to precipitate. As a result, a three-dimensional, spider's web-type network was created, by means of which the individual fibers of the fiber matrix of the paper were “glued” to one another. This friction lining had a porosity of 80% (not on the plate).
[0041] The elastomer used was an ABS elastomer available from Emerald Inc.
[0042] The friction lining produced in this manner was then adhered to a metal support. The metal used was an aluminum-magnesium alloy (AlZn5,5 Mg Cu).
[0043] Naturally, it would also be possible to use other metal supports, for example other aluminum alloys or aluminum as such or alternatively steel, etc.
[0044] A motorcycle clutch was fitted with the friction element produced in this manner and the counter plate used was also made from an aluminum-magnesium alloy (AlZn5,5MgCu) with a Brinell hardness HB=85.
[0045] The wear behavior of this friction unit was then determined by ascertaining the wear rate by measuring the difference in thickness subsequent to the respective wearing. The wear rate of both the friction lining itself, i.e. the friction lining plate, and the aluminum counter plate was determined and the result is set out in FIG. 1 . The wear rate in μm is plotted on the ordinate and the latex content as a % is plotted on the abscissa.
[0046] Curve 1 in FIG. 1 plots the wear rate of the friction lining plate and curve 2 that of the aluminum counter plate.
[0047] In preparing FIG. 1 , different latex contents, i.e. friction linings made from paper with different proportions of latex, were tested for their wear behavior. As may be seen from the graph, latex proportions of 5%, 24% and 40% were tested.
[0048] The graph clearly demonstrates that the wear rate of the aluminum counter plate drops, the higher the proportion of latex in the friction lining is, whereas conversely, the wear rate of the friction lining plate increases significantly as the latex content in the friction paper is increased. An optimum value for this friction unit in terms of wear behavior was specifically observed in the range of between 20 and 30% of latex or elastomer in the friction lining, whereas in terms of more gentle operation of the counter plate made from aluminum, proportions of elastomer of up to 40%, in particular between 30 and 40%, may be used in the friction lining and it is clearly evident that with a latex content above 40%, for example at 45%, the wear rate of the friction lining plate rises disproportionately and contents of latex or elastomer in excess of 40% are no longer practicable because the friction lining plate wears too quickly.
[0049] These tests were also repeated using other latexes, namely SBR, IR and NR, and resulted in essentially the same curves and it was found that with regard to the friction unit as a whole, an elastomer proportion of between 30 and 40% in the friction paper is optimum.
[0050] The embodiments illustrated as examples represent possible variants of the friction lining and it should be pointed out at this stage that the invention is not specifically limited to the variants specifically illustrated, and instead the individual variants may be used in different combinations with one another and these possible variations lie within the reach of the person skilled in this technical field given the disclosed technical teaching. Accordingly, all conceivable variants which can be obtained by combining individual details of the variants described and illustrated are possible and fall within the scope of the invention.
[0051] The objective underlying the independent inventive solutions may be found in the description.
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The invention relates to a method of producing a friction lining whereby a friction paper is displaced with a latex based on an elastomer and fibers of the friction paper are then bonded one another due to precipitation of the elastomer out of the latex. A non-surface active protective colloid is added to the latex as a suspension agent before applying it to the friction paper.
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RELATED APPLICATIONS
This patent application claims priority to Indian patent application serial number 1917/CHE/2007, having title “Prioritising Data Processing Operations”, filed on 27 Aug. 2007 in India (IN), commonly assigned herewith, and hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The increasing use of applications with significant data throughput requirements, such as online transaction processing applications, combined with the increasing use of file servers and rich media data servers, has led to an input/output (I/O) intensive application space which demands fast processing of large volumes of data. Such I/O intensive environments can have large, sustained workloads involving a wide range of I/O data transfer sizes as well as periodic burst accesses, depending on the applications involved.
When applications which are executing in parallel demand fast processing, an acceptable level of performance on a per application basis becomes a major customer requirement. Even in systems with resources such as large memory, multiple CPUs and associated resource management utilities, I/O subsystem bottlenecks may exist because the I/O system as a whole may not be configured to run optimally. Furthermore, applications for which I/O operations are critical, such as online transaction processing, currently compete equally for resources with applications for which I/O is non-critical, negatively impacting the critical application's requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 illustrates a storage area network according to an embodiment of the present invention;
FIG. 2 is a high-level overview of a processing system;
FIG. 3 illustrates the configuration of a host, intelligent switch and storage device of the storage area network of FIG. 1 in more detail;
FIG. 4 is a flow diagram illustrating the process of resource tuning for prioritisation according to an embodiment of the present invention;
FIG. 5 is a flow diagram illustrating a host storage stack layer registration process according to an embodiment of the invention;
FIG. 6 is a flow diagram illustrating a network storage stack layer registration process according to an embodiment of the invention;
FIG. 7 is a flow diagram illustrating the steps performed in processing user prioritisation instructions according to an embodiment of the invention; and
FIG. 8 is a flow diagram illustrating the steps performed in synchronised tuning of the host and network stack layers according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a storage area network (SAN) 1 includes a plurality of hosts 2 a , 2 b , 2 c , each having two host bus adaptors (HBAs) 3 a , 4 a , 3 b , 4 b , 3 c , 4 c connected via a plurality of first data links 5 to a plurality of intelligent switches 6 a , 6 b . The intelligent switches 6 a , 6 b route data between the hosts 2 a , 2 b , 2 c and a plurality of storage elements 7 a - d connected to the intelligent switches 6 a , 6 b via a plurality of second data links 8 . The plurality of hosts 2 a - c are, in the present example, servers, although they may alternatively be client computers. The storage elements 7 a - 7 c comprise disk drive arrays 7 a , 7 b , 7 c and a tape library 7 d . The first and second data links 5 , 8 between the hosts 2 a - c , intelligent switches 6 a , 6 b and storage arrays 7 a - d are, in the present example, fibre channel connections, but can alternatively be other connections such as ethernet connections, SCSI (Small computer System Interface) interfaces or TCP/IP connections, as known to those skilled in the art. The network of HBAs 3 a - 3 c , 4 a - 4 c , data-links 5 , 8 , and switches 6 a , 6 b that connect the hosts 2 a - 2 c and the storage elements 7 a - 7 d make up what is known as the fabric of the storage area network 1 .
A third data link 9 is provided between the hosts 2 a - c , switches 6 a , 6 b and storage arrays 7 a - d , and is used to carry storage network stack resource control data according to the present invention, as will be described in more detail below. The third data link 9 in the present example comprises a TCP/IP data link, although the fibre channel connections 5 , 8 can alternatively be used, or alternative connections known to those skilled in the art.
Each host 2 a , 2 b , 2 c , is allocated a storage area which can be accessed through the fabric of the SAN 1 . The storage area may be distributed over different storage elements 7 a - 7 d . A LUN or Logical Unit Number (also referred to as Logical Unit i.e. LU), corresponds to an actual or virtual portion of a storage element. For example, a LUN may correspond to one or more disks in a disk drive array.
The hosts 2 a - 2 c may be connected in a local area network (LAN) to a number of client computers (not shown). The client computers may be directly connected to the SAN 1 with their own data links, such as fibre channel links, or indirectly connected via the LAN and the hosts 2 a - 2 c.
FIG. 2 is a high-level overview of a processing system, such as those operating on the hosts 2 a - 2 c , illustrating the inter-relationship between software and hardware. The system includes hardware 20 , a kernel 21 and application programs 22 . The hardware is referred to as being at the hardware level 23 of the system. The kernel 21 is referred to as being at the kernel level or kernel space 24 and is the part of the operating system that controls the hardware 20 . The application programs 22 running on the processing system are referred to as being at a user level or user space 25 .
FIG. 3 illustrates the host 2 a , intelligent switch 6 a and storage array 7 a of FIG. 1 in more detail. The host 2 a runs the HP UX™ operating system and includes a number of applications 26 operating in user space 27 , the applications generating I/O operation requests 28 to be processed in kernel space 29 . The kernel space 29 includes a file system 30 , volume manager 31 , multipathing driver 32 , device driver 33 , in the present example a SCSI device driver, and host bus adaptor driver 34 , each forming a layer of what is referred to as the host storage software stack. Other layers are possible in addition to or in place of the layers illustrated in FIG. 3 , for instance a filter driver or a device driver above or below any of these layers performing specialised operations, or specific to a mass storage protocol such as iSCSI. Also, a fibre channel driver and/or an Infiniband driver could form part of the host storage software stack.
The kernel space 29 also includes the HBAs 3 a , 4 a of the host 2 a , which are controlled by the host bus adaptor driver 34 and connect to data link 5 linking the host 2 a to the intelligent switch 6 a and, in turn, via data link 8 to storage array 7 a.
Each of the layers of the host storage software stack has a respective tuner module 35 - 39 arranged to support tuning of the layer for prioritisation control. The tuners interface with a stack interface service (SIS) 40 implemented as a pseudo driver module in kernel space 29 . The stack interface service 40 receives commands from a priority and resource manager 41 , also implemented as a pseudo driver module in kernel space 29 . The stack interface service 40 is arranged to receive data from a user administrative control application 42 running in user space 27 and from a SAN resource agent 43 . The user administrative control application 42 receives user inputs 44 via a user input interface which could be a command line interface or a graphical user interface.
The intelligent switch 6 a and the storage array 7 a are referred to as layers of the network storage software stack and are also each provided with a respective tuner 45 , 46 arranged to support tuning of their resources for prioritisation control. The network stack layers 6 a , 7 a are also provided with a respective network stack agent 47 , 48 , which interfaces with the tuner 45 , 46 . The SAN resource agent 43 is configured as a daemon process running in user space 27 and is used to interface with the network stack agents 47 , 48 of the SAN components via the third data link 9 .
FIG. 4 is a flow diagram illustrating the process of resource tuning for prioritisation at the host 2 a , intelligent switch 6 a and storage array 7 a illustrated in FIGS. 1 and 3 .
In a first stage in the process, the layers 30 - 34 of the host storage software stack register with the stack interface service 40 (step S 1 ).
FIG. 5 illustrates the steps involved in the registration of each of the host storage stack layers 30 - 34 . The SIS driver 40 is loaded into the kernel 29 along with the priority and resource manager 41 (step S 1 . 1 ). The individual layer 30 - 34 is then loaded into the kernel 29 (step S 1 . 2 ). When a layer is loaded in the kernel, this layer will register with the SIS 40 using an ioctl interface (step 1 . 3 ). In particular, the storage layer issues an ioctl call to the driver 40 having the following parameters:
ioctl
(Device Descriptor,
Stack Identification No.,
Control Option,
Supported Attributes,
Tuning Function Pointer (Function Parameters)
)
The definitions of the storage layer ioctl parameters are set out below in table 1.0.
TABLE 1.0
No.
Parameter
Definition
1
Device Descriptor
Stack interface service driver descriptor
2
Stack
Indicates the layer that is registering with
Identification No.
the SIS driver
3
Control Option
Indicates to the SIS driver whether the
layer opts in or out of resource control
4
Supported Attributes
The attributes which this tuner can support,
for instance application id/process id, I/O
type, I/O request size, storage device or
LUN
5
Tuning Function
A function pointer supplied by the stack
Pointer
layer for tuning control.
Each host storage stack layer therefore indicates, via the ioctl call, whether or not it can control its resources so as to prioritise I/O operations based on attributes such as a particular application or process identification number, an input/output type or request size or an end LUN. The ‘control option’ parameter is used to specify whether the layer opts in or out of resource control in general and the ‘supported attributes’ parameter is used to specify the particular attribute(s) of I/O operations that the layer can support for prioritisation. The tuning function pointer is used to control the tuning of the layer for resource prioritisation when required.
The stack interface service 40 communicates the ioctl call parameters received from each stack layer to the priority and resource manager 41 using a function call exposed by the priority and resource manager 41 to the SIS 40 (step S 1 . 4 ).
The priority and resource manager 41 records the host storage stack layers that register, together with an indication as to whether they have opted for resource control via the ‘control option’ parameter (step 1 . 5 ) and, if so, records the attributes that can be controlled, as specified in the ‘supported attributes’ parameter (step S 1 . 6 ).
Referring again to FIG. 4 , following the host registration process, a network stack layer registration process is performed (step S 2 ).
FIG. 6 illustrates the network stack layer registration process. The SAN resource agent 43 issues a request for registration to the network stack agent 47 , 48 of each network stack layer 6 a , 7 a (step S 2 . 1 ). The network stack agent 47 , 48 of each layer responds with a PriorityControlResponse indicating that registration is complete (step S 2 . 2 ).
The PriorityControlResponse returned to the SAN resource agent 43 includes a header, stack identification number, control option and supported attributes, as defined in table 2.0 below.
TABLE 2.0
No.
Parameter
Definition
1
Header
Indicates to the stack interface service that
this is a network stack response
2
Stack
Indicates the layer that is registering with
Identification No.
the SIS driver (intelligent switch, storage
array etc)
3
Control Option
Indicates to the SIS driver whether the
layer opts in or out of resource control
4
Supported Attributes
The attributes which this tuner can support,
for instance a storage device, end LUN, or
an array controller port
The SAN resource agent 43 receives the PriorityControlResponse and communicates the data received in the response to the stack interface service 40 via an ioctl call (step S 2 . 3 ). The parameters in the ioctl call between the SAN resource agent 43 and the stack interface service 40 are parameter numbers 1 to 4 listed in table 1.0, namely the device descriptor, stack identification number, control option and supported attributes, where the stack identification number, control option and supported attributes are taken from the PriorityControlResponse.
The stack interface service 40 communicates the ioctl parameters to the priority and resource manager 41 (step S 2 . 4 ) using a function call exposed by the priority and resource manager 41 to the SIS 40 . The priority and resource manager 41 records the network stack layers that register, together with an indication as to whether they have opted for resource control via the ‘control option’ parameter (step S 2 . 5 ) and, if so, records the attributes that can be controlled, as specified in the ‘supported attributes’ parameter (step S 2 . 6 ).
Referring to FIG. 4 , once the SAN stack layer registration process (S 2 ) is complete, user instructions can be received via the user administrative control module 42 (step S 3 ).
Via the user administrative control module 42 , users, for instance system administrators, can select tuning of the resources of the host and network stack layers according to a number of factors. For instance, the user can specify tuning to prioritise the resources based on the attributes of I/O operations to be processed, such as the I/O type, for instance read or write, the I/O operation size, for instance greater or less than 4 Kb, 8 Kb, 16 Kb etc, the end LUN, an application name or a process identification number. The user can also specify a validity period for which the priority request is required and a quantity indicating the proportion of the resource which is to be allocated to the prioritised I/O operation, for instance allocated as a percentage.
FIG. 7 illustrates the steps performed in processing user instructions.
User requirements for prioritisation control are received as user inputs 44 , via an input device such as a keyboard or mouse (not shown), at the user administrative control module 42 (step S 3 . 1 ). Once the user administrative control module 42 determines that user requirements have been received (step S 3 . 2 ) it communicates the requirements to the stack interface service driver via an ioctl call (step S 3 . 3 ) of the form:
ioctl
(Device Descriptor,
Command,
Attribute type,
Attribute value,
Validity period,
Resource quantity
)
The definition of the parameters of the ioctl call between the user administrative control module and the stack interface service module are set out in table 3.0 below.
TABLE 3.0
No.
Parameter
Definition
1
Device Descriptor
SIS driver descriptor
2
Command
Indicates to the SIS whether the user
wants priority to be turned on or off
3
Attribute type
The attribute type to be prioritised
4
Attribute value
The value for the attribute type
5
Validity period
The duration for which the priority request
is valid
6
Resource quantity
The percentage of the resource which is to
be allocated for prioritisation
The stack interface service 40 communicates the user control parameters it receives in the ioctl call to the priority and resource manager 41 (step S 3 . 4 ) using a function call exposed by the priority and resource manager 41 to the SIS 40 . The priority and resource manager 41 records the user control parameters (step S 3 . 5 ) and identifies any derived values from the parameters (step S 3 . 6 ). For instance, an end primary attribute such as an end LUN would result in a derived attribute of the port of an array controller which is associated with the end LUN. The priority resource manager 41 then determines (step S 3 . 7 ) whether priority control according to the user request is possible and returns an indication to the user via the stack interface service 40 and user administrative control module 42 that the request has either failed (step S 3 . 8 ) or has been successful (step S 3 . 9 ).
Referring to FIG. 4 , once the user instructions have been received and processed, and in the case that the user request is successful (step S 3 . 9 ), synchronised tuning of the resources of the host and network stack layers can be performed (step S 4 ).
FIG. 8 illustrates the steps performed in synchronised tuning of the host and network stack layers.
Referring to FIG. 8 , the priority and resource manager 41 activates or deactivates the tuning function of the host storage stack layers that have registered for resource control by setting the value of the tuning function pointer provided in the ioctl call of each host storage stack layer accordingly, so as to implement the desired prioritisation (step S 4 . 1 ). The priority and resource manager 41 also issues a PriorityControlCommand to each registered layer of the network stack, via the SAN resource agent and the respective network stack agents (step S 4 . 2 ).
The PriorityControlCommand has the parameters set out in table 4.0 below.
TABLE 4.0
No.
Parameter
Definition
1
Header
Indicates the destination stack layer
2
Control
Tuner on or off
3
Attribute type
For instance, whether based on array
controller port or end LUN
4
Attribute value
Value of the specified attribute type
The priority and resource manager 41 then updates a priority resource control map that it stores which associates user needs with stack tuner support allocations, and links the associated host and/or network stack layers that are supporting each priority request (step S 4 . 3 ). A typical resource control map would have the values set out in table 5.0 below.
TABLE 5.0
Tuner
Attribute
Attributes
Validity
Layer Id
function/request
Specified
Supported
%
Period
File
FS_ResourceControlFunction
Application
Application
50%
60
System
Id, end
Id
minutes
LUN
HBA I/F
HBA_IF_ResourceControlFunction
End LUN
End LUN
50%
60
driver
minutes
Storage
ARRAY_ResourceControlRequest
End LUN
End LUN
50%
60
Array
minutes
Meanwhile, the host and network stack layers implement the priority control based on their received user requirements (steps S 4 . 4 and S 4 . 5 ). Prioritisation of I/O throughput is accordingly implemented across the storage software layers of a computer storage system in a synchronised manner, based on user attribute requirements.
In an example of the present invention, three applications A1, A2 and A3 operate in the user space 27 . A1 uses a logic unit number LUN1 for read operations and A2 uses the logic unit number LUN1 for write operations. A3 uses LUN2 for both read and write operations. The user could, for instance, specify:
Attribute types: Application ID, I/O type, end LUN
Attribute value: A1, Reads, LUN1
The resulting priority resource allocation would accordingly be 100% of the file system resources allocated to A1 and 100% of the driver resources for I/O operations to LUN1 for reads only.
Alternatively, the user could specify:
Attribute types: Application ID, end LUN
Attribute value: A1, LUN1
The resulting priority resource allocation would accordingly be 100% of the file system resources allocated to A1 and 50% of the driver resources for I/O operations to A1 and A2 (since both access LUN1). Net priority for A1 will therefore be 100% of the file system resources and 50% of the driver resources.
In the case that a user choice is incorrectly specified, for instance in the case that an impossible combination is specified such as A1 with attributes I/O type and end LUN and values ‘writes’ and ‘LUN2’, the priority and resource manager 41 observes read and write patterns to end LUNs from A1 and highlights the possibility of an anomaly to the user.
Current work load managers, such as the HPUX™ process resource manager support specific CPU/Memory and Disk I/O bandwidth prioritisation localised to one layer of the storage software stack. The user administrative control module 42 according to embodiments of the present invention is arranged to expose an application programmable interface (API) for priority attribute specification to enable tuning control by work load managers. This can enable the prioritisation infrastructure of the present invention to interact with existing work load managers in conjunction with CPU/Memory allocations so that prioritisation clashes do not occur.
The user administrative control module 42 also indicates to users that manually tuning layers of the host and/or network stack from user space can override the tuning performed by the prioritisation infrastructure of the present invention or may be overridden by the prioritisation infrastructure of the present invention.
The priority and resource manager 41 , according to embodiments of the invention, is arranged to control each of the layers in the host stack and network. Each layer, in turn, controls and assigns its internal resources based on their availability and controllability to that layer for priority support. For example, in the host stack the multipathing layer 32 can be controlled by detecting the turn around time of data being routed and choosing paths with the shortest turn-around time for allocation to prioritised applications. The paths allocated to prioritised I/O operations will therefore be dynamic in nature, as determined by the multipathing layer. Considering another example, in the network stack, the tuner 45 in the intelligent switch 6 a is, in certain embodiments, arranged to monitor slow response paths and to take the decision to reroute prioritised I/O operations appropriately to less loaded paths. Similarly, the array tuner 46 can also allocate more I/O command processing resources to a LUN used by high priority applications, or assign ownership of a LUN to a controller which is loaded less that other controllers. In all of the examples above, resource control is dependent on the capabilities of that layer, as would be appreciated by those skilled in the art.
Whilst specific examples of the host and network layer registration processes have been provided, the invention is not limited to these examples. For example, the SIS driver module 40 and priority and resource manager 41 need not be loaded prior to the layers 30 to 34 , 6 a , 7 a , of the host and network stacks, but can be loaded afterwards. The SIS driver module 40 can, in this case, be configured to trigger the layers to register through a further ioctl interface. Other arrangements are also possible, as would be apparent to those skilled in the art.
Also, whilst the invention has been described with regards to implementing resource prioritisation on host 2 a , intelligent switch 6 a and storage array 7 a of FIG. 1 , the invention can also be applied to the resources of other combinations of hosts 2 a , 2 b , 2 c , intelligent switches 6 a , 6 b and storage elements 7 a , 7 b , 7 c , 7 d.
The present invention may be implemented as computer program code stored on a computer readable medium. Furthermore, whilst the invention has been described based on a Unix-based operating system, namely HPUX™, it can also be applied for other operating systems, the implementations of which would be apparent to the skilled person from the present disclosure.
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The invention relates to a system and method for prioritizing one or more data processing operations in a computer storage system, the computer storage system including a plurality of modules, the method comprising receiving a command indicating one or more data processing operations to which priority is to be assigned and interfacing with each of the modules so as to prioritize the one or more data processing operations over other data processing operations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This continuation in part application claims the benefit of patent application Ser. No. 13/433,247, filed Mar. 28, 2012.
FIELD OF THE INVENTION
This invention, relates to lath furring strips. In particular, this invention relates to a low-profile lath furring strip with improved water resistance.
BACKGROUND OF THE INVENTION
The present invention is directed to overcoming problems associated with securing a lath to a sheathing (or a wall structure). In wall construction, plaster is generally applied to a flexible lath material instead of directly attaching the lath to a rigid structure, such as sheathing, because the current means of attaching a lath directly to a rigid structure can cause cracks. By applying plaster to a metal lath (which include structures such as welded wire, woven, wire, and expanded metal lath), the plaster cracks less frequently than if compared to applying the plaster directly to the sheathing. The current method of fastening laths to sheathing is either, with staples, nails or screws. Although a moisture barrier, such as building paper, can be placed between the lath and the sheathing, the moisture barrier must be penetrated by fasteners to secure the lath. This penetration creates holes which diminish the waterproofing features of the moisture barrier. When fasteners are driven into the sheathing, not only is the moisture, barrier penetrated by the fastener, but often times the moisture barrier is torn by the lath, creating more, possible water intrusion. Screws that press metal lath tear and cut the moisture barrier as they press the metal lath into the moisture barrier and sheathing. Since plaster is water absorbent, it can transmit water to more expensive and structurally important components of the building, such as the sheathing or the framing.
Lath furring strips are one way to reduce the number of penetrations into the moisture, barrier, because the lath is attached and secured to a furring strip, and not the sheathing or framing directly. An example of a lath furring strip, is disclosed in U.S. Pat. No. 1,405,579 to Graham. This patent discloses placing a metal lath on a furring strip, which provides permanent spaces between the lath and the framing, which permits the ready application and attachment of continuous mesh reinforcements on a vertical stud. By using lath furring strips, fewer fasteners are needed to attach the furring strip, to the sheathing, thus fewer penetrations are made into the moisture barrier. Furring strips have the added function of creating an air space between the sheathing and the lath, which serves the purpose of allowing the finishing material to key better, and creates insulation.
However, there are still problems with current lath furring strips. Although the use of furring strips reduces the number of holes in the moisture barrier compared to securing the lath to moisture barrier directly, water can still seep into the sheathing and framing via the holes that were created by the furring strip fasteners. A problem with adding additional waterproofing layers to the furring strip is that any additional waterproofing on the furring strip would increase the profile height of the lath furring strip. For proper plastering of walls, the plaster thickness is commonly ⅞ of an inch, and the total height from the bottom of the furring strip cannot exceed ⅜ of an inch. However, one drawback of using a lath furring strip with a profile of less than ⅜ of an inch is that it may reduce the attachment strength on the furring strip where the lath is secured. This is due to the fact that an attachment hole, where a wire tie or clamp secures the lath to the furring strip, is situated oh the mounting leg of a lath furring strip. The mounting leg is what gives most of the height to the lath furring strip. The attachment hole cannot be too large because the larger the attachment hole, the less metal there is between the outer edge of the attachment hole and the outer edge of the mounting leg. The less metal there is on this mounting leg, the more easily the lath can break off of the furring strip due to the small amount of metal holding the tie, lath, and mounting leg together. Although one might consider reducing the side of the attachment hole on the mounting leg, it takes skill insert wire ties through a lath and attachment hole, and reducing the size of the hole to leave more metal in between the attachment hole and the edge of the mounting leg would make it much more difficult for the practitioner, to secure the lath to the mounting leg.
Therefore, there is a need for lath furring strips with properties that increase waterproofing without increasing the profile of the plaster thickness beyond ⅞ of an inch, and maintain mounting leg strength at the attachment site of the lath. Additionally, there is a need to integrally combine lath furring strips with other construction devices to simplify and to increase water proofing qualities of other construction devices that are attached to a wall or framing.
SUMMARY OF THE INVENTION
In view of the foregoing, the present invention is directed to a lath furring strip and assembly of a lath furring system on a wall that allows for better waterproofing while maintaining mounting leg strength near a lath attachment hole.
It is a purpose of the present invention to provide a low-profile lath furring strip that is more water resistant than currently available lath furring strips. The furring strip can be mounted onto the sheathing, framing or studding with a water resistive backing to reduce water seepage from the plaster to the wall, while maintaining a low height profile for proper plaster coating wall construction.
The present invention introduces such refinements. In a preferred embodiment, the invention comprises a lath furring strip that has a flexible elastic water resistive backing, such as a rubber sheet, on the bottom of the lath furring strip, which adheres or is secured to a moisture barrier such as building paper. The furring strip further comprises a mounting leg used to attach lath to furring strip. The total height from the top of the mounting leg to the bottom of the mounting plate (including all attachments to the base of the furring strip) is 0.365 inches or less. The mounting leg is hemmed such that there is additional metal between the edge of an attachment hole for a lath and the edge of the mounting leg. The fastener that attaches the wire lath to the furring strip can be a wire clip, a C ring, a wire tie, or other means to fasten a lath to a furring strip. The lath furring strip can also be incorporated into termination points, channel screeds, drips screeds and weep screeds to increase waterproofing material between a wall and plaster.
The rubber sheet can be fixed to the lath furring strip and has an adhesive coating, which may have a peelable layer, to temporarily secure the mounting plate on the furring strip to a solid barrier. A mounting device, such as a nail or screw, is inserted through the lath furring strip, to secure the furring strip to the sheathing or framing, and penetrates the moisture barrier. The furring strip may have pre-cut holes for mounting, or may have no mounting holes in its prefabrication embodiment, whereby the mounting holes are created with self-tapping screws or other mounting devices. The rubber backing on the furring strip aids in waterproofing because when the nail or screw that secures the furring strip to the sheathing applies pressure to the rubber backing, the rubber backing is squeezed such that it at least partially fills in any gaps that would normally allow water to seep through the mounting hole and building paper to the other side of the lath furring strip. This prevents water from seeping through any holes that were in the building paper and damaging more expensive structures such as sheathing, framing, or studding.
Incorporating a thick rubber sheet to the bottom of a lath furring strip increases waterproofing, but if a rubber sheet is too thick, such as 1/32, 1/16 or ⅛ of an inch, it would significantly raise the lath furring strip. This presents a problem because, the thicker the rubber sheet, the greater the height of the furring strip mounting leg. Preferably, the attachment hole is 5/16 of an inch for ease of a practitioner inserting an attachment device such as a wire tie. As the height of the lath furring strip increases with added layers such as, rubber strips, the mounting legs must decrease, to keep the overall height of the lath furring strip at or below 0.365 inches since, the entire plastering thickness cannot exceed ⅞ of an inch. The lath furring strip can preferably be made from steel or other metals such as Galvanized steel or stainless steel.
In one embodiment of the present invention, the lath furring strip can be of different shapes, such as a shape that ills an inside corner, or a shape that fits an outside corner. The lath furring strip that fits an inside corner comprises two sides that mount against the solid barrier, such as sheathing, framing, wail, studding, or moisture barrier. Extending from each mounting plate is a mounting leg that is bent inward relative to the mounting plates of the lath furring strip. The lath is attached via attachment holes on the mounting legs. In the embodiment, where the lath furring strip fits an outside corner, the furring strip has two plates that mount against the solid barrier or moisture barrier on sheathing. Extending from each mounting plate is a mounting leg that is bent outward relative to the mounting plates of the lath furring strip. The height of the furring strip from the base of the furring strip or the moisture barrier to the tip of the mounting leg, where the lath is attached, cannot exceed 0.365 inches. In the corner lath furring strip embodiments, the furring strip comprises a flexible elastic, water resistant barrier, a first mounting plate for mounting said furring strip onto a solid barrier, a second mounting plate adjacent to, and substantially perpendicular to the first mounting plate, a mounting leg extending substantially perpendicular from the first mounting plate, a second mounting leg adjacent to, and substantially perpendicular to the second mounting plate, a first attachment hole for attaching lath to the furring strip to the first mounting leg, and a second attachment hole for attaching the lath to the second mounting leg. The first mounting plate is substantially parallel to the second mounting leg. The second mounting plate is substantially parallel to said first mounting leg. The first mounting plate is substantially perpendicular to said first mounting leg. The second mounting plate is substantially perpendicular to said second mounting leg. The mounting legs can either be bent inward (for use as an inside corner lath furring strip) or outward (for use as an outside corner lath furring strip) with respect to the mounting plates of the lath furring strip.
In another embodiment of the present invention, the lath furring strip can have a mounting leg of different shapes. By bending or curving the mounting leg, the height of the overall lath furring strip (including all flexible elastic water resistive barriers) can still remain at of under 0.365 inches. The advantage, of a bent leg is that more metal can be between the attachment hole where the lath attaches to the lath furring strip, and the lengthwise edge of the mounting leg. In one embodiment with a bent mounting leg, the mounting leg can have a hairpin loop such, that the leg is hemmed. In another embodiment of a bent mounting leg, the mounting leg can be bent such that the mounting leg has an additional extension leg that protrudes perpendicularly form the mounting leg. Preferably, the mounting leg and the extended part of the mounting leg are each equal, to or less than 0.365 inches, and does not increase the total profile height of the lath furring strip to greater than 0.365 inches. Preferably, the size of the attachment hole for the lath is 5/16 of an inch. When a rubber backing is added to these furring strips, it raises the height of the furring strip. Since the height, of the furring strip cannot exceed 0.365 inches, the height of the mounting leg must be reduced. Reducing the height of the mounting leg by bending the mounting leg in various configurations solves the problem increasing the amount of metal between the edge of the attachment hole and the edge of the mounting leg.
In another, embodiment of the present invention, the flexible elastic water resistive barrier fits within a recessed area around the mounting hole, or if the mounting hole is not pre-punched, in an area that will become the mounting hole. This recessed area may be a continuous recessed area that runs substantially along the length of the furring strip, or the recessed area may be localized to just around where the mounting hole is or will be. The flexible elastic water resistive barrier can be a rubber gasket that is a long strip, which runs, across a continuous recessed groove on the furring strip, or the flexible elastic water resistive barrier can be a small rubber gasket that fits within a punched-out area localized to the mounting hole area. The punched-out area can be circular or another shape where the gasket fits snugly within the recessed punched-out cavity. The gasket can have a pre-punched hole for a nail or screw to enter, or can be solid, and a hole will be made when a nail or screw pierces the gasket when it attached to the solid barrier. The advantage of a flexible elastic water resistive barrier, in the recessed groove or cavity is that when these gaskets are squeezed due to the pressure caused by a nail or screw securing the lath furring to the sheathing or framing, the rubber fills in spaces in the mounting hole where water might have seeped into or out of, had there been no gasket. Preferably, the lath furring strip can have attachment holes on the mounting leg to attach the lath to the furring strip, as previously described. The mounting legs can have the same hemmed mounting legs as previously described to increase the strength of the mounting leg near the attachment holes.
In another embodiment of the present invention, the lath furring strips in the previously, mentioned embodiments can be assembled with the lath and attached to sheathing and framing with termination points such as channel screeds or termination stops to form a lath and furring attachment system. The lath furring strip can be of the shape of any of the aspects previously mentioned aspects, and can have the flexible elastic water resistive barrier of any of the previously mentioned embodiments. In one embodiment, the lath and furring attachment system is comprised of a furring, a lath, and attachment device for securing the lath to the furring strip, a moisture barrier such as building paper, and another attachment device for securing the furring strip to a solid barrier such as sheathing or framing. The attachment device to attach the lath to the furring can be a tie (such as a wire tie, preferably 18 gauge), a clip, or C ring. A C ring may have the advantage of reducing the height profile of the assembled lath and furring system because wire ties have extensions that may protrude up through the plaster, while a C rings do not.
To apply plaster, an important aspect is the termination point. An effective method of achieving this termination is through a termination stop such as J-Moulding or Milcor, which is commonly used, around windows or doors. J-Moulding provides a clean transition from stucco to an alternative surface. A channel screed can also be used in a lath furring system which creates a recessed reveal that offers an architectural accent while providing a control joint to help minimize cracking. A moisture barrier such as building paper can be placed in between the J-Moulding termination stop of channel screed and the sheathing. When termination points are added, this allows water to migrate through the furring system when installed at termination points above doors and windows. Preferably, in one embodiment, the moisture barrier can be layered such it lays on top of the termination stop but behind the furring strip. The channel screed or termination stop can also have the previously mentioned embodiments of the flexible elastic water resistive barrier incorporated into it. The termination stop and channel screed can be attached to the solid barrier via attachment devices such as screws or nails. The height of the furring strip from the tip of the mounting leg to the bottom of the furring strip used in this embodiment still is a maximum of 0.365 inches. Lath is attached to the furring strip via attachment wholes on the mounting leg. The lath furring strips of this embodiment can be of any of the shape, and can have the waterproofing embodiments waterproofing embodiments previously described, or other embodiment with a flexible elastic water resistant barrier and bent mounting leg on a lath furring strip.
In another embodiment of the invention, a lath mounting device for mounting to a wall is comprised of a mounting leg, a first mounting plate and a second mounting plate. The first mounting plate has a front side and back side. The first mounting leg is formed at a substantially right angle to the front side of the first mounting plate and has at least one hole formed in the mounting leg for attaching lath. The second mounting plate is connected to the first mounting plate in a manner to permit the second mounting plate to be substantially parallel to the back side of the first mounting plate, the second mounting plate has a length greater than the first, mounting plate. The second mounting plate has a terminal end that includes an angled leg that crosses the plane of the first mounting plate. The lath mounting device provides a unitary structure that creates two layers of plates to inhibit water penetration to the wall and also provides an angled leg formed with the device to channel water away at the bottom of the wall.
In another embodiment, the terminal end of the second, mounting plate that includes an angled leg that, crosses the plane of the first mounting plate creates weep screed that will prevent water from wicking up into the exterior plaster walls and also will allow water that may get into the walls to migrate out. This type of furring strip allows water to drip from the plaster on the outside of a wall by a window to drip down and away from the wall from an extension leg from the drip screed, which is part of the lath furring strip. The weep screed has a longitudinal backing which is a second mounting plate that lies against a wall or sheathing, which is adjacent to the first mounting plate of the furring strip, forming a double layer of protection made from the furring strip material. A moisture, barrier, such as building paper, adds, another layer of protection by lying over the lath furring strip drip screed and over the mounting device, such as a screw, which secures the lath furring strip weep screed to the wall or sheathing. This moisture barrier adheres though ah adhesive to the mounting plate of the lath furring strip such that water cannot seep up the furring strip to the holes creating by the mounting device such as a screw. The maximum height from the backing of the lath furring strip weep screed mounting plate to the top of the mounting leg, which attaches the lath, is 0.365 inches, and to reduce the height of this mounting leg, embodiments, such as the ones previously described, may be employed.
In another, embodiment, the terminal end of the second mounting plate that includes an angled leg that crosses the plane of the first mounting plate creates a drip screed that will prevent water from wicking up into the exterior plaster walls and also will allow water that may get into the walls to migrate out. This type of furring strip allows water to drip from the plaster on the outside of a wall by a window to drip down and away from the wall from an extension leg from the drip screed which is part of the lath furring strip. The drip screed has a longitudinal backing that lies against a wall or sheathing, which is adjacent to the first mounting plate, of the furring strip, forming a double layer of protection made from the furring, strip material. A moisture barrier, such as building paper, adds another layer of protection by lying over the lath furring strip drip screed and over the mounting device, such as a screw, which secures die lath furring strip drip screed to the wall or sheathing. This moisture barrier adheres though an adhesive to the first mounting plate of the lath furring strip such that water cannot seep up the furring strip to the holes creating by the mounting device, such as a screw. The maximum height from the backing of the lath furring strip drip screed mounting plate to the top of the mounting leg, which attaches the lath, is 0.365 inches, and to reduce the height of this mounting leg, embodiments, such as the ones previously described, may be employed.
In another embodiment, the terminal end of the second mounting plate that includes an angled leg that crosses the plane of the first mounting plate. The angled leg is substantially at a 90 degree angle from the second mounting plate and extends beyond the mounting leg. This angled leg has an additional bend that is substantially parallel to both the first and second mounting plates, which creates a termination stop. The two mounting plates provide an additional layer of furring material between the lath and the wall or sheathing. A screw, nail, or other mounting device secures the lath furring strip termination stop to the wall. Preferably, a moisture barrier, such as building paper is placed on top of the first mounting plate of the furring strip closest to the lath, and covers the mounting device such that water cannot enter the a hole created by the mounting device into the wall or sheathing. The moisture barrier preferably has an adhesive that secures the moisture barrier to the top of first mounting plate nearest the mounting leg to prevent any water from the lath to get in between the moisture barrier and the hole created by the mounting device. The maximum height from the back of the second mounting plate to the top of the mounting leg, which attaches the lath, is 0.365 inches, and to reduce the height of this mounting leg, embodiments that reduce the height of the mounting leg, such as the ones previously described, may be employed. The termination stop furring strip preferably has a total profile height of ⅞ of an inch from the mounting plate against the wall to the end of the termination stop leg.
In another embodiment of the invention, the lath furring strip is integral with a decorative metal trim, commonly referred to as a “reveal” that is used in construction of structures that will have a plaster exterior finish. Architects may specify that at various points on a wall that a reveal should be incorporated with lath furring strip to change the aesthetics of the plaster finish. In this unique embodiment, the lath furring strip will preferably incorporate lath furring at a consistent three eights of an inch and may provide openings every three and one quarter-inches on the lath mounting leg for the wire tie method of lath attachment. The lath furring strip is installed to the wall or framing by fasteners, such as self-tapping screws, that secure mounting plates to a wall or framing covered by a moisture barrier, such as waterproof building paper. This embodiment has bottom mounting plates on each side of the reveal. The bottom side of the mounting plates attach to the wall or framing and form a bottom mounting plane against the wall. On top of each bottom mounting plate is a parallel top mounting plate, connected through a bend between the top and bottom mounting plates, forming a dual layer mounting plate on each side of the reveal. The reveal can preferably have triangular shaped protrusions, extending beyond the plane formed by the attached lath. Between the two triangular shaped protrusions is a recessed region that acts as part of the decorative trim. The embodiment may further have the flexible elastic water resistive backing on the furring strip to prevent moisture from seeping through holes created by the fastening device previously described, which can preferably be 1/32, 1/16, or ⅛ of an inch. This embodiment can also have the hemmed mounting legs to increase the amount of metal between the attachment holes on the mounting leg and the edge of the mounting leg to increase the stability of the structure between the attachment hole and the mounting leg edge. The lath furring strip has mounting legs with holes such that lath can be attached to this embodiment via a wire tie or other attachment device. The height of the lath furring strip from the bottom mounting planes of the furring strip to the top of the mounting legs is preferably 0.365 inches or less so that the lath can be at a consistent ⅜ of an inch from the wall or framing.
In still a further embodiment of the lath furring strip reveal, a moisture barrier can preferably be installed over the fasteners, and over the top mounting plates. This process will eliminate all of the penetrations in the moisture barrier secured by the lath. This process will eliminate the need for additional layers of moisture barriers that would be required around, other types of decorative metal trim.
In another embodiment, the lath furring strip, is a two-piece expansion joint used in construction of structures that will have a plaster finish on the exterior. Since construction codes call for plaster-finished exteriors to have expansion, joints at specific intervals, this embodiment allows for the expansion and contraction of materials due to temperature changes. In this unique embodiment each expansion joint is integral with a lath furring strip. This embodiment has two separate pieces, each piece can secure lath via an attachment device such as a wire tie, through holes on mounting legs. Each of the expansion joints can be secured to a wall or framing through via mounting devices such as screws, self-tapping screws, or nails. The two-piece expansion joint can be installed to provide a variable size to the expansion joint width depending on the width the architect would specify in the plans. In the first expansion joint, there are a is a bottom mounting plate and a top mounting plate, forming a dual layer mounting plate where the plates are substantially parallel to each other. The bottom side of the mounting plates attach to the wall or framing and form a bottom mounting plane against the wall. The dual layer mounting plates can be secured to a wall or framing by the use of a screw or nail. Extending substantially perpendicular from the top mounting plate is a mounting leg, which has holes for securing lath to the first expansion joint. The bottom mounting plate extends past the mounting leg to a distance, such that the second expansion joint can overlap the first expansion joint. As the bottom mounting plate extends past the mounting leg, it bends to form a horizontal termination leg, which is parallel to the bottom mounting plate, forming a dual layered bottom mounting plate and horizontal termination leg. Extending substantially perpendicular from the horizontal termination leg is a vertical termination leg, extending preferably seven eights of an inch. Extending substantially perpendicular from the vertical termination leg is a termination flange.
A second expansion joint can be placed over the first expansion joint such that the horizontal termination leg of the second expansion joint is on top of the horizontal-termination leg of the first expansion joint. The second expansion joint is able to sit flush with the first expansion joint because the second horizontal termination leg is raised compared to the horizontal termination leg on the first expansion joint. This raised horizontal termination, leg is achieved through a flared region on the bottom mounting plate on the second expansion joint. The bottom side of the mounting plate attaches to the wall or framing and form a bottom mounting plane against the wall. The flare extends away from the plane of the wall when the furring strip secured, creating a space for the first expansion joint to fit under the second expansion joint. This design is unique in that it provides a pre-tensioned bend in the metal to allow for a tight seal when the expansion joints are secured to a wall or framing with a lath furring strip. This greatly improves moisture intrusion protection. Parallel and on top of the bottom mounting plate on the second expansion joint is a top mounting plate formed by a bend between the top and bottom mounting plates. Extending substantially perpendicular from the top mounting plate is a mounting leg for attaching lath. The second expansion joint is secured to a wall or framing via a mounting device such as a screw, self-tapping screw, or nail. Preferably, between the wall and the two-piece expansion joint is a moisture barrier. Preferably, a water barrier will be installed over the fasteners that secure the expansion joints to the wall to eliminate all of the penetrations in the moisture barrier around the expansion joints. Preferably, the distance from the bottom mounting planes to the top of each mounting leg that secures the lath through attachment holes is 0.365 inches or less so that lath can be incorporated a consistent ⅜ of an inch from the wall or framing. This embodiment may further have the flexible elastic water resistive backing on the expansion joints, which can preferably be 1/32, 1/16, or ⅛ of an inch, to prevent moisture from seeping through holes created, by the fastening device previously described. This embodiment may also have the hemmed mounting legs to increase the amount of metal between the attachment holes on the mounting legs and the edge of the mounting leg to increase the stability of the structure between the attachment holes and the mounting leg edges.
In another embodiment of the invention, a lath furring strip is incorporated with a window furring strip. This embodiment is for use around windows constructed with plaster depth grounds incorporated in the window design from the manufacturer. The furring strip has a bottom mounting plate which is parallel and integral with a top mounting plate, formed by a bend between the two mounting plates. Extending substantially perpendicular is a mounting leg for securing lath to the mounting leg via a hole on the mounting leg. Preferably, the distance from the plane formed by the bottom of the bottom mounting plate and the top of the mounting leg is not greater than 0.365 inches so that lath can be secured at a uniform ⅜ of an inch from the wall or framing. This embodiment is unique in that it designed to have a pre-tensioned shape in the metal or the strip to allow the embodiment to seal tightly against the window flange and also has a water resistant lath furring strip, which prevents water from penetrating the wall or framing. Preferably, a moisture barrier is placed on top of the top mounting plate and on top of the fastening device, which eliminates any moisture barrier penetration around the window and the need for additional water barrier product, such as Biuthane or rubber to be layered into the window flashing. Extending from the bottom mounting plate is a flared region that angles away form the plane of the bottom mounting plate. Extending from this flared region is a flashing plate. The combination of the flare and the flashing plate creates a space such that the flashing plate can lay on top of the window flange. When the furring strip is secured to the wall or framing, the flashing plate of the furring strip is pressed against the window flashing, creating a more waterproof barrier between the two. Preferably, the bottom mounting plate can have a flexible elastic barrier to improve water resistance, which can preferably be 1/32, 1/16, or ⅛ of an inch, and can prevent water from seeping from the plaster into the wall or framing. Preferably, a moisture barrier may be placed on top the top mounting plate such that any hold created by the screw or other mounting device the secured the furring strip to the wall is covered. Preferably, the mounting leg can be a hemmed mounting leg such that more metal is between any attachment hole on the mounting leg and the edge of the mounting leg.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and various other objects and advantages of the invention will be described and understood from the following description of the preferred embodiments of the invention, the same being illustrated in the accompanying drawing.
FIG. 1 a is a side elevation view of a lath furring strip with a rubber backing, and a single mounting leg.
FIG. 1 b is a perspective view of a lath furring strip having a rubber backing.
FIG. 2 a is a side elevation view an inside corner lath furring strip having a rubber-backing.
FIG. 2 b is a perspective view of an outside corner lath furring strip.
FIG. 3 a is a side elevation view of outside corner lath furring strip.
FIG. 3 b is a perspective view of an outside corner lath furring strip.
FIG. 4 a is a side elevation view of a lath furring strip having a hemmed mounting leg.
FIG. 4 b is a perspective view of a lath furring strip having a hemmed mounting leg.
FIG. 4 c is a side elevation view of a lath furring strip having a bent mounting leg.
FIG. 4 d is a perspective view of a lath furring strip having a bent mounting leg.
FIG. 5 a is a side elevation view of a lath furring strip having a continuous recess for a rubber gasket.
FIG. 5 b is a perspective view of a lath furring strip having a continuous recess for a rubber gasket.
FIG. 6 a is a sectional view of a lath furring strip having punched holes with rubber gasket inserts.
FIG. 6 b is a side elevation view of a lath furring strip having punched holes with rubber gasket inserts.
FIG. 6 c is a perspective view of a lath furring strip having punched holes with rubber gasket inserts.
FIG. 7 is a side elevation view of an assembled lath and lath furring strip mounted to a sheathing and framing.
FIG. 8 is a side elevation view of an assembled lath and lath furring strip mounted to a sheathing and framing with overlapping waterproof paper.
FIG. 9 a is a side elevation view of a furring strip integrated with a weep screed.
FIG. 9 b is a side elevation view of a furring strip integrated with a weep screed, and with an assembled lath and mounting screw.
FIG. 10 a is a side elevation view furring strip integrated with a termination stop.
FIG. 10 b is a side elevation view of a furring strip integrated with a termination stop and assembled lath and mounting screw.
FIG. 11 a is a side elevation view of a furring strip integrated with a drip screed.
FIG. 11 b is a side elevation view of a furring strip integrated with a drip screed and assembled lath and mounting screw.
FIG. 12 a is a side elevation view of a reveal furring strip.
FIG. 12 b is a side elevation view of a reveal furring strip assembled with a lath and moisture barrier.
FIG. 13 a is a side elevation view of a two-piece expansion joint furring strip.
FIG. 13 b is a side elevation view of a two-piece expansion joint furring strip assembled with a lath and moisture barrier.
FIG. 14 a is a side elevation view of a window furring strip.
FIG. 14 b is a side elevation view of a window furring strip assembled with a lath and moisture barrier.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims. Preferable embodiments of the present invention are described with reference to the FIGS. 1-14 . FIG. 1 , FIG. 5 , and FIG. 6 show various embodiments of increasing the waterproofing characteristics of the lath furring strip. FIG. 2 , FIG. 3 , and FIG. 4 show various embodiments of the shape of the lath furring strip without any waterproofing elements, but can incorporate the waterproofing elements of the embodiments in any other figure. FIG. 7 and FIG. 8 show various embodiments of how the lath furring strip and lath are assembled, and may incorporate any of the waterproofing or lath shapes in any of other figures. FIG. 9 , FIG. 10 , FIG. 11 , FIG. 12 , FIG. 13 , and FIG. 14 show various embodiments of integrating a lath furring strip with termination stops, screeds, such as weep screed and drip screed, window furring, reveal, trims, and two-piece expansion joints. These embodiments can be combined with other embodiments described below.
FIG. 1 a and FIG. 1 b depict a lath furring strip 10 which has a mounting plate 20 and a mounting leg 2 , which is substantially perpendicular to the mounting plate 20 . On the bottom 22 of the mounting plate 20 is a flexible elastic water resistive barrier 6 such as a rubber sheet, fixed to the bottom side 22 of the furring strip 10 . The height of the lath furring strip 10 from the bottom of the flexible elastic resistive barrier 6 to the top of the mounting leg 12 does not exceed 0.365 inches. The mounting side 20 has a top side 16 and a bottom side 22 . A mounting hole 8 traverses the mounting plate 20 and goes through the top side 16 to the bottom side 22 . A nail or screw can be inserted into the mounting hole 8 to secure the lath furring strip 10 to the solid barrier, such as sheathing, framing, studding, or wall, and may attach to a solid barrier through an intermediary moisture barrier, such as a building paper. The mounting hole can also be created by the use of self tapping screws. The mounting leg 2 , where the lath is attached, may attach attaches via a clip, wire tie, C ring, or other means of securing a lath to the attachment hole 14 . The attachment hole may span both the mounting plate 20 and mounting leg 2 . The mounting leg 2 is integral with lath furring strip 10 and created by a bend 4 that forms a substantially perpendicular mounting leg 2 relative to the mounting plate 20 . The flexible elastic water resistive barrier 6 may have an, adhesive coating on the bottom of the flexible/elastic water resistive barrier 6 such that the furring strip 10 can adhere to a solid barrier or moisture barrier.
FIG. 2 a and FIG. 2 b show two views of an example of a furring strip 30 used for an inside corner of a wall. A first side 32 of the furring strip 30 has a mounting hole 36 . A screw or nail can be used to secure the first mounting plate 32 to a solid barrier such as a wall, sheathing, or framing, which has corner, and may attach to the solid barrier through an intermediary moisture barrier, such as building paper. A second mounting plate 34 of the furring strip 30 also has a second mounting hole 38 and is secured to a solid barrier. The corner 58 of the furring strip 30 nestles into the corner of the structure which the furring strip 30 attaches to. The furring strip 30 has a first mounting leg 40 and a second mounting leg 54 , which are each equal or less than 0.365 inches from the top of the mounting leg 46 to the bottom of the first mounting plate 32 or second mounting plate 34 of furring strip 30 . An attachment hole 60 on the first mounting plate 32 and an attachment hole 52 on the second mounting plate are used to attach a lath to the furring strip via a wire tie, clip or C ring. The attachment hole 60 may span both the first mounting plate 32 and the first mounting leg 40 through the corner 44 of the first mounting plate 32 and first mounting leg 40 . Similarly, the attachment hole 52 on the second mounting plate 34 may span the corner 56 of the second mounting plate 34 to the second mounting leg 54 . In a cross sectional view of the furring strip 30 , the furring strip 30 forms an open square-like structure as shown in FIG. 2 a , where the first mounting plate 32 and the second mounting plate 34 are two sides of the open square, with the corner 58 between these two mounting plates 32 , 34 . The first mounting side 32 and the first mounting leg 40 are at substantially a right angle to each other, and meet via a corner 42 . The second mounting plate 34 and second mounting leg 54 are substantially at a right angle to each other and meet via a corner 56 . A lath can take the cornering shape of the furring strip 30 by attaching a lath that is perpendicular to the mounting legs 40 , 54 , and parallel to the two mounting plates 32 , 34 via attachment devices that connect the lath to the attachment holes 52 , 60 . The furring strip 30 can have a flexible elastic waterproof barrier as shown in FIG. 1 , FIG. 5 . FIG. 6 , or other type of flexible elastic water resistive barrier.
FIG. 3 a and FIG. 3 b show two views of an example of a furring strip 70 meant for use on an outside corner of a wall. A first mounting plate 76 of the furring strip 70 has-a mounting hole 80 where a screw or nail can be inserted and secures the furring strip 70 to a solid barrier such as a sheathing, framing, or wall. A mounting hole 82 on a second mounting plate 74 secures the furring strip 70 to a solid barrier on an outside corner. The corner 88 of the furring strip 70 nestles in the corner of a wall for attachment. Extending from the first mounting plate 74 and the second mounting plate 76 are a first mounting leg 78 and a second mounting leg 72 respectively. The first mounting leg 78 is substantially perpendicular to the first mounting plate 76 and meet at a corner 98 . The second mounting leg 72 is substantially perpendicular to the second mounting, plate 74 and meet at a corner 96 . The height of furring strip 70 from the tip 92 of the first mounting leg 78 to the base of the first mounting plate 76 is equal to or less than 0.365 inches. Likewise, height from the the tip 94 of the second mounting leg 72 to the base of the second mounting plate 74 is also equal to or less than 0.365 inches. An attachment hole 86 secures a lath to the furring strip 70 , and this attachment hole 86 may span both the first mounting side 76 and first mounting leg 78 . Another attachment hole 84 secures a lath the furring strip 70 , and this attachment hole 84 may span both the second mounting plate 74 and second mounting leg 72 . The first and second, mounting plates 74 , 76 can have the flexible elastic waterproof barriers as depicted in FIG. 1 , FIG. 5 , FIG. 6 , or other embodiments of a flexible elastic waterproof barrier.
FIG. 4 a and FIG. 4 b are two views of another embodiment of a furring strip 100 . In this embodiment, the mounting leg 122 is hemmed, such that it is bent on an edge 102 . The height from the bottom 114 of the furring strip 100 to the top of the bent edge 102 is no greater than 0.365 inches. This bend forms a hairpin loop 104 with an opening 106 , which increases the amount of total furring strip material from the attachment hole 124 to the edge of the mounting leg 122 . The furring strip 100 has a mounting hole 188 within the mounting plate 120 . A screw, nail, or other attachment device secures the furring strip 100 to a solid barrier, such as sheathing, framing, or wall. On top of this solid barrier there may be a moisture barrier such as building paper. The mounting plate 120 can have a flexible elastic water resistive barrier 116 on the bottom 114 of the mounting plate 120 , or can have flexible elastic water resistive barriers of other embodiments as depicted in FIG. 1 , FIG. 5 , FIG. 6 , or other embodiments. The feature of a hemmed mounting leg 122 in FIG. 4 b , increases the strength of the mounting leg 122 because of additional furring strip material between the attachment hole 124 and the edge of the mounting leg 122 . The furring strip 100 has an attachment hole 124 for attaching a lath to the furring strip 100 .
FIG. 4 c and FIG. 4 d depict another embodiment of a furring strip 110 that increases the total amount of furring strip 110 material (such as steel or stainless steel) that is on the mounting leg 142 . The mounting leg 142 can be bent perpendicularly to make an edge 140 , such that the extension leg 138 of the mounting leg 142 is no longer than 0.365 inches, and the mounting leg 142 with the attachment hole 126 is also no longer than 0.365 inches. The attachment hole 126 may span the mounting plate 144 through a corner 134 that is formed between the mounting leg 142 and the mounting plate 144 . The total height from bottom 130 of the mounting plate 144 to the top of the extension leg 138 is no greater than 0.365 inches. The furring strip 110 may incorporate various embodiments of a flexible elastic water resistive barrier such as the embodiments depicted in FIG. 1 , FIG. 5 , FIG. 6 or other embodiment of a flexible elastic waterproof barrier on a furring strip.
FIG. 5 a and FIG. 5 b illustrate two views of a furring strip 150 with a recessed groove 154 for a rubber gasket 152 . The recessed groove 154 allows flexible elastic water resistive barrier, such as a rubber gasket 152 to line a mounting hole 168 without increasing the overall height of the furring strip 150 , such that the distance from the bottom side 172 of the mounting plate 164 to the tip 174 of the mounting leg 170 does not exceed 0.365 inches. The recessed groove 154 can be within the bottom side 172 of mounting plate 164 of the furring strip 150 . The top surface 178 of the mounting plate 164 , which has a mounting hole 168 can be raised but to provide a thickness of the recessed area of the furring strip 150 material equal to the thickness of the furring strip 150 material through the rest of the mounting plate 164 . The recessed groove 154 can be implemented in other designs of furring strips, such as the ones illustrated in FIG. 2 , FIG. 3 , or FIG. 4 . The recessed groove 154 can have a variety of shapes that enable it to fit a rubber gasket 152 . A first side 156 of the recessed groove 154 can be angled towards a mounting hole 168 , forming an obtuse angle from the bottom side 172 of the furring strip 150 towards the mounting hole 168 , and a second side 158 of the recessed groove 154 , which is closer to the mounting leg 170 also forms an obtuse angle from the bottom side 172 of the mounting plate 164 towards the mounting hole 168 . The top surface of the recessed groove 154 can be flat with no angles such that it fits a rubber gasket 152 with a flat top side. The recessed groove 154 can also be of other shapes that fit differently shaped gaskets.
In another embodiment, the recessed groove can be angled from the bottom side 172 of the mounting plate 164 such that a first side of the flare 160 closest to the mounting leg 170 , and the recessed groove closest to the non-raised portion 162 of the furring strip 150 , both recess in a perpendicular fashion in relation to the bottom side 172 of the mounting plate 164 before being angled in toward each other. A nail or screw attaches the furring strip 150 to a solid barrier such as a sheathing, wall, or framing by securing the furring strip 150 through via the mounting device through the mounting hole 168 . The furring strip 150 also has an attachment hole 173 to secure the lath to the furring strip 150 .
FIG. 6 a , FIG. 6 b , and FIG. 6 c illustrate three views of a furring strip 180 with punched holes 196 for a rubber gasket 198 . This feature enables the furring strip 180 to have an flexible elastic water resistive barrier nestled within the furring strip 180 , but does not add any height to the furring strip 180 , such that the height from the tip 182 of the mounting leg 184 to the bottom of the bottom of the mounting plate 188 does not exceed 0.365 inches. The furring strip 180 is secured to a solid barrier such as sheathing, framing, or a wall via a screw or nail that goes through the mounting hole 196 and rubber gasket 198 . The rubber gasket 198 can have a hole 200 within it, such that the nail or screw can pass through the mounting side 190 more easily. The top of the mounting plate 192 can have a raised region 194 on top of the recessed cavity 202 which contains the mounting hole 196 , such that the thickness of mounting plate 190 around the recessed cavity 202 is equal to the thickness of mounting plate 190 in the raised regions. The mounting leg 184 is substantially perpendicular to the mounting plate 190 and meet at a corner 186 . The rubber gasket 198 can have circular shape, or other shape that can fit sit inside the recessed cavity 202 . The furring strip 180 has an attachment hole 203 to secure a lath to the furring may be on the mounting leg 184 . The recessed cavity 202 embodiments can be utilized in other furring shapes, such as the ones depicted, in FIG. 1 , FIG. 2 , FIG. 3 , and FIG. 4 .
FIG. 7 shows an illustration of a lath furring strip system 210 attached to a wall, which is comprised of sheathing 220 and framing 222 . The lath furring strip 214 is secured to the sheathing 220 and framing 222 via a screw 218 . In this embodiment, there is a channel screed 230 also secured, to the sheathing 220 and framing 222 , via two screws 224 . A metal lath 212 is attached to the mounting leg 228 via a wire tie 226 . Between the furring strip 214 and the sheathing 220 is a moisture barrier 216 , such as building paper. This barrier runs the entire length under the furring strip 214 and channel screed 230 . The screws 218 , 224 pierce the moisture barrier 216 . The furring strip 214 can have the flexible elastic water resistive barrier embodiments of FIG. 1 , FIG. 5 , and FIG. 6 to protect water from seeping from the pierced moisture barrier 216 to the sheathing 220 and framing 222 . By securing the furring strip 214 with the screw 218 or other mounting device, the flexible elastic water resistive barrier squeezes into a shape where it fills in gaps in a mounting and prevents, water from seeping to the sheathing 220 or framing 222 . In this embodiment of a lath and lath furring strip system, 210 a channel screed 230 creates a recessed reveal which offers an architectural accent while providing a control joint to help minimize cracking.
FIG. 8 is an illustration of a lath and lath furring strip system 240 where a furring strip 256 is secured to sheathing 246 and framing 248 via a mounting screw 260 . This embodiment also has a termination stop called a J-channel stop 242 , such as Milcor, which provides for better water drainage. A lath 258 is attached to a mounting leg 254 of the furring strip 256 . The termination stop 242 is attached to the sheathing 246 and framing 248 via a mounting screw 244 . A moisture barrier 252 sits on the top side 242 of a termination stop 242 . The moisture barrier 252 is also situated between the lath furring strip 256 and the sheathing 246 and is penetrated by the screw 260 of the lath furring strip 256 . To prevent moisture from passing from the lath furring strip system 240 into the sheathing 246 or framing 248 , the bottom of the lath furring strip 256 can have a flexible elastic water resistive barrier, such as the ones described in the embodiments of FIG. 1 , FIG. 5 , and FIG. 6 .
FIG. 9 a and FIG. 9 b depict embodiments, of an integrated lath furring strip weep screed 270 , and a lath furring strip weep screed 270 with an assembled lath and mounting device 290 . The lath furring strip weep screed 270 has a mounting leg 272 that has a profile height from the bottom of a second mounting plate 278 to the top of the mounting leg 272 of 0.365 inches or less. The mounting leg 272 has an attachment hole for attaching a lath 292 to the mounting leg 272 via an attachment device such as a wire tie 298 . The mounting leg 272 is substantially at a right angle to a first mounting plate 274 . A hairpin loop 276 bends the furring strip material substantially 180 degrees such that there is an extra layer of furring strip 270 material creating a second mounting plate 278 behind die first mounting plate 274 . A screw 288 or other mounting device secures the lath furring strip weep screed 270 into a wall or sheathing through both the first mounting plate 274 and second mounting plate 278 . A moisture barrier 294 , such as building paper, is placed between the lath and the furring strip mounting side 274 , which covers a hole created by the screw 288 or other mounting device, which secures the lath furring strip weep screed 270 to the wall. A moisture barrier 294 adheres to the top side of the first mounting plate 274 , which covers the screw 288 and top side of the first mounting plate 274 through an adhesive layer 296 which prevents water from seeping in between the lath 292 and the top side of the first mounting plate 274 . The second mounting plate 278 extends past the mounting leg 272 and angles toward the lath 292 and forms a first weep leg 280 . The first weep leg 280 is bent back at a point 284 to form a second weep screed leg 282 which also is angled to form a side 286 that sits flush with the wall. This allows, water to drip from the plaster on the lath 292 away from the wall.
FIG. 10 a and FIG. 10 b depict embodiments of an integrated lath furring strip termination stop 300 , and a lath furring strip termination stop assembly 330 with a mounting device 316 and lath 322 . The lath furring strip termination stop 300 has a mounting leg 306 that has a profile height from the bottom of the second mounting plate 308 to the top of the mounting leg 306 of 0.365 inches or less. The mounting leg 306 has an attachment hole for attaching a lath 322 to the mounting leg 306 via an attachment device such as a wire tie 324 . The mounting leg 306 is substantially at a right angle to a first mounting plate 304 . A hairpin loop 302 bends the furring strip material substantially 180 degrees such that there is an extra layer of furring strip material which make the first mounting plate 304 and the second mounting, plate 308 parallel to each other. A screw 316 or other mounting device secures the lath furring strip termination stop 300 into a wall or sheathing through both the furring strip mounting side 304 and termination stop mounting side 308 . A moisture barrier 320 adheres to the top side of the first mounting plate 304 , which covers the screw 288 and top side of the first mounting plate 304 through an adhesive layer 318 which prevents water from seeping in between the lath 322 and the top side of the first mounting plate 304 . The second mounting plate 278 extends past the mounting leg 272 and turns at substantially a right angle angles toward the lath 322 and forms a termination stop leg 310 . The termination stop leg 310 is bent at substantially a 90 degree angle to become parallel to the second mounting plate 308 . This allows water to drip from the plaster on the lath 292 away from the wall. This termination stop structure is used where the plastering of a wall ends and other material begins, and prevents water from seeping into a wall.
FIG. 11 a and FIG. 11 b depict embodiments of an integrated lath furring strip with a drip screed 340 , and a lath furring strip drip screed assembly 360 with a mounting device 362 and lath 358 . The lath furring strip drip screed 340 has a mounting leg 350 that has a profile height from the bottom of the second mounting plate 344 to the top of the mounting leg 350 of 0.365 inches or less. The mounting leg 350 has an attachment hole for attaching a lath 358 to the mounting leg 350 via an attachment device such as a wire tie 353 . The mounting leg 350 is substantially at a right angle to first mounting plate 352 . A hairpin loop 342 bends the furring strip material substantially 180 degrees such that there is an extra layer of furring strip material creating the second mounting plate 344 behind the first mounting plate 352 . A screw 362 or other mounting device secures the lath furring strip drip screed 340 into a wall or sheathing through both the first mounting plate 352 and second mounting plate 344 . A moisture barrier 356 , such as building paper, is placed between the lath 358 and the first mounting plate 352 , which covers a hole created by the screw 362 or other mounting device which secures the lath furring strip 340 to the wall. The moisture barrier 356 adheres to the first mounting plate 352 by having an adhesive layer 354 . The second mounting plate 344 extends past the mounting leg 350 and angles toward the lath 358 and away from a wall, such that any water would fall down the drip screed leg 346 or off of an extension of that leg 348 away from the wall or window.
FIG. 12 a and FIG. 12 b depict an embodiment of a lath furring strip with a reveal 370 and an assembled lath furring strip with a reveal 390 . The assembled lath furring strip with a reveal includes an attached lath 386 and a moisture barrier 384 . The embodiment of the lath furring strip with a reveal 370 and assembled lath furring strip with a reveal 390 is integrated with decorative metal trim. It is this decorative metal trim which is commonly referred to as a reveal 383 . The lath furring strip with a reveal 370 , 390 , has two inner side protrusions 380 , 318 and two outer protrusions 378 , 379 which form two triangular-like shapes that form the reveal 383 and two furring strip sections 385 , 387 on each side of the reveal 383 . The outer protrusions 378 , 379 extend and form an obtuse angle with bottom mounting plates 376 , 377 (forming bottom mounting planes at the base of the bottom mounting plates 376 , 377 ) that may be placed against a wall framing that has a moisture barrier 384 . The bottom mounting plates 376 , 377 are bent into second mounting plates 374 , 375 on top of the bottom mounting plates 376 , 377 . Extending perpendicular from the top mounting plates 374 , 375 are mounting legs 372 , 373 which has attachment holes for securing lath 386 by way of a wire tie 388 or other mechanism that can attach lath 386 to a furring strip 370 , 390 . The height of the furring strip with a reveal 370 , 390 from the base of the furring strip 370 , 390 to the top of the mounting leg 388 is 0.365 inches or less so that the lath 386 can be consistently laid at ⅜ of an inch away from the framing. The furring strip with a reveal 370 , 390 is secured to the framing by fasteners that penetrate both the first mounting plate 376 , second mounting plate 374 , and moisture barrier 384 . The bottom mounting plates 376 , 377 are pressed against the moisture barrier 384 when secured to the framing via the screw or other mounting device. This pressure prevents moisture from seeping in from the plaster to through holes in the moisture 384 . The lath furring strip with a reveal 370 , 390 can have the added strength of a hemmed mounting leg 122 as shown in FIG. 4 b . Additionally, other embodiments featuring a furring strip with a reveal 370 , 390 can have the flexible water resistive barrier 6 as shown in FIG. 1 a or 166 in FIG. 4 b , to further prevent seepage of water from plaster through holes created through the moisture, barrier 384 by nails or screws that penetrate the moistures barrier 384 that hold the lath furring strip with a reveal 370 , 390 in place.
FIG. 13 a and FIG. 13 b depict a two-piece expansion joint 400 and an assembled two-piece expansion joint 440 with lath 416 , wire ties 432 , screws 418 , and moisture barrier 420 . Construction codes call for plaster-finished exteriors to have expansion joints at specific intervals allowing for the expansion and contraction of materials that occur during temperature changes throughout the day. In a first piece 411 , there is a bottom mounting plate 428 and a top mounting plate 430 . The top mounting plate 430 has a mounting leg 434 for attaching lath 416 to the mounting leg 434 with a wire tie 432 or other means for attachment. The top mounting plate 430 is substantially parallel to the bottom mounting plate 428 . The bottom mounting plate 428 , which at its base forms a bottom mounting plane, extends past the mounting leg 434 . The bottom mounting plate 428 is bent to then form an integral first overlapping plate 426 on top of the first mounting plate 428 . Extending perpendicular from the first overlapping plate 426 is a first joint-termination leg 424 , which extends beyond the plane of the top of the mounting leg 434 and beyond the lath 416 when assembled. Extending perpendicular to the first joint-termination leg 424 is a first overhanging leg 422 . The first expansion joint 411 can be placed at various distances from a second expansion joint 413 and the second expansion joint 413 is capable of sliding over the first expansion joint 411 . The second expansion joint 413 has a bottom mounting plate 410 , which at its base forms a bottom mounting plane. One on end of the bottom mounting plate 410 is a flashing 408 that rises and then forms the second expansion joint overlapping plate 406 . The flashing 408 provides a pre-tensioned bend in the metal to allow for a tighter seal against the first expansion joint 411 when a screw 418 secures the second expansion joint 413 to a wall or framing through a moisture barrier 420 . The second expansion joint 413 has a second overlapping plate 406 , which is substantially parallel to the first expansion joint overlapping plate 426 , such that the second expansion joint overlapping plate 406 lays on top of the first expansion joint overlapping plate 426 when assembled together to form the two-piece expansion joint 400 , 440 . Extending substantially perpendicular from the second expansion joint overlapping plate 406 is a second expansion joint termination leg 404 . Extending substantially perpendicular from the second expansion joint termination leg 404 is a second overhanging leg 402 . The first overhanging leg 422 and second overhanging leg 402 are substantially in the same plane as each other. The space between the first termination leg 424 and second termination leg 404 can expand, or contract when the temperature changes. The second overlapping plate 406 can slide back and forth over the first overlapping plate 426 when the temperature changes. The second expansion joint 410 has an top mounting plate 412 on of its bottom mounting plate 12 . Extending perpendicular from the top mounting plate 412 is a second mounting leg 432 , where lath 416 is attached through a hole on the mounting leg 414 . Both the first expansion joint 411 and second expansion joint 413 secured to a wall or framing by penetrating the top and bottom mounting plates 430 , 428 , 412 , 413 of each expansion joint 411 , 410 to a wall of framing via a screw 418 or other mounting device. The first expansion joint 411 and the second expansion joint 413 can have the added strength of a hemmed mounting leg 122 as shown in FIG. 4 b . Additionally, other embodiments featuring a two piece expansion joint 400 , 440 can have the flexible water resistive barrier 6 as shown in FIG. 1 a or 166 in FIG. 4 b , to further prevent seepage of water from plaster through holes created through the moisture barrier 420 by the screws 418 that penetrate the moisture barrier 420 that hold two-piece expansion joint 400 , 440 to the wall or framing. The height of the first expansion joint 411 and the second expansion joint 413 from the base of each expansion joint 411 , 413 to the top of each mounting leg 434 , 414 is 0.365 inches or less so that the lath 416 can be consistently laid at ⅜ of an inch away from the framing.
FIG. 14 a and FIG. 14 b depict a window lath furring strip 450 and an assembled window lath furring strip 470 assembled with a lath 468 , wire tie 466 , moisture barrier 464 , over a window flange 463 of a window 462 . The lath-furring strip 450 , 470 has a bottom mounting plate 456 and an integral top mounting plate 458 . A bottom mounting plane is formed at the base of the bottom mounting plate 456 . Extending from the fop mounting plate 458 is a mounting leg 460 where lath 468 attaches to the mounting leg 460 via a wire tie 466 . Extending from the bottom mounting plate 456 , beyond the mounting leg 460 is a flare 454 designed to have a pre-tensioned shape in the metal to allow the furring, strip 450 to seal tightly against the window flange 463 when a screw 472 penetrates through the top mounting plate 458 and the bottom mounting plate 456 into a wall or framing. This creates a tight seal between the lath furring strip 450 and the window flange 463 , which prevents moisture that may gather around the window 462 from seeping from the plaster on the lath 668 into the wall. A moisture barrier 464 is installed on top of the head of the screw 474 , on the top mounting plate 458 to eliminate any moisture barrier penetration from plaster to the wall created by the penetration of the screw 472 into the top mounting plate 458 , and bottom mounting plate 456 into the wall. The furring strip 450 , 470 can have the added strength of a hemmed mounting leg 122 as shown in FIG. 4 b . Additionally, other embodiments featuring a window furring strip 400 can have the flexible water resistive barrier 6 as shown in FIG. 1 a , or 166 in FIG. 4 b , to further prevent seepage of water from plaster through holes created by a screw 472 . The height of the window, furring strip 450 , 470 from the bottom mounting plate 456 to the plane formed by the top of the mounting leg 460 is 0.365 inches or less so that the lath 468 can be consistently laid at ⅜ of an inch away from the framing.
The invention has been described in terms of preferred embodiments thereof, but is more broadly applicable as will be understood by those skilled in the art. The scope of the invention is only limited by the scope of the following claims and equivalents thereof.
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The present invention provides a lath furring strip having a height not exceeding 0.365 inches which has improved waterproofing capabilities by incorporating the lath furring strip into other architectural structures such as reveals, expansion joints, and window flange, coverings. By integrating these structures with a lath furring strip having water proofing features, there is increased water proofing of the entire architectural structure. One of more moisture barriers can easily be applied to the wall or furring strips that prevents seepage of moisture from the stucco on the lath to a wall or framing.
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CROSS REFERENCE TO RELATED APPLICATIONS
This Application claims priority to U.S. Provisional Application No. 61/178,711, which was filed on May 15, 2009, and which is herein incorporated by reference in its entirety.
FIELD
This application describes fungicidal compositions that control mold and fungus infection in grasses, in particular turf grasses. More specifically, the compositions comprise a fungicide that inhibits mitochondrial respiration at the QoI site, (QoI inhibitor), a contact fungicide, a demethylation inhibitor and pigments.
BACKGROUND
Fine turf grass species are grown on golf course greens, fairways and tee boxes, as well as turf farms and many other locations. In northern regions, such as Canada and the northern United States, which are subject to temperate climates in the late summer and early fall and snow conditions in late fall and early winter certain moulds such as dollar spot, Sclerotinia homeocarpa , and snow molds, such as Microdochium nivale, Typhula incarnata and Typhula ishikariensis , represent a chronic problem for turf grass growers.
If left untreated in the late summer and fall, turf grass is predisposed to damage caused by Sclerotinia homeocarpa in the late summer and fall and the snow molds in late fall and over winter to spring. S. homeocarpa attacks most turf grasses grown in the South. Bent grass, common and hybrid bermuda grass and zoysia are most susceptible to S. homeocarpa attacks. The dollar spot disease occurs from spring through fall, and is most active during moist periods of warm days (about 70° F. to about 85° F.) and cool nights (about 60° F.) in the spring, early summer and fall.
Where the mold infection is extensive, the recovery of the turf grass can be delayed well into the growing season and seriously affect the ability of the turf grass to recover, leaving areas of dead patches. Further, turf grasses weakened or damaged by these molds are extremely slow to recover in the spring and are often invaded by undesirable opportunistic weedy grass species such as creeping bent grass ( Agrostis palustris ) and annual bluegrass ( Poa annua ).
A typical snow mold prevention program requires a mold inhibiting fungicide to be applied to turf grass prior to permanent winter snow cover. Typical programs consist of three applications prior to permanent snow cover and an additional application after the snow cover is gone in the spring. Several commercial fungicide products have been approved for use against dollar spot and snow mould species.
COMPASS (trifloxystrobin; (αE)-α(methoxyimino)-2-[[[(E)-[1-[3-(trifluoromethylphenyl]ethylidine]-amino]oxy]methyl]benzenacetic acid methyl ester) is an aromatic dioxime fungicide which has been approved for the control of leaf spot, Fusarium patch and brown patch diseases in turf grass. Trifloxystrobin is a quinone outside inhibitor (QoI) and a member of the class of aromatic dioxime fungicides described in U.S. Pat. No. 5,238,956, the contents of which are incorporated in their entirety herein.
ROVRAL GREEN GT (iprodione; 3-(3,5-dichlorophenyl)-N-(1-methylethyl)-2,4-dioxo-1-imidazolidinecaboximide) is a dicarboximide fungicide for pink snow mold control at a rate of 250 ml/100 m 2 and for gray snow mould control at a rate of 375 ml/100 m 2 . Iprodione is a member of the class of 3-phenyl hydantoin compounds described in U.S. Pat. No. 3,755,350, the contents of which are incorporated in their entirety herein. The effectiveness of iprodione to control the spread of snow mold in turf grasses (especially the gray snow molds T. incarnata and T. ishikariensis ) is highly variable due to the varying amounts of fungus inoculums, the varying length of snow cover under which snow mould inoculums thrive and the varying winter temperatures that exist across the country from year to year. Thus, in order to effectively control against a spectrum of snow moulds a relatively high dose may be required as well as multiple applications.
Phthalocyanines are known pigments having many applications, such as pigments for inks and coatings and even for turf grass paints. See, for example, DE 2,511,077, the contents of which are incorporated in their entirety herein, and JP 03/221576, the contents of which are incorporated in their entirety herein. Copper phthalocyanine has been used, but only in combination with certain other active ingredients, for enhancing turf quality. For example, U.S. Pat. No. 5,599,804, the contents of which are incorporated in their entirety herein, describes a method of combating fungi and enhancing turf quality in turf grass by applying in specific ratios certain phthalocyanines in combination with phosphorous acid or an alkaline earth metal salt thereof or with certain monoester salts of phosphorous acid. U.S. Pat. No. 5,643,852, the contents of which are incorporated in their entirety herein, describes a method of enhancing turf quality in turf grass by applying in specific ratios certain phthalocyanines in combination with (i) phosphorous acid or an alkaline earth metal salt thereof or certain monoester salts of phosphorous acid and (ii) certain ethylene bisdithiocarbamate contact fungicides. U.S. Pat. No. 5,336,661, the contents of which are incorporated in their entirety herein, describes a method of treating bent grass and enhancing turf quality by applying in specific ratios (i) certain monoester salts of phosphorous acid and (ii) a metallic ethylene bisdithiocarbamate contact fungicide. This patent also describes a specific composition containing a combination of aluminum tris(O-ethylphosphonate) (fosetyl-al) and a manganese-zinc ethylene bisdithiocarbamate complex (mancozeb) used in a form (FORE fungicide) believed to have contained an unknown amount of the phthalocyanine compound Pigment Blue 15.
It has been unexpectedly discovered that compositions comprising any two of the following three fungicides: (i) a QoI inhibitor fungicide, (ii) a contact fungicide, and (ii) a demethylation inhibitor; and certain pigments show superior mold control abilities than compositions with similar fungicides but without the pigments.
DETAILED DESCRIPTION
QoI inhibitor fungicides include trifloxystrobin. Contact fungicides include fludioxinil, iprodione and chlorothalonil, and iprodione and fludioxinil involve signal transduction in their mode of action. Demethylation inhibitors include triticonazole and propiconazole. Pigments include phthalocyanines such as Green pigment (Green 7) and Pigment Blue 15.
To determine the superiority of various compositions comprise a QoI inhibitor fungicide, a contact fungicide, and a demethylation inhibitor with pigments over a composition containing three classes of fungicides but without pigments, trials were conducted at the following sites: 1. University of Massachusetts, Vermont Site; 2. University of Wisconsin, Sentry Site; 3. University of Wisconsin, Iron Mountain Site; 4. University of Wisconsin, Champion Mich. Site; 5. University of Wisconsin, Edina Minn. Site; 6. Oregon State University, Sun River Site; 7. Washington State University, McCall Site; 8. Washington State University, Chewelah Site; and 9. Washington State University Pullman Site.
A general procedure for the application of the compositions described is as follows. Treatment plots were, for example, 6 feet×7 feet with three replications in a randomized complete-block design. Treatments were applied from late-October to mid-November. In several instances, the compositions were applied at 80 GPA with a bicycle-wheeled CO 2 pressurized (40 psi) sprayer with 11008 flat fan TeeJet nozzles.
Several sites have intermittent snow cover throughout the winter with periods of continuous snow cover. Once the snow melted, or is mechanically removed, individual plots were evaluated for pink ( M. nivale ) and/or gray ( Typhula spp .) snow mold disease severity (% area infected) and turf grass quality (rated on a scale of 1 to 9, with 9 being excellent).
Table 1 shows the effect of a composition containing differing amounts of a QoI inhibitor fungicide (trifloxystrobin), a contact fungicide (iprodione), a demethylation inhibitor (triticonazole) and a pigment (phthalocyanine Green pigment) in comparison with a standard combination of three classes of fungicides combined for snow mold control that does not contain any pigments (INSTRATA, manufactured by SYNGENTA) on Turf Quality (TQ) or Turf Color (TC). The scale is from 1 to 9 with 1=poor and 9=excellent. INSTRATA was used as a control because it is a snow mold product that has three classes of fungicides but does not have any pigments.
TABLE 1
Pink and Gray snow mold sites a
Mean of
Treatment b
1
2
3
4
5
6
7
8
9 d
all Sites
Untreated
5.7
4.5
6
3.3
6.3
1.5
2.3
1
1.7
4
(A + B + C): 4 oz/1000 sq ft +
7
8
7.8
7.8
8.3
6.5
5.7
5
4.7 e
7
(C + D): 0.85 oz/1000 sq ft
(A + B + C): 5 oz/1000 sq ft +
7
8
7.8
7.8
8
7.3
5.7
6.3
4.7 f
7
(C + D): 0.85 oz/1000 sq ft
INSTRATA c : 9.3 oz/1000 sq ft
5.7
6.8
6
6.3
7
4.3
5.7
5.7
4
6
a Sites: 1. University of Massachusetts, Vermont site; 2. University of Wisconsin, Sentry Site; 3. University of Wisconsin, Iron Mountain Site; 4. University of Wisconsin, Champion MI Site; 5. University of Wisconsin, Edina MN Site; 6. OSU, Sun River Site; 7. Washington State University McCall Site; 8. Washington State University Chewelah Site; 9. Washington State University Pullman Site.
b A = trifloxystrobin; B = iprodione; C = Phthalocyanine Green pigment (Green 7); D = triticonazole (3 lb ai/gal).
c INSTRATA = commercial standard without pigment (propiconazole + fludioxinil + chlorothalonil).
d Pink snow mold site.
e (A + B + C): 4 oz/1000 sq ft.
f (A + B + C): 5 oz/1000 sq ft.
A composition comprising A+B+C+D is the equivalent of INSTRATA+a pigment. In other words, using such a composition, a direct comparison can be made to demonstrate the superior effects of a composition containing the three classes of fungicides with a pigment vs. a composition containing only the three classes of fungicides (i.e., without a pigment). The results show that in every site where the composition containing the three classes of fungicides with a pigment is used, the TQ and TC are superior to INSTRATA. This means that the turf recovers better and looks better using the composition containing the three classes of fungicides with a pigment vs. INSTRATA.
The results from site 9, in which a composition comprising two fungicides (A+B) and C show that the composition of two fungicides and a pigment is at least as good as INSTRATA, if not slightly better. This is surprising because INSTRATA has three fungicides (but no pigment). In other words, an effect similar to using three fungicides can be achieved by the use of two fungicides and a pigment.
Table 2 shows the effect of a composition containing differing amounts of a QoI inhibitor fungicide (trifloxystrobin), a contact fungicide (iprodione), a demethylation inhibitor (triticonazole) and a pigment (phthalocyanine Green pigment) in comparison with INSTRATA on percentage disease infestation by site. The scale is from 1 to 9 with 1=poor and 9=excellent.
TABLE 2
Pink and Gray snow mold sites
Mean of
Treatment
1
2
3
4
5
6
7
8
9 d
all Sites
Untreated
56.7
76.3
43.8
96.3
17.5
73.8
28.3
73.3
51.7
58
(A + B + C): 4 oz/1000 sq ft +
11.7
0
0
3
0
6.3
5.3
6.7
0 e
4
(C + D): 0.85 oz/1000 sq ft
(A + B + C): 5 oz/1000 sq ft +
8.7
0
0
1.3
5
8.8
2
1.7
2.7 f
3
(C + D): 0.85 oz/1000 sq ft
INSTRATA: 9.3 oz/1000 sq ft
2.3
0.5
0
13.8
0
21.3
0
0
1.7
4
d Pink snow mold site.
e (A + B + C): 4 oz/1000 sq ft.
f (A + B + C): 5 oz/1000 sq ft.
The results in Table 2 show that the composition containing the three classes of fungicides with a pigment cures about the same percentage of disease infestation as INSTRATA. In other words, the composition disclosed is as effective as INSTRATA in killing mold. The superior benefits of a composition additionally comprising a pigment, such as a phthalocyanine, include better recovery of the turf after the winter, during the spring green up; better health of the turf; and better aesthetics (the turf looks visual better).
Once again, same results are seen at site 9 as in Table 2: a composition of two fungicides and a pigment is surprisingly as effective as one with three fungicides.
Therefore, compositions comprising two fungicides and a pigment are within the scope of this disclosure. Such compositions include a QoI inhibitor fungicide with a contact fungicide, and a pigment; a QoI inhibitor fungicide, a demethylation inhibitor, and a pigment; a contact fungicide, a demethylation inhibitor, and a pigment.
The QoI inhibitor fungicide, contact fungicide, the demethylation inhibitor; and the pigment may be in any ratio within the composition. Examples of suitable ratios are shown in Table 3.
TABLE 3
Component (g/L)
Lower end
Higher end
QoI inhibitor
1
2
3
4
5
6
7
8
9
10
fungicide
Contact
50
50
50
50
50
50
50
50
50
50
fungicide g
Demethylation
12
16
20
25
29
33
37
41
45
50
inhibitor
Pigment
20
22
24
26
29
32
34
36
38
40
g the amount of the contact fungicide is kept constant as a reference point.
Other exemplary compositions of trifloxystrobin, iprodione, and phthalocyanine Green pigment include those shown in Table 4, suspended in water.
TABLE 4
Component (g/L)
Lower end
Higher end
Trifloxystrobin
1.30
1.34
1.37
1.40
1.44
1.47
1.50
1.54
1.57
1.60
Iprodione
21.2
21.6
22.2
22.6
23.2
23.6
24.2
24.6
25.2
25.6
Phthalocyanine
5.5
5.6
5.7
5.8
5.9
6.0
6.1
6.2
6.3
6.4
Table 5 shows the superior effects of a composition containing 1.47 g/L of trifloxystrobin, 29.41 g/L of iprodione, 3.14 g/L of triticonazole, and 6 g/L of phthalocyanine over a commercially available solution of INSTRATA. The four-component composition and INSTRATA were applied to a bent grass/ Poa plot at Westmount Golf & Country Club in Kitchener, Ontario, Canada.
TABLE 5
Amount applied
Total disease
Composition applied
(mL/m 2 )
area (%)
TQ
None (untreated)
0
83
1
Trifloxystrobin: 1.47 g/L +
100
0
8.7
Iprodione: 29.41 g/L +
Triticonazole: 3.14 g/L +
133
0
9
Phthalocyanine: 6 g/L
177.5
0
9
INSTRATA
300
2
6.6
As the results show, application of the four-component composition of trifloxystrobin, iprodione, triticonazole, and phthalocyanine is superior to INSTRATA. Not only does the four-component composition provide better disease control than INSTRATA (as measured by the % area affected)—0% vs. 2% but the TQ is better 8.7 to 9 vs. 6.6. Additionally, excellent results can be achieved by using significantly lower amounts of the composition (100 mL/100 m 2 to 177.5 mL/m 2 ) vs. INSTRATA (300 mL/m 2 ). This is significant not only from an environmental perspective in that fewer chemicals are applied to the soil but also from an economic perspective in lower costs.
It should be understood that this disclosure is intended to cover compositions comprising, consisting essentially of, and consisting of at least two fungicides selected from the group consisting of a QoI inhibitor fungicide, a contact fungicide, and a demethylation inhibitor; and a phthalocyanine pigment. Without being bound by theory, it is believed that the various fungicides act in synergy with the pigment, thereby resulting in the superior effects observed.
The disclosure also is intended to cover methods of treating various turf species by application of the described compositions. Turf species that the described compositions can be used on include creeping bent grass, colonial bent grass, annual bluegrass, other Poa species of grasses, Bermuda grass, Rye grass, and other common grasses of golf courses, sport fields and sod farms.
The described compositions may be applied to healthy or diseased turfs. Prophylactic application to healthy turf may be helpful in preventing turf diseases. Application to turf containing one or more turf diseases is helpful in treating the one or more turf diseases. The turf diseases that the described compositions can treat include dollar spot, brown patch, anthracnose, gray leaf spot, and diseases of golf courses, sport fields, and sod farms. The described compositions are also helpful in improving turf quality after snow cover release in spring.
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The present invention relates to novel compositions comprising a fungicide that inhibits mitochondrial respiration at the QoI site, (QoI inhibitor), a contact fungicide, a demethylation inhibitor and pigments, which are highly suitable for controlling unwanted phytopathogenic fungi. Moreover, the fungicidal compositions are able to control mold and fungus infection in grasses, in particular turf grasses.
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RELATED DOCUMENTS
The present application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/015,631, filed Dec. 20, 2007, which is herein incorporated by reference in its entirety.
RIGHTS OF U.S. GOVERNMENT
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Contract No. N00173-D-02-2003 awarded by the Naval Research Laboratory.
BACKGROUND
Dynamic imaging systems, mounted on a moving platform, tracking a moving target object, or both, include an aiming structure such as a gimbal assembly and controls to point a camera system independently from the platform (e.g. aircraft, satellite, vehicle, etc.) on which it is mounted. Meanwhile, the camera system itself may include optics of various types as well as a plane for receiving an image. The plane of the image may be a focal plane array (FPA), film, or the like.
One problem of concern to scientists in atmospheric research, as well as those involved with imaging from aircraft or spacecraft, is the influence of jitter in destroying the alignment of a focal plane, such as that for film or a sensor array. The misalignment may be from any source, resulting in rotation of the focal plane structures with respect to a mount, optics, or an object being imaged through those optics. Thus, it would be an advance in the art to find a means to stabilize a focal plane array with respect to an image viewed, thus removing a significant amount of the disparity between the jitter motion of the focal plane array with respect to the optics, imaged object, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate various embodiments of the principles described herein and are a part of the specification. The illustrated embodiments are merely examples and do not limit the scope of the claims.
FIG. 1 is a diagram of an illustrative imaging system, according to one embodiment of principles described herein.
FIG. 2 is a diagram of rotational axes within an illustrative imaging system, according to one embodiment of principles described herein.
FIGS. 3A and 3B are diagrams showing the motion of an image on a focal plane during an integration period, according to one embodiment of principles described herein.
FIG. 4 is a perspective view of an illustrative two axis gimbaled imaging system, according to one embodiment of principles described herein.
FIG. 5 is a perspective view of an illustrative three axis image stabilization system, according to one embodiment of principles described herein.
FIG. 6 is an exploded perspective view of an illustrative three axis image stabilization system incorporated into a two axis gimbaled imaging system, according to one embodiment of principles described herein.
FIG. 7 is a cross-sectional diagram of an illustrative three axis image stabilization system incorporated into a two axis gimbaled imaging system, according to one embodiment of principles described herein.
FIG. 8 is a flow chart showing an illustrative control system for a three axis piezo stabilized imaging system, according to one embodiment of principles described herein.
FIG. 9 is a flow chart of an illustrative method for stabilizing an image system using a three-axis piezoelectric-stabilized, optical system, according to one embodiment of principles described herein.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
In view of the foregoing, an apparatus and method in accordance with the invention provide piezoelectric drivers operating at frequencies associated therewith to drive movement of a focal plane array about the effective center of its optical system.
Electro-optical imaging relies on a focal plane, such as a focal plane array (FPA) of sensors receiving photons (i.e., light, electromagnetic radiation), typically integrated over a period of time. The incoming radiation is detected by the sensors to cause a particular intensity of the resulting signal. While integrating light, an imaging system or imager (e.g., focal plane array, camera plane, etc.) appears to smear or spread the incoming light over a larger area thereof than should accurately represent the object being imaged in the presence of vibration in the imaging system.
Smearing degrades image quality. In a sense, smearing represents lost information. More accurately, perhaps, smearing represents misplaced information that has been distributed over an area larger than it should have been, thus distorting the image and providing misinformation. Nevertheless, the result of smearing ends up typically obscuring the desirable information of an image.
Vibrating equipment is a simple reality. It is the normal result of the complex interactions between pieces of hardware connected in any configuration having a moving part. A system subject to vibration may be subject to numerous modes, frequencies, amplitudes, and other characterizations of vibration. Any particular part, item, or system may move with respect to, or because of an interaction with any other particular part connected thereto. This is typically true regardless of how securely fastened a part is to another. Vibration isolation may be greater or lesser between different parts in an assembly, and the range of transmission may vary widely. The more or less tractable the analysis problem of determining vibrational modes and frequencies and compensating for them passively, the more likely will be the need for some type of active isolation or correction.
Vibration, or relative motion of a focal plane array with respect to its optics, or simply with respect to its target is called jitter. Jitter may be characterized as motion at a sufficiently high frequency and amplitude to cause smearing within about an order of magnitude of a picture element (pixel) of a focal plane array. Thus, more than about one tenth of a pixel of distance in smearing of an image is often unacceptable. A smearing distance of less than about one tenth of a pixel is usually satisfactory for many applications of a dynamic camera relying on a focal plane array.
Various systems exist to control pointing and tracking of cameras and other imaging devices. However, in certain scientific applications, the pointing and stabilization of a platform containing a camera on a gimbaled mount is insufficient. For example, the dynamics of a spacecraft, rocket motor, camera, various other equipment, and the like may introduce vibrations at various frequencies and amplitudes. A complete analysis of all possible vibrational frequency sources and resonances consequent thereto is often virtually impossible. Correction of such vibrations, if known, may not be tractable. Thus, it is not uncommon for a certain amount of “jitter” to exist in some aspect of a camera or other imaging system.
For example, a focal plane array may be thought of as a destination of rays of electromagnetic radiation (e.g., light) leveraged across a fulcrum represented by optical elements, the mounting system, or the like, while the opposite of the end of that lever represented by the ray is the imaged object, acting as the source or reflector of “light” (e.g. some spectrum of radiation) to be detected by the focal plane array. Accordingly, a comparatively small amount of rotation of a focal plane array in any dimension (e.g., about any axis) represents a comparatively much larger displacement of the opposite end of that ray rotated about the fulcrum, at the object or “viewed object” end of the ray.
Consequently, the comparative distance between the focal plane and its related optics, compared to the relative distance between those same objects and an object viewed, presents a tremendous multiplier or leverage. Accordingly, in a typical system where, for example, a meter of area in a scanned object or region may be represented by the light transmitted to a single pixel of a focal plane array, will be distorted if that focal plane array is allowed to distort or smear by a significant fraction of the size of a pixel.
In one example, a rotation of a focal plane array resulting in one pixel of displacement of the location of reception of a ray in the focal plane array during an integration period, where that ray represents, for example, one square meter of a target, can completely smear that square meter of target in the resulting image. Accordingly, it is desirable to maintain stability of a focal plane array within a distance of approximately one order of magnitude less than the size of a pixel.
For example, 10 percent of a pixel width variation or jitter may be acceptable, still rendering a substantially clear image. By contrast, jitter on the order of the size of a pixel, which is very likely in a nonstabilized system, will often render an image much less clear or maybe unusable.
Accordingly, what is needed is a method for very high frequency stabilization of a focal plane array through small displacements. What is also needed is a mechanism for stabilizing such a focal plane array in accordance with its rate of rotation about three axes, in order to compensate about those three axes for such rotation due to jitter.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present systems and methods. It will be apparent, however, to one skilled in the art that the present apparatus, systems and methods may be practiced without these specific details. Reference in the specification to “an embodiment,” “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least that one embodiment, but not necessarily in other embodiments. The various instances of the phrase “in one embodiment” or similar phrases in various places in the specification are not necessarily all referring to the same embodiment.
FIG. 1 is a diagram of an illustrative imaging system ( 100 ) which includes a camera body ( 115 ) which contains a focal plane ( 120 ). A lens ( 110 ) contains optics which focus light from an exterior scene ( 130 ) onto the focal plane ( 120 ). In this example, the lens ( 110 ) accepts light rays ( 125 ) through an aperture ( 112 ) and focuses the light rays ( 125 ) onto the focal plane ( 120 ) to produce an image ( 135 ) which is sensed by the focal plane ( 120 ).
The focal plane ( 120 ) is made up of a number of pixels ( 122 ). Each pixel ( 122 ) senses the portion of the image which is focused on it and produces an electrical signal which is proportional to that portion of the image. The number of pixels ( 122 ) in the illustrated focal plane ( 120 ) has been greatly reduced for clarity of illustration. Modern electronic camera systems typically include a focal plane made up of millions of pixels which provide the imaging resolution required to sense fine details in the exterior scene ( 130 ). However, the pixels ( 122 ) require a brief “integration time” during which each pixel ( 122 ) accumulates electrical charges proportional to the intensity of incident light. This “integration time” is analogous to the exposure time in a film camera. The optimal integration time for an imaging system ( 100 ) varies according to a number of factors, including the brightness of the exterior scene ( 130 ), the wavelength of light sensed by the focal plane ( 120 ), the light gathering capabilities of the lens system ( 110 ), and other factors. Ideally, the integration time is long enough for the pixels ( 122 ) to convert the incident optical energy into a significant electrical charge, but not so long that the individual pixels ( 122 ) become saturated.
Significant motion of the scene, objects within the scene, or imaging system during the integration time results in motion of the image ( 135 ) on the focal plane ( 120 ). This motion can move light which was previously incident on a pixel to neighboring pixels ( 122 ). This produces undesirable “smearing” in the image recorded by the focal plane ( 120 ). Smearing of the image results in a loss of image quality and information. Particularly when fine details in the image are important, such as aerial photography, smearing can unacceptably degrade the image quality.
Some motions of the imaging system produce less smearing of the optical image than others. For example, pure translation of the camera system with respect to the scene typically results in low amounts of smear because absolute translation of the focal plane array would be insignificant with respect to an image some kilometers distant. For example, one millimeter of displacement in pure translation is simply one millimeter of displacement with respect to a target.
However, even small rotations of the imaging system can produce significant amounts of smear. For example one millimeter of motion of the focal plane array ( 120 ) with respect to an optical fulcrum ( 128 ) represents, typically several centimeters, maybe even several meters of apparent displacement for rays of electromagnetic energy arriving from a targeted object.
FIG. 2 is a diagram which illustrates rotation of an imaging system ( 100 ) about three orthogonal axes X, Y, Z. As discussed above, the optical rays ( 125 , FIG. 1 ) passing through the lens ( 110 ) and striking the focal plane ( 120 ) can be thought of as a lever with a fulcrum ( 128 ) which is relatively close to the focal plane ( 120 ). Consequently, a small motion of the focal plane ( 120 ) about the fulcrum ( 128 ) can produce a large shift in the scene ( 130 ).
Rotation of the imaging system ( 100 ) about the X and Y axes results in a translation of the image ( 135 , FIG. 1 ) across the two dimensional focal plane ( 120 ). For example, for a scene at a range of 1500 meters, a rotation of a given camera about the X or Y axis of a single milliradian could result in a movement of the field of view by over a meter. Rotation of the imaging system about the Z axis results in a corresponding rotation of the scene on the focal plane. The Z axis, or bore axis, is typically defined as a line which passes through the center of the optics and strikes the center of the focal plane ( 120 ). The amount of smearing produced from bore axis rotation can be dependent on a number of factors, including the current field of view of the camera. For example, the edges of a wide angle field of view produced by a fish eye lens would be relativity sensitive to bore axis rotations, while a narrower field of view may be less sensitive.
The human hand typically generates jitter that ranges from 0 to 20 Hz. Consequently, for handheld camera that image within the visible spectrum, controlling frequencies between 10 Hz and 20 Hz can significantly decrease the amount of jitter-induced smear. For applications where a camera is attached to a moving vehicle, such as a boat, truck or airplane, higher frequency vibrations can be much more prevalent. For example, vibration levels from 10 Hz to 500 Hz can be significant depending on the camera, optics, and focal plane.
FIGS. 3A and 3B illustrate smearing of an image ( 135 ) on a focal plane ( 120 ) which may result from rotations of the imaging system during an integration period. FIG. 3A shows the translation of the image ( 135 ) on the focal plane ( 120 ) that results from rotations about the X and Y axes. Specifically, the X translation ( 305 ) is produced by rotations of imaging system ( 100 ) about the Y axis and the Y translation ( 310 ) is produced by rotations of imaging system ( 100 ) about the X axis. As a result of these rotations, the image moves across the focal plane during the integration period to a second location ( 300 ). This produces image smear and a corresponding loss of optical quality and information.
FIG. 3B illustrates the effects of rotations of the imaging system about the Z axis, which produces a corresponding rotation of the image ( 135 ) on the focal plane. As can be seen from the illustration, the displacement of the image ( 315 ) on the focal plane is greater on the perimeter of the image than in center of the image. Consequently, imaging systems with larger fields of view can be more sensitive to Z axis rotation than systems with narrower fields of view.
As discussed above, dynamic imaging systems, such as imaging systems on an aircraft, can produce large amounts of relative motion between the imaging system and the target scene. A gimbaled system can be used to point the camera at the target scene and to compensate for relatively slow motions of the aircraft or other platform. FIG. 4 is a perspective view of an illustrative two axis gimbaled imaging system ( 400 ). The gimbaled imaging system ( 400 ) uses a two axis gimbal ( 405 ) to support and point a ball ( 410 ) which contains the lens and focal plane. Typical gimbaled systems provide an elevation rotation ( 420 ) about an X axis and an azimuth rotation ( 425 ) about a Y axis. By actuating motors which control motion about these two axes, the ball ( 410 ) can be oriented so that imaging systems looking out from one or more apertures ( 415 ) can be pointed in any direction within the range of motion provided by the gimbal. Consequently, the two axis gimbal can point the imaging system at a target or move across a scene independently from the motion of the mobile platform. The gimbaled imaging system ( 400 ) is a relatively massive device and consequently can typically only compensate for slower motions (such as motions below about 10 Hz). Further, the gimbaled imaging system ( 400 ) has extremely limited ability to compensate for rotations about the bore axis. Undesirable bore axis rotations can frequently occur in aircraft optical sensors as the result of pitch, roll, and heading perturbations in the aircraft motion.
As discussed above, higher frequency motions of the platform can also be produced by a mobile platform or the surrounding environment. For example, on an aircraft mounted optical system, vibrations produced by mechanical motion and turbulence can produce undesirable jitter and corresponding smear of the images. The gimbal ( 405 ) is unable to compensate for this higher frequency motion or rotations about the bore sight of the optical sensor. Consequently, to reliably produce high quality imagery, an image stabilization system may be incorporated within the optical system.
FIG. 5 is an exploded perspective view of an illustrative three axes image stabilization system ( 500 ). The three axes image stabilization system ( 500 ) includes an X-Y stage ( 530 ) and a rotational stage ( 525 ) which is nested into the interior of the X-Y stage ( 530 ). The focal plane ( 510 ) is contained within a carrier ( 515 ). The carrier ( 515 ) which is attached to the upper surface of the rotational stage ( 525 ). An electrical connector ( 520 ) allows the electrical signals produced by the individual pixels which make up the focal plane to be read. These stages ( 525 , 530 ) move the focal plane to compensate for higher frequency jitter.
According to one illustrative example, the rotation stage ( 525 ) and X-Y stage ( 530 ) may be actuated by piezo electric actuators. Piezo electric actuators apply a voltage to a piezo active material which expands or contracts a distance which corresponds to the applied voltage. Typically this expansion or contraction is less than 1% of the overall size of the piezo active element. This change in the geometry of the piezo active material is extremely rapid and can produce a large amount of force.
In one embodiment, the piezo stages may be formed from a single monolith piece of metal which has been machined to form flexural joints which are moved by the piezoelectric actuators. This approach results in an extremely rigid stage which prevents the undesirable motion of the focal plane and allows for high frequency control of the focal plane position. For example, in the configuration illustrated in FIG. 5 , the piezo stages ( 525 , 530 ) may exhibit natural frequencies between approximately 300 to 500 Hz. Less rigid optical stages can be undesirable because they may allow the focal plane to move out of focus. Further, rigid stages are desirable because the data generated by angular rate sensors located in a separate location can be used to directly determine the motion of the focal plane to an acceptable level of accuracy.
According to one illustrative embodiment, the X-Y stage ( 530 ) can produce motions on the order of 100 microns and the rotational stage can produce motion on the order of 10 milliradians. Although this range of motion is relatively small, the stages produce enough travel to effectively cancel undesirable jitter-induced smearing. Integration times for many optical systems are typically on the order of milliseconds. Consequently, the magnitude of jitter-induced image translation on the focal plane during the integration period can be relatively small, typically on the order of 1 to 100 microns. The magnitude of the image translation can be a function of a number of parameters including the optical configuration of the system.
Each axis of the stages ( 525 , 530 ) may also include a sensor which provides information about the current position of the stage. For example, various capacitive, inductive, optical or strain gage based sensors may be incorporated into the piezo stage to provide the desired feedback regarding the stage's current position.
FIG. 6 is an exploded perspective view of the three axis image stabilization system incorporated into the ball ( 410 ) of a two axis gimbaled imaging system ( 400 , FIG. 4 ). According to one illustrative embodiment, an optical bench ( 635 ) provides a rigid and stable platform to which the other components are mounted. The X-Y stage ( 530 ) is mounted to the under side of the optical bench, with the rotational stage ( 525 ) mounted within the central cavity of the X-Y stage ( 530 ). The focal plane ( 510 ) is mounted to the upper surface of the rotational stage ( 525 ). According to one illustrative embodiment, the focal plane ( 510 ) may be an infrared (IR) detector which senses optical wavelengths in the infrared portion of the electromagnetic spectrum. Infrared focal planes can provide a number of benefits including night vision, high visibility of heat sources, detection of chemicals, and other advantages. However, infrared focal planes typically have longer integration times and are consequently more susceptible to jitter-induced smearing.
IR optics ( 630 ) are attached to the optical bench over the focal plane ( 510 ) such that optical energy from the exterior scene is focused onto the focal plane ( 510 ). According to one illustrative embodiment, an independent visible camera ( 615 ) with its associated visible optics ( 620 ) may also be included in the ball ( 410 ).
Three angular rate sensors ( 625 ) are attached to the optical bench ( 635 ) in three different orientations. According to one illustrative embodiment, these angular rate sensors ( 625 ) detect rotations about three orthogonal axes. According to one illustrative embodiment, the angular rate sensors may be mechanical gyroscopes, ring laser gyroscopes, magnetohydrodynamic rate sensors, micro-electro-mechanical-systems (MEMS) gyroscopes or the like. The angular rate sensors ( 625 ) may be selected according to various parameters, such as values for bandwidth, accuracy, drift, and the like. The signals generated by the angular rate sensors ( 625 ) are utilized by the image stabilization control system to determine how to move the focal plane.
Additionally or alternatively, other methods of measuring jitter may be used. In some embodiments, a sensor array may be utilized to detect either the absolute angle or the angular rate or both. These measurements may be made from a variety of locations, including at the optics ( 620 , 630 ), at the gimbal ( 405 ), or at a focal plane ( 510 ) itself. For example, the imagery generated by the visible camera ( 615 ) may be utilized to sense angular rotations of the optical assembly. The visible camera ( 615 ) may have a much higher frame rate than the IR camera. By using a real time change detection algorithm or other suitable method, changes between frames in the visible data could be used to detect jitter. This illustrative method of sensing jitter could be used to supplement the angular rate sensors ( 625 ) or could be used independently.
A front cover ( 610 ) and a rear cover ( 640 ) attach to the optical bench ( 635 ) to protect the optical components and form the outer shell of the ball ( 410 ). The front cover ( 610 ) has two apertures ( 415 ) through which the IR and visible sensors ( 515 , 615 ) receive optical energy from the surrounding scene. These apertures ( 415 ) may be covered by windows to protect the interior components. According to one illustrative embodiment, the front cover ( 610 ) and rear cover ( 640 ) may form hermetical seals with the optical bench ( 635 ) to provide a controlled environment within the ball ( 410 ).
FIG. 7 is a cross-sectional diagram of the illustrative image stabilization system incorporated into the gimbaled imaging system ( 400 ). The resulting system ( 400 ) has five controlled degrees of freedom: two coarse rotational degrees of freedom provided by the two axis gimbal ( 405 ) and finer three degrees of freedom provided by the image stabilization system ( 500 , FIG. 5 ). As discussed above, the azimuth stage ( 700 ) and the elevation drive ( 710 ) of the gimbal ( 405 ) provide pointing and lower frequency corrections. The elevation drive ( 710 ) is connected to a pivot point in the gimbal arms and rotates the ball ( 410 ) about its center.
For higher frequency image stabilization, the three axis image stabilization system ( 500 , FIG. 5 ) actuates the X-Y stage ( 530 ) and the rotation stage ( 525 ) to cancel out undesirable motion of the image across the focal plane ( 510 ). The piezoelectric actuators may be activated to move the focal plane array ( 410 ) about the X, Y, and Z axes at a rate, displacement, or both, equal and opposite to those imposed by vibration or jitter. As discussed above, the optical bench ( 625 ) provides a common reference point and stable platform for the various components which make up the ball ( 410 ). The X-Y stage ( 530 ) controls motion parallel to the plane of the focal plane ( 510 ) and the rotation stage ( 525 ) provides rotation about a bore axis ( 720 ) which passes through the center of the IR optics ( 630 ).
When the control system determines that a rotation of the optical system has occurred during an integration period, the appropriate control signals are sent to the X-Y stage ( 530 ) and the rotation stage ( 525 ). Actuation of the X-Y stage ( 530 ) translates both the attached rotational stage ( 525 ) and the focal plane ( 510 ). Rotations of the rotational stage ( 525 ) move only the attached focal plane ( 510 ).
FIG. 8 is a flow chart showing an illustrative control system ( 800 ) for a three axes piezo stabilized imaging system. According to one illustrative embodiment, angular rate sensor signals ( 815 ) enter the system from the angular sensors ( 625 , FIG. 6 ). These signals ( 815 ) are received by a filtering module ( 820 ) which pre-filters the sensor signals ( 815 ). According to one illustrative embodiment, the filtering module ( 820 ) may include a high pass filter which shapes the response in the operating frequency band of the image stabilization system. The filtered signals are then passed to a signal conversion module ( 825 ). The signal conversion module ( 825 ) converts the filtered signals into an angular rate by applying sensor specific calibrations. For example, each sensor may have an angular sensitivity which can be expressed in terms of radians per second per volt. The signal conversion module ( 825 ) converts the signal voltage by applying the angular sensitivity to produce angular rate data expressed in terms of radians per second. This output data is received by an integrator ( 835 ) which integrates the angular rate data with respect to time to generate an instantaneous rotation in radians. This rotation is mapped into optical space by the mapping module ( 845 ). According to one illustrative embodiment, the mapping module ( 845 ) converts the rotation in radians into displacement of the image across the focal plane. For example, the mapping module ( 845 ) may use geometric and optical properties of the system to convert the rotation of the optical bench into displacement of the image across the focal plane.
This displacement ( 850 ) is passed into a summing module ( 860 ) where it is combined with the measured piezo position ( 880 ) and the output of a piezo transfer function ( 855 ). The measured piezo position ( 880 ) represents the current position of the piezo stage, and consequently, the current position of the focal plane. The piezo feed-forward transfer function ( 855 ) is a model of the piezo stage behavior which provides information about the frequency domain response of the piezo stage.
If the combination of the three inputs to the summing module ( 860 ) results a zero, the focal plane is already in the desired position and no response is necessary. If the result of the summing function is non-zero, the focal plane needs to be moved to a new location to compensate for jitter-induced motion of the image across the focal plane. This is output as an error ( 863 ). This error ( 863 ) is received by a controller ( 865 ) which controls the motion of the piezo stages. According to one illustrative embodiment, the controller ( 865 ) may be a proportional-integral-derivative (PID) controller. The PID controller uses a control loop to correct for the error ( 863 ) by outputting control signals to the piezo stages and using capacitive or inductive sensors within the piezo stages to determine if the desired motion was produced.
According to one illustrative embodiment, the output of the controller ( 865 ) may be filtered by an output filter module ( 870 ). The output filter module ( 870 ) may include a number of functions, such as notch filters which prevent the excitation of undesirable structural modes and a low pass filter which imposes a cut-off frequency on the controller. The notch filters allow the controller to continue to control the piezo stages at frequencies higher than one or more structural modes. The low pass filter limits the control signals to a desired frequency range and reduces undesirable high frequency noise. A piezo command ( 875 ) is generated by the output filter module ( 870 ) and passed to the piezo stage. The control system ( 800 ) described above can be replicated for each control axis within the image stabilization system and can correct for jitter frequencies below one hertz up to hundreds of hertz.
FIG. 9 is a flow chart of an illustrative method for stabilizing an image system using a three-axes piezoelectric-stabilized, optical system. In a first step, an angular rate of rotation of the optical assembly is measured (step 900 ). As described above, this measurement may be made using a number of methods, including magnetohydrodynamic gryoscopes. The current position of each of the three controllable axes of the piezo stages are then measured (step 910 ). According to one illustrative embodiment, the X and Y axes measurements are produced by inductive sensors and the rotational measurement is produced by a strain gage. The angular rates are then integrated to determine the absolute short term attitude of the optical assembly (step 920 ). The absolute attitude is then mapped into motion of the image on the focal plane (step 930 ). The current position of the three controllable axes is then compared to the desired position of the focal plane (step 940 ). If the current position of the three controllable axes is substantially equal to the desired position, no action is taken. However, when an error is detected, the appropriate piezo stages are actuated to minimize the error, thereby reducing jitter-induced smear (step 950 ). This process is repeated throughout the integration period. After the integration period ends, the current frame is read out of the focal plane array and the piezo stages are reset to their neutral positions to prepare for the next integration period (step 960 ).
The preceding description has been presented only to illustrate and describe embodiments and examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
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An image stabilization system includes an optical assembly configured to receive electromagnetic radiation emitted by a target and produce focused image of the target; a focal plane array, the focal plane array being configured to receive the image and integrate at least a portion of the electromagnetic radiation making up the image to produce an electrical representation of the image; sensors configured to provide kinematic data; a control system receiving the kinematic data and estimating jitter-induced motion of the image on the focal plane and outputting a control signal; and actuators configured to receive the control signal and to translate the focal plane along two orthogonal axes and rotate the focal plane about a third orthogonal axis such that jitter-induced motion of the image on the focal plane is reduced.
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The present application is a Continuation-in-Part Application of U.S. application Ser. No. 08/683,401, filed Jul. 18, 1996 and abandoned as of Jun. 18, 1997, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to a method and device for detecting the mass of fiber material in a sliver or other elongated body being processed. The invention is concerned particularly with fiber mass detection in rotor spinning machines, but it may be applied in other types of machines as well.
BACKGROUND OF THE INVENTION
Known rotor spinning machines include many spinning stations. Each is sometimes referred to as a "spinning box." A sliver or a fiber strip is applied to each such station. A so-called feed trough is located at the entrance to each spinning station to receive the fiber strip and press it against a rotating feed roller, so that the fiber material will be drawn over the feed trough by the feed roller. The feed trough can be constructed as a type of lever or flap which is pivotally mounted and extends in the vicinity of the feed roller approximately tangentially thereto. After the feed roller, the fiber material is taken up by a separating roller where the fibers are separated.
The weight of fibers advanced per unit of time by the feed roller is an important factor with respect to the size of the yarn produced at the spinning station of a rotor spinning machine. Also, the uniformity of the mass of fibers along the length of the strip forming the input to the spinning station is an important factor with respect to the uniformity of the resulting yarn. However, if the thickness or mass of the fiber material is to be measured in the vicinity or region of a spinning station, then it is necessary to arrange measuring devices, such as measuring hoppers etc., upstream or downstream of the spinning station. But, this can only be done where space for a measuring device is available along the route of the supplied fiber material. If this space is available, a measuring device can be provided. However, this generates resistance in the fiber material which needs to be overcome and which can influence the fiber material in an unexpected manner.
SUMMARY OF THE INVENTION
An object of the invention is to provide a method and a device to obviate the above-mentioned disadvantages and allow the mass of fiber material drawn into a spinning station rotor to be measured.
This object is attained by detecting the mass of the fiber material in the region of a feed roller of a spinning station of a rotor spinning machine. A device suited to this end comprises a measuring element on the feed trough, which measuring element is constructed to transmit a signal corresponding to the mass of fiber material on the feed trough. This measuring element preferably is integrated into the feed trough structure.
Measuring elements of this type can trace the surface of the fiber material, can follow the thickness irregularities, and can effect deflections which can be converted into information relating to a path or a pressure. Accordingly, the measuring elements comprise tracer elements which are connected to a pressure measuring element or path measuring element. More particularly, resistance strain gauges, optically or capacitively operating path recorders, or pneumatically or piezoelectrically operating pressure recorders can be provided as measuring elements.
Multiple advantages are obtained in this manner. On the one hand, the fiber material is required to pass through fewer elements, each of which may have an unfavorable effect on the material. On the other hand, the spinning machine requires one element less, so that the spinning station and its environment remains more accessible. A further advantage is that the generated measurement signals are particularly suitable for controlling the spinning station in such a manner that the spinning station can be directly regulated. Mass fluctuations in the fiber material can be obviated in the spinning station itself by way of a suitable control intervention. The possibility of examining the quality of the fiber material prior to processing into yarn is also made available in this manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in further detail in the following with the aid of examples and with reference to the attached drawings, in which:
FIG. 1 is a schematic showing of a side view of a fiber feeding and measuring system for delivering fibers to a rotor spinning station;
FIG. 2 is a schematic view similar to FIG. 1 showing an embodiment constructed in accordance with the present invention;
FIG. 3 is a plan view of the fiber supply trough of an embodiment constructed in accordance with the invention;
FIG. 4 is a view similar to FIG. 2 but showing another embodiment;
FIG. 5 is a view similar to FIG. 4 but showing an embodiment of the invention in which a guide presses the incoming fiber strip against the feed trough and an adjacent tracer element;
FIG. 6 is a view similar to FIG. 5 showing another form of means for deriving an electrical signal from the sensing of the fiber mass;
FIG. 7 is a view of another embodiment similar to FIG. 5 but having a different sensing system;
FIG. 8 is a view generally similar to FIG. 1 but showing an embodiment in which a capacitive sensing system gauges the mass of the fiber strip being drawn into the spinning station; and
FIG. 9 is a graph illustrating the paths of the measurement values and derived signals.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a device with a feed trough 1. In this case, the feed trough is mounted so as to rotate about an axis 2 within a restricted range and comprises a guide surface 3 for fiber material 5. The surface 3 is arranged approximately tangential to the circumference of a feed roller 4 so long as the feed trough is in its operative position. Located downstream of the feed roller 4 is a separating roller 6. In addition, guides 7 for the fiber material are provided upstream, for guiding the fiber material onto the feed trough 1. Also arranged on the feed trough 1 is an angle transmitter 8 which serves as a measuring element. This determines an angle which is proportional to the thickness or mass of the fiber material 5 between the guide surface 3 and the feed roller 4. The angle transmitter 8 is connected via a line 10 to an evaluating unit 11. This has the tasks of supplying the measuring element with energy, of detecting and amplifying signals from the measuring element and of offering the possibility of calibration, zero point adjustment, normalization of the signals and/or compensation of interferences. In the same context, a displaceable feed trough may be provided in place of the illustrated pivotable feed trough. A path would then need to be recorded rather than an angle.
FIG. 2 shows a further embodiment in which a measuring element 12 is fitted beneath the guide surface 3 in the supply trough 1. The measuring element 12 comprises a tracer element 13 and an evaluation circuit 14. In this case, the tracer element 13 is constructed as a resilient measuring bar having a fiber contacting portion which can flex toward and away from the adjacent surface of the feed roll 4 in response to the pressure variations generated as a fiber strip of fluctuating mass or thickness is drawn between the roll 4 and element 13. Resistance strain gauges are fitted on the element 13 in a bridge circuit. The evaluation circuit is connected to the bridge circuit and comprises, for example, an amplifier. Here too, the output signal can be transmitted via a line 15 to an evaluation unit.
FIG. 3 is a plan view of the supply trough 1 in which an outlet duct 16 for the fiber material is particularly visible. The outlet duct 16 is defined laterally by projecting limits 17. The guide surface 3 of the feed trough 1 comprises a window 18, through which the tracer element 13 can project.
FIG. 4 shows an embodiment in which the tracer element 13 is connected to a lever system 19. This in turn cooperates with a path recorder 20. In this case, the tracer element 20 is loaded by a spring, not shown, which presses the tracer element against the fiber material 5.
FIG. 5 shows an embodiment with a projecting tracer element 21, which is arranged opposite an additional guide 22 also arranged on the feed trough 1. The tracer element 21 acts upon a spring 23, which is provided with resistance strain gauges. These are again arranged in a bridge circuit. An evaluation circuit 24 with an amplifier is also provided.
FIG. 6 shows an arrangement of a tracer element 21 comparable to that of FIG. 5, although in this case the tracer element 21 cooperates with a lever system 25 which can amplify or reduce the deflections of the tracer element 21 depending on its design. Here too, a path recorder 26 is provided for detecting the deflections of the lever system 25.
FIG. 7 shows a system which operates according to a passive pneumatic measuring principle. Here, the guide 22 comprises an aperture 27 leading to the fiber material. The aperture 27 acts as a measuring element and is connected via a line 28 to a pressure converter 29. The line 28 is also connected via a pilot nozzle 30 to a supply line 31. The pressure converter 29 can thus be connected to a pilot chamber as disclosed in Swiss Patent Application CH 1828/95 and its counterpart U.S. Application filed Jun. 21, 1996 in the names of inventors Francçois Baechler and Jurg Zehr, the disclosures of which are incorporated herein by reference. In this case, the supply line 31 preferably serves a plurality of spinning stations, with the pressure being the same for all the feed troughs connected thereto.
FIG. 8 shows a system with a capacitively operating measuring element 42 arranged on the guide 7 directly upstream of the feed roller 4. The capacitance of the measuring element is built into a bridge circuit, which is in turn connected to an evaluation unit 41.
The method of operation of the different systems is as follows: In the embodiment according to FIG. 1, the position of the feed trough 1, which is expressed by the angle 9, provides a measurement for the thickness or mass of the fiber material 5. In this case, it is necessary for the feed trough 1 to be spring-loaded and mounted so as to be easily displaceable. A signal, which expresses the angle 9, is transmitted via the line 10 to the evaluation unit 11, which displays the signal or prepares it in such a manner that it can be used for a form of control or monitoring which takes the angle 9 into account.
In the embodiment according to FIG. 2, an optimum operating point for the measurement system is sought by adjusting the distance between the feed trough 1 and the feed roller 4 and the feed trough 1 is then fixed in this position. The fiber material therefore only moves the tracer element 13, which bends a measuring bar to a greater or lesser degree. The bending is detected in a manner known per se by resistance strain gauges.
Also in the embodiment according to FIG. 4, only the tracer element 13 moves and this in turn moves a lever 40, whose deflection is detected.
The tracer elements 13, 21 as shown in FIGS. 2 to 6 are much smaller in dimension and have a weight which is much smaller than that of the feed trough 1. Therefore such tracer elements 13, 21 have a much reduced inertia and can much better follow variations of the thickness of the fiber material. Such tracer elements may also detect variations of shorter wavelength in the fiber mass.
Comparable processes occur in the embodiments according to FIGS. 5 and 6, with the difference that in these cases it is no longer necessary to adjust the position of the feed trough 1 relative to the feed roller 4. In this case, it is necessary to adjust the position of the guide 22 and its distance from the guide surface of the trough 1 in order to obtain the optimum operating point.
In the embodiment according to FIG. 7, it is also necessary to adjust the position of the guide 22. However, in this case the pressure in the line 31 and the size of the nozzle 30 also plays a part in obtaining an optimum method of operation.
In the embodiment according to FIG. 8, the feed trough 1 can be arranged so that it is fixed in position. The mass of the fiber material 5 supplied as a fiber strip is measured as close as possible to the feed roller 4.
The embodiments shown in FIGS. 5 to 8 additionally (to the lower inertia of the tracer or measuring elements) are advantageous in that the fiber material is not compressed as much as in the clearance between the feed trough 1 and the feed roller 4, or the rate of compression may be chosen or influenced by corresponding dimensions. This is due to the fact that the measuring elements are located upstream of the feed roller or the clearance or gap between the feed roller and the feed trough. Therefore, the friction between the fiber mass and the sensor is smaller and the sensor may react better to variations of the fiber mass. In such case, variations in the fiber mass are known at a time when the variations can be corrected more easily by an action on the feed roller.
The systems illustrated in FIGS. 1 to 8 have different characteristics, as is shown in FIG. 9. In FIG. 9, values for the mass of the fiber material are indicated on the axis 32 and values of an electrical signal (for example in volts or amperes, of a frequency or of a digital signal) are indicated on the axis 33, and values corresponding to a physical measurement (e.g. values corresponding to an angle, a pressure, a force or a path) are indicated on the axis 34. As the straight line 35 indicates, it can be assumed that a linear correlation exists between the last mentioned values and the values of electrical signals. In contrast, it depends upon the measurement principle whether a linear correlation exists between the values corresponding to a deflection and the values corresponding to a mass. The lines 36 and 37 illustrate the correlation in a system according to FIG. 1 and systems according to FIGS. 4, 6 and 8. A curve 38 illustrates the correlation in the systems according to FIGS. 2 and 5, whilst the line 39 illustrates the correlation in pneumatically operating systems according to FIG. 7. From these characteristic curves 36, 37, 38 and 39, it is possible to select a working range within which the fluctuations in mass should approximately fall by correspondingly adjusting the feed trough 1 relative to the feed roller 4 or adjusting the guide 22 relative to the guide surface of the trough 1.
Conditions similar to those in rotor spinning machines are present also in other types of spinning machines operating according to the known principles of air-spinning, wrap-spinning and friction-spinning, and the measuring elements described above may also be used in relation to such spinning machines or processes.
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The invention relates to a method and device for detecting the mass of fiber material (5) which is processed in a rotor spinning machine to form yarn. In order to obtain a measurement signal which is a function of the mass of fiber material and which can also be used for controlling or monitoring a spinning station without requiring an independent measuring device, this measurement signal is detected in the spinning station of a rotor spinning machine on the feed trough (1) thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a technology for transmitting a signal for a terrestrial digital broadcasting using synchronous optical network (SONET)/synchronous digital hierarchy (SDH) communication system.
2. Description of the Related Art
To improve image quality and to achieve advanced features in television, terrestrial digital broadcasting services are being offered. Specifically, terrestrial television broadcasting is digitalized, and then transmitted from towers on the ground (such as Tokyo Tower) to broadcast stations.
The mainstream method of transmitting signals of terrestrial digital broadcasting is the wireless signal transmission method (refer to “Digital Terrestrial Television Transmitter System in Tokyo Tower”, Tomohito Ikegami et al., NEC Giho Vol. 57, No.4/2004, pp. 49-54).
However, because wireless transmission is used for various purposes other than terrestrial digital broadcasting, many frequencies are competing with each other. Thus, there is a strong demand to transmit signals of terrestrial digital broadcasting by using fixed cables.
However, it is very difficult to transmit signals of terrestrial digital broadcasting by using fixed cables, because it entails many advanced specifications of interfaces between devices. Thus, none of the broadcast stations have realistic plans to implement cable signal transmission.
One approach is to build new cables dedicated for terrestrial digital broadcasting, connecting the broadcast stations. However, this is unfeasible because enormous costs are required.
It is therefore imperative to use existing general-purpose lines so that broadcast stations can realize cable signal transmission for terrestrial digital broadcasting without difficulty.
SUMMARY OF THE INVENTION
It is an object of the present invention to at least solve the problems in the conventional technology.
An apparatus according to one aspect of the present invention, which is for transmitting terrestrial digital data using a synchronous-optical-network system or a synchronous-digital-hierarchy system, includes a synchronous-difference calculating unit that calculates a synchronous difference between a standard signal used in the synchronous-optical-network system or the synchronous-digital-hierarchy system and a first synchronous signal that synchronizes with a leading position included in image data of the terrestrial digital data; and a transmission processing unit that transmits the synchronous difference together with the terrestrial digital data to a destination.
The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a transmitting system according to an embodiment of-the present invention;
FIG. 2 is a functional block diagram of a transmitter and an ADM shown in FIG. 1 ;
FIG. 3 is a functional block diagram of a transmission processing unit shown in FIG. 2 ;
FIG. 4 describes how differences between broadcasting TS synchronous signals and 8K synchronous signals are extracted;
FIG. 5 describes how differences between synchronous clock signals and the 8K synchronous signals are extracted;
FIG. 6 is an example of a data structure mapped in a frame by a VC3 mapping unit;
FIG. 7 is a functional block diagram of a reception processing unit shown in FIG. 2 ;
FIG. 8 describes how the broadcasting the TS synchronous signals are reproduced; and
FIG. 9 describes how the synchronous clock signals are reproduced.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Exemplary embodiments of the present invention will be described-below with reference to accompanying drawings. The present invention is not limited to these embodiments.
A transmitter according to the present invention functions as a source transmitter and a destination transmitter. The source transmitter calculates differences between standard synchronous signals in the SONET/SDH communication system, and signals of terrestrial digital broadcasting (hereinafter, “terrestrial digital broadcasting signals”). The calculated differences and the terrestrial digital broadcasting signals are stored in a frame (such as a SONET/SDH frame), and the frame is transmitted to the destination transmitter.
The destination transmitter that receives the frame reproduces signals equivalent to the terrestrial digital broadcasting signals of the source transmitter, based on the differences and the terrestrial digital broadcasting signals stored in the frame.
FIG. 1 is a block diagram of a transmitting system according to an embodiment of the present invention. In the transmitting system, a transmitter 100 and a transmitter 200 are connected to an add/drop multiplexer (ADM) 300 and an ADM 400 , respectively. The ADM 300 and the ADM 400 are connected through an SDH synchronous network 50 .
The transmitter 100 calculates the differences between the terrestrial digital broadcasting signals and the standard synchronous signals, and transmits the calculated differences and the terrestrial digital broadcasting signals to the transmitter 200 . When data is received from the transmitter 100 , the transmitter 200 reproduces signals equivalent to the terrestrial digital broadcasting signals that the transmitter 100 acquired, based on the differences and the terrestrial digital broadcasting signals received.
The terrestrial digital broadcasting signals include broadcasting transport stream (TS) signals, broadcasting TS synchronous signals, and synchronous clock signals. The broadcasting TS signals are image data signals of terrestrial digital broadcasting, the broadcasting TS synchronous signals are signals that synchronize with a starting point in each image data in the broadcasting TS signals, and the synchronous clock signals are used when the destination transmitter receives and reproduces terrestrial digital broadcasting signals.
The ADM 300 acquires data from the transmitter 100 and stores the data in a frame. The ADM 300 then transmits the frame to the ADM 400 through the SDH synchronous network 50 . When the ADM 300 acquires a frame, the ADM 300 extracts data in the acquired frame, and passes the extracted data to the transmitter 100 . The ADM 300 also passes standard synchronous data received from outside to the transmitter 100 .
FIG. 2 is a functional block diagram of the transmitter 100 and the ADM 300 shown in FIG. 1 . Descriptions of the transmitter 200 and the ADM 400 are omitted because they have the same configurations as those of the transmitter 100 and the ADM 300 .
The transmitter 100 includes a phase locked loop (PLL) 110 , an 8K-hertz (Hz)-frame-synchronous-signal generating unit 120 , a transmission processing unit 130 , and a reception processing unit 140 . The ADM 300 includes a virtual concatenation 3 (VC3) mapping unit 310 , an electrical/optical (E/O) processing unit 320 , an optical/electrical (O/E) processing unit 330 , and a VC3 demapping unit 340 .
The PLL 110 matches a frequency of an input signal and a frequency of an output signal. Thus, the PLL 110 passes standard synchronous signals input from the ADM 300 to the 8K-frame-synchronous-signal generating unit 120 without changing the frequency.
The 8K-frame-synchronous-signal generating unit 120 generates standard synchronous signals of 8 KHz (hereinafter, “8K synchronous signals”), based on the standard synchronous signals received from the PLL 110 . The generated 8K synchronous signals are then passed to the transmission processing unit 130 and the reception processing unit 140 .
FIG. 3 is a functional block diagram of the transmission processing unit 130 shown in FIG. 2 . The transmission processing unit 130 includes an image packet extracting unit 131 , a generic framing procedure (GFP) capsuling unit 132 , a synchronous-signal-difference extracting unit 133 , a synchronous-signal digitalizing unit 134 , a synchronous clock-difference extracting unit 135 , and a synchronous-clock digitalizing unit 136 .
The image packet extracting unit 131 extracts an image packet from the broadcasting TS signals, and passes the extracted-image packet to the GFP capsuling unit 132 . The GFP capsuling unit 132 capsules the image packet using a GFP capsuling method, and passes the capsuled image packet (hereinafter, “capsuled image data”) to the ADM 300 .
The synchronous-signal-difference extracting unit 133 acquires the broadcasting TS synchronous signals and the 8K synchronous signals, and extracts the differences between each of the broadcasting TS synchronous signals and each of the 8K synchronous signals. The synchronous-signal-difference extracting unit 133 then passes the extracted differences to the synchronous-signal digitalizing unit 1 , 34 . The synchronous-signal digitalizing unit 134 digitalizes the differences, and passes the digitalized differences (hereinafter, “synchronous difference data”) to the ADM 300 .
FIG. 4 describes how the differences between the broadcasting TS synchronous signals and the 8K synchronous signals are extracted. A counter circuit (not shown) of a predetermined high-frequency clock starts counting from a leading edge of an 8K synchronous signal of a cycle of 125μseconds. The counting stops when a leading edge of a broadcasting TS synchronous signal is generated. The counted value is the synchronous difference data. If a leading edge of a broadcasting TS synchronous signal is not generated within the 125μ cycle of the 8K synchronous signal, absence of broadcasting TS synchronous signal difference data is notified to the synchronous-signal-difference extracting unit 133 . The absence can be recognized when a next leading edge of the 8K synchronous signal is detected while the counting is in progress. Alternatively, the absence can be recognized when a next leading edge of the 8K synchronous signal is detected, and the counter circuit is reset to start counting again.
Returning to FIG. 3 , the synchronous clock-difference extracting unit 135 acquires the synchronous clock signals and the 8K synchronous signals, extracts differences between the signals, and passes the extracted differences to the synchronous-clock digitalizing unit 136 . The synchronous-clock digitalizing unit 136 digitalizes the differences acquired from the synchronous clock-difference extracting unit 135 , and passes the digitalized differences (hereinafter, “clock difference data”) to the ADM 300 .
FIG. 5 describes how the differences between the synchronous clock signals and the 8K synchronous signals are extracted. The counter circuit of a predetermined high-frequency clock starts counting from a leading edge of an 8K synchronous signal of a cycle of 125μ seconds. The counting stops when a first leading edge of a synchronous clock signal is generated. The counted value is the clock difference data. If a leading edge of a synchronous clock signal is not generated within the 125μ cycle of the 8K synchronous signal, absence of synchronous-clock-signal difference data is notified to the synchronous clock-difference extracting unit 135 . The absence can be recognized when a next leading edge of the 8K synchronous signal is detected while the counting is in progress. Alternatively, the absence can be recognized when a next leading edge of the 8K synchronous signal is detected, and then the counter circuit is reset to start counting again.
Returning to FIG. 2 , the VC3 mapping unit 310 acquires the capsuled image data, the synchronous difference data, and the clock difference data from the transmission processing unit 130 . The GFP is used for mapping data in a frame.
FIG. 6 is an example of a data structure mapped in a frame by the VC3 mapping unit 310 . The frame includes a section overhead (SOH), a path overhead (POH), a VC3#1, a VC3#2, and a VC3#3. The VC3#1, the VC3#2, and the VC3#3 each includes a mapping region for presence or absence of broadcasting TS synchronous signal difference data/difference value, a mapping region for presence or absence of synchronous-clock-signal difference data/difference value, and a mapping region for broadcasting TS packets.
The SOH is a region that stores data required for maintenance and operation of transmission path switching data. The POH is a region that stores data required for maintenance and operation of each unit segment of mapping regions. The mapping region for presence or absence of broadcasting TS synchronous signal difference data/difference value stores the synchronous difference data (the region includes a 16 bit region so that a counted value is input as a binary code). When there is no synchronous difference data, data informing absence of the broadcasting TS synchronous signal difference data is stored.
The mapping region for presence or absence of synchronous-clock-signal difference data/difference value stores the clock difference data (the region includes a 16 bit region so that a counted value is input as a binary code). When there is no clock difference data, data informing absence of the synchronous-clock-signal difference data is stored. The mapping region for broadcasting TS packets stores the capsuled image data.
Returning to FIG. 2 , the E/O processing unit 320 acquires the frame in electrical signals from the VC3 mapping unit 310 , converts the frame into optical signals, and transfers the frame in optical signals to the ADM 400 through the SDH synchronous network 50 .
When the O/E processing unit 330 receives the frame in optical signals from the SDH synchronous network 50 , the O/E processing unit 330 converts the frame into electrical signals, and passes the frame in electrical signals to the VC3 demapping unit 340 . Upon receiving the standard synchronous signals, the O/E processing unit 330 passes the standard synchronous signals to the PLL 110 .
The VC3 demapping unit 340 acquires the frame from the O/E processing unit 330 , extracts the capsuled image data, the synchronous difference data, and the clock difference data from the frame, and passes the extracted data to the reception processing unit 140 .
FIG. 7 is a functional block diagram of the reception processing unit 140 . The reception processing unit 140 includes a broadcasting TS extracting unit 141 , a memory 142 , a synchronous-difference extracting unit 143 , a TS-synchronous-signal reproducing unit 144 , a lead control unit 145 , a clock-difference extracting unit 146 , a synchronous-clock reproducing unit 147 , and a PLL 148 .
The broadcasting TS extracting unit 141 acquires the capsuled image data from the ADM 300 , extracts the image packet from the capsuled image data, and stores the image packet in the memory 142 . The memory 142 is a storing unit that stores image packets.
The synchronous-difference extracting unit 143 acquires the synchronous difference data from the ADM 300 , extracts the synchronous differences from the synchronous difference data, and passes the synchronous differences to the TS-synchronous-signal reproducing unit 144 .
The TS-synchronous-signal reproducing unit 144 acquires the synchronous differences from the synchronous-difference extracting unit 143 , and the 8K synchronous signals from the 8K-frame-synchronous-signal generating unit 120 , respectively. Based on the acquired data, the TS-synchronous-signal reproducing unit 144 reproduces broadcasting TS synchronous signals equivalent to those of a source transmitter.
FIG. 8 describes how the broadcasting TS synchronous signals are reproduced. The counter circuit starts counting from a leading edge of an 8K synchronous signal. When a counted value reaches a point that equals the synchronous difference, the point becomes a leading edge of a broadcasting TS synchronous signal. By repeating such a processing, the TS-synchronous-signal reproducing unit 144 reproduces broadcasting TS synchronous signals. The TS-synchronous-signal reproducing unit 144 passes the reproduced broadcasting TS synchronous signals to the lead control unit 145 and a host computer (not shown).
Returning to FIG. 7 , the lead control unit 145 passes the image packets stored in the memory 142 to the host computer, as broadcasting TS signals. The broadcasting TS signals include image data, and each image data includes a plurality of image packets. The lead control unit 145 controls a flow of the image packets to the host computer, so that a leading image packet in an image data synchronizes with a broadcasting TS synchronous signal received from the TS-synchronous-signal reproducing unit 144 .
The clock-difference extracting unit 146 acquires the clock difference data from the ADM 300 , extracts the clock differences from the clock difference data, and passes the clock differences to the synchronous-clock reproducing unit 147 .
The synchronous-clock reproducing unit 147 acquires the clock differences from the clock-difference extracting unit 146 , and the 8K synchronous signals from the 8K-frame-synchronous-signal generating unit 120 , respectively. Based on the acquired data, the synchronous-clock reproducing unit 147 reproduces synchronous clock signals equivalent to those of the source transmitter.
FIG. 9 describes how the synchronous clock signals are reproduced. The counter circuit starts counting from a leading edge of an 8K synchronous signal. When a counted value reaches a point that equals the clock difference, the point becomes a leading edge of a synchronous clock signal. By repeating such a processing, the synchronous-clock reproducing unit 147 reproduces synchronous clock signals. The synchronous-clock reproducing unit 147 passes the reproduced synchronous clock signals to the host computer through the PLL 148 . A description of the PLL 148 is omitted here because it is the same as the PLL 110 shown in FIG. 2 .
In the transmitter 100 according to the present embodiment, the GFP capsuling unit 132 generates the capsuled image data, the synchronous-signal digitalizing unit 134 generates the synchronous difference data, and the synchronous-clock digitalizing unit 136 generates the clock difference data. The transmitter 100 transmits such data to the transmitter 200 through the ADM 300 .
In the transmitter 100 , when a frame is received, the broadcasting TS extracting unit 141 extracts the broadcasting TS signals, the TS-synchronous-signal reproducing unit 144 reproduces broadcasting TS synchronous signals, and the synchronous-clock reproducing unit 147 reproduces synchronous clock signals.
Thus, cable signal transmission for terrestrial digital broadcasting can be realized by using existing general-purpose lines without difficulty. Specifically, terrestrial digital data can be transmitted without requiring advanced specifications, and without deteriorating image quality. Moreover, the terrestrial digital data can be precisely reproduced.
Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.
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An apparatus for transmitting terrestrial digital data using a synchronous-optical-network system or a synchronous-digital-hierarchy system includes a synchronous-difference calculating unit that calculates a synchronous difference between a standard signal used in the synchronous-optical-network system or the synchronous-digital-hierarchy system and a first synchronous signal that synchronizes with a leading position included in image data of the terrestrial digital data; and a transmission processing unit that transmits the synchronous difference together with the terrestrial digital data to a destination.
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This application is a continuation of U.S. application Ser. No. 08/368,609, filed Jan. 4, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of providing shock absorbing or cushioning mats for athletic equipment. More particularly, the invention pertains to mats for cushioning non-horizontal structural elements of gymnastic equipment, such as a balance beam and the like.
2. Description of the Prior Art
Until now, the design of gymnastic mats has been directed toward protecting gymnasts and other athletes from injuries due to impact with the floor or ground.
For example, U.S. Pat. No. 3,636,576 to Nissan for a Roll-Fold Floor Mat for Gymnastic and Athletic Purposes discloses a plurality of abutting rectangular mat sections having varying dimensions which permit the mats to be "roll-folded" together. These mats are designed to cover a gymnasium floor, and no suggestion is made that the mats be used to provide protection to gymnasts from impact with gymnastic equipment.
U.S. Pat. No. 3,242,509 also to Nissan for a Gymnastic Floor Covering discloses rectangular mats having interconnecting edges for forming a large continuous cushioned floor surface. A recess is formed in the bottom surface along an edge of the mat. The opposing edge has a tongue formed on the bottom surface for being received in the recess of an adjacent mat. The tongue portion has hook fastener material sewn thereon, the recess having loop fastener material sewn thereon whereby adjacent edges may be secured together. While there is a suggestion that the mat may be used to cover exposed parts of gymnastic apparatus, there are no structural provisions for covering non-horizontal parts of gymnastic apparatus.
U.S. Pat. No. 2,944,815 to Moyer for a Method of Mounting of Gymnastic Equipment discloses the use of strips or sections of mats which may be rearranged on a base about gymnastic equipment standards, as the standards are moved closer or farther apart. FIG. 1 of the No. '815 patent discloses a cut-away section of the mat. This cut-away section provides clearance for the gymnastic equipment standards. The cut-away section is spaced from the standards, and shows cushioning on only two sides of the standards. The mat extends vertically upward only a small percentage of the height of the standard, providing virtually no protection against collision with the standard. It is clear that this mat is not designed to protect a user from injuries due to contact with the standards; rather, it is designed to protect the user from injuries due to impact with the floor.
U.S. Pat. No. 2,429,939 to Masterson et al. for a Convertible and Demountable Gymnastic Chair discloses a rectangular mat which in one aspect covers the horizontal cross member of the structure. The mat lies between the opposed, substantially vertical support members, providing no protection for the user from contact with the same. As in the other references, the concern of the inventors is protection from injury due to contact with the ground as opposed to contact with the vertical support members of the gymnastic equipment.
U.S. Pat. No. 2,187,676 to Biewen for an Absorbent Floor Mat discloses a floor covering having a U-shaped vertical slot therein for providing protection to the floor surrounding a toilet. There is no suggestion that the floor covering be used to provide protection to the user from impacts with the toilet. Additionally, no means are shown for securing the floor mat to the commode.
Gymnastics, as well as other forms of athletics, are pursued at various skill levels by millions of people. Often, these persons are beginners or poorly trained and the possibility of injury due to contact with the equipment is high. Even at higher skill levels the risk of injury remains high due to the more complicated and intense use these athletes make of the equipment. Attempts have been made by gymnasts and their coaches and instructors to cushion the structural members of gymnastic equipment, since accidental collision with the support leg or base of a piece of equipment can cause serious injury to the gymnast. A conventional gymnastic mat, generally a rectangular piece of 1 inch thick closed-cell foam, covered by resin impregnated nylon cloth, is often leaned against the equipment in an effort to provide the needed cushioning.
The current method of laying a conventional gymnastic mat against a piece of gymnastic equipment presents several problems. First, a mat which is leaned against a piece of equipment will rarely remain in that position. It will tend to slide across the smooth floor of a gymnasium or other floor surface. Second, because a conventional mat is intended to be laid on a flat surface, its use as a cushion around the support leg and/or base of gymnastic equipment is unwieldy and can obstruct the gymnast's access to the equipment, creating additional safety hazards. Additionally, the mat will often fail to cover other portions of the gymnastic equipment which should not be left exposed. Third, the relatively thin rectangular mat commonly used does not provide enough cushion to offer protection from injury, especially when contacted at high speed. Finally, a conventional mat leaned against equipment is not sufficiently rigid to prevent it from flexing about the equipment. As the mat flexes, it will tend to move out of position, exposing portions of the equipment. Flexing also reduces the effectiveness of the mat by causing the force of an impact to be distributed over a relatively small portion of the shock absorbing area.
An additional need exists for specialized matting for use with a balance beam. A standard balance beam is just 4" wide, and is positioned about 4 feet off the ground. When a gymnast is learning and practicing mounts and dismounts on the balance beam, there is a strong probability that she will misstep, causing her to fall from the balance beam to the floor. When more difficult maneuvers, such as aerial cartwheels, front and back handsprings, and front and back aerial somersaults, are performed on the balance beam, the potential injury to the gymnast is even greater due to the momentum resulting from the maneuver. A coach or "spotter" must stay with the gymnast along the balance beam at all times, to assist the gymnast should she begin to fall. This prevents a gymnastic coach from working with more than one gymnast at a time. A need therefore exists for a protective mat which can be used in training and practicing balance beam maneuvers, to protect the gymnast from injury during the inevitable falls that occur. A mat for use with a balance beam should not only provide cushioned protection, but should additionally provide a sufficiently rigid surface, close to the top of the balance beam, to allow the gymnast to regain her footing or balance, thereby preventing injury.
There is a demonstrated need in the field of athletics and gynmastics for a mat which overcomes the aforementioned problems and provides athletes with protection from injuries resulting from collisions with and falls from the equipment they are using.
SUMMARY OF THE INVENTION
The present invention is a gymnastic mat having a substantially vertical slot defined therein, the vertical slot having at least one substantially vertical engaging edge for allowing the gymnastic mat to be mountably received about a substantially vertical support member of a piece of athletic or gymnastic equipment. While the mat may have any shape and dimensions, it is preferably relatively thick in comparison to standard gymnastic floor mats, to provide protection about the entire length of the structural support member. Additionally, the mat contains a rigid horizontal layer or plate for providing support therein for a gymnast to recover her footing from misteps, and missed mounts and dismounts. The slot with the engaging edge permits the mat to substantially surround the support member, and resist accidental dislodging from the support member.
Means for attaching additional mats is provided such that the size and shape of the protected area may be changed to correspond to the type of equipment and ability of the user. The slot or slots provided in the mats may be of any desired size and shape, provided at least one engaging edge exists on at least one of the mats for securing the mat structure to the support member or structure of the athletic equipment.
A first object of the invention is to provide a cushioned, protective covering for substantially non-horizontal structural members of athletic and gymnastic equipment.
A second object of the invention is to provide a cushioned, protective covering which may be readily mounted and dismounted.
A third object of the invention is to provide a cushioned, protective covering which resists accidental dislodging.
A fourth object of the invention is to provide a method for changing the dimensions of the cushioned, protective covering by allowing additional mats to be easily added to the first or base mat.
A fifth object of the invention is to provide a cushioned, protective covering which will break the fall of a gymnast on a balance beam.
A sixth object of the invention is to provide a method for learning gymnastic maneuvers on the balance beam with reduced risk of injury to the gymnast.
This invention can be broadly summarized as a mat having an outer covering, a shock absorbing material within the covering, and a substantially vertical slot therethrough, the slot having an engaging edge for permitting the mat to be received and retained about the vertical support member of a piece of athletic or gymnastic equipment.
This invention can also be summarized as a method of protecting users from injury due to impact with the non-horizontal support members of athletic and gymnastic equipment, by disposing a gymnastic mat having a slot with an engaging edge therein about the support member prior to use.
An additional mat may be likewise disposed about the athletic equipment and secured to the first or base mat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the mat, having a slot with a circular terminus, as used with a tubular vertical support member.
FIG. 2 is a perspective view of a preferred embodiment of the mat, having a T-shaped slot, as used with a tubular vertical support member.
FIG. 3 is a perspective view of a preferred embodiment of the mat having an L-shaped slot.
FIG. 4 is a cut-away view of a preferred embodiment of the mat having a U-shaped slot.
FIG. 5 is a perspective view of a preferred embodiment of the mat having a detachable extension mat mounted thereto, the extension mat having a U-shaped slot.
FIG. 6 is a perspective view of a preferred embodiment of the mat having a T-shaped slot, with the detachable extension mat spaced therefrom.
FIG. 7 is a perspective view of a preferred embodiment of the mat having the extension mat mounted thereto positioned to be received on a balance beam.
FIG. 8 is a perspective view of a preferred embodiment of the mat, having the extension mat mounted thereto, received on a balance beam.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 of the drawings, the mat 10 comprises an outer cover 22, having formed therein a substantially vertical slot 100, with at least one engaging edge 26 therein. Means for cushioning 20 is encased in protective outer cover 22 (see FIG. 8). The outer cover 22 may be comprised of at least one layer of a flexible, preferably puncture resistant material. Alternatively, the cover may be comprised of several layers of material (not shown), each layer contributing to the outer cover's overall strength and providing other distinct advantages such as puncture resistance, water proofing and durability. In the preferred embodiment, a single layer of vinyl coated nylon is preferred for the outer cover 22 due to its relatively high strength and low cost.
The outer cover 22 has a top surface or face 30, a bottom surface or face 32 and at least one wall 34 connecting the top and bottom surfaces. While the mat 10 may be of any shape, a cubic mat, as shown in the drawings, is preferred. The cubic mat is composed of a square top surface 30, a square bottom surface 32, a front wall 34a, a rear wall 34b and two side walls 34c, 34d, each of the side walls 34c, 34d forming right angles with its adjacent front and rear walls, 34a, 34b, respectively. The top surface 30 and the bottom surface 32 are joined at or proximate their peripheries respectively to the top and bottom edges of the walls 34.
A slot 100 in the outer cover 22 extends vertically from top surface 30 to bottom surface 32, and perpendicularly inward from front wall 34a, ending in a slot terminus 38. In a preferred embodiment, slot 100 may be narrower at its opening 36 in front wall 34a, than at its terminus 38, thus forming an engaging edge 102 between the terminus 38 and the front wall 34a.
The slot 100 may be of any shape suitable for receiving the support member to be cushioned. FIG. 1 illustrates a preferred embodiment of the mat 10, having a circular slot terminus 38, in use with a piece of gymnastic equipment having a support member 50 which is substantially vertically oriented and substantially tubular in shape. A vault or spingboard is an example of such equipment. The slot 100 is of a uniform width from its opening 36 at the front wall 34a, extending inward toward the slot terminus 38. The slot terminus 38 is a circle of a diameter greater than the width of the slot 100 and which will accommodate the tubular support member 50. The flexibility of the cushioning material (See FIG. 8) allows the slot 100 to widen slightly as the support member 50 is pushed past the engaging edges 102, into position at the terminus 38 of slot 100.
FIG. 2 illustrates an alternative preferred embodiment of the mat 10, having a T-shaped slot 110, in use with a piece of gymnastic equipment having a support member 50 which is substantially vertically oriented and substantially tubular in shape. The distal end of the bottom portion of the "T" defines the opening 36 in the front wall 34a. The bottom portion of the "T" defining the slot 110 having a uniform width from the opening 36 at the front wall 34a to the engaging edges 103. The upper portion of the "T" defines the terminus 40 of the T-shaped slot 110. The terminus 40 is spaced from the front wall 34a by the lower portion of the T-shaped slot 110. The terminus 40 is substantially square or rectangular in shape and extends laterally on either side of the T-shaped slot 110. The width of the terminus 40 is greater than that of the lower portion of the T-shaped slot 110 and sufficient to accommodate the tubular support member 50. The T-shaped slot 110 provides a pair of substantially vertical engaging edges 103 spaced on either side of the lower portion of the T-shaped slot 110 from one another. The engaging edges 103 are defined by the respective right angles formed between the upper portion and the lower portion of the "T". The flexibility of the cushioning material (See FIG. 8) allows the slot 110 to widen slightly as the support member 50 is pushed through the opening 36, past the engaging edges 103, into position at the terminus 40 of slot 110.
FIG. 3 illustrates another alternative preferred embodiment of the mat 10, having an L-shaped slot 120. The distal end of the upper portion of the "L" defines the opening 36 in the front wall 34a. The upper portion of the "L" defining the slot 120 having of a uniform width from the opening 36 at the front wall 34a to the engaging edge 104. The lower portion of the "L" defines the terminus 42 of the L-shaped slot 120. The terminus 42 is spaced from the front wall 34a by the upper portion of the L-shaped slot 120. The terminus 42 is substantially square or rectangular in shape and extends laterally on one side of the upper portion of the L-shaped slot 120. The width of the terminus 42 is greater than that of the L-shaped slot 120 and sufficient to accommodate the tubular support member 50. The L-shaped slot 120 provides a substantially vertical engaging edge 104 on one side of the slot 120. The engaging edge 104 is defined by the respective right angle formed between the upper portion and the lower portion of the "L". The flexibility of the cushioning material (See FIG. 8) allows the upper portion of the L-shaped slot 120 to widen slightly as the support member 50 is pushed through the opening 36, past the engaging edge 104, into position at the terminus 42 of slot 120.
With reference to FIGS. 1, 2 and 3, the engaging portion of the outer cover 22, that is the portion between the front wall 34a and the engaging edges 102, 103, and 104, must be sufficiently rigid to resist accidental dislodging of the mat 10 from the support member 50 due to an impact. At the same time, it must be flexible enough to permit the mounting and dismounting of the mat 10 about the support member 50 when desired (see FIGS. 1 and 2). This can be achieved by properly dimensioning the width of the engaging edge 102, 103, and 104 with respect to its length and the rigidity of the cushioning material 20.
While the previous discussion has referred to a substantially vertical slot, the slot may have sides that are sloped as little as forty-five degrees (45°) relative to the ground or floor. Likewise, the engaging edges may also be sloped relative to the ground or floor to provide more secure contact with the variety of support members likely to be encountered in use with gymnastic and athletic equipment.
Any resilient, shock absorbing material, alone or in conjunction with other shock absorbing materials, may be used as the cushioning means. The shock absorbing materials may be combined with rigid materials, as discussed below, to form the cushioning means 20. Alternatively, air, preferably at a pressure greater than one atmosphere may be used as the cushioning means (not shown).
With continuing reference to FIG. 4, in the preferred embodiment the cushioning means 20 is composed of several layers of various shock absorbing and rigid materials, disposed in a variety of orientations. Directly beneath and adjacent to top surface 30 of the outer cover 22 is a substantially horizontal layer of cushioning material 60. In the most preferred embodiment the cushioning material 60 is comprised of a cross-linked polyethylene. While at least one layer is necessary, any number of layers may be used, including layers of various types of cushioning materials (not shown).
Disposed beneath the layer of cushioning material 60 is a substantially horizontal rigid layer 62. The rigid layer 62 is preferably composed of 1/4 inch thick plywood, although any relatively rigid material would suffice. In addition to providing form to the mat structure, the rigid layer 62 distributes the force of impact over the entire horizontal surface area of the mat 10.
Beneath the rigid layer 62 are a plurality of vertical baffle partitions 64. The baffle partitions 64 are parallel to one another, and preferably parallel to the front wall 34a in which the slot 100, 110, 120 is defined. A baffle partition 64 should be adjacent and parallel to front wall 34a and rear wall 34b. In a preferred embodiment, the baffle partitions 64 are approximately 1 1/2 inches thick and spaced approximately 8 inches apart. The baffle partitions 64 are preferably composed of a cross-linked polyethylene foam, although other resilient materials would be suitable. In addition to creating compartmentalized structural spaces within the outer cover 22, the baffle partitions 64 provide structural support to the mat 10. The baffle partitions 64 provide some resiliency against impact.
Filling the compartmentalized spaces defined by the baffle partitions 64 is a baffling material 66. In the preferred embodiment, the baffling material 66 is composed of a polyurethane foam, although other resilient materials or mixtures of resilient material may be used. The baffling material 66 provides the majority of the mat's 10 resiliency or cushioning effect.
The outer cover 22 may be of any dimensions that are suitable for encasing the cushioning means 20.
In FIG. 4, means for allowing the outer cover 22 to be fitted securely over the cushioning means 20 is shown. An aperture 24 in the cover 22 may be fitted with a zipper 26, hook and loop fastener (not shown), snaps (not shown), valve (not shown) or other fastener (not shown), to seal the cover 22 closed once it is fitted on the cushioning means 20. In an alternative preferred embodiment, aperture 24 is not closed with a fastener. Instead, an overlap of material (not shown) is provided, covering the cushioning means 20 which would otherwise be exposed through the gap left by aperture 24. In an additional preferred embodiment (not shown), the outer cover 22 is permanently sewn or otherwise affixed to cushioning means 20, eliminating the need for aperture 24.
With reference to FIGS. 5 and 6 a second mat 80 may be provided. The second mat 80 has a slot 130 formed therein, the slot 130 being U-shaped in the embodiment shown. A plurality of strips of hook fastener material 70 may be distributed about the periphery of the second mat 80, the strips 70 preferably sewn to the respective outer cover of the mats 80. The second mat 80 can then be removably attached to the mat 10 (hereinafter the first mat) which has loop fastener material strips 72 affixed about its periphery. Thus two or more mats may be removably secured together, to provide varying sizes for use with a variety of athletic equipment, and varying ability levels of the athlete. Any conventional means for securing, such as the hook and loop fastener material may be used.
The slot 130 of the second mat, like the slot 110 of the first mat 10, may be of any shape suitable to the equipment being used.
FIGS. 7 and 8 illustrate the first mat 10 and the second mat 80 in use with a balance beam 52. With reference to FIGS. 5, 6, 7 and 8, in this preferred embodiment the engaging edges 103 are associated with the first mat 10. This provides a secure mounting to the supporting structure 54 of the balance beam 52. The balance beam 52 is of uniform width, and so the U-shaped slot 130 of the second mat 80 is also of uniform width, and dimensioned to receive the end of balance beam 52. The second mat 80 is secured to the first mat 10 using the hook and loop fasteners 70, 72. Second mat 80 provides a close fitting about the balance beam 52 itself, just below its top surface, without leaving any gaps. When used with a balance beam 52, the top surface 31 of the second mat 80 is approximately two inches (2") below the tipper surface of the balance beam 52. In use, if the gymnast misteps, or misses a mount or dismount, she is presented with a rigid, yet cushioned surface on which she may attempt to recover or right herself, and avoid injury.
With further reference to FIGS. 7 and 8, the mats 10, 80 may be mounted about the support member or members 54 of various types of athletic equipment, including gymnastic equipment. In preparation for use of the equipment, the opening 36 in the mat 10 is urged past the support member 54 until the engaging edge or edges 103 of the mat 10 come into operative contact with the support member 54. The second mat 80 may then be secured around the equipment to provide close contact around the equipment. The athletic equipment may then be used in relative safety, the athlete protected from injuries resulting from impact with the supporting structure of the equipment. The second mat 80 may be removed for transportation or storage by first disengaging the hook and fastener attachments and then exerting a force in the horizontal plane, away from the piece of athletic equipment to urge the mat 80 out of contact with the support member 54. Likewise, the first mat 10 may be removed by exerting a force in the horizontal plane, away from the piece of athletic equipment to urge the engaging edges 103 of the mat 10 out of operative contact with the support member 54.
In compliance with the statutes, the invention has been described in language more or less specific as to structural features and process steps. While this invention is susceptible to embodiment in different forms, the specification illustrates preferred embodiments of the invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and the disclosure is not intended to limit the invention to the particular embodiments described. Those with ordinary skill in the art will appreciate that other embodiments and variations of the invention are possible which employ the same inventive concepts as described above. Therefore, the invention is not to be limited except by the claims which follow.
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A gymnastic mat having a substantially vertical slot along one edge thereof and at least one engaging edge defined in the slot for removably mounting the gymnastic mat about the non-horizontal support members of various types of athletic and gymnastic equipment; and a method for using such a mat. The mat may have a substantially rigid upper surface to permit the gymnast to regain her footing or balance thereon. Additional gymnastic mats are attachable to the first gymnastic mat to modify the shape and size of the protected area.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to methods for recording images and apparatuses for recording images such as copying machine, facsimile and printer, and more particularly, to a method and an apparatus for recording images by intermittently allowing colorant particles to be ejected on a recording medium, thereby selectively applying on or permeating the particles into the medium to form images thereon.
2. Description of the Background Art
A conventional image recording apparatus has been proposed, by which colorant is evaporated, then ionized, and ejected intermittently based on an electrical signal corresponding to image data to be recorded, whereby the colorant is applied on or permeated into a recording medium to provide images. Such an image recording apparatus is for example disclosed by Japanese Patent Laying-Open No. 8-300803. The image recording apparatus will be now described.
FIG. 8 is a view for use in illustration of an example of a conventional image recording apparatus. In FIG. 8, the image recording apparatus includes a printing head 1 . Printing head 1 is formed by integrating a heating device 10 to heat and evaporate colorant, a charging device 30 to charge the evaporated colorant, and an ejecting device 50 to intermittently eject the charged colorant based on an electrical signal corresponding to image data to be recorded.
Heating device 10 includes an electrical heater 10 B. Charging device 30 includes an ionization electrode portion 30 A having a needle shape for example, and a counter electrode portion 30 B having a plate shape. In ejecting device 50 , a back plate electrode portion 50 C is provided at the back of a recording medium RM in order that the charged colorant through an ejecting outlet 90 onto recording medium RM for ejection with electrostatic force, an intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ) is provided around ejecting outlet 90 , and an intermediate electrode driving control portion 50 E is also provided. Intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ) has a so-called shutter function to physically or electrically control the ejection of the colorant. Intermediate electrode driving portion 50 E outputs a driving signal corresponding to an input electrical signal corresponding to image data and controls intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ) in a shutter manner. An insulating plate 50 D is provided around intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ).
In printing head 1 , powder ink IP is previously stored. Heating device 10 to heat ink IP is provided at the lower half of printing head 1 . At the upper half of printing head 1 , a wire electrode from 50 μm to 80 μm is provided as charging device 30 to charge heated and evaporated ink IPG. At the upper part of printing head 1 , an ejecting outlet 90 of φ300 μm to allow evaporated ink IPG to be ejected therethrough is provided, and intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ) having an inner diameter of φ300 μm is provided to surround ejecting outlet 90 .
The operations of the image recording apparatus shown in FIG. 8 will be now described. During printing, ink IP is heated to 200°C. and evaporated. When colored inks are used, the colorant may include as a base, anthoraisothiazole, quinophthalone, pyazolonazo, pyiidone azo, styryl or the like for yellow, anthraquinone, dicyanoimidazole, thiadiazoleazo, tricyanovinyl, or the like for magenta, and azo, anthraquinone, naphthoquinone, indoaniline, or the like for cyan. Evaporated ink IPG is ionized by applying a voltage at +5 kV to charging device 30 . Ionized evaporated ink IPG is controlled to be ejected on recording medium RM in response to application of a prescribed voltage to back plate electrode portion 50 C and intermediate electrode portion 50 A ( 50 A 1 , 50 A 2 , 50 A 3 ).
The image recording apparatus shown in FIG. 8 however suffers from the following disadvantage. When ink is ionized by a strong electric field in the vicinity of ionization electrode portion 30 A, the ionization efficiency is low, i.e., the efficiency of transporting of evaporated ink IPG into a possible ionization area and the efficiency of ionization of evaporated ink IPG thus transported in total are low, therefore the ratio of effective evaporated ink which can be controlled for ejection is small, and the recording speed is low. If an electric field to ionize evaporated ink IPG is generated, air in the vicinity of ionization electrode portion 30 A is also ionized. Therefore, the ions act as a driving force to cause a flow of ionized air, evaporated ink IPG present in the area where the ionized air flows is brought by the flow and sticks to counter electrode portion 30 B. As a result, the percentage of evaporated ink IPG which can be used for recording is low.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and an apparatus for recording images, which allows for increase in the charging efficiency of colorant particles, the charge amount, the use efficiency and the recording speed and permits good picture qualities to be provided.
In order to achieve this object, an image recording method according to the present invention includes the following characteristics. More specifically, the method includes the steps of generating colorant particles from ink colorant, charging the generated colorant particles, and intermittently ejecting the charged colorant particles onto a recording medium by electrostatic force based on an electrical signal corresponding to prescribed image data.
The colorant particles are transported sequentially from the generating step to the charging step and to the ejecting step.
The generating step may further include the steps of heating and evaporating ink colorant, cooling, solidifying and agglomerating the evaporated ink colorant, thereby granulating the colorant into colorant particles.
In the image recording method as described above, the colorant particles generated in the generating step are transported sequentially from the generating step to the charging step and the ejection step, and therefore the colorant particles may securely gone through each step, so that the use efficiency of the colorant in image recording may be improved and the charge amount may become even.
Since the colorant particles are transported while controlling the flow of air including the colorant particles in the above image recording method, the colorant particles generated in the generating step are transported surely to the following steps in the flow of air. The airflow is controlled, and therefore the colorant particles will not be attached in an undesired location in the flow path or the amount of ejection in the ejection step will not be uneven. Thus, the colorant particle density may be improved to increase the recording speed as a result.
In order to achieve the above-described object of the present invention, an image recording apparatus according to the present invention records prescribed images on a recording medium using ink colorant has the following characteristics. More specifically, the apparatus includes a generating portion which generates colorant particles from ink colorant, a charging portion which charges the generated colorant particles, an ejecting portion which intermittently ejects the charged colorant particles onto the recording medium by electrostatic force based on an electrical signal corresponding to prescribed image data, and a transport portion which sequentially transports the colorant particles from the generating portion to the charging portion and the ejecting portion.
Therefore, the generated colorant particles are surely passed through each portion, the use efficiency of the colorant is improved and the charge amount may become even.
In the above image recording apparatus, the generating portion may include a heating portion for heating and evaporating colorant, and a granulating portion for cooling, solidifying and agglomerating the colorant evaporated by the heating portion, thereby granulating the colorant into colorant particles.
The granulating portion may include a particle size control portion which controls the particle size in granulating the ink colorant evaporated by the heating portion.
Therefore, the particle size of the ink colorant is controlled at a size suitable for recording by the particle size control portion, and good quality images result.
The transport portion as described above may include an airflow generating portion to generate an airflow for sequentially transporting the colorant particles from the generating portion to the charging portion and the ejecting portion, and a flow control portion to control the generated airflow.
Therefore, generated colorant particles are surely transported to each portion by the transport portion. Furthermore, the flow control portion may control the airflow, which prevents the colorant particles from being attached in an undesired location in the flow path, and the ejection amount from becoming uneven, so that the recording speed may be improved.
The charging portion as described above has its lengthwise direction corresponding to the transport direction of the colorant particles, and may include corona discharge means which is arranged in axial symmetry in a cross sectional direction corresponding to the transport direction.
Thus, the air ions generated by corona discharge at the charging portion may move along the line of electric force and impinge the colorant particles being transported to charge the colorant particles, and therefore almost the entire colorant may be charged, so that the charging efficiency may be improved. As a result, the ejection speed and the recording speed increase, and good quality recorded images may be stably provided.
A flow of ionized air is generated at the charging portion by corona discharge, but the colorant particles are transported in an airflow by the transport portion, and therefore the amount of colorant particles drawn to the ionized airflow at the charging portion attached to an undesired part of the charging portion may be reduced.
Since at the charging portion the ionized air impinges upon all the colorant particles transported by corona discharge, few uncharged particles are generated, and variations in the charge amount may be restrained as well. Furthermore, the lengthwise direction of the charging portion corresponds to the transport direction of colorant particles, and therefore a long time period may be secured for charging the colorant particles, which may increase the charge amount.
In the image recording apparatus as described above, a circulating flow path structure to sequentially circulate the colorant particles through the generating portion, charging portion and ejecting portion may be employed.
Thus, the colorant particles circulate each portion in the image recording apparatus, and colorant particles not used for recording may be recycled. These unused colorant particles are once again transported to the charging portion, has its charge amount increased and is then used for recording, which improves the use efficiency of the colorant particles. In addition, since the charge amount for colorant particles increases, the ejection speed increases, and an increased recording speed results.
The above-described generating portion may be an ultrasonic vibrating portion which vibrates ink colorant by an ultrasonic to generate colorant particles.
The above-described transport portion may include a speed control portion to limit the transport speed of colorant particles. Thus, the transport speed of colorant particles may be controlled such that images may be appropriately recorded.
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
FIG. 1 is a view for use in illustration of an image recording apparatus according to a first embodiment of the present invention;
FIG. 2 is a graph showing the distribution of the charge amount of colorant particles according to the present invention and a conventional method;
FIGS. 3A and 3B are graphs showing the relation between the granulating condition and particle size in the image recording apparatus shown in FIG. 1;
FIGS. 4A and 4B are views for use in illustration of a charging device applied in an image recording apparatus according to a second embodiment of the present invention;
FIG. 5 is a view for use in illustration of an image recording apparatus according to a third embodiment of the present invention;
FIG. 6 is a view for use in illustration of an image recording apparatus according to a fourth embodiment of the present invention;
FIG. 7 is a view for use in illustration of an image recording apparatus according to a fifth embodiment of the present invention; and
FIG. 8 is a view for use in illustration of a conventional image recording apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Image recording methods and apparatuses according to first to fifth embodiments of the present invention will be now described in conjunction with the accompanying drawings.
First Embodiment
An image recording apparatus according to a first embodiment of the invention shown in FIG. 1 has a tubular chamber 12 to heat and evaporate solid ink, charge the evaporated ink particles for electrostatic control, and form images on a recording surface of a recording medium RM. There are provided in chamber 12 , sequentially from one end to the other end, a transport device 6 to transport gaseous ink particles in chamber 12 , a heating device 11 to heat and evaporate the solid ink, a granulating device 2 to form evaporated ink into prescribed particles, a charging device 3 to charge the evaporated ink particles, a flow control device 4 to control an airflow including the charged ink particles, an ejecting device 5 to allow the charged ink particles to be ejected onto a recording surface of recording medium RM, and a filter 7 A to let out the airflow from chamber 12 while preventing the ink particles from being passed therethrough.
Transport device 6 is provided at one end of chamber 12 and has a DC micro-fan 6 A and a fan driving portion 6 B which controls driving of DC micro-fan 6 A. DC micro-fan 6 A is driven by fan driving portion 6 B to generate an airflow including evaporated ink particles from the one end side to the other end side in chamber 12 . Heating device 11 includes an ink pot 11 A to pre-store powder colorant CP and an electric heater 11 B provided under ink pot 11 A to heat and evaporate power colorant CP. Next to heating device 11 in chamber 12 , there is provided a granulating device 2 which agglomerates evaporated colorant CPG obtained by heating powder colorant CP by heating device 11 and granulates the colorant into a suitable size for image forming to generate colorant particles CPS. In order to generate colorant particles CPS, provided at the wall of the flow path of evaporated colorant CP in granulating device 2 is a flat heating element 2 A such as a heat-resisting resin film with a little conductivity which generates heat by Joule heat under the control of heating control portion 2 B. Next to granulating device 2 in chamber 12 , a charging device 3 to charge colorant particles CPS is provided. Charging device 3 includes for example an electrode 3 A and an electrode 3 B used for forming an electric field for corona discharge in order to generate ions. Electrodes 3 A and 3 B provided opposite to each other with the flow path of colorant particles CPS therebetween, and application of potentials is controlled by corresponding potential control portions 3 A 1 and 3 B 1 . Next to charging device 3 in chamber 12 , a flow control device 4 is provided. Flow control device 4 has for example a plurality of flow control plates 4 A arranged parallel to each other in the flow path containing colorant particles CPS. Next to flow control device 4 in chamber 12 , an ejecting device 5 is provided. Ejecting device 5 is provided with an ejecting outlet 9 of φ300 μm opposite to the recording surface of recording medium RM for ejecting colorant particles CPS toward the recording surface, and there are intermediate electrode portions 5 A ( 5 A 1 , 5 A 2 ) of inner diameter of φ300 μm surrounding ejecting outlet 9 at both surfaces of an insulating plate 5 D. A back plate electrode 5 C is provided at a gap from insulating plate 5 D so that colorant particles CPS may be transported toward the recording surface of recording medium RM from the inside of chamber 12 . Back plate electrode 5 C is provided at a surface opposite to the recording surface of recording medium RM, and potentials applied to the electrode are controlled by a potential control portion 5 C 1 . Next to ejecting device 5 in chamber 12 , a filter 7 A is provided. Filter 7 A is provided to recover unused colorant particles CPS. The operations of the image recording apparatus as shown in FIG. 1 will be now described.
In a stand-by state, DC micro-fan 6 A is started to generate an airflow in the direction denoted by the arrow X in chamber 12 . At the time of printing, powder colorant CP is heated to 200° C. and evaporated by heating device 11 . When colored ink is used as colorant, the colorant may include as a base, anthoraisothiazole, quinophthalone, pyazolonazo, pyridone azo, styryl or the like for yellow, anthraquinone, dicyanoimidazole, thiadiazoleazo, tricyanovinyl, or the like for magenta, and azo, anthraquinone, naphthoquinone, indoaniline, or the like for cyan.
When colorant CP is evaporated and transported to granulating device 2 , the colorant is cooled, solidified, and agglomerated into colorant particles CPS. When evaporated colorant CP spontaneously cools without heat generated by heating element 2 A, colorant particles CPS having an average particle size of 0.8 μm are generated. Meanwhile, if evaporated colorant CP is gradually cooled as granulating device 2 is heated by heating element 2 A, the heat generated by heating element 2 A may be controlled by heating control portion 2 B to control the particle size of colorant particles CPS. Then, colorant particles CPS are transported to charging device 3 . Electrode 3 A has a sharp tip end directed to the flow path of colorant particles CPS, and electrode 3 B has a plate shape. Herein, electrode 3 A may be a needle electrode or may have a sharp tip end extending for the size of the cross section in the vertical direction to the flow path direction of colorant particles CPS or may be in other forms.
Electrode 3 B may be a plate shaped electrode expanded fully over the upper wall in charging device 3 in chamber 12 . Thus, a potential difference in such a level to cause air to be ionized around electrode 3 A is provided between the two electrodes by potential control portions 3 A 1 and 3 B 1 , so that the ions move toward electrode 3 B according to the electric force line generated between the electrodes. At this time, the ions impinge upon and are attached to colorant particles CPS being transported, and colorant particles CPS are charged as a result. More specifically, if −5 kV is applied to electrode 3 A and 0 V to electrode 3 B by potential control portions 3 A 1 and 3 B 1 ,—ions move from electrode 3 A to electrode 3 B, and therefore colorant particles CPS are negatively charged. The airflow containing charged colorant particles CPS is controlled by control plates 4 A in flow control device 4 and transported to ejecting device 5 such that colorant particles CPS are supplied evenly on the recording surface of recording medium RM. Ejecting device 5 is provided with a prescribed voltage at intermediate electrode portion 5 A ( 5 A 1 , 5 A 2 ) and at back plate electrode portion 5 C, and charged colorant particles CPS are ejected onto the recording surface of recording medium RM through ejecting outlet 9 . More specifically, a voltage of 0 V or −500 V is applied to intermediate electrode portion 5 A ( 5 A 1 , 5 A 2 ) by an output signal from an intermediate electrode driving control portion 5 E corresponding to an electrical signal for image data to be recorded, while back plate electrode portion 5 C is provided with a voltage in the range from +1.0 kV to +2 kV by potential control portion 5 C 1 . Herein, an electric field formed at ejecting outlet 9 controls colorant particles CPS to be ejected by electrostatic force. For example, if OV is applied to both intermediate electrode portions 5 A 1 and 5 A 2 , charged colorant particles CPS are ejected through ejecting outlet 90 , and an image is printed on the recording surface of recording medium RM.
According to this embodiment, heating device 11 , granulating device 2 , charging device 3 , and ejecting device 5 to generate (by heating and granulating colorant), charge and eject colorant particles CPS are sequentially provided, and transport device 6 to sequentially transport colorant particles CPS to these devices is provided so that generated colorant particles CPS surely pass through each device, and the use efficiency improves and the charge amount becomes even. Particularly in charging device 3 , colorant particles CPS are transported in an airflow and therefore may be restrained from being drawn to and from being attached to electrode 3 B. The colorant becomes solid particles by providing granulating device 2 , and therefore ionized air generated by charging device 3 may move according to the electric force line to impinge upon and charge colorant particles CPS. Therefore, almost the entire evaporated colorant CPG may be charged, in other words, the charging efficiency significantly improves. In general, the contact charging method which allows charged particles and particles to be changed to contact is often employed for advantages in the time constant and the charge amount. If the contact charging method is employed in this embodiment, colorant particles CPS to be charged in the order of 1 μm and contacting charged members can hardly be separated. Therefore, this embodiment employs the method of charging colorant particles by allowing ions to be attached to colorant particles CPS as described above, so that the charged colorant particles CPS may be readily effectively utilized.
The result of measurement of the charging efficiency for colorant particles CPS according to this embodiment is given in FIG. 2 . FIG. 2 shows the charge amount distribution of ink particles which passed the charging area. The ordinate represents the mass amount of ink particles, the abscissa the charge amount of an ink particle. The measurement result of the charging efficiency of colorant particles in the conventional image recording apparatus in FIG. 8 is shown in solid line B, and the measurement result of the charging efficiency of colorant particles according to the embodiment shown in FIG. 1 is shown in solid line A. As shown in FIG. 2, in the measurement result of the charging efficiency of colorant particles CPS in the conventional image recording apparatus, a lot of uncharged colorant particles exist, while in the image recording apparatus according to this embodiment shown in FIG. 1, as shown in solid line A, there is almost no entirely uncharged colorant particles though the charge amount varies among colorant particles CPS.
Furthermore, by controlling the temperature gradient related to heating by heating element 2 A in granulating device 2 and the transport speed of colorant particles CPS, the particle size of colorant particles CPS may be controlled as desired as shown in FIGS. 3A and 3B. FIG. 3A shows the relation between the particle size of colorant particles CPS and the temperature gradient related to heating by heating element 2 A, and FIG. 3B shows the relation between the particle size of colorant particles CPS and the transport speed. The particle size may be increased for example by gradually cooling colorant particles CPS in granulating device 2 by controlling heat generated by heating element 2 A with heating control portion 2 B. Using fan driving portion 6 B as shown in FIG. 3B, the transport speed of colorant particles CPS by DC micro-fan 6 A in granulating device 2 may be lowered to increase the particle size.
According to this embodiment, colorant particles CPS are transported directly by air and indirectly by DC micro-fan 6 A. In general, the weight of micro-particles having a particle size of 1 μm may be ignored in a mobile medium, and therefore the use of airflow as in this embodiment is preferable for the transport of colorant particles CPS as compared to the method using a belt or roller where a complex structure is required and colorant particles CPS are undesirably deposited. In this embodiment, the air over the heating surface by electric heater 11 B in heating device 11 flows and is exchanged so that the saturated vapor immediately above the evaporation surface of colorant particles CP by electric heater 11 B is lowered, and the amount of evaporated powder colorant CP is effectively increased as well. Meanwhile, if the airflow in chamber 12 is greatly disturbed, colorant p articles CPS could be attached in an undesired location in the flow path, or the ejection amount could vary. However, according to this embodiment, since the airflow containing colorant particles CPS is controlled by the plurality of control plates 4 A, such disadvantage could be significantly alleviated. The airflow controlling method treats the speed as a parameter, and therefore the airflow containing colorant particles CPS may be formed into a turbulent flow or stream line flow. Based on the measurement, the stream line flow significantly reduced the sticking of colorant particles CPS in an undesired location in chamber 12 , and the density of colorant particles CPS was increased in the vicinity of ejecting outlet 9 by placing colorant particles CPS in the stream line of the airflow generated in the vicinity of ejecting outlet 9 . As a result, the recording density related to image recording on the recording surface of recording medium RM was improved. For example, in a device having a flow path cross section as large as 20×20 mm, and a total length of 200 mm, a stream line was provided at an airflow rate of 0.35 m/s. Therefore, when Reynolds number Re =v·d /v(v: flow rate, d: flow path size, v. air kinematic viscosity), the flow path and flow rate need only be set to satisfy Re <500. Since the flow rate acts upon the condition setting with great sensitivity, the use of fan driving portion 6 B for fine tuning related to DC micro-fan GA permits these controls to be readily made.
Second Embodiment
A charging device according to a second embodiment applied to the image recording apparatus according to the present invention will be now described.
FIGS. 4A and 4B are diagrams showing essential part of a charging device 31 . FIG. 4A is a side view of the essential part of charging device 31 , while FIG. 4B is a front view of the essential part. The arrow in broken line in FIG. 4B indicates the direction of transporting ions of air generated in neighborhood of electrode 31 A and the direction X denoted by the arrow in FIG. 4A indicates the direction of transporting colorant particles CPS by the airflow. The lengthwise direction of charging device 31 matches the direction of airflow X, and the cross-sectional direction to the airflow direction X is in axial symmetry. An electrode 31 A is a tungsten wire having a diameter of several ten μm, and an electrode 31 B is an aluminum tube having an outer diameter of 20 mm, and a thickness of 1mm. When 0 V and −5 kV are applied to electrodes 31 A and 31 B, respectively through potential control portions 32 A and 32 B, for example, positive ions generated around electrode 31 A move toward electrode 31 B. As shown in FIG. 4B, the cross-sectional direction of the airflow is in axial symmetry in charging device 31 , and therefore, the ions move in every direction at the cross section. Thus, all the colorant particles CPS transported into charging device 31 impinge ions of air and are charged, in other words, there will be no uncharged colorant particles, and variations in the charge amount for colorant particles CPS are reduced. Furthermore, since the airflow direction X matches the lengthwise direction of charging device 31 , the effect of charging colorant particles CPS may last long, which may increase the charge amount for colorant particles CPS. The charge amount for colorant particles CPS may be also controlled by adjusting the size of charging device 31 in the lengthwise direction.
Note that colorant particles CPS may be transported using transport device 6 as shown in FIG. 1 .
Third Embodiment
An image recording apparatus according to a third embodiment of the present invention will be now described. FIG. 5 shows the structure of this image recording apparatus according to the third embodiment. In FIG. 5, the portions denoted by the same reference characters as those in FIG. 1 have the same structure and operate in the same manner as those in the image recording apparatus according to the first embodiment, and will not be described. Portions different from those in FIG. 1 will be described. FIG. 5 is different from FIG. 1 in that in a closed annular chamber 13 , an airflow including colorant particles CPS sequentially passed through a generation device for colorant particles CPS (a heating device 11 and a granulating device 2 ), a charging device 3 , a flow control device 4 , and an ejecting device 5 is once again circulated through these devices. Since chamber 13 is apparently highly tightly sealed, the airflow circulates within chamber 13 at a flow rate with a small variation. By allowing colorant particles CPS to circulate through the devices, colorant particles CPS not used for recording will be re-used. Furthermore, the colorant particles CPS not used for recording are highly likely to have a small charge amount, and therefore, may be transported to charging device 3 once again through transport device 6 , heating device 11 and granulating device 2 , so that the charge amount increases in charging device 3 . These colorant particles CPS having their charge amounts increased will be later used for recording through flow control device 4 and ejecting device 5 , which improves the use efficiency for colorant particles CPS. Since the charge amount for colorant particles CPS increases, the speed at which colorant particles CPS are ejected from ejecting outlet 9 increases, which results in improvement in the recording speed.
Corona discharge is employed for generating ions in charging devices 3 and 31 described above, but the photoelectric conversion effect or the like may be used as well. Ink in a powder state at room temperatures is used as colorant CP to be heated in heating device 11 , but ink in a liquid state at room temperatures may be used. In this case, the time and energy required for evaporating colorant CP in heating device 11 are advantageously reduced.
Forth Embodiment
An ultrasonic vibrating device may be provided in place of heating device 11 and granulating device 2 such that liquid ink may be formed into fine ink particles and colorant particles CPS may be provided.
FIG. 6 is a diagram of an image recording apparatus provided with such an ultrasonic vibrating device. In FIG. 6, ultrasonic vibrating device 100 is provided in place of heating device 11 and granulating device 2 in FIG. 1 . Ultrasonic vibrating device 100 has a portion to previously store liquid colorant CP and a control device 101 to output an ultrasonic to stored colorant CP. In operation, colorant CP is vibrated by an ultrasonic output from control device 101 and formed into fine colorant particles CPS. Colorant particles CPS thus generated are sequentially transported to the respective portions, as is the case with FIG. 1 .
Fifth Embodiment
In FIG. 7, an ultrasonic vibrating device 100 is provided in place of heating device 11 and granulating device 2 in FIG. 5 . Ultrasonic vibrating device 100 has a portion to previously store liquid colorant CP and a control device 101 to output an ultrasonic to colorant CP. In operation, colorant CP is vibrated by an ultrasonic output from control device 101 and formed into fine colorant particles CPS. Colorant particles CPS thus generated are sequentially transported to the respective portions, as is the case with FIG. 5 .
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
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An image recording apparatus includes a heating portion and a granulating portion to generate colorant particles, a charging portion to charge the generated colorant particles, an ejecting portion to intermittently eject the charged colorant particles onto a recording medium in response to an electrical signal corresponding to image data to be recorded, and a transport portion to sequentially transport the colorant particles through these portions. The heating portion heats and evaporates solid or liquid colorant. The evaporated colorant is transported to the granulating portion, cooled, solidified and agglomerated into colorant particles. The colorant particles are transported to the succeeding charging portion, charged there and transported to the ejecting portion. The charged colorant particles are electrically induced toward a recording medium through an ejection hole and ejected onto a recording medium, so that the colorant particles stick and permeates to the medium according to image data.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an automatic sewing machine, and more particularly to a sewing direction control apparatus for sewing machine.
[0003] 2. Description of the Prior Art
[0004] Computer control sewing machines are usually used to embroider complicated patterns automatically rather than manually, whereby to enhance the quality of the embroidery pattern, or used to stitch buttons or create decorative patterns on sewing products, whereby to improve sewing speed or accuracy. The existing computer control sewing machine essentially comprises a clamp on a work platform to clamp and fix the sewing product to be embroidered, the clamp is driven by a movement device to perform two-dimensional movement on the work platform with respect to the sewing head of the sewing machine, and the sewing product will move along with the clamp, so that patterns can be embroidered on the sewing product.
[0005] The sewing head of the existing computer control sewing machines is designed to be able to sew the sewing product only in a specific direction, so that the sewing product has to be inserted from the specific direction into the sewing head and should be aligned to the needle, then the sewing thread above the sewing machine can be formed into a loop to form lock stitch seam by cooperating with the sewing thread from the thread spool which is at the lower portion of the sewing machine. However, when moving in a two-dimensional manner along the work platform, the sewing product might approach the needle from any direction, resulting in poor stitching or deviation of sewing thread.
[0006] To solve the above defects, U.S. Pat. No. 4,498,404 discloses an automatic sewing apparatus which uses a manipulator arm to replace the conventional 2D movement device. The manipulator arm includes three rotation axes, so that the sewing product can be better controlled by the manipulator arm to rotate between the needle and the work platform, ensuring that the sewing product is kept being inserted into the sewing head from a specific direction. An Italian patent B093A 000113 discloses another sewing apparatus, wherein a lever with a needle is arranged above the needle plate of the sewing head, and below the needle plate is disposed a thread shaft with a hook. The lever and the thread shaft rotate together to maintain the relative position between the needle and the hook unchanged, ensuring that the sewing product is kept being inserted into the sewing head from a specific direction.
[0007] However, the above two sewing apparatuses still have the following disadvantages:
1, for automatic sewing machines, the sewing product must be moved intermittently and rapidly a very small distance at a time during sewing operation, so that the manipulator arm for moving the sewing product should have excellent acceleration ability and should be capable of precisely controlling the distance that the sewing product moves, resulting in a high manufacturing and maintenance cost of the manipulator arm. 2, there are various types of automatic sewing machines, however, the positioning device which maintains the relative position between the needle and the hook unchanged by using the synchronous rotation of the lever and the thread shaft is inapplicable to the sewing machines with cylinder bed head. Therefore, it is still unable to solve the sewing direction problem.
[0010] The present invention has arisen to mitigate and/or obviate the afore-described disadvantages.
SUMMARY OF THE INVENTION
[0011] The primary objective of the present invention is to provide a low cost sewing direction control apparatus for sewing machine which provides accurate sewing operation and is suitable for use in various automatic sewing machines.
[0012] To achieve the above objective, a sewing direction control apparatus for sewing machine in accordance with the present invention comprises:
a base plate; a transmission element being a circular ring-shaped structure mounted on the base plate and centrally provided with a circular cavity, a sewing product being fixed at a bottom of the cavity and located corresponding to the needle; a driving element including a servo motor connected to a driving shaft, and a disc-shaped driving unit connected to an end of the driving shaft, the end of the driving shaft being connected to a center of the driving unit, the driving unit is located at a periphery of and connected to the transmission element, the servo motor driving the driving unit to rotate and consequently rotating the transmission element and the sewing product, a sewing direction of the needle being tangent to a rotation direction of the sewing product.
[0016] The sewing direction control apparatus for sewing machine in accordance with the present invention uses teeth engagement to perform highly accurate, intermittent and fast movement, therefore, the direction control apparatus of the present invention has low cost, and is suitable for various types of automatic sewing machines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a sewing direction control apparatus for sewing machine in accordance with a preferred embodiment of the present invention;
[0018] FIG. 2 is a cross sectional view of the sewing direction control apparatus for sewing machine in accordance with the preferred embodiment of the present invention;
[0019] FIG. 3A is an operational view showing that the slide rack of the present invention moves away from the base plate;
[0020] FIG. 3B is an operational view showing that the slide rack of the present invention is engaged with the base plate;
[0021] FIG. 4 is a perspective view of a sewing direction control apparatus for sewing machine in accordance with another preferred embodiment of the present invention;
[0022] FIG. 5 is a cross sectional view of the sewing direction control apparatus for sewing machine in accordance with the another preferred embodiment of the present invention; and
[0023] FIG. 6 is an operational view of the sewing direction control apparatus for sewing machine in accordance with the another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.
[0025] Referring to FIGS. 1 and 2 , a sewing direction control apparatus for sewing machine in accordance with a preferred embodiment of the present invention comprises a base plate 10 , a transmission element 20 disposed on the base plate 10 , a sewing plate 30 disposed in the transmission element 20 to fix a sewing product A, and a slide rack 40 and a driving element 50 disposed at one side of the base plate 10 .
[0026] The base plate 10 is rectangular and centrally provided with a hole 11 and a flange 12 around the hole 11 . The base plate 10 is an X-Y planar surface with an X direction and a Y direction. In this embodiment, as shown in FIG. 1 , the base plate 10 is further provided with two protrusions 13 which are located adjacent to the hole 11 an a corner of the base plate 10 .
[0027] The transmission element 20 is a circular ring-shaped structure located around the hole 11 of the base plate 10 . As shown in FIG. 2 , the transmission element 20 is centrally provided with a circular cavity 21 , an annular slot 211 around the bottom of the circular cavity 21 , and a plurality of positioning pins 212 disposed at the bottom of the cavity 21 and located around the bottom of the annular slot 211 . An annular engaging portion 22 extending outward from the bottom of the cavity 21 is formed with an annular groove 221 which is located around the periphery of the transmission element 20 . The annular groove 221 and the cavity 21 open in opposite directions and separated from each other by the wall of the cavity 21 . The transmission element 20 is provided with a threaded surface 23 around the outer peripheral surface of the annular engaging portion 22 . The annular groove 221 of the transmission element 20 is located corresponding to the flange 12 of the base plate 10 , namely, the flange 12 is received in the annular groove 221 , and an annular bearing 24 is disposed between the flange 12 and the annular groove 221 to enable the transmission element 20 to rotate with respect to the flange 12 . In this embodiment, the transmission element 20 is provided with four spaced positioning pins 212 .
[0028] The sewing plate 30 is a circular structure received in the cavity 21 of the transmission element 20 and provided with a plurality of ears 31 around a periphery thereof. The ears 31 each have a pivot hole 311 and are located corresponding to the positioning pins 212 of the transmission element 20 in such a manner that the positioning pins 212 of the transmission element 20 are inserted in the pivot holes 311 of the sewing plate 30 , so as to fix the sewing plate 30 to the annular slot 211 of the transmission element 20 . In this embodiment, the sewing plate 30 is provided with four spaced ears 31 to cooperate with the positioning pins 212 .
[0029] The slide rack 40 , as shown in FIG. 1 , is disposed on the X-Y surface and fixed at one side of the base plate 10 which is perpendicular to the direction Y. The slide rack 40 a rectangular structure which is centrally provided at a top surface thereof with a rack plate 41 which is located higher than the X-Y surface. The slide rack 40 is provided with an abutting protrusion 43 at one side thereof adjacent the base plate 10 , the abutting protrusion 43 is located corresponding to the protrusions 13 of the base plate 10 and extends in the direction Y. the slide rack 40 is further provided with a passage 42 corresponding to the rack plate 41 . In this embodiment, the slide rack 40 is driven by a linear movement device (not shown) to move linearly along the direction Y of the X-Y surface, so as to move close to or away from the base plate 10 .
[0030] The driving element 50 , as shown in FIG. 1 , is mounted on the slide rack 40 and comprises a servo motor 51 disposed on the rack plate 41 , a driving shaft 511 located below the servo motor 51 and inserted in the rack plate 41 , and a driving unit 52 connected to one end of the driving shaft 511 . The driving unit 52 is a disc structure. In this embodiment, around the outer peripheral surface of the driving unit 52 is formed a threaded surface, and the end of the driving shaft 511 is connected to the center of the driving unit 52 . The driving unit 52 is located on the X-Y surface and extends out of the passage 42 of the slide rack 40 to mate with the threaded surface 23 of the transmission element 20 .
[0031] A control element 60 , as shown in FIGS. 1 , 3 A, 3 B, is pivoted to the two protrusions 13 of the base plate 10 and comprises a control unit 61 and an elastic unit 62 . The control unit 61 is reversed U-shaped and includes an operating section 611 , a connecting section 612 and an engaging section 613 . A conjunction between the operating section 611 and the connecting section 612 is pivoted to one of the protrusions 13 adjacent the transmission element 20 , so that the operating section 611 and the engaging section 613 approximately extend in the direction X and toward the transmission element 20 , and the free end of the engaging section 613 is a threaded structure. The elastic unit 62 is approximately L-shaped and includes a stationary section 621 and an abutting section 622 . A connecting hole 623 is formed at the conjunction between the stationary section 621 and the abutting section 622 to enable the elastic unit 62 to be pivoted to the one of the protrusions 13 adjacent the transmission element 20 in such a manner that the end of the stationary section 621 of the elastic unit 62 is pressed against another one of the protrusions 13 which is located farther away from the transmission element 20 , and the end of the abutting section 622 is pressed against the connecting section 612 of the control unit 61 .
[0032] As shown in FIG. 3A , when the base plate 10 moves away from the slide rack 40 , the connecting section 612 of the control unit 61 will be pushed by the abutting section 622 of the elastic unit 62 , the engaging section 613 of the control unit 61 will be engaged with the threaded surface 23 of the transmission element 20 , and the driving unit 52 of the driving element 50 will be disengaged from the transmission element 20 to enable the transmission element 20 to be engaged with and fixed by the control unit 61 . As shown in FIG. 3B , when the base plate 10 move toward the slide rack 40 , the operating section 611 of the control unit 61 will be pushed by the abutting protrusion 43 of the slide rack 40 , so that the engaging section 613 of the control unit 61 will be disengaged from the threaded surface 24 of the transmission element 20 , and the driving unit 52 of the driving element 50 will be engaged with the threaded surface 24 of the transmission element 20 to enable the transmission element 20 to be rotated by the driving unit 52 .
[0033] The abovementioned are the structural relations of the main components of the first preferred embodiment. It is to be noted that the present invention also provides another embodiment; its structure is explained as follows.
[0034] Referring to FIGS. 4 and 5 , in this embodiment, around an outer peripheral surface of the annular engaging portion 22 of the transmission element 20 is provided a driven belt 25 , and a driving belt 53 winds around the driven belt 25 and the driving unit 52 of the driving element 50 to rotate the transmission element 20 . At a corner of the base plate 10 is disposed a pallet 14 which is higher than the X-Y surface. The servo motor 51 of the driving element 50 is inserted in the pallet 14 , the driving shaft 511 of the servo motor 51 is connected to the driving unit 52 , the driven belt 25 of the transmission element 20 located toward the driving unit 52 , and the driving belt 53 winds around the driven belt 25 and the driving unit 52 of the driving element 50 . When the servo motor 51 rotates the driving unit 52 , the driving unit 52 will drive the transmission element 20 to rotate on the base plate 10 via the driving belt 53 . In this embodiment, the driven belt 25 and the driving belt 53 are timing belts, which are engaged with each other via teeth engagement.
[0035] FIG. 6 shows that the sewing direction control apparatus for sewing machine in accordance with the present invention is used in combination with a needle 71 of a sewing head 70 . As shown in FIG. 6 , when the slide rack 40 moves toward the base plate 10 , the sewing product A is fixed on the sewing plate 30 and located corresponding to the needle 71 of the sewing head 70 , and the preset sewing path of the needle 71 extends along the direction Y. The transmission element 20 is rotated by the driving element 50 . Meanwhile, the sewing product A is caused to rotate clockwise, so that the sewing direction is maintained tangent to the rotation direction of the sewing product A, thus fixing the sewing direction of the sewing machine, making the sewing machine perform sewing operation by moving along the desired sewing direction, and consequently improving the sewing speed and quality. Furthermore, the sewing direction control apparatus for sewing machine in accordance with the present invention uses teeth engagement to perform highly accurate, intermittent and fast movement, therefore, the direction control apparatus of the present invention has low cost, and is suitable for various types of automatic sewing machines.
[0036] While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
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A sewing direction control apparatus for sewing machine, comprising: a base plate ( 10 ), a circular ring-shaped transmission element ( 20 ) dispose on the base plate ( 10 ) and a driving element ( 50 ) with a driving unit ( 52 ). During sewing, the driving unit ( 52 ) drives the transmission element ( 20 ), rotating a sewing product (A) placed at the center of the transmission element ( 20 ) with the driving element ( 52 ), thereby controlling the sewing direction of the sewing product (A), and thus improving the sewing accuracy. The direction control apparatus has low cost, and is suitable for various types of automatic sewing machines.
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BACKGROUND OF THE INVENTION
This invention is related to side wheels for motorcycles and in particular to side wheels which are retractable when not in use and extendable for assistance in stop-and-start driving, slow-speed operation and parking.
Since the introduction of motorcycles, there have been various attempts at holding them upright and yet allowing the pleasure of balancing them when riding. Motorcycling is an intriguing extension of the individual rider. It provides satisfaction from its accomplishment without the aid of side wheels. Most development in balancing motorcycles, therefore, has been confined largely to improvement of kickstands and other minor aids to holding them upright when stopped. Notably different, however, have been some side wheels that follow the curves of the road and allow a rider to tip when turning. But such aids have not been successful as a result of a desire of nearly all who ride to balance for themselves. Consequently, this invention provides a balancing aid for use when the motorcycle is in stop-and-start operation as an option to match the needs and capabilities of all riders while still maintaining the balancing motivation and achievement of motorcycling when riding.
For even the strong and daring, however, large touring motorcycles are cumbersome and dangerous to handle when not being driven and when stopping and starting. Non-driving burdens and problems do not provide pleasure from motorcycling. This invention alleviates the unpleasant and unrewarding features of motorcycling, particularly tour cycling with large touring motorcycles.
A major feature not addressed in motorcycling is that it is participated in often jointly with a partner who may not be able to handle a large motorcycle or even a tall, light motorcycle during stop-and-start operations. The social aspect limits the amount of motorcycling that will be engaged in by even ardent enthusiasts of the sport. A large motorcycle that is optionally as challenging as the strongest riders desire and yet so nimble and easy to handle that a delicate, small lady can master it with pleasure can satisfy all types of individuals. A female cycling passenger can become an addict of the sport with this invention.
Relatively affluent, generally elderly and often partially incapacitated individuals comprise a large portion of large-motorcycle touring enthusiasts. For them, the practicality of avoiding the burdens and problems of motorcycling are particularly significant and often crucial.
Psychological studies have shown that the greatest dangers to motorcycling are related to stop-and-start traffic conditions and parking. This is mostly because increased attention is required at the same time that handling the motorcycle also demands attention. Safety is too often the loser.
Further, it has been found that mood and emotional conditions of riders fluctuate in ways that make motorcycling sporadically dangerous for even the best cyclists. For those mental conditions in which the dangers of stop-and-start driving require vehicle stability like that of an automobile, this invention is particularly advantageous. It is for all.
Patents found in the art include the following: U.S. Pat. No. 4,637,624 Shar Jan. 20, 1987 U.S. Pat. No. 4,638,880 Togashi Jan. 27, 1987 U.S. Pat. No. 4,693,488 Bermecco Sept. 15, 1987 U.S. Pat. No. 4,223,906 Gratza Sept. 23, 1980 U.S. Pat. No. 4,133,402 Soo Hoo Jan. 9, 1979 U.S. Pat. No. 4,095,823 Nishida Jun. 20, 1978 U.S. Pat. No. 3,980,150 Gigli Sept. 14, 1976
Most of these are so related to kickstands that comment does not appear to be merited. Two of them, the Soo Hoo and Gigli patents, relate to wheeled undercarriage supports. They are different from this invention in that they are devised to replace the balancing feature of motorcycling, rather than to stop-and-start conditions at low cost optionally. Although both the Soo Hoo and Gigli devices are optional and can be used for stop-and-start driving as well as for fast driving, they are less stable for stop-and-start driving, for parking and for handling when not driving. They provide expensive features which cyclists desire to avoid. In particular, they feature tip-adjustment, springs and terrain-contour adjustment that are neither needed for safety nor warranted to derogate the pleasure of motorcycling.
SUMMARY OF THE INVENTION
One object of this invention is to provide low-cost, convenient, safe, reliable and attractive side wheels for large motorcycles which are used generally for touring.
Another object is to provide upright stability of a motorcycle in stop-and-start traffic.
Another object is to provide upright stability for stopping, starting and parking a relatively large motorcycle for individuals with relatively short legs, for individuals whose psychological conditioning hinders sufficient attention for safety in stop-and-start traffic, for individuals whose mental and emotional state at the time of driving hinders safety in stop-and-start traffic, for individuals whose legs are not sufficiently strong to hold up a large motorcycle and for individuals whose legs may be incapacitated.
Another object is to provide upright stability at an optional basis for different drivers.
Another object is to provide upright stability on an optionally manual or automatic basis.
Still another object is to provide automatic upright stability at selectively different speeds for up-and-down actuation of retractable side wheels.
The present invention accomplishes the above and other objects providing a motorcycle with retractable stop-support side wheels parallel to the back wheel. The side wheels lock in place when down at each side of the motorcycle for stop-and-start driving, for parking and for handling the motorcycle when it is not being ridden. Hydraulic cylinders are employed to activate struts on which the side wheels are positioned pivotally at either the outside edge of crash bars of motorcycles having suitable crash bars or between top and bottom mounting positions for crash bars for motorcycles not having suitable crash bars. A mounting angle bracket is shaped for various types of motorcycles for pivotal attachment of the struts. Manual or automatic operation with selective-speed up-and-down actuation are optional.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings which are used to illustrate the preferred embodiments the invention are as follows:
FIG. 1 is a sectional cutaway left-side view of the rear section of a motorcycle with the left side wheel down and with the fender and covering parts of the motorcycle omitted for exposing components of the invention;
FIG. 2 is an enlarged sectional view of a mechanical wheels-down locking mechanism employed to assure that wheels stay down for safety when being stopped, started, parked, worked on, moved or otherwise handled when not being ridden;
FIG. 3 is a top sectional view of the rear section of a motorcycle with seat, baggage compartments and covering components omitted for exposing components of the invention;
FIG. 4 is is a cutaway rear view of a motorcycle with outside components omitted for illustrating the stop-support wheels in a down position in solid lines and in a retracted position in dashed lines. The left side of FIG. 4 illustrates a mounting bracket attached to a crash bar. The right side illustrates a mounting bracket attached to a motorcycle without a crash bar and with a cross-section of streamlined covering integrated with the structure of the motorcycle;
FIG. 5 is a schematic representation of the flow diagram of the hydraulic system for up-and-down actuation of the stop-support wheels;
FIG. 6 is a schematic diagram of the electrical system employed to actuate the hydraulic mechanism for retracting and extending stop-support wheels; and
FIG. 7 is a top view of stop-support-wheel controls at the front section of a motorcycle with a windshield and control panel attached to the frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a stop-support wheel 1 is rotatably attached to a strut 2. The strut 2 is pivotally attachable to a dihedral-angled attachment bracket 3 that is attachable to motorcycle frame 4. The attachment bracket 3 can be attached to a suitable crash bar 5 at the top bracket 3 and to the frame 4 at suitable frame bolt positions 6 at the bottom of the bracket 3. Alternatively, the bracket 3 can be attached to suitable frame attachment means in the vicinity of attachment means for attaching a shock absorber 7 and an optional crash bar 5. for attachment of the bracket 3 to a crash bar 5, various conventional attachment means 8 can be utilized. A strut-pivot bearing member 9 is attachable to an attachment-bracket outside wall 10. A strut pivot axle 11 is pivotally attachable to a strut-pivot bearing member 9 and can be pivotally anchored to attachment-bracket inside wall 12. The strut-pivot bearing member 9 can be a simple U clamp or a sophisticated bearing.
To retract or to extend the stop-support wheel 1, a strut-actuation arm 13 is extended at a suitable angle from the strut-pivot axle 11 and swiveled by means of a hydraulic cylinder 14 attached pivotally to a cylinder bracket 15 that is attached rigidly to attachment bracket 3. A piston shaft 16 is attached pivotally to the strut-actuation arm 13 and actuated linearly in both directions by a piston 17. Hydraulic fluid is pumped into and out from the cylinder 14 with hydraulic pump 18 through the wheels-up line 19 and wheels-down line 20 at respective wheels-up-line attachment 21 and wheels-down-line 22 to the cylinder 14.
Referring to FIGS. 1 and 2, the strut 2 can be locked mechanically in a wheels-down position by preventing the strut-actuation arm 13 from pivoting with in-line positioning of front over-lock arm 23 that is pivotally attachable to actuation arm 13 and rear over-lock arm 24 that is pivotally attachable to attachment-bracket outside wall 10. The front and rear over-lock arms 23 and 24 are pivotally attachable to each other and at an over-lock pivot position 25. An over-locking arrangement occurs when the over-lock pivot position 25 traverses an over-lock centerline 26 between front-over-lock-arm pivot-point 27 and rear-over-lock-arm pivot-point 28. The over-locking arrangement is maintained by a rotational bias with lock spring 29 in a wheels-down swivel direction to where a front lock shoulder 30 on front over-lock arm 23 is buttressed against rear lock shoulder 31 on rear over-lock arm 24.
Referring further to FIGS. 1 and 2, wheels-down directional pumping of fluid by hydraulic pump 18 is stopped automatically when switch arm 32 on rear over-lock arm 24 is caused to engage shut-off switch 33 which is connected to electrical lines that operate the hydraulic pump 18. Wheels-up directional pumping by hydraulic pump 18 actuates piston-shaft-shoulder cam 34 against front-over-lock-arm cam 35 to position the over-lock-pivot-position 25 at an unlocked side of the over-lock centerline 26 to allow the stop-support wheels 1 to be raised. The piston-shoulder cam 34 is attached to a piston-shaft shoulder 36 with an actuation-over-stroke slot 37 that allows travel of the piston shaft 16 in a wheels-up direction without raising the wheels 1 until the over-lock arrangement is in an unlocked position with the over-lock position at the opposite side of the over-lock centerline 26 from the locked position illustrated.
Referring yet further to FIGS. 1 and 2, up-and-down positioning of stop-support wheels 1 at both sides of a motorcycle frame 4 can be equalized by means of a torque arm 38 positioned under and extended from side-to-side of frame 4. There is no straight-through vacancy at the position of the strut-pivot axle 11 in most present motorcycles. It is possible, however, to construct motorcycles with such a vacancy. In the event that motorcycles are constructed with such a vacancy for utilizing this invention, one cylinder arrangement, rather than two, can be employed in the same working relationship. Alternatively also, a hydraulic equalization system can be employed as described below. The torque arm 38 is attachable pivotally to a torque-arm attachment extension 39 from the attachment-bracket inside wall 12. A torque-arm lever 40 is attachable rigidly to the torque arm 38 and attachable pivotally to a torque-arm connector 41. An equalizer lever 42 can be attached rigidly to the strut-pivot axle 11 at suitable angle between the strut 2 and the strut-actuation arm 13. Also, the working relationship of the torque arm 38 can be utilized with suitable construction for operating struts at both sides of frame 4 with a single hydraulic cylinder at one side.
Reference is made now to FIGS. 1, 3, 5 and 6 in relation to the hydraulic system. Typically supported by luggage-rack and rear-fender braces 43 behind a motorcycle real wheel 44 for add-on units are an electrical pump motor 45, hydraulic pump 18, accumulator 46 and overflow tank 47. These components can be positioned separately on a motorcycle or grouped in a figurative hydraulics case 48. Either the motor 45 or the pump 18 can be reversible to pressurize hydraulic fluid through the wheels-down line 20 for lowering the wheels 1 through wheels-up line 19 for raising wheels 1. The wheels 1 on struts 2 can be held in an up or down position or at any position in between up and down by shutting off fluid flow at pump-down valve 49 and pump-up valve 50 at the pump 18 by a pump switch 51 in proximity to a driver of a motorcycle. The pump switch 51 can be positioned on preferably the right handlebar of a motorcycle or such other location as preferred.
Preferably for safety and reliability with unlike duplicity, the mechanical over-lock system can be employed in conjunction with a wheels-down emergency system with or without the above optional electrical-switch operation of the valves 49 and 50. A high level of safety is provided for individuals who can not hold a motorcycle up with their legs and feet when the motorcycle is stopping or starting. Their life is in danger to drive a motorcycle at all if the stop-support wheels 1 are not as reliable as the legs of a strong motorcyclist. With this invention, the stop-support wheels 1 are far more reliable than the legs of any rider. This maximized safety factor is one of the fundamental features of this invention.
The emergency wheels-down hydraulic system is actuated by pressure in the accumulator 46 that is released by an emergency handle 52 in convenient proximity to a driver. There can be mechanical or hydraulic communication through emergency wheels-down line 53 from the handle 52 to accumulator-release valve 54. Pressurized gas or liquid in accumulator 46 is directed against hydraulic fluid in wheels-down line 20. This causes wheels 1 to be extended downwardly immediately and locked by the aforesaid over-lock system. This emergency wheels-down hydraulic system is employed only if there is an electrical failure and stop-support wheels are necessary for the particular driver. Until system electricity is available, the wheels 1 will remain in locked position down. Travel at speeds of 35 miles per hour is safe on relatively side-to-side level terrain with slow turns for purposes of obtaining assistance. A backup electrical source 55 also can be employed to assist an electrically locking system and/or an over-lock system as further duplicity for safety of individuals who prefer a higher safety factor equal to automobiles and yet like the thrill of motorcycling.
When hydraulic fluid is pressured by the accumulator 46 into wheels-down lines 20, fluid in the cylinder 14 and in the wheels-up line is directed into overflow tank 47 until re-circulated by re-activation of pump 18 with electrical current. Fluid pressured from accumulator 46 can be directed through accumulator lines 55 to wheels-down line 20. Overflow fluid can be directed to the overflow tank 47 through over line 56 in traverse of the pump 18 and valves 49 and 50 with one-way-valve action in relation to accumulator-pressured fluid.
The accumulator 46 can be any known type such as air-pressured with a separate motor or fluid-pressured with fluid from pump 18 against either a resilient member or against sealed air or other gas for accumulated resilience. Types of accumulators which do not release gas into the lines are preferable.
Referring now to FIG. 4, when crash bar 5 is not available or if available, is not suitable for support of attachment bracket 3, the the attachment bracket 3 can be bolted or otherwise attached with bolting means in the vicinity of shock-absorber attachments 57. All known motorcycles provide bottom-crash-bar and foot-rest bolting means 58 near the bottom of both sides of frame 4. The also provide top-crash-bar bolting means 59 in the vicinity of the shock-absorber attachments 57. The attachment bracket can be attached to the frame 4 independently of whether or not there are crash bars on particular motorcycles. The left side of FIG. 4 illustrates a rear view of an attachment bracket 3 clamped to a crash bar 5. The right side of FIG. 4 illustrates a rear view of an attachment bracket 3 shaped appropriately and attached to bolting means 59 at the top and to the frame 4 at the bottom as illustrated in FIG. 1. Also illustrated in FIG. 4 is a representative motorcycle covering 60 that is used on some present models of motorcycles. Motorcycles which have the covering 60 in a streamline form over the frame 4 also may have crash bars that are not suitable for attachment of the bracket 3. Beneath the cover 60 however, are the same mounting means 58 and 59 to which an appropriately-shaped bracket 3 can be attached. In conformity with the streamlined contouring of the covering 60, an appropriate strut-pivot-axle orifice 61 can be provided for inserting the strut-pivot axle 11 into strut-pivot bearing member 9 without any of the attachment mechanism visible or in a position to obstruct streamline effects of the covering 60. The back of a driver's seat 62 is shown in FIG. 4, but rear fenders, baggage containers and a passenger seat 63 have been omitted to illustrate the components of this invention. Above a rear bumper 64 available on some large touring motorcycles is a convenient position for the hydraulic case 48.
It can be observed in FIG. 4 that stop-support wheels 1 can provide a measure of safety even when in a wheels-up position. They can be made to protrude far enough to the sides to prevent a motorcycle from falling completely on its side. This also prevents a motorcycle from pinning an individual under it easily. Further, it holds the motorcycle in a partially-tipped position from which it can be uprighted with relatively little effort. When traveling at wheels-up speeds, the wheels 1 can be carried at selectively low positions to further aid balancing and tipping for turning, provided extreme tipping is not required. Typically for touring travel on large, heavy motorcycles, extreme tipping is not encountered or necessary.
The tires on wheels 1 can be relatively straight-bottomed rather than round-bottomed as illustrated in FIG. 4 for the motorcycle wheel 44 in comparison to a stop-support wheel 1.
FIG. 5 illustrates in schematic flow diagram the components of the hydraulic system described above. In addition is an accumulator-charge valve 65 through which pressured gas or liquid is directed under pressure into the accumulator 46. Hydraulic lines are fluid conduits referred to in common vernacular. Fluid pressured from pump 18 with valve 49 open is directed through wheels-down lines or conduits 20 to wheels-down-line attachment 22 at cylinder 14 to lower the wheels 1. To raise the wheels 1, either the electrical pump motor 45 or the pump 18 can be reversed to cause fluid to flow under pressure the opposite direction through valve 50 and wheels-up lines or conduits 19. The piston 17 is caused thereby to travel in the direction of fluid flow for raising and lowering the struts 2 and wheels 1 attached accordingly. For emergency lowering of the wheels 1, emergency handle 52 is operated to open accumulator-release valve 54 with emergency-wheels-down line 55. Fluid, either gas or liquid, released from accumulator 46 enters wheels-down line 20 through accumulator line 55. Appropriately-operated valve 49 prevents fluid from returning to the pump 18 through wheels-down line 20 while allowing the fluid to flow through appropriately-operated valve 50 from wheels-up line 19, through the pump or a pump reservoir if employed and into the overflow tank 47. The accumulator can be recharged through accumulator-charge valve 65.
Referring now to FIG. 6 electrical-control diagram, a master switch 66 receives electrical current from an electrical-supply source 67, or from an optional emergency electrical-supply source 68, and directs it selectively throughout the electrical system. The optional emergency electrical-supply source can be turned on with emergency switch 69. The fundamental use of the current is to operate pump motor 45 and optionally electrically-operated accumulator motor 70. To operate motors 45 and 70 with desired selectivity, however, electrical controls are employed in the following manner.
A predetermined low-voltage wheels-up relay switch or solenoid 71 and wheels-down relay switch or solenoid 72 direct predetermined higher-voltage current to optionally reversible pump motor 45. If a non-reversible pump motor 45 is employed with reversible gears for the pump 18, then current can be directed from either the master switch 66 or form a single relay switch 71. If an electrically-operated accumulator 46 is employed, current is directed to accumulator motor 70 in accordance with requirements relayed by pressure-sensitive relay switch 73. Return current from low-voltage relay switches and high-voltage motors can be routed to the electrical-supply sources 67 and 68 as diagrammed with directional arrows and electrical-flow lines.
Panel indicator lights 74 for manual control and optionally automated controls 75 are supplied with current through the master switch 66 with control feed-back information to the master switch. The master switch can be a multi-functional single unit which includes the function of pump switch 51 or multiple single-function switches of conventional design. The panel indicator lights 74 can indicated whether left and right wheels 1 are up or down. This allows a motorcycle driver to actuate lowering or raising of the wheels 1 by choice. If automated controls 75 are employed, they can be turned off and on at the master switch. If turned on, the automated controls 75 can be set to raise or lower the wheels according to selected speed of the motorcycle by a speedometer-actuated relay switch 76. The master switch 66 and optional unit switches can be positioned variously with respect to handlebars 77 and a front panel section 78. An emergency handle could be positioned on the left handlebar with manual functions of up-and-down switching with the master switch positioned on the right handlebar. The automated controls can be positioned at a front panel section 78 at the center of the handlebars or on a suitable from section of the frame 4. The speedometer-relay switch can be positioned in proximity to a speedometer.
The panel indicator lights 74 can function also as an indicator of whether the electrical system is functioning. If the panel indicator lights do not turn on with actuation of the master switch, then the motorcycle should no be ridden in wheels-up mode by a person who cannot maintain the motorcycle in an upright position without the stop-support wheels 1. If the panel lights cease to function while driving and it is necessary for a driver to utilize the stop-support wheels 1, then the emergency handle 52 can be utilized to actuate the accumulator-release valve 54 when the vehicle speed is selectively low and the operating terrain is sufficiently smooth and horizontal.
FIG. 7 illustrates preferred positioning of the panel lights 74, the automated controls 75, the speedometer-actuated relay switch 76, the pump switch 51 and the emergency handle 52 in relationship with the handlebars 77 and a front panel section 78. The switches, exclusive of the emergency handle, can be integrated into one master switch 66 represented and described in relation to FIG. 6, or alternatively, separated as individual control units as shown in FIG. 7. If a single master switch 66 is employed, it can be positioned in the panel section 78 in the vicinity of where automated controls 75 are depicted with current conveyed through power line 79 as illustrated in FIG. 3.
In conclusion, a motorcycle stop-support wheel mechanism with great merit and utility has been invented and described. All foreseeable variations, modifications and forms of the invention as described in the following claims are included in the invention.
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A motorcycle is provided with retractable stop-support side wheels (1) parallel to the back wheel (44). The side wheels (1) lock in place when down at each side of the motorcycle for stop-and-start driving, for parking and for handling the motorcycle when it is not being ridden. Hydraulic cylinders (14) are employed to activate struts (2) on which the side wheels (1) are positioned pivotally at either the outside edge of crash bars (5) of motorcycles having suitable crash bars or between top mounting positions (59) for crash bars and bottom crash-bar and foot-rest mounting means (58) for motorcycles not equipped with suitable crash bars. An attachment angle bracket (3) is shaped for various types of motorcycles for pivotal attachment of the struts (2). Manual or automatic operations with selective-speed up-and-down actuation are optional.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Reference is made to U.S. application Ser. No. 12/777,329, filed May 11, 2010, entitled “Self-Assembled Nanostructures,” with the named inventors Darren Makeiff and Rina Carlini, the disclosure of which is totally incorporated herein by reference.
PARTIES TO A JOINT RESEARCH AGREEMENT
This application is a result of activities undertaken within the scope of a joint research agreement between Xerox Corporation and the National Research Council of Canada that was in effect on or before the date the research leading to this application was made.
BACKGROUND
Disclosed herein are organogel compositions comprising alkylated benzimidazolone compounds and organic liquids.
An organogel is a three-dimensional network of non-covalently interacting molecules with interstitial spaces filled by organic liquid. Low molecular weight organogels are a rapidly developing class of such materials, in which small molecular building blocks can self-assemble via non-covalent interactions (i.e., hydrogen bonding, pi-stacking, van der Waals, metal-ligand, or the like) into nano or microscale assemblies that can further organize into a three-dimensional network capable of rigidifying entire fluids at very low concentrations.
The “bottom up” self-assembly of molecular building blocks into nanostructured materials has attracted significant interest for advanced materials research. Nanostructured materials with controlled size, shape, and function are important for numerous industrial applications. Low molecular weight organogels are a rapidly developing class of such materials, in which small molecular building blocks self-assemble into hydrogen-bonded assemblies that can form a three-dimensional network capable of rigidifying entire fluids at very low concentrations. The use of organogel materials is diverse and spans many applications such as medicine, electronics, printing, personal care, and environmental remediation. Although a large number of organogelator compounds have been reported by many researchers, the rational design and synthesis of new organogelators remains a significant challenge since the gel properties in a given liquid cannot be predicted from the molecular structures alone. In addition, not all self-assembling nanostructures form gels when placed in contact with a liquid.
SUMMARY
Disclosed herein is a composition comprising an organogel which comprises: (a) an alkylated benzimidazolone compound; and (b) an organic liquid. Also disclosed herein is a composition comprising an organogel which comprises: (a) an alkylated benzimidazolone compound of the formula
or
wherein: (i) Y is: (A) —O—; (B) —S—; or (C) —NH—; (ii) R c is an alkyl group, including substituted and unsubstituted alkyl groups, wherein hetero atoms either may or may not be present in the alkyl group; and (iii) R d is a divalent moiety; and (b) an organic liquid. Further disclosed is a composition comprising an organogel which comprises: (a) an alkylated benzimidazolone compound of the formula
wherein R c is: (i) a branched unsubstituted alkyl group of the formula
wherein m is an integer and p is an integer; (ii) a branched unsubstituted alkyl group of the formula
wherein s is an integer and t is an integer; (iii) a branched unsubstituted alkyl group of the formula
wherein u is an integer and v is an integer; or (iv) a multi-branched unsubstituted alkyl group of the formula
wherein q is an integer and r is an integer; and (b) an organic liquid.
DETAILED DESCRIPTION
The alkylated benzimidazolone compounds disclosed herein form gels by dissolution in an organic liquid with heating, and then cooling the resulting solution to result in gel formation. This process is attributable to the hierarchical self-assembly of the alkylated benzimidazolone molecules into a porous nanoscale gel network, which can entrap solvent molecules and rigidify the entire volume of liquid.
Heteroaromatic groups such as the benzimidazolone (BZI) group form reversible hydrogen bonds, resulting in the formation of oligomers or supramolecular polymers held together by non-covalent hydrogen bonds instead of covalent bonds. The BZI group is a conformationally restricted (rigid) cyclic urea fused to a benzene ring, which has strong hydrogen-bonding capability via two —NH donor groups and a lone —C═O acceptor group. Below are shown some examples of hydrogen bonding motifs for BZI derivatives, where association may occur via 2-point or 1-point hydrogen-bonding interactions, or combinations thereof:
While many BZP compounds form hydrogen-bonded structures and self-assembling nanostructures, most of these structures are hard and highly crystalline in nature. The formation of soft organogels from such materials is of a different nature.
The organogels disclosed herein are formed with alkylated benzimidazolone compounds. These compounds include compounds of the formulae
wherein:
R a and R b each, independently of the other, are (a) hydrogen atoms, or (b) alkyl groups, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkyl groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkyl group, in one embodiment with at least about 1 carbon atom, in another embodiment with at least about 6 carbon atoms, and in yet another embodiment with at least about 12 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 36 carbon atoms, although the number of carbon atoms can be outside of these ranges, provided that at least one of R a and R b is a hydrogen atom;
R 1 , R 2 , R 3 , and R 4 each, independently of the others, are:
(a) hydrogen atoms;
(b) alkyl groups, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkyl groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkyl group, in one embodiment with at least about 1 carbon atom, in another embodiment with at least about 6 carbon atoms, and in yet another embodiment with at least about 12 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 36 carbon atoms, although the number of carbon atoms can be outside of these ranges;
(c) aryl groups, including substituted and unsubstituted aryl groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the aryl group, in one embodiment with at least about 5 carbon atoms, in another embodiment with at least about 6 carbon atoms, and in yet another embodiment with at least about 12 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 36 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like;
(d) arylalkyl groups, including substituted and unsubstituted arylalkyl groups, wherein the alkyl portion of the arylalkyl group can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkyl group, in one embodiment with at least about 6 carbon atoms, in another embodiment with at least about 7 carbon atoms, and in yet another embodiment with at least about 12 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 32 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like; or
(e) alkylaryl groups, including substituted and unsubstituted alkylaryl groups, wherein the alkyl portion of the alkylaryl group can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylaryl group, in one embodiment with at least about 6 carbon atoms, in another embodiment with at least about 7 carbon atoms, and in yet another embodiment with at least about 12 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 32 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like;
provided that at least one of R 1 , R 2 , R 3 , R 4 , and R 5 is —X—R c , wherein:
(f) —X— is a linking group between R c and the aromatic group, with examples including (but not being limited to):
(i) —O—; (ii) —S—; (iii) —SO—; (iv) —SO 2 —; (v) —NH—(C═O)—; (vi) —(C═O)—NH—; (vii) —NH—(C═S)—; (viii) —(C═S)—NH—; (ix) —NH—; (x) —NH—(C═O)—NH—; (xi) —NH—(C═S)—NH—; (xii) —NH—(C═O)—O—; (xiii) —NH—(C═O)—S—; (xiv) —O—(C═O)—NH—; (xv) —S—(C═O)—NH—; (xvi) —NH—(C═S)—O—; (xvii) —NH—(C═S)—S—; (xviii) —O—(C═S)—NH—; (xix) —S—(C═S)—NH—; (xx) —(C═O)—O—; (xxi) —(C═O)—S—; (xxii) —O—(C═O)—; (xxiii) —S—(C═O)—; (xxiv) —(C═S)—O—; (xxv) —(C═S)—S—; (xxvi) —O—(C═S)—; (xxvii) —S—(C═S)—; (xxviii) —O—(C═O)—O—; (xxix) —O—(C═S)—O—;
or the like, as well as combinations thereof;
(g) R c is an alkyl group, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkyl groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkyl group, in one embodiment with at least about 6 carbon atoms, in another embodiment with at least about 12 carbon atoms, and in yet another embodiment with at least about 18 carbon atoms, and in one embodiment with no more than about 100 carbon atoms, in another embodiment with no more than about 50 carbon atoms, and in yet another embodiment with no more than about 32 carbon atoms, although the number of carbon atoms can be outside of these ranges;
wherein two or more of R a , R b , R 1 , R 2 , R 3 , and R 4 can be joined to form a ring;
wherein the substituents on the substituted alkyl, aryl, arylalkyl, and alkylaryl groups can be (but are not limited to) hydroxy groups, halogen atoms, amine groups, imine groups, ammonium groups, cyano groups, pyridine groups, pyridinium groups, ether groups, aldehyde groups, ketone groups, ester groups, amide groups, carbonyl groups, thiocarbonyl groups, sulfate groups, sulfonate groups, sulfonic acid groups, sulfide groups, sulfoxide groups, phosphine groups, phosphonium groups, phosphate groups, nitrile groups, mercapto groups, nitro groups, nitroso groups, sulfone groups, acyl groups, acid anhydride groups, azide groups, azo groups, cyanato groups, isocyanato groups, thiocyanato groups, isothiocyanato groups, carboxylate groups, carboxylic acid groups, urethane groups, urea groups, silyl groups, siloxyl groups, silane groups, mixtures thereof, or the like, wherein two or more substituents can be joined together to form a ring.
The formula
encompasses structures of the formula
wherein R a ′ has the same definition as R a and can be either the same as or different from R a , R b ′ has the same definition as R b and can be either the same as or different from R b , and R d is a difunctional moiety that bridges two or more benzimidazole groups, with examples of suitable R d groups including (but not being limited to):
(a)—(CH 2 ) n —;
(b)—X—(CH 2 ) n —X′—;
(c)—[(XCH 2 CH 2 ) n ]X′—;
(d)—[(C═O)—(CH 2 ) n —(C═O)]—;
(e)—X—[(C═O)—(CH 2 ) n —(C═O)]—X′—;
(f)—X—[(C═O)—X′—(CH 2 ) n —X″—(C═O)]—X′″—;
(g)—[(C═O)—X—(CH 2 ) n —X′—(C═O)]—;
or the like, wherein X, X′, X″, and X′″ each, independently of the other, are defined as O, S, or NH, and n is an integer, in one embodiment at least about 1, and in one embodiment no more than about 50. Specific examples of R d also include large branched alkylated functional groups such as
or the like, as well as mixtures thereof, wherein X, X′, X″, and X′″ each, independently of the other, are defined as O, S, or NH.
In one specific embodiment, exactly one of R 1 , R 2 , R 3 , R 4 , and R 5 is —X—R c .
In one specific embodiment, R 2 is —X—R c and R 1 , R 3 , and R 4 are hydrogen atoms. In another specific embodiment, R 2 is —X—R c , R 1 , R 3 , and R 4 are hydrogen atoms, and R a and R b are hydrogen atoms.
In one specific embodiment, —X—R c is
wherein —Y— is —O—, —S—, or —NH—. In another specific embodiment, —X—R c is
wherein —Y— is —NH—.
In one specific embodiment, the compound is of the formula
In another specific embodiment, the compound is of the formula
In yet another specific embodiment, the compound is of the formula
In still another specific embodiment, the compound is of the formula
In one specific embodiment, the compound is of the formula
wherein R d is
or the like, as well as mixtures thereof.
Specific examples of R c groups include (but are not limited to):
(a) branched unsubstituted alkyl groups of the formula
wherein m is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 17, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of m can be outside of these ranges, and wherein p is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 17, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of p can be outside of these ranges, including specific values such as:
(i) m=11, p=9; (ii) m=7, p=5;
or the like;
(b) branched unsubstituted alkyl groups of the formula
wherein s is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 49, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of s can be outside of these ranges, and wherein t is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 59, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of t can be outside of these ranges;
(c) branched unsubstituted alkyl groups of the formula
wherein u is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 49, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of u can be outside of these ranges, and wherein v is an integer, in one embodiment 0, in another embodiment at least about 1, and in yet another embodiment at least about 3, and in one embodiment no more than about 59, in another embodiment no more than about 11, and in yet another embodiment no more than about 5, although the value of v can be outside of these ranges;
(d) multi-branched unsubstituted alkyl groups of the formula
wherein q is an integer, in one embodiment at least about 1, in another embodiment at least about 4, and in yet another embodiment at least about 6, and in one embodiment no more than about 18, in another embodiment no more than about 12, and in yet another embodiment no more than about 10, although the value of q can be outside of these ranges, and wherein r is an integer, in one embodiment at least about 1, in another embodiment at least about 4, and in yet another embodiment at least about 6, and in one embodiment no more than about 18, in another embodiment no more than about 12, and in yet another embodiment no more than about 10, although the value of r can be outside of these ranges, including specific values such as:
or the like, as well as mixtures thereof.
Alkylated benzimidazolone compounds can be prepared as disclosed in, for example, U.S. Pat. Nos. 7,503,973 and 7,938,903, and in Copending application U.S. Ser. No. 12/777,329, the disclosures of each of which are totally incorporated herein by reference.
The alkylated benzimidazolone compounds disclosed herein can be used to form organogels with an organic liquid. Any desired or effective organic liquid can be used, including (but not limited to) hydrocarbons, including aliphatic and aromatic hydrocarbons, alcohols, amines, esters, ethers, mercaptans, acids (including carboxylic acids, sulfonic acids, or the like, as well as mixtures thereof), sulfones, anhydrides, acid halides, siloxanes, polymeric liquids, ionic liquids, or the like, as well as mixtures thereof.
Specific examples of suitable organic liquids include (but are not limited to):
linear, branched, and/or cyclic unsubstituted aliphatic hydrocarbons, such as butanes, pentanes, such as n-pentane, isopentane, neopentane, cyclopentane, or the like, hexanes, such as n-hexane, isohexane, neohexane, cyclohexane, or the like, heptanes, such as n-heptane, isoheptane, neoheptane, cycloheptane, or the like, octanes, such as n-octane, isooctane, neooctane, cyclooctane, or the like, nonanes, decanes, such as n-decane, isodecane, neodecane, decadehydronaphthalene, or the like, undecanes, dodecanes, such as n-dodecane, isododecane, neododecane, or the like, tridecanes, tetradecanes, such as n-tetradecane, isotetradecane, neotetraadecane, or the like, pentadecanes, such as n-pentadecane, isopentadecane, neopentadecane, or the like, hexadecanes, such as n-hexadecane, isohexadecane, neohexadecane, or the like, heptadecanes, such as n-heptadecane, isoheptadecane, neoheptadecane, or the like, octadecanes, such as n-octadecane, isooctadecane, neooctadecane, or the like, nonadecanes, eicosanes, such as n-eicosane, isoeicosane, neoeicosane, or the like, naphthenes, or the like, as well as mixtures thereof;
linear, branched, and/or cyclic substituted aliphatic hydrocarbons, such as chloroform, carbon tetrachloride, 1,2-dichloroethane, or the like, as well as mixtures thereof;
linear, branched, and/or cyclic unsubstituted aliphatic alcohols, such as methanol, ethanol, propanols, butanols, pentanols, hexanols, heptanols, octanols, nonanols, decanols, undecanols, dodecanols, tridecanols, tetradecanols, pentadecanols, hexadecanols, heptadecanols, octadecanols, nonadecanols, eicosanols, or the like, as well as mixtures thereof;
unsubstituted aromatic and heteroaromatic hydrocarbons, such as benzene, toluene, xylenes, mesitylene, styrene, pyridine, pyrrole, furan, pyrazine, or the like, as well as mixtures thereof;
substituted aromatic and heteroaromatic hydrocarbons, such as fluorobenzene, chlorobenzene, bromobenzene, iodobenzene, nitrobenzene, or the like, as well as mixtures thereof;
aliphatic and aromatic amines, such as methyl amine, ethyl amine, propyl amine, butylamine, pentylamine, hexylamine, octylamine, decylamine, dodecylamine, octadecylamine, triethyl amine, diisopropyl ethyl amine, aniline, methyl anthranilate, or the like, as well as mixtures thereof;
aliphatic and aromatic esters, such as methyl acetate, ethyl acetate, butyl acetate, amyl acetate, methyl hexanoate, methyl octanoate, methyl myristate, methyl oleate, methyl linoleate, methyl benzoate, ethyl benzoate, benzyl benzoate, or the like, as well as mixtures thereof;
aliphatic and aromatic ethers, such as diethyl ether, dipropyl ethers, dibutyl ethers, dipentyl ethers, anisole, diphenyl ether, or the like, as well as mixtures thereof;
with examples of suitable substituents including (but not being limited to) hydroxy groups, halogen atoms, amine groups, imine groups, ammonium groups, cyano groups, pyridine groups, pyridinium groups, ether groups, aldehyde groups, ketone groups, ester groups, amide groups, carbonyl groups, thiocarbonyl groups, sulfate groups, sulfonate groups, sulfonic acid groups, sulfide groups, sulfoxide groups, phosphine groups, phosphonium groups, phosphate groups, nitrile groups, mercapto groups, nitro groups, nitroso groups, sulfone groups, acyl groups, acid anhydride groups, azide groups, azo groups, cyanato groups, isocyanato groups, thiocyanato groups, isothiocyanato groups, carboxylate groups, carboxylic acid groups, urethane groups, urea groups, silyl groups, siloxyl groups, silane groups, mixtures thereof, or the like, wherein two or more substituents can be joined together to form a ring;
or the like, as well as mixtures thereof.
The alkylated benzimidazolone compound is present in the organic liquid in any desired or effective amount to form an organogel, in one embodiment at least about 0.05% by weight, in another embodiment at least about 0.1% by weight, and in yet another embodiment at least about 1% by weight, and in one embodiment no more than about 20% by weight, in another embodiment no more than about 10% by weight, and in yet another embodiment no more than about 5% by weight, although the amount can be outside of these ranges.
The organogel compositions disclosed herein can be used in a wide variety of applications, including (but not limited to) thickening agents for numerous products, such as paints, coatings, lubricants, adhesives, personal care products, pharmaceutical and dermatological gels, and even in certain food products, and they can be used in tissue engineering, biomineralization (as templates), catalysis, gel-based scaffolds for energy transfer and light harvesting, and the like.
Specific embodiments will now be described in detail. These examples are intended to be illustrative, and the claims are not limited to the materials, conditions, or process parameters set forth in these embodiments. All parts and percentages are by weight unless otherwise indicated.
The compounds in Examples I and II were used to gel organic liquids by the vial inversion method as described in, for example, Fages, F. Low Molecular Mass Gelators , Vol. 256, 2005 in Topics in Current Chemistry, the disclosure of which is totally incorporated herein by reference. Gels were prepared by placing a specified amount of gelator powder in a vial with an appropriate organic solvent. The mixtures were then heated to a specified temperature for a certain period of time until a homogeneous mixture or clear solution was obtained, followed by cooling and standing at room temperature for at least 30 min. The gels were then qualitatively evaluated using the “inversion test,” which entailed inverting the gel sample and observing the flow behavior. If the material did not flow or fall under its own weight under gravity, the material was classified as a gel.
The minimum gelator concentration (MGC) is the minimum concentration of a gelator required to gel a liquid, usually expressed in weight %. The MGC can be determined by pre-weighing amounts of gelator and forming gels with the same amount of solvent followed by inversion test examination; alternatively, the gel can be successively diluted, reheated, cooled, and then examined by the inversion test.
The gel-sol transition temperature for the gelators were measured using the “dropping ball” method. In this method, a 2 mm stainless steel ball is carefully placed on top of a sample of gel in a sealed vessel. The gel is then slowly heated at a rate of about 1-2° C./min and the position of the ball is observed. The temperature at which the ball touches the bottom of the vessel is taken to be the gel-sol transition temperature. The gel-sol transition temperatures determined in this manner are dependent on other parameters, which are held constant, such as the total amount of organogel (organogelator and solvent), organogelator concentration, ball size/weight, and vessel dimensions.
Example I
Synthesis of 5-(2′-decyltetradecanamido)-2-benzimidazolone
Step 1: Preparation of 2-decyltetradecanoyl chloride
2-Decyltetradecanoic acid (ISOCARB 24, obtained from Sasol America, TX, 7.09 g, 0.0192 mol) and dry tetrahydrofuran (100 mL) were added to a 250 mL single-neck round-bottom flask under inert atmosphere. Oxalyl chloride (6.8 mL, 0.0779 mol, obtained from Sigma-Aldrich, Milwaukee, Wis.) was added dropwise, followed by a catalytic amount of N,N-dimethylformamide (0.30 μL, 3.87 mmol). The mixture was stirred for 30 min until gas evolution was observed to cease. The mixture was then stirred for an additional 90 min before the solvent was removed by rotary evaporation to afford a viscous, pale yellow oil. The acid chloride compound thus obtained was used in the next step without further purification.
Step 2: Preparation of 5-(2′-decyltetradecanamido)-2-benzimidazolone
5-Aminobenzimidazolone (2.93 g, 19.6 mmol, obtained from TCI America, Oregon, USA) and triethylamine (4 mL, 28.7 mmol) were dissolved in 20 mL N-methylpyrrolidinone in a 250 mL round-bottom flask under inert atmosphere. To this solution, a second solution of 2-decyltetradecanoyl chloride from Step 1 dissolved in dry THF (150 mL) was slowly added. After stirring overnight, deionized water was added and the mixture was poured into 300 mL ethyl acetate and washed with three 100 mL portions of deionized water. The organic layer was then concentrated by rotary evaporation until a white slurry was obtained. The solid was collected by filtration and washed with cold ethyl acetate to give 5-(2′-decyltetradecanamido)-2-benzimidazolone as a white solid (7.18 g). The product was identified by 1 H and 13 C NMR spectroscopy and ESI-MS and was of satisfactory purity. The compound was believed to be of the formula
Gelation of Cyclohexane and Organogel Formation
The compound thus prepared was used for gelling cyclohexane. 5-(2′-Decyltetradecanamido)-2-benzimidazolone (41.7 mg) and cyclohexane (1 mL) were placed in a sealed vessel and mixed and heated until a clear, homogeneous solution was obtained. After slowly cooling and allowing the vessel to stand at room temperature for at least 30 min, a clear, transparent gel was formed, which did not fall or flow upon inverting the vessel.
Inversion tests were also repeated at varied concentrations of 5-(2′-decyltetradecanamido)-2-benzimidazolone in cyclohexane, and the MGC was determined to be 4.0 wt %.
Additional organogels were formed with 5-(2′-decyltetradecanamido)-2-benzimidazolone in other organic solvents. The results were as follows:
Solvent
Appearance
MCG (wt. %)
ethylene glycol
opaque gel
0.1
methanol
opaque gel
0.9
ethanol
opaque gel
1.0
2-propanol
opaque gel
0.9
aniline
turbid gel
<4.0
benzyl benzoate
turbid gel
0.6
cyclohexane
transparent gel
0.4
decalin
transparent gel
0.4
dodecane
turbid gel*
0.2
paraffin oil
turbid gel*
0.3
2,2,4-trimethylpentane
turbid gel*
<5.0
1,2-dimethoxyethane
opaque gel
<2.0
canola oil
turbid gel
0.6
*= minor liquid phase separation occurred over time.
Determination of the Gel-to-Sol Transition Temperature
The “dropping ball” method was used to determine the gel-to-sol transition temperature for two of the above gels. A stainless steel ball (2 mm diameter) was carefully placed on the top of the gel formed from ˜10 wt % 5-(2′-decyltetradecanamido)-2-benzimidazolone in cyclohexane. The vessel, a 1 dram vial with an outer diameter of 15 mm and a height of 45 mm, containing the gel was sealed and slowly heated in an oil bath at a rate of approximately 1-2° C./min. The ball touched the bottom of the vial at 45° C., which was taken to be the gel-to-sol transition temperature.
Example II
Synthesis of 5-(2′-hexyldecanamido)-2-benzmidazolone
Step 1: Preparation of 2-hexyldecanoyl chloride
2-Hexyldecanoic acid (JARCHEM, 6.61 g, 0.0258 mol, obtained from Jarchem Industries Inc., New Jersey, USA) and dry THF (50 mL) were added to a 250 mL single-neck round-bottom flask under inert atmosphere. Oxalyl chloride (9.0 mL, 0.103 mol, obtained from Sigma-Aldrich) was added slowly, dropwise, followed by a catalytic amount of DMF (0.30 mL, 3.87 mmol). The mixture was stirred for 30 min until gas evolution was observed to cease. The mixture was then stirred for an additional 90 min before the solvent was removed by rotary evaporation to afford a viscous mixture containing precipitates. The acid chloride compound thus obtained was used in the next step without further purification.
Step 2: Preparation of 5-(2′-hexyldecanamido)-2-benzmidazolone
5-Aminobenzimidazolone (3.86 g, 25.8 mmol, obtained from TCI America, Oregon, USA) and triethylamine (5.4 mL, 38.7 mmol) were dissolved in 20 mL N-methylpyrrolidinone in a 250 mL round-bottom flask under inert atmosphere. To this solution, a second solution of 2-hexyldecanoyl chloride from Step 1 dissolved in dry THF (50 mL) was slowly added. After stirring overnight, deionized water was added and the mixture was poured into 300 mL ethyl acetate and washed with three 100 mL portions of deionized water. The organic layer was then concentrated by rotary evaporation until a white slurry was obtained. The solid was collected by filtration and washed with cold ethyl acetate to give 5-(2′-hexyldecanamido)-2-benzmidazolone as a white solid (6.37 g). The product was identified by 1 H and 13 C NMR spectroscopy and ESI-MS and was of satisfactory purity. The compound was believed to be of the formula
Gelation of Toluene and Organogel Formation
5-(2′-Hexyldecanamido)-2-benzmidazolone (29.9 mg) and toluene (1 mL) were placed in a sealed vessel and mixed and heated until a clear, homogeneous solution was obtained. After slowly cooling and allowing the vessel to stand at room temperature for at least 30 min, a turbid gel was formed, which did not fall or flow upon inverting the vessel.
Inversion tests were also repeated at varied concentrations of 5-(2′-hexyldecanamido)-2-benzmidazolone in toluene, and the MGC was determined to be between 2.5-3.0 wt %.
Additional organogels were formed with 5-(2′-hexyldecanamido)-2-benzmidazolone in other organic solvents. The results were as follows:
Solvent
Appearance
MCG (wt. %)
ethylene glycol
opaque gel
0.2
aniline
transparent gel
<5.0
benzyl benzoate
turbid gel
0.6
cyclohexane
transparent partial gel
10.0
decalin
turbid gel
<2.5
benzene
turbid gel
<4.0
toluene
turbid gel
<3.0
xylenes
turbid gel
<2.0
mesitylene
transparent gel
<5.1
styrene
turbid gel
<4.0
dodecane
turbid gel
<11.0
Determination of the Gel-to-Sol Transition Temperature
The “dropping ball” method was used to determine the gel-to-sol transition temperature for 5-(2′-hexyldecanamido)-2-benzmidazolone in toluene. A stainless steel ball (2 mm diameter) was carefully placed on the top of the gel formed from ˜3 wt % 5-(2′-hexyldecanamido)-2-benzmidazolone in toluene. The vessel, a 1 dram vial with an outer diameter of 15 mm and a height of 45 mm, containing the gel was sealed and slowly heated in an oil bath at a rate of approximately 1-2° C./min. The ball touched the bottom of the vial at 85° C., which was taken to be the gel-to-sol transition temperature.
Example III
Synthesis of bis-[5,5-(9′,10′-dinonyloctadecanamido)-2-benzimidazolone]
Step 1: Synthesis of 9,10-dinonyloctadecanoyl dichloride
9,10-dinonyloctadecanoic acid (PRIPOL 1006, 3.44 g, 6.07 mmol) and dry THF (50 mL) were added to a 250 mL round-bottom flask under inert atmosphere and cooled to 0° C. Oxalyl chloride (3.20 mL, 36.7 mmol) was added slowly, dropwise, followed by DMF (0.140 mL, 1.81 mmol). The mixture was then slowly allowed to warm to room temperature and stirred for 3.5 h before the solvent was removed by rotary evaporation and dried in vacuo to give a pale yellow oil. The diacid chloride compound thus obtained was used in the next step without further purification.
Step 2: Synthesis of bis-[5,5-(9′,10′-dinonyloctadecanamido)-2-benzimidazolone]
5-Aminobenzimidazolone (1.92 g, 12.8 mmol), triethylamine (2.5 mL, 1789 mmol), and dry N-methylpyrrolidinone (20 mL) were mixed in a 100 mL round-bottom flask under inert atmosphere. To this solution a second solution of 9,10-dinonyloctadecanoyl dichloride from Step 1 dissolved in dry THF (50 mL) was slowly added. After stirring overnight, deionized water (50 mL) was added to the beige suspension and the solid was collected by vacuum filtration and washed with deionized water to give bis-[5,5-(9′,10′-dinonyloctadecanamido)-2-benzimidazolone] as a beige powder (4.87 g). The product was identified by 1 H and 13 C NMR spectroscopy and ESI-MS and was of satisfactory purity. The product was believed to be of the formula
Other embodiments and modifications of the present invention may occur to those of ordinary skill in the art subsequent to a review of the information presented herein; these embodiments and modifications, as well as equivalents thereof, are also included within the scope of this invention.
The recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefor, is not intended to limit a claimed process to any order except as specified in the claim itself.
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Disclosed is a composition comprising an organogel which comprises: (a) an alkylated benzimidazolone compound; and (b) an organic liquid.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to sewing machines and in particular to a new and useful guide mechanism for a sewing machine which aids in the automatic production of curved seams that are parallel to the curved edge of material carrying the seams.
A sewing machine is known from German Patent No. 25 22 422 for the automatic production of curved edge parallel seams where a guide arm is arranged on one side of the needle and a pressure stamp is on the opposite side of the needle. The driving mechanism of the pressure stamp is a pneumatic cylinder which is controlled, over a solenoid valve, by a device for scanning the edge of the sewing material in the outer curved region that deviates from a straight line. The cylinder is activated in order to lower the pressure stamp onto the sewing material for the production of a curved edge parallel seam, at a lateral distance from the needle, and to press the material on its bearing surface to produce a braking force. The sewing material is turned by the continuing cloth feed, about the pressure stamp, at an axis of rotation corresponding to the course of the edge. The pressure must be so great that the narrowest arc on a workpiece can still be exactly controlled to obtain an edge-parallel seam. But this has the result that the edge-parallel control of all arcs with a larger radius of curvature is no longer possible or only possible with very stiff materials. The distance of the guide arm from the needle must correspond to the desired distance of the seam from the edge of the sewing material, which results from the narrowest arc of the contour of the sewing material. Likewise the distance to the touch-down point of the pressure stamp from the needle must correspond to the narrowest arc of the sewing material curved edge.
Since the touch-down point of the pressure stamp is with all larger arcs outside the center of the radius of curvature, the pressure of the pressure stamp can only be overcome in very stiff materials by the reaction force acting on the sewing material when its lateral edge is pushed toward the guide arm during its rotation so that the sewing material is moved under the pressure stamp transversely to the direction of feed away from the guide arm. Consequently arcs with a larger radius of curvature can only be controlled in an edge-parallel manner, in very stiff sewing materials.
In order to improve the material rotation and feed control, it has already been suggested (German OS No. 27 16 914) to control the force acting on the pressure stamp in dependence on the size of the radius of curvature in such a way that it increases with a decreasing radius of curvature. But even with this type of contour control it is not possible to obtain a contour-correct edge-parallel seam in soft materials because the inherent stiffness of the material is not sufficient to transform the force acting as a torque, with the pressure stamp attached, and the cloth feed continuing to work, with which the material is pushed with its lateral edge during its rotation about the pressure stamp against the guide arm, partly away from the guide arm for transverse displacement under the pressure stamp, so that it acts on the sewing material. Because of the low inherent stiffness, the edge zone of the sewing material pushed during the rotation against the guide arm yields upwardly on the guide arm. It is thus raised and frequently even rolled upwardly.
In the area of the arcs with a radius which is greater than the smallest radius of curvature this results in a different distance of the seam from the lateral edge than the distance from a straight course of the edge or at the narrowest arc of the sewing material. In bordering, the upwardly rolled edge zones are enveloped by the bordering ribbon and sewn in. The outer contour of the sewing material is thus partly considered falsified. In shoe patterns, which have practically always a special design effect due to the outer shape which must orient itself to the shape of the human foot, this can lead to a complete failure of the action intended with the design of a pattern and to a considerable deterioration of the fitting form.
SUMMARY OF THE INVENTION
Accordingly an object of the present invention is to provide a mechanism for forming curved edge parallel seams, in an automatic manner, which can form such seams in all materials including materials of low inherent stiffness, and wherein the accuracy of the curved edge parallel seam can be controlled.
Another object of the invention is to provide such an accurate control by intermittently activating a pressure stamp which presses down on a material to be sewn to cause an edge of the material to rotate about the pressure point by a selected amount but only during the period that the pressure stamp is activated.
The intermittent drive of the pressure stamp ensures that the sewing material is admitted in rapid succession with braking force pulses and is turned by the continuing cloth feed in small angular amounts, while its pressure is relieved in the intervals between two pressure phases and therefore can yield away from the guide arm transversely to the direction of feed, to the extent that it is displaced with its lateral edge toward the guide arm, without having to overcome the resistance of the pressure stamp. In this way the sewing material constantly corrects its position relative the guide arm and permits the sewing of an absolutely contour-correct edge-parallel seam, independent of the radius of curvature of the outer arcs of the sewing material edge.
A particularly good adaptation of the aligning movement and of the yielding movement for correcting the position of the sewing material results from another feature of the invention. According to this other feature a further object of the invention is to provide the pressure stamp to have a movement which can be controlled with respect to the angular position of the main shaft of the sewing machine.
Another object of the invention is to provide for the activation of the pressure stamp substantially during a phase of feeding for the cloth.
According to another inventive feature, it is of advantage to use, as a driving mechanism for the pressure stamp, a preferably adjustable pulse generator. This can be of a pneumatic or electrical type.
Another object of the invention is to provide a mechanism whereby the braking force of the pressure stamp can be adjusted by varying the initial stress of a spring arranged on a piston rod of a compressed air cylinder controlling the pressure stamp.
In order to be able to handle, with equally good results, sewing material that is particularly sensitive to pressure, it is possible according to the invention, to use a pulsating air current to produce the braking force.
A further object of the invention is to provide a mechanism for automatically producing curved edge-parallel seams which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a side elevational view, in a simplified form, showing the head region of a sewing machine where the cloth presser has been omitted for clarity;
FIG. 2 is a top plan view of a workpiece on a work support area of the sewing machine and the guide arm for its contour edge;
FIG. 3 is a pneumatic wiring diagram of an example for controlling and moving the pressure stamp; and
FIG. 4 is a side elevational view and schematic diagram of a second example for controlling and moving the pressure stamp.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to the drawings in particular, the invention embodied therein in FIG. 1 comprises a guide mechanism for a sewing machine having a head portion 1, for automatically producing edge-parallel curved seams by intermittently activating a cylinder 14 to intermittently press a pressure stamp 15 down against work material W, while the work material continues to be fed by a cloth feeder 7 so that an edge of the material is forced to turn around the pressure point of the pressure stamp and form a small portion of an arc of the finished curved seam area. The cylinder 14 is operated only intermittently and for short periods so that the material, regardless of its lack of stiffness, will accurately form into a curved outer contour without distortion.
An ascending and descending needle bar 2 is mounted in the sewing machine head 1, which carries, at its bottom end, the thread-carrying needle 3. The needle cooperates with a looper (not shown) arranged under a throat plate 5 and secured in work support plate 4 for forming the seam. The looper is accessible by retracting a work support plate slide 6. For feeding workpiece W, needle bar 2 performs, together with the cloth feeder 7 which performs a rectangular movement in known manner, a movement in a feeding direction shown at arrow V in FIG. 2. The toothed web 8 of the cloth feeder passes upwardly through a slot 9 in throat plate 5 for the feeding movement during a feeding phase, to act on workpiece W. A guide arm 10 is provided for guiding workpiece W on one side of needle 3, which is secured by means of a screw passing through an oblong slot 11 on throat plate 5. The distance of guide arm 10 from needle 3 is adjustable to set the distance between the workpiece edge and a seam N. On the side of needle 3 opposite guide arm 10 is arranged the pressure stamp 15 formed by the piston rod of the compressed air cylinder 14 which is secured over an angle support 13, onto head 1. Compressed air cylinder 14 has two pressure lines 16, 17 shown in FIG. 3. Its piston can thus receive compressed air from both sides alternately over a reversing valve 19.
In order to adjust the pressure of pressure stamp 15, compression spring 20 is arranged at the end of piston rod 15 projecting at the top from the housing of compressed air cylinder 14, whose initial stress can be varied by means of a knurled nut 21.
A reflex-light barrier consisting of a transmitter 22 and a receiver 23 and secured on an angle support 24, serves to scan the outer edge of workpiece W and controls, in the example shown in FIG. 3, over a suitable amplifier circuit, a solenoid valve 25. Valve 25 is disconnected when the reflection surface on throat plate 5 of the sewing machine is covered by workpiece W and connected when the reflection surface is no longer covered by workpiece W. Solenoid valve 25 is held by spring force in switching position a, in which pressure line 28 connected with compressed air source 26 and following maintenance unit 27, is connected over pressure connection P, load connection B and a line 29 with output A of a two-way or double relief valve 30 acting as an OR-element.
Output A of two-way valve 30 is connected by a line 31 with control connection Y of reversing valve 19. Reversing valve 19 is held in switching position a by the generated compressed air. The compressed air is fed to one side of working piston 18 of compressed air cylinder 14, over the pressure connection P connected to a compressed air source 26a, and load connection A of reversing valve 19, a pressure line 32, and line 17 connected to line 32. The other side of the piston is vented over lines 16 and 33 and connections B and R of reversing valve 19.
Pressure line 32 is connected over a throttle relief valve 34 and line 35 with control connection Y of a pulse valve 36, whose control connection Z is connected by a line 37 with line 33. The output A of pulse valve 36 is connected over a line 38 with control connection Z of reversing valve 19. In pressure line 33 is arranged a throttle relief valve 39, which is connected over a line 40 with the second input of two-way valve 30. Finally pulse valve 36 is connected over line 41 with load connection A of solenoid valve 25, which is vented in switching position a, over a line of solenoid valve 25 and vent connection R.
In the example for controlling and moving pressure stamp 15 according to FIG. 4, a synchronizer 47 is arranged at the free end of arm shaft 46 of the sewing machine, which consists of two slip rings 48 and 49, of which slip ring 49 serves to supply the current. Slip ring 48 has an insulation zone 50 extending over 180° thereof. Slip ring 48 cooperates with a brush 52 and slip ring 49 with a brush 51. Brush 51 is connected by a line 53 with one contact 54 of a switch 55, whose other contact 56 is connected by a line 57 with the positive pole of a D.C. source 58. Brush 52 of slip ring 48 is connected by a line 59 with one side of the armature winding of a solenoid valve 25, whose other side of the armature winding is connected by a line 60 with the negative pole of D.C. source 58. Switch 55 is actuated by a relay 61, which is controlled over an amplifier circuit by reflex-light barrier 22/23.
Synchronizer 47 is arranged on main shaft 46 in such an angular position that the conductive segment of slip ring 48 is connected during the feeding phase of cloth feed 7 over brush 52 and line 59 with the armature winding of solenoid valve 25a, so that solenoid valve 25a is connected in the feeding phase of cloth feed 7, provided contacts 54 and 56 of switch 55 are closed. This is the case when the light beam emitted from transmitter 22 is reflected by the reflection surface of throat plate 5 to receiver 23, and its photocell is constructed so that the scanning area is not covered by workpiece W. That is, when one of the arcs 42 to 45 approaches workpiece W, of stitch-forming area.
MODE OF OPERATION
Reflex-light barrier 22/23 forming a scanning device for the edge of the sewing material and controlling solenoid valve 25 or 25a, is so designed that solenoid valve 25 or 25a is disconnected in the darkened state hence when workpiece W is inserted under the presser foot with the starting point under needle 3 and interrupts the light beam emitted by sender 22, so that it does not reflect to receiver 23, and is held by spring action in switching position a. In this switching position, compressed air appears in the example of the control according to FIG 3, on control connection Y of reversing valve 19 over line 28 connected with compressed air source 26 and with maintenance unit 27, as well as pressure connection P, load connection B, line 29, two way valve 30 and line 31. Valve 19 thus assumes switching position a, in which one side of working piston 18 of compressed air cylinder 14 receives compressed air over pressure connection P and load connection A of reversing valve 19, and lines 32 and 17, so that pressure stamp 15 is lifted from workpiece W. The other side of working piston 18 of compressed air cylinder 14 is vented over lines 16, 33 and connection B and R of reversing valve 19. At the same time compressed air appears on control connection Y of pulse valve 36 over throttle relief valve 34 and line 35, which is this held in the represented switching position b in which control connection Z of reversing valve 19 is vented over lines 38, connection A and P of valve 36, line 41, and connections A and R of solenoid valve 25.
The sewing machine is switched on for the formation of the edge-parallel seam N (FIG. 2) by which a strip bordering the edge of workpiece W can be sewn on if needed. As soon as the edge of the sewing material releases the scanning point of edge scanner 22/23 in a convex course of the sewing material edge, e.g. as in 42, 43, 44 and 45 (FIG. 2), the light beam of transmitter 22, which is no longer interrupted, is reflected by and strikes the photocell of receiver 23, so that solenoid valve 25 is connected over an amplifier circuit and is brought into switching position b. In this switching position b the compressed air flow from pressure line 28 over pressure connection P and load connection A of solenoid valve 25 through line 41, over pressure connection P and connection A of pulse valve 36, which is in switching position b, and line 38, as well as control connection Z to the control piston of reversing valve 19. Valve 19 is thus moved into switching position b. The compressed air now appearing at pressure connection P of reversing valve 19 flows over connections P and B and lines 33 and 16 to the other side of working piston 18 of compressed air cylinder 14 and forces working piston 18 with pressure stamp 15, down with a pressure against workpiece W. This pressure can be adjusted by varying the initial stress of compression spring 20, so that a broken force is exerted on workpiece W at a lateral distance from needle 3. The first side of piston 18 of compressed air cylinder 14 is vented over lines 17, 32 and connections A and S of reversing valve 19. Together with the supply of compressed air over line 16 to the second side of working piston 18 of compressed air cylinder 14, compressed air flows over line 37 to the side Z of the control piston of pulse valve 36 and moves it into switching position a. In this switching position, the compressed air supply over control connection Z of pulse valve 19 is interrupted, and line 38 is vented over connection R of pulse valve 36, so that the pressure on control connection Z of valve 19 drops. At the same time, compressed air, adjustably delayed by line 33 over throttle relief valve 39, is fed to control connection Y of reversing valve 19 over line 40, two-way valve 30 and line 31. Reversing valve 19 is thus switched into switching position a. Compressed air is thus supplied briefly over load connection A and lines 32 and 17 to the first side of working piston 18, while the second side of the piston is vented over lines 16, 33 and connections B and R of reversing valve 19. The piston rod of compressed air cylinder 14 forming pressure stamp 15 is then lifted from workpiece W and pressure relieved. In switching position a of reversing valve 19 the control piston of pulse valve 36 is admitted, adjustably delayed, together with the compressed air supply over lines 32 and 17 over throttle relief valve 34, line 35, and control connection Y, and pulse valve 36 is thus displaced into switching position b. In this position, the compressed air pressure connection P of pulse valve 36 moves the control piston of reversing valve 19 into switching position b over its load connection A, line 38 and control connection Z. The supply of compressed air over connection A of reversing valve 19 and lines 32 and 17 to the first side of working piston 18 of compressed air cylinder 14 is thus interrupted, connection A of reversing valve 19 is vented over S, and the other side of working piston 18 is again admitted with compressed air over connection B of reversing valve 19 and lines 33 and 16, so that pressure stamp 15 is pressed immediately against workpiece W. This change in the direction of the compressed air, and thus the mutual admission of working piston 18 in rapid succession takes place as long as there is compressed air at the load connection A of solenoid valve 25, hence with solenoid valve 25 connected. The frequency of the movement of the piston rod of compressed air cylinder 14 forming pressure stamp 15 can be varied by adjusting throttle relief valves 34 and 39. This system forms thus an adjustable pulse generator for controlling the intermittently driven pressure stamp 15.
While pressure stamp 15 is pressed intermittently against workpiece W and brakes it, cloth feed 7 continues to work. Workpiece W is thus turned counterclockwise about pressure stamp 15. If the arc thus to be controlled has a radius which is greater than the distance between pressure stamp 15 and a guide edge of guide arm 10, the edge of the workpiece is pushed against the guide edge of guide arm 10, because pressure stamp 15 does not act in the center of the curvature of the arc, and would be raised on the latter. In the intervals between two pressure phases, workpiece W is pressure-relieved by pressure stamp 15. It can therefore yield to the left during its rotation, bearing on guide arm 10, under pressure stamp 15 transverse to the direction of feed arrow V, related to FIG. 2. This way a contour correct edge-parallel seam can be obtained, even with relatively thin and less stiff materials.
With equally good results a pulsating air current could replace pressure stamp 15 for the production of the braking force. This arrangement looks like FIG. 1 except without spring 20 and wheel 21 and with the air stream coming from the lower end of 15.
By interrupting the light beam emitted by transmitter 22 at the end of an arc, due to a position change of workpiece W, solenoid valve 25 is disconnected and moved again into switching position a under spring action. In this position, the control piston of reversing valve 19 receives, over control connection Y, compressed air supplied over connections P and B of solenoid valve 25, line 29, two-way valve 30, and line 31, and is moved into switching position a. The first side of working piston 18 of compressed air cylinder 14 receives air, over connections P and A of reversing valve 19 and lines 32 and 17, while the other side of working piston 18 is vented over lines 16 and 33 and connections B and R of reversing valve 19. Pressure stamp 15 is lifted from workpiece W.
If the beam of reflex-light barrier 22/23 is interrupted by workpiece W during the swing of the latter, switch 55 is open in the second example (FIG. 4) of the comtrol of the movement of pressure stamp 15, and solenoid valve 25a is thus disconnected. It is held in switching position a by spring force. In this switching position a, compressed air appears at pressure connection P over load connection B and line 17 on the first side of working piston 18 of compressed air cylinder 14, pressure stamp 15 is lifted from workpiece W, while the second piston side is vented over line 16 and connection A and R of solenoid valve 25a.
When one of the arcs 42 to 45 approaches the stitchforming area and releases the beam emitted by transmitter 22, so that it is reflected from the reflection surface of throat plate 5 to receiver 23, striking its photocell, relay 61 is excited over an amplifier circuit, which closes contacts 54 and 56 of switch 55. As long as contacts 54 and 56 are closed, the circuit leading from the positive pole of D.C. source 58 over line 57, switch 55, line 53, brush 31, synchronizer 47, brush 52, line 59, over the armature winding of solenoid valve 25a to the negative pole of D.C. source 58 is closed during the revolution of the main shaft 46, when the conductive segment of slip ring 48 passes over brush 52 and is interrupted when insulation zone 50 of slip ring 48 passes over brush 52. With the circuit closed, solenoid valve 25a is thus connected, and assumes switching position b, while it is disconnected when the circuit is interrupted and is thus forced by spring force into switching position a. Solenoid valve 25a assumes thus at each revolution of main shaft 46 successively switching positions a and b, alternating in a rotation of 180°, namely switching position b in the feeding phase of cloth feed 7, which starts in needle feed-sewing machines approximately after the needle enters the cloth. It ends shortly before the needle leaves the cloth again. In this feeding phase of cloth feed 7, (switching position of solenoid valve 25a), the second side of working piston 18 of compressed air cylinder 14 is admitted over connections P and A of solenoid valve 25 a and line 16 with compressed air, while compressed air-cylinder 14 is vented on the first side of working piston 18 over line 17 and connections B and R of solenoid valve 25a, so that pressure stamp 15 is pressed in the feeding phase of cloth feed 7 against workpiece W, which is thus braked. Workpiece W reserves thus a counterclockwise aligning movement about pressure stamp 15 by cloth feed 7 which is enhanced in needle feed-sewing machines by the needle.
During the rotation of main shaft by 180° following the feeding phase of cloth feed 7, solenoid valve 25a is disconnected and assumes switching position a. Compressed air cylinder 14 is thus vented on the second side of working piston 18 over line 16 and connection A and R of solenoid valve 25a, while the first side of working piston 18 is admitted with the compressed air supplied from the compressed air source over connections P and B of solenoid valve 25a and line 17, thus lifting pressure stamp 15 from workpiece W and relieving it of pressure. As described above, workpiece W which is pushed during its aligning movement with its edge against guide arm 10, can yield to the left with pressure stamp 15 lifted and pressure-relieved respectively, under the latter transverse to the direction of feed, arrow V, related to FIG. 2. Due to the intermittent movement of pressure stamp 15 adapted to the feeding phase of cloth feed 7, each aligning movement is followed by a yielding movement, so that an exact contour-correct control of arcs 42 to 45 is achieved.
By interrupting the beam of edge scanner 22/23 at the end of an arc, relay 61 is disconnected. Contacts 54 and 56 of switch 55 are thus opened, and solenoid valve 25a is disconnected. It it held in switching position a by spring force, in which the first side of working piston 18 of compressed air cylinder 14 is admitted over connections P and G and line 17, and compressed air cylinder 14 is vented on the second side of working piston 18 over line 16 and connections A and R. Pressure stamp 15 is therefore lifted from workpiece W.
At the end of the seam, the sewing machine stops in the raised position of the needle, independent of the control of the movement of pressure stamp 15, and workpiece W is removed, after cutting off the threads and the bordering ribbon, if any, and lifting the presser foot, after which the next workpiece is inserted and the above described cycle can start again.
While specific embodiments of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A sewing machine with guide mechanism for automatically producing a curved edge parallel seam comprises a scanning unit for scanning the edge of a workpiece and sensing when the edge of the workpiece moves away from an edge guide which indicates the presence of a curved edge, a workpiece feeder for feeding the workpiece along the guide edge, a workpiece pressure stamp for applying pressure on the workpiece at a point spaced from the guide to cause rotation of the workpiece about the point when the pressure stamp is activated and a circuit connected between the scanning unit and the pressure stamp for intermittently activating the pressure stamp when the scanner senses the presence of a curved edge area of the workpiece.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for desorbing materials from a loaded ion exchange resin.
[0002] The ion exchange resin may be any suitable resin that can be loaded with target materials that include non-ferrous metals such as copper, nickel and cobalt; noble metals such as gold and silver; and refractory metals such as molybdenum and wolfram. The exchange resin may also be suitable for any other metal, non-metal, organic substances, non-organic substances and compounds thereof.
BACKGROUND OF THE INVENTION
[0003] There is at present a wide selection of technology that can be used for desorbing materials from resins. Some technologies are better suited than others for particular applications and, therefore, selecting the most appropriate technology is an important factor in achieving a high desorption rate and cost effectiveness.
[0004] Generally speaking desorption processes for desorbing material from a resin may be carried out as either batch or continuous operations which usually corresponds to the apparatuses for carrying out processes having either so-called fixed-beds or moving-beds.
[0005] Apparatuses with fixed-beds are at present the most widely used in industry. For example, a text by Abrams I. M. entitled “Type of ion-exchange systems” (Ion Exchange for Pollution Control, eds. C. Calmon and H. Gold, CRC Press, Boca Raton, vol. 1, pp. 71-850, 1979) describes that fixed-bed equipment items have been operated for more than. 25 years and are still presently in use for softening 1500 mega-litres/day of water at the Metropolitan Water District of Southern California.
[0006] A text by Salem E. entitled “Equipment operation and design” (Ion Exchange for Pollution Control, eds. C. Calmon and H. Gold, CRC Press, Boca Raton, vol. 1, pp. 87-100, 1979) describes that the desorption cycle of most fixed-bed apparatuses involves: firstly backwashing a bed of full loaded or saturated resin; settling the bed; feeding desorption solution through the bed; displacement of desorption solution (or slow rinse); and finally rinsing the resin before supplying a pregnant solution to the bed again.
[0007] The backwashing stage removes suspended particles, which have accumulated within the resin bed and eliminates channels that, may have formed during the sorption stage. Backwashing also helps to break up agglomerates formed between suspended particles and the ion-exchange resin.
[0008] The settling stage follows the backwashing stage and is important to avoid channeling of fluid through the bed.
[0009] Desorption is accomplished by passing desorption solution through the bed to convert the resin to the desired form. After an adequate volume of desorption solution has made contact with the resin, displacement of desorption solution from the bed takes place.
[0010] Rinsing of the resin with demineralised water is normally used to remove the last residues of desorption solution from the bed.
[0011] Upon completion of the rinsing stage, the liquid phase containing targeted material to be sorbed into the resin during a sorption stage enters at the top of the column when the column is operated in co-current or at the bottom of the column when the column is operated in countercurrent.
[0012] U.S. Pat. No. 4,412,866 describes a modification of a batch-fixed bed process and in particular relates to a simulated moving-bed in which separate zones are defined, each of which include one or more discrete vessels. The zones correspond to the functions of the process; typically sorption, displacement, desorption and rinsing. Booster pumps connected in series with the vessels maintain a desired pressure head for each zone. The functions of each zone are rotated in sequence, the sequence being timed in relation of the migration of the front between adjacent phases in the fluid loop circulating through the zones.
[0013] Another type of absorption/desorption processes is a continuous process. Generally speaking an absorption/desorption process is classified as a continuous process when sorption, rinsing and desorption are conducted simultaneously and the product flow is uninterrupted. The use of a moving bed of resin allows one to obtain continuous operation and the main advantage is the high processing efficiency.
[0014] As with batch processes, continuous processes can be operated as either co-current or countercurrent.
[0015] Not all processes described as continuous are truly continuous processes. Truly continuous processes operate without interruption of either resin or liquid flows. Semicontinuous processes are often characterised by a short residence period in which ion-exchange absorption occurs (i.e. the service mode) followed by a period when the resin bed is moved (the moving mode). However, because the periods for both modes are very short, the processes virtually behave as a continuous one. More than a hundred semicontinuous processes are known, but only about six have any real industrial significance.
[0016] To our understanding the widest known process of this type is the so-called Higgins Loop (and is described in the text by Higgins, I. R. and Roberts, I. T. “A countercurrent solid-liquid contactor for continuous ion-exchange”. Eng Prog. Symp. Ser., 50, 87-94, 1950). The Higgins Loop is a continuous countercurrent ion-exchange process for liquid phase separations of ionic components using solid ion-exchange resin.
[0017] The Higgins Loop comprises a vertical cylindrical vessel containing a packed-bed of ion-exchange resin that is separated into four operating zones by butterfly or loop valves. These operating zones—adsorption, desorption, backwashing and pulsing—function like four separate vessels.
[0018] The Higgins Loop treats liquids in the sorption zone with resin while the ions are removed from loaded resin in the desorption zone simultaneously. Intermittently, a small portion of resin is removed from the respective zone and replaced with stripped or loaded resin at the opposite end of that zone. This is accomplished hydraulically by pulsation of the resin through the loop. The result is a continuous process that contacts liquid and resin in countercurrent flow.
[0019] It is an object of the present invention to provide an alternative method and apparatus for desorbing materials sorbed on a resin that is capable of producing a concentrated eluate stream.
SUMMARY OF THE INVENTION
[0020] According to the present invention there is provided an apparatus for desorbing substances from an ion exchange resin having impurities and targeted materials sorbed thereon, the apparatus including:
[0021] first and second chambers that are adapted so that when in use, resin is supplied to the first chamber and conveyed from the first chamber to the second chamber, and a desorption solution is supplied to the second chamber and conveyed from the second chamber to the first chamber such that,
[0022] i) impurities having less affinity for the resin than the targeted material can be desorbed from the resin and targeted material can be sorbed onto the resin from the desorption solution, and thereby create conditions whereby an impurity stream having a high concentration of impurities and a relatively low concentration of targeted material can be discharged from the first chamber, and
[0023] ii) targeted material can be desorbed from the resin in the second chamber and create conditions whereby a rich stream having a low concentration of impurities and a relatively high concentration of targeted material can be discharged from lower regions of the first and/or second chambers.
[0024] In addition, when the apparatus is in use, it is preferred that the resin flows downwardly in the first chamber and upwardly in the second chamber, and that desorption solution flows in countercurrent to the direction of flow of resin in said chambers.
[0025] It is even more preferred that the impurities stream be discharged from an upper region of the first chamber.
[0026] It is preferred that the first and second chambers be connected in fluid communication such that the desorption solution can be conveyed from the second chamber to the first chamber.
[0027] According to the present invention there is also provided an apparatus for desorbing material from a loaded ion exchange resin, the apparatus including:
[0028] first and second chambers that are adapted so that in use, resin can move downwardly in the first chamber and upwardly in the second chamber and desorption solution can flow in counter current to the resin;
[0029] first and second inlets for supplying loaded resin to the first chamber and desorption solution to the second chamber respectively, and first and second outlets for discharging a liquid from the apparatus and stripped resin from the second chamber respectively;
[0030] means for facilitating the transferal of resin from the first chamber to the second chamber and conveying the resin upwardly in the second chamber; and
[0031] in use, a first stream of desorption solution containing a relatively high concentration of impurities and a low concentration of targeted materials can be discharged from the first outlet, a second stream of desorption solution containing a relatively high concentration of targeted material and a low concentration of impurities can be discharged via the first outlet from lower regions of the first and/or second chambers and/or taken from desorption solution passing from the second chamber to the first chamber, and a stripped resin can be discharged from the second outlet of the second chamber.
[0032] Advantages provided by the present invention include:
[0033] ii) impurities having less affinity for the resin than the targeted material are desorbed from the resin before the targeted material and thus the first stream of desorption solution has a higher concentration of impurities can be discharged from the first chamber where the desorption solution first comes into contact with the resin;
[0034] iii) upon desorption of the impurities from the resin, the capacity of the resin to absorb targeted materials increases which allows the first chamber to have a zone for re-adsorbing targeted materials onto the resin; and
[0035] iv) targeted materials desorbed from the resin passes into the desorption solution and thereby increases the density of the solution so that it tends to settle under gravity in the chambers and thus facilitate the second stream of desorption solution containing a relatively high concentration of targeted substances and a low concentration of impurities to be discharged from the lower region of the apparatus.
[0036] It is preferred that the desorption of impurities from the resin occurs in an upper zone of the first chamber and thereby allows further targeted material to be sorbed onto the resin in the upper zone. In other words, the upper zone forms re-adsorption zone.
[0037] It is preferred that the first and second chambers be connected in fluid communication such that the liquid head in the second chamber causes the desorption solution to flow upwardly in the first chamber.
[0038] It will be appreciated that as a result of the desorption solution being supplied into the second chamber, the predominant direction of flow of desorption solution is from the second chamber into the first chamber. It will also be appreciated that the net upwardly flow of desorption solution in the first chamber will be substantially equal to the rate at which the first stream of desorption solution is discharged from the first chamber.
[0039] It is preferred that the first outlet for discharging the first stream of desorption solution be in an upper region of the first chamber. An advantage provided by this preferred feature is that the desorption solution first comes into contact with the resin in the upper region of the first chamber and impurities having less affinity for the resin than the targeted material can be withdrawn from the upper end of the first chamber.
[0040] It is preferred that the second outlet for discharging stripped resin be located in the upper region of the second chamber. An advantage provided by this preferred aspect is that the resin is progressively exposed to a desorption solution having lower concentrations of targeted materials as the resin moves upwardly in the second chamber and thereby creates a larger potential for desorption of targeted materials from the resin in the second chamber before the resin is discharged from the apparatus.
[0041] It is preferred that a passageway extend downwardly from the second outlet for conveying stripped resin to an intermediate chamber before being discharged from the apparatus.
[0042] It is preferred that the first and second inlets for supplying resin and desorption solution into the first and second chambers respectively be located in the upper region of the chambers.
[0043] It is preferred that the apparatus have control means for controlling the rate of removal of resin from the second chamber. In use, the control means measures the liquid level of the desorption solution in the first chamber to control the rate at which resin is removed form the second chamber.
[0044] It is preferred that the second chamber have another inlet for supplying a concentrated solution of targeted materials into the second chamber. We have found that adding a concentrated solution into the second chamber further increases the concentration of the targeted materials in the second stream of desorption solution (ie an eluate stream) and decreases the concentration of impurities in the second stream.
[0045] The preferred features of two embodiments of the present invention will now be described.
[0046] It is preferred that the first and second chambers be interconnected by a passageway that extends from the first chamber to the second chamber, the passageway being adapted for conveying the resin and desorption between the chambers.
[0047] According to one embodiment of the invention, it is also preferred that the first and second chambers be interconnected in U-shape having a base and two arms whereby the first and second chambers form the arms of the U-shape and the base provide the passageway.
[0048] It is preferred that the second stream of desorption solution containing a high concentration of desorbed material be discharged from the passageway extending between the first and second chambers. In the instance when the first and second chambers are interconnected in a U-shape, the second stream of desorption solution having a high concentration of targeted material is discharged from the base of the U-shape.
[0049] According to another embodiment of the invention, it is the preferred that the first and second chambers be arranged such that one of the chambers is located inside the other chamber.
[0050] It is even more preferred that the second chamber be located concentrically within the first chamber.
[0051] In the instance when the second chamber is located within the first chamber, it is preferred that the first chamber have an opening facing downwardly so that desorption solution from the second chamber can flow into the second chamber and that the resin from the second chamber enter the first chamber through the opening and be forced to move upwardly therein.
[0052] It is preferred the second stream of desorption solution be discharged from the first chamber at a location below the opening of the second chamber.
[0053] It is preferred that a bottom wall of the first chamber be declined toward an outlet for discharging the second stream of desorption solution having a high concentration of targeted substances.
[0054] According to the present invention there is provided a method for desorbing substances from an ion exchange resin having impurities and targeted materials sorbed thereon, the method including treating an ion exchange resin in an apparatus having first and second chambers, wherein the method includes the steps:
[0055] a) desorbing impurities from the resin in the first chamber using a desorption solution so that targeted materials having more affinity for the resin than the impurities can be sorbed onto the resin from the desorption solution and thereby creating conditions whereby a stream having a high concentration of impurities and a low concentration of targeted material can be discharged from the first chamber; and
[0056] b) desorbing targeted materials from the resin treated according to step a) in the second chamber using the desorption solution and thereby create conditions whereby a stream having a high concentration of targeted materials and a low concentration of the impurities can be discharged from the apparatus.
[0057] According to the present invention there is also provided a method for desorbing substances from a resin in an apparatus having first and second chambers connected in fluid communication, the method including the steps of:
[0058] a) supplying a loaded resin having targeted materials and impurities sorbed thereon to the first chamber and the resin moving in a downward direction therein;
[0059] b) conveying the resin from the first chamber to the second chamber and moving the resin in an upward direction therein;
[0060] c) supplying a desorption solution to the second chamber such that the solution flows downwardly in the second chamber and upwardly in the first chamber in countercurrent flow to the resin;
[0061] d) discharging stripped resin from the second chamber;
[0062] e) discharging a first stream of desorption solution containing a high concentration of impurities and a low concentration of targeted substances from the first chamber; and
[0063] a) discharging a second stream of desorption solution containing a relatively high concentration of targeted material and a relatively low concentration of impurities from a lower region of the first and/or second chambers and/or from the solution being conveyed between the chambers.
[0064] It is preferred that any two or more of steps a) to f) be carried out simultaneously.
[0065] It is preferred that the impurities on the resin have less affinity for the resin than the targeted materials so that when the resin is contacted by the desorption solution in the first chamber, the impurities tend to be desorbed from the resin before desorption of the targeted materials.
[0066] It is preferred that the desorption of impurities from the resin occurs in an upper zone of the first chamber and thereby allows further targeted material to be sorbed into the resin in the upper zone.
[0067] It is therefore preferred that the first stream discharged in step e) be discharging the upper region of the first chamber.
[0068] It is preferred that targeted materials desorbed from the resin and dissolved into solution increase the density of the solution thus causing fractions of the solution having high concentrations of targeted solutions to settle under gravity toward the lower regions of the first and second chambers.
[0069] It is therefore preferred that the second stream discharged in step f) be discharged from the solution being conveyed between the chambers or from the lower regions of the first and/or second chambers.
[0070] It is preferred that the rate, at which resin is discharged in step d), be controlled by the liquid level in the first chamber.
[0071] It is preferred that the resin discharged in step d) be discharged from upper regions of the second chamber.
[0072] It is preferred that the method also include supplying a concentrated solution of targeted substances into the second chamber. We have found that adding a solution of concentrated solution into the second chamber further increases the concentration of the targeted substances in the second stream of desorption solution (ie an eluate stream) and decreases the concentration of impurities in the second stream.
[0073] It is preferred the temperature of the concentrated solution range from approximately 60 to 100° C.
[0074] It is preferred that the additional solution be supplied into the second chamber at a location between the upper and lower regions of the second chamber.
[0075] The method of the present invention may also include any one of the features of the apparatus described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] Two preferred embodiments of the present invention will now be described with reference to the accompanying drawings, of which:
[0077] FIG. 1 illustrates an apparatus for desorbing material from a resin according to one embodiment of the invention, wherein the apparatus includes two chambers one chamber is located inside the other;
[0078] FIGS. 2 and 3 illustrate the embodiment shown in FIG. 1 with additional features;
[0079] FIG. 4 illustrates an apparatus for desorbing material according to an alternative embodiment, wherein the apparatus includes two chambers interconnected in a U-shape; and
[0080] FIGS. 5 and 6 illustrate the embodiment shown in FIG. 4 with additional features.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0081] The two preferred embodiments have a number of features in common and the same reference numerals have been used to identify the same or alike features on both embodiments where possible.
[0082] The preferred embodiment illustrated in the FIG. 1 comprises an apparatus having two chambers in which an inner chamber 1 is located concentrically within the outer chamber 2 .
[0083] The inner chamber 1 has an inlet valve 14 for supplying desorption solution to the inner chamber and an outlet for stripped resin. Extending from the outlet is a conduit that feeds stripped resin into an intermediate tank 7 . The lower end of the inner chamber 1 has an opening facing downwardly so that desorption solution flows downwardly in the inner 1 chamber and upwardly in the outer chamber 2 in the direction of the dashed arrows.
[0084] The liquid head of desorption solution in the inner chamber 1 causes the desorption solution to flow upwardly in the outer chamber 2 .
[0085] The outer chamber 2 has a resin inlet or spigot 5 for supplying saturated resin into the outer chamber 2 . Resin in the outer chamber 2 moves downwardly in the direction of the arrows shown in solid lines in countercurrent to the desorption solution. The resin is also forced through the opening in the inner chamber 1 and upwardly in the inner chamber 1 in the direction of the arrows shown in solid lines in countercurrent flow to the desorption solution.
[0086] In use, loaded resin enters through the spigot 5 and contacts the loaded resin in the top of the outer chamber 2 . At first instance, impurities having less affinity for the resin than the targeted material are desorbed from the resin. As a result, a stream of desorption solution having a high concentration of impurities is discharged via outlet drain 3 .
[0087] Upon desorption of the impurities form the resin, the capacity of the resin for sorbing targeted material may increase such that an upper region of the outer chamber 1 in which the impurities are desorbed may also form a re-adsorption zone for re-adsorbing the targeted material onto the resin. Normally, the re-adsorbing zone formed in the upper region of the first chamber 1 keeps the concentration of the targeted materials low in the stream of desorption solution discharged via the outlet drain 3 .
[0088] The loaded resin migrates down past the re-adsorption zone and into the inner chamber 1 where targeted material is desorbed in a desorption zone of the apparatus.
[0089] Resin moves along the inner and outer chambers 1 and 2 using any suitable means such as resin pulsation. In the case of the embodiment shown in FIGS. 1 to 3 , resin pulsation is carried out by opening valve 13 for discharging resin from apparatus, closing valve 14 so as interrupted the supply of desorption solution and pumping air into the column via the spigot 6 located on the top of the re-adsorption zone.
[0090] Electrodes 9 and 10 , which measure the level of desorption solution in the outer chamber 2 of the apparatus control the rate at which resin is removed from the apparatus. Resin movement within the chambers 1 and 2 may take place periodically once every 0.5-3.0 hours and continue for about 0.5-2.0 minutes depending on the properties of the resin, the targeted material and the conditions of the desorption process.
[0091] Desorption solution is pumped into the inner chamber 1 via the spigot 4 and the valve 14 . Desorption solution strips the target material from the oversaturated resin during its movement past desorption zone 1 downwardly to the bottom of the apparatus. A stream of desorption solution containing a high concentration of targeted material and a low concentration of the impurities is discharged from the bottom of the apparatus via the pipe 8 . The flow of solution from the bottom of the apparatus is regulated using valve 15 .
[0092] A screen 11 at the bottom of the apparatus retains the resin in the outer chamber 2 as solution is discharged.
[0093] FIGS. 2 and 3 illustrate the apparatus shown in FIG. 1 having an inlet 12 for supplying a concentrated solution of targeted materials into the middle of the inner chamber 1 . We have found that the addition of a concentrated solution to the inner chamber 1 reduces the concentration of impurities and increases the concentration of targeted material discharged from the apparatus through valve 15 .
[0094] FIG. 3 illustrates the apparatus fitted with a heat exchange means for preheating the desorption solution supplied into the inner chamber 1 via inlet 12 and valve 14 for aiding the desorption of material from resin to the desorption solution. The desorption solution is preferably heated to a temperature ranging from 60° C. to 100° C.
[0095] The apparatus is also includes external insulation for maintaining the temperature of the desorption solution in the chambers 1 and 2 .
[0096] FIG. 4 illustrates an alternative embodiment in which the chambers 1 and 2 are interconnected in a U-shape. Specifically, chambers extend upwardly from opposite ends of a horizontal passageway that interconnects the chambers. The diameter of the passageway is substantially the same as the diameter of the chambers 1 and 2 such that the resin can be conveyed from chamber 2 to chamber 1 using the pulsation techniques described above.
[0097] The passageway also provides fluid communication between the chambers 1 and 2 such that liquid head of desorption solution in chamber 1 causes desorption solution to flow upwardly in the outer chamber 2 .
[0098] Moreover, the embodiment shown in FIGS. 4 to 6 includes the same features as the embodiment shown in FIGS. 1 to 3 and can be operated in the same manner. The same reference numerals have been used on both embodiments to show the same features.
[0099] It is envisaged that the embodiments of the present invention can be operated so that the resin and desorption solution flow continuously and in countercurrent. However, it will appreciated by those skilled in the art that the flow of desorption solution and the movement of resin may be intermittent and in general terms, a continuous desorption process is one in which resin moves intermittently through a desorption apparatus. In particular, the movement of resin in a desorption apparatus normally involves an the resin being moved along the bed in intermitted increments whereby a slug of resin is discharged from an end of the bed and the rest of the resin moves in a direction along the bed.
[0100] The present invention will now be described with reference to the following non-limiting examples.
EXAMPLE 1
[0101] This example illustrates the desorption of copper from the resin that was saturated during the treatment of a waste-water steam of a copper electroplating plant. The example was carried out using the apparatus design as shown on FIG. 4 .
[0102] The copper concentration in the rinse water was about 50-80 ppm and the resin loading capacity reached 28-32 g/l.
[0103] The desorption trial was performed in a 150 L-plastic U-shape column in accordance with the embodiment shown in FIG. 4 . The loaded resin entered the column via the spigot 5 located on the lid of the column. After desorption the fully stripped resin was removed on an hourly basis from the column through the transfer pipe and the intermediate tank 7 . The resin passed through the column at a rate of 20 L/hr.
[0104] A 7% solution of sulphuric acid was used as the desorption solution. A desorption stream was pumped at a rate of about 22 L/hr into the top of the desorption zone of the column via the spigot 4 with valve 14 in the open position.
[0105] A waste stream was removed via the drainage 3 at the rate of 11.51/hr-12.51/hr. The copper concentration in the waste stream was less than 200 ppm and was returned together with the rinse water to the sorption stage.
[0106] An eluate stream was collected from the bottom of the column through screen 11 and pipe 8 . The eluate solution was discharged at a rate of 9.5-10.51/hr using valve 15 . The copper concentration reached 60 g/l in the eluate stream, very near to the maximum of the solubility of the copper sulphate (CuSO 4 .5H 2 O) (bluestone). The eluate stream is analytically and economically suitable for the direct copper recovery using the well-known methods such as copper electrowinning or cupric sulphate precipitation.
[0107] It is envisaged that an eluate stream formed by the above example can be used directly in a copper-electroplating bath and the waste rinse water containing copper can be returned to the production circuit a copper electroplating plant. It is also envisaged that the treated water may be returned to a water system of the copper electroplating plant.
EXAMPLE 2
[0108] This example illustrates desorption of nickel from the resin, which was loaded during the sorption recovery of nickel from high-pressure laterite leach slurry. The example was carried out using the apparatus shown in FIG. 4 .
[0109] Elemental analysis for the loaded resin is shown in Table 2.1.
[0110] The desorption equipment consisted of a U-shape plastic laboratory column with volume 750 ml. The resin flowed through the column at a rate of 100 ml/hr.
[0111] A 10% solution of hydrochloric acid was used as a desorption liquor. The solution was pumped into the column via the spigot 4 and the valve 14 and flowed through the desorption and re-absorption zones at rate about 160 ml/hr. The flow of the desorption solution was divided to two unequal parts:
[0112] i) The waste solution stream, which was collected after desorption from the drainage 3 at volume about 100 ml/hr and input to the sorption stage together with the pregnant leach slurry.
[0113] ii) The resulting eluate stream, which was collected from the bottom of the column via the pipe 15 and the opened partly valve 8 at volume 60 ml/hr. Elemental analysis for the eluate and waste streams are set out below in Table 2.1.
TABLE 2.1 Results of the elemental analysis of the starting and resulting products. Loaded resin, Eluate stream Waste stream, Elements g/l ppm ppm Ni 36.81 59 510 382 Co 1.65 1 460 493 Mn 2.16 701 2 750 Mg 3.40 72 2 560 Fe 0.18 127 <0.001 Cu 0.27 69 0.08 Zn 0.22 141 86 Ca 0.35 103 396 Si 0.02 30 0.24 Cr 0.01 1.34 0.65 Al 0.24 123 6.05
[0114] These results of the example show that the concentration of nickel in the eluate was about 60 g/l, which we estimate to be approximately 60% greater than the loading capacity of the pregnant resin. It is also noted that the majority of impurities, for example magnesium and manganese were discharged in the waste solution discharged via outlet 3 and as a result, the high concentrated eluate is suitable for nickel electrowinning recovery.
EXAMPLE 3
[0115] This example illustrates desorption of copper from a saturated resin, which was previously loaded during the sorption copper recovery from the heap leaching liquor. The copper concentration was between 2 g/l to 6 g/l.
[0116] The loading capacity of the resin, involved in this copper trial, was 55-64 g/l. During this test the resin flowed through the desorption column at a rate of approximately 100 ml/hr.
[0117] The desorption trial was performed in a 750 ml borosilicate glass column in accordance with the apparatus shown in FIG. 6 . The U-shape column was fully insulated to keep the temperature within the column between 60-70° C.
[0118] A 10% solution of sulphuric acid was used as a desorbent, which was preheated up to 60-70° C. using an electric heater, on the inlet 4 of the desorption solution. The flow of the desorbent was maintained at rate of about 75 ml/hr
[0119] In addition, a preheated mother liquor, after the precipitation of the copper sulphate, was pumped into the middle of chamber 1 through the inlet tube 12 with a throughput of about 85 ml/hr. In this mother liquor, the copper concentration was about 45 g/l.
[0120] A waste stream was removed from chamber 2 through the drainage 3 at rate of ˜60 ml/hr and the copper concentration was less than 100 ppm. This waste solution may be reused in the copper heap leaching process.
[0121] A saturated eluate stream was collected from the bottom of the apparatus via the pipe 8 and the adjusting valve 15 at a rate of 100 ml/hr, with a copper concentration of about 100 g/l and temperature ˜65° C.
[0122] The eluate stream was cooled to 20° C. with continuous mixing and approximately 234 g of the copper sulphate crystals were precipitated from every litre of the eluate stream. After filtration of the copper sulphate crystals, the mother liquor with the copper concentration about 45 g/l was heated to ˜70° C. and reused to supply inlet tube 12 .
EXAMPLE 4
[0123] This example illustrates the desorption of molybdenum from a loaded resin that was saturated during adsorption from molybdenum-containing solutions. The molybdenum concentration of these solutions was ˜1 g/l, so the equilibrium loading capacity of the resin was about 100 g/l.
[0124] A desorption trail was performed in a 30 L column in accordance with the apparatus shown in FIG. 1 . The loaded resin was placed into the outer chamber 2 of the column via the spigot 5 . During this trail the resin flow was maintained at rate of ˜3 l/hr.
[0125] A 10% ammoniac solution was used as a desorbent. This solution was pumped into the inner chamber 1 of the column via the spigot 4 with valve 14 in the open position. The throughout was kept 4 l/hr.
[0126] A waste solution stream with a molybdenum concentration of less than 200 ppm was collected from drainage 3 at rate of about 2 l/hr and returned with the pregnant solution on the sorption stage.
[0127] A saturated eluate stream was collected from the bottom of the column through the screen 11 and the pipe 8 . The volume of the removed eluate was regulated using the valve 15 . The molybdenum concentration of the eluate stream was ˜150 g/l and the main impurities concentrations were negligible. The solution is suitable for the economical recovery of the chemical grade ammonium paramolibdate.
EXAMPLE 5
[0128] This example illustrates a method of nickel desorption from a saturated resin with the nickel loading capacity of about 42 g/l. The resin was loaded during the sorption nickel recovery from the atmospheric leach laterite slurry.
[0129] A desorption equipment consisted of a 750 ml column in accordance with the embodiment shown in FIG. 3 . The loaded resin was placed into the column through the spigot 5 . The resin flow during this test was kept at rate of ˜100 ml/hr.
[0130] A 10% solution of sulphuric acid was used as the desorption solution. The throughout of the desorbent was regulated by the peristaltic pump and maintained at rate of ˜75 ml/hr. The desorbent was pumped into the top of the desorption zone of the column via the spigot 4 and the valve 14 .
[0131] The solution after the nickel electrowinning process contained 43 g/l and was pumped into the middle of the desorption zone of the column at rate of ˜85 ml/hr through the drainage 12 .
[0132] A waste solution stream (about 60 ml/hr) was removed from the column via the drainage 3 . This solution contains about 200 ppm of nickel may be reused in the leaching process.
[0133] An eluate stream was collected from the bottom of the column through the valve 15 and the pipe 8 at rate of about 100 ml/hr and contained about 85 g/l of nickel. This solution may be used for the nickel electrowinning.
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The present invention relates to a method and apparatus for the continuous countercurrent desorption of targeted materials including metals, non-metals and inorganic and/or organic compounds of thereof, wherein the desorption method is divided to the two modes namely: (I) desorption and (II) re-absorption. The desorption of the target material from the loaded resin using the fresh desorbent takes place in mode (I). According to mode (I) loaded resin moves upwardly in a chamber. According to mode (II) impurities are desorbed from resin and targeted material in solution can be re-absorbed. The resin moves downwardly in another chamber during mode (II). Concentrated eluates, which are suitable for the direct economical recovery of chemical elements and/or compounds thereof, can be produced using the present invention. The apparatus of the present invention includes desorption and re-absorption zones that are configured using a “pipe-in-pipe” construction or a U-shape construction.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/120,574, filed Feb. 18, 1999, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a system and method for preventing biological contamination of a semi-permeable membrane in a reverse osmosis system.
2. Background Information
Reverse osmosis systems are used to purify water by supplying a pressurized feed water stream to one side of a semi-permeable membrane in a reverse osmosis device. The pressure is maintained at a level sufficient to force the water through the membrane while retaining dissolved impurities on the feed water side. One important application is the purification of water used for human consumption. Purification removes impurities which make the water unsafe or unpotable, or which impart an undesirable taste or appearance to the water.
The treatment of water that contains microorganisms can limit the useful life of the semi-permeable membrane. The microorganisms tend to become imbedded and multiply in the membranes, causing clogging and fouling of the reverse osmosis unit. Further, the multiplying presence of the microorganisms increases the adverse consequences of their presence in the feed water. Treatment of water to combat microorganisms reduces the presence and effect of the microorganisms in proportion to the number of organisms present. Therefore, the multiplying of microorganisms on the semi-permeable membrane reduces the purity of product water from the reverse osmosis device and requires more aggressive measures to kill the microorganisms in the product water.
Large municipal and industrial reverse osmosis systems utilize out of system scrubbing of the semi-permeable membranes, careful chemical treatment of the feed water, and/or special chemical flushing cycles to control the buildup of microorganisms and other impurities on the semi-permeable membrane. However, such techniques are impractical for small point of use systems, such as under-sink home units, which must be small, simple, and reliable. These systems should require infrequent servicing and preferably be operable without electric power. Typically these systems will operate to purify water during and following the dispensing of water from the system and then shut down for period of hours or even days. During the shut down period the feed water is stagnant against the semi-permeable membrane, providing conditions that are conducive to multiplication of microorganisms present in the feed water.
Accordingly, there is a need for a simple and reliable device to prevent biological contamination of the semi-permeable membrane in a reverse osmosis device.
SUMMARY OF THE INVENTION
An apparatus for providing a predetermined volume of biocidally treated water to a feed water side of a reverse osmosis device when it is shut down. A biocide dispenser treats a predetermined volume of water from a source with a biocidal agent. A valve, coupled to the source of the predetermined volume of water, transfers the predetermined volume of water to the feed water side of the reverse osmosis device. A controller, coupled to the valve, causes the transfer of the predetermined volume of water after a source of feed water connected to the feed water side of the reverse osmosis device is shut off, and then causes the predetermined volume of water to remain in the feed water side of the reverse osmosis device while the reverse osmosis device is shut down.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a reverse osmosis system with an embodiment of the invention.
FIG. 2 is a schematic diagram of another reverse osmosis system with another embodiment of the invention.
FIG. 3 is a schematic diagram of a reverse osmosis system with another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic drawing illustrating one type of reverse osmosis system that includes an embodiment of the present invention. Feed water 100 is supplied to the system and passed through a filter 102 to remove sediment and other particles. An on-off valve 104 controls the admission of feed water to the system. The on-off valve is controlled by sensing the pressure 106 in a supply line 131 which supplies purified product water. When the pressure in the supply line drops, indicating that product water is being drawn from the system, the on-off valve 104 opens to begin a purification cycle that replenishes the water being dispensed.
The feed water enters a reverse osmosis device 108 . The reverse osmosis device has a feed water side 110 and a product water side 114 separated by a semi-permeable membrane 112 . The pressure of the feed water on the feed water side of the membrane forces water to pass through the membrane to the product water side. The semi-permeable membrane holds back impurities in the water so that the product water is highly purified while the feed water becomes more concentrated with regard to the impurities present.
Concentrated feed water is discharged through a discharge line 116 . Reverse osmosis devices generally discharge a greater amount of the water than product water. It is necessary to maintain a flow rate on the feed water side of the membrane to prevent a buildup of impurities on the membrane. A back pressure controller 118 senses the pressure 120 in the discharge line. The back pressure controller maintains a sufficient pressure to drive the reverse osmosis process and prevent the pressure from rising to the point where the membrane would be damaged.
Purified product water collects on the product water side 114 of the reverse osmosis device 108 . The product water is discharged through a product water line 124 through a one-way valve 126 . Product water is accumulated in a storage device 128 because product water is produced relatively slowly, generally at a much lower rate than would necessary to produce product water on demand. The storage device illustrated is a squeeze water type accumulator. The product water is collected in a storage bladder 130 that expands as it is filled within the outer housing of the storage device. When product water is dispensed by opening dispensing valve 132 allowing product water to flow from the dispensing spigot 134 , the pressure in the supply line 131 drops. The pressure drop turns on the on-off valve 104 and a squeeze water valve 136 which causes concentrated feed water to be supplied to the outside of the storage bladder 130 thereby pressurizing the product water in the bladder and forcing it into the supply line 131 , through the dispensing valve 132 , and out the dispensing spigot 134 . The reverse osmosis device 108 operates in a purifying cycle that begins when product water is dispensed causing the on-off valve 104 to open and ends when the storage device 128 is full causing the on-off valve 104 to close. When the purification cycle is complete, the reverse osmosis device is shut down, a condition that may continue for a number of hours or even days.
When the reverse osmosis device 108 is shut down and the on-off valve 104 is closed to shut off the supply of feed water 100 , a control valve 146 is opened causing a flow of water through a biocide dispenser 144 to supply a predetermined quantity of water to the feed water side 110 of the reverse osmosis device. The control valve is opened for a period time required to transfer the desired quantity of water. The length of time the control valve is open can be controlled by various means such as hydraulic or electrical timing. The predetermined quantity of water contains a biocidal agent added by the biocide dispenser. This treated predetermined quantity of water fills the feed water side 110 of the reverse osmosis device and remains there during the period when the reverse osmosis device is shut down.
The biocide dispenser 144 may dispense biocidal agents such as iodine, chlorine, or hydrogen peroxide. The biocide should be chosen with consideration for the types of biological contaminants present in the feed water and for the type of membrane 112 used in the reverse osmosis device. Some biocides are deleterious to some types of semi-permeable membranes. One form of biocide is an iodinator in the form of an iodinated resin which releases iodine as the feed water flows through the resin bed. Water containing 0.5 to 15 ppm of iodine has been found to be an effective biocidal solution. Ideally, little to none of the biocide will pass through the semi-permeable membrane to appear in the product water. The small volume of biocidal solution used and the use only when the reverse osmosis system is shut down, reduces the opportunity for biocide to find its way into product water. Nonetheless, it may be desirable to provide treatment of the product water to remove any traces of the biocide and/or make provisions for purging the product water side of the reverse osmosis device before collecting product water following a shut down of the system.
FIG. 2 shows another type of reverse osmosis system with another embodiment of the present invention. In this system, the product water storage device 228 is a gas pressurized accumulator. During a purification cycle, the product water flows into the storage bladder 230 of the accumulator which expands against a gas, such as air, inside the sealed housing of the accumulator. This form of accumulator stores the product water under pressure and does not require the squeeze water supply to pressurize the product water for dispensing. It will be appreciated that the configuration of the present invention is unaffected by the type of storage used in the reverse osmosis system.
In the embodiment of the invention illustrated in FIG. 2, a biosump 142 is provided to accumulate a predetermined quantity of feed water through a one-way valve 140 when feed water is being supplied to the system through the on-off valve 104 . The biosump includes a gas pressure type fluid accumulator that accumulates feed water until a pressure equilibrium is established. When the purification cycle ends, the on-off valve 104 will close and the pressure on the feed water side 110 of the reverse osmosis device 108 will begin to fall. The feed water accumulated in the biosump will flow through the biocide dispenser 144 and through the control valve 146 which is controlled 148 by the pressure of the inlet line to the reverse osmosis device. This causes a predetermined quantity of biocidally treated water to fill the feed water side 110 of the reverse osmosis device, the accumulator of the biosump being a metering device for the water transferred to the reverse osmosis device after shut down. As a result, the feed water side of the reverse osmosis membrane 112 is bathed in a biocidal solution during the periods when the reverse osmosis system is shut down.
The term “predetermined quantity” is used to mean a quantity of water established by the operating conditions of the reverse osmosis system. For example, in the embodiment shown in FIG. 1 the predetermined quantity of water transferred to the feed water side 110 of the reverse osmosis device will be determined by the length of time the control valve 146 is open and the rate of flow through the valve. In the embodiments shown in FIGS. 2 and 3, the predetermined quantity of water held in the biosump is determined by the dimensions and operating pressure of the gas pressure accumulator used for the biosump and by the pressure at which the water is supplied to the gas pressure accumulator. It will be appreciated that the predetermined quantity is increased if the water is supplied at a higher pressure. Ideally the predetermined volume transferred from the biosump to the feed water side of the reverse osmosis device is substantially the same or only slightly greater than the volume of the feed water side so that the biocidal agent is conserved and the need to replenish the biocidal agent is reduced.
FIG. 3 shows a reverse osmosis system with another embodiment of the present invention. In this embodiment, the biosump 142 is filled with a predetermined quantity of product water through a one-way valve 340 . As in the previous embodiment, the drop in pressure on the feed water side 110 of the reverse osmosis device 108 causes a predetermined quantity of water to flow from the biosump through a biocide dispenser 144 when the control valve 146 opens in response to the drop in pressure 148 on the feed water side 110 of the reverse osmosis device. The use of product water rather than feed water in the biosump may be advantageous when the quality of the feed water is such that it would foul the biocide dispenser.
While the biosump has been described with embodiments that use an air pressure type accumulator, it will be appreciated that other embodiments of the invention could use a squeeze water type accumulator for the biosump. It will also be appreciated that additional embodiments of the invention could combine the biosump with the product water accumulator and use a single accumulator to provide the function of both the biosump and the product water accumulator.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.
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An apparatus for providing a predetermined volume of biocidally treated water to a feed water side of a reverse osmosis device when it is shut down. A biocide dispenser treats a predetermined volume of water from a source with a biocidal agent. A valve, coupled to the source of the predetermined volume of water, transfers the predetermined volume of water to the feed water side of the reverse osmosis device. A controller, coupled to the valve, causes the transfer of the predetermined volume of water after a source of feed water connected to the feed water side of the reverse osmosis device is shut off, and then causes the predetermined volume of water to remain in the feed water side of the reverse osmosis device while the reverse osmosis device is shut down.
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This application is a continuation of application Ser. No. 07,838,598, filed Feb. 19, 1992, which is a continuation of application Ser. No. 07/590,112, filed Sep. 28, 1990, both of which have been abandoned.
BACKGROUND OF THE INVENTION
The invention relates to the use of non-peptide compounds to prevent cell death characteristic of neurological disease or injury.
Calcium-dependent mechanisms have been proposed to mediate the cell death that occurs in many neurological disorders, including: Alzheimer's disease, which is characterized by degeneration of cholinergic cells in the ventral forebrain as well as of cortical and hippocampal cells; Parkinson's disease, which is characterized by degeneration of dopaminergic cells in the substantia nigra; Huntington's disease, which is characterized by a degeneration of the GABAergic (gamma amino butyric acid) cells in the basal ganglia; AIDS dementia, which involves a degeneration principally of subcortical neurons; stroke and related ischemic disorders; epilepsy; motor neuron diseases; peripheral nerve degeneration; and head and spinal cord injuries (Schanne et al., 1979, Science, 206:699; Siesjo, 1981, J. Cereb. Blood Flow Metab., 1:155; Schwarcz et al., 1984, Life Sci., 35:19; Simon et al., 1984, J. Cereb. Blood, Flow. Metab., 4:350; Ben-Ari, 1985, Neurosci., 14:375; Beal et al., Nature, 330:649; Badalamente et al., 1986, J. Hand Surg., 11-B:337; Garthwaite et al., 1986, Neurosci., 18:437-447; Choi, 1987, J. Neurosci., 7:380; Maragos et al., 1987, Trends. Neurosci., 10:65; Olney, 1987, In: Excitatory Amino Acid Transmission, T. P. Hicks, et al., Eds., Liss, pp.217; Meyer, 1989, Brain Res. Rev., 14:227; Herrling, 1989, In: The NMDA Receptor, J. C. Watkins, et al., Eds., Oxford, pp. 177; Girault et al., 1990, Trends Neurosci., 13:325; Dreyer et al., 1990, Science, 248:364).
There is converging evidence that a calcium-dependent protease activity (CAPA) may be responsible for the cellular destruction that occurs in these neuropathological states (Leonard and Salpeter, 1982, Exp. Neurol., 76L121; Smith and Amaducci, 1982, Neurochem. Res., 7:541; Iizuka et al., 1986, J. Neurosurg., 65:92; Siman et al., 1989, J. Neurosci., 9:1579). The protease Calpain I has been causally linked to neuromuscular neuropathy (Leonard et al., 1982, Exp. Neurol., 76:121), as well as to neuronal death induced by excitatory amino acids (EAA) (Siman et al., 1989, J. Neurosci., 9:1579).
Endogenous EAA include glutamate and aspartate, which normally appear to function as neurotransmitters, but are thought to be damaging when released excessively within the nervous system. Excessive release or infusion of EAA leads to calcium-related neuronal death, and may be an etiological agent in a number of degenerative neuropathologies, including Alzheimer's disease, Parkinson's disease, Huntington's disease, stroke, epilepsy, motor neuron diseases, and head injuries (Schanne et al., 1979, Science, 206:699; Schwarcz et al., 1984, Life Sci., 35:19-32; Ben-Ari, 1985, Neurosci., 14:375; Beal et al., 1986, Nature, 330:649; Badalamente et al., 1986, J. Hand Surg.,. 11-B:337; Garthwaite et al., 1986, Neurosci., 18:437; Choi, 1987, J. Neurosci., 7:380; Maragos et al., 1987, Trends, Neurosci., 10:65; Olney, 1987, In: Excitatpry Amino Acid Transmission, T. P. Hicks, D. Lodge, and H. McLennan, Eds., Liss, pp. 217; Faden et al., 1989, Science, 244:798; Herrling, 1989, In: The NMDA Receptor, J. C. Watkins et al., Eds., Oxford, pp. 177; Choi et al., 1990., Ann. Rev. Neurosci., 13:171; Girault et al., 1990, Trends Neurosci., 13:325).
Endogenous EAA toxicity may be a fundamental mechanism of cell death, mediating the ultimate neuronal destruction wrought by a multitude of injuries or diseases of the central nervous system. Because of the convergence of evidence suggesting that CAPA may be a fundamental, obligatory event underlying neuronal death in a variety of neuropathological conditions, treatments that reduce CAPA or the events leading to CAPA (such as excitatory amino acid receptor activation) could prove to have widespread use as neurotherapeutics for a diverse range of neurological disorders. For example, the non-competitive excitatory amino acid receptor antagonist, MK-801, has been shown to block both EAA- and ischemia-induced neuronal damage in vivo (Foster et al., 1987, Neurosci. Let. 76:307, Gill et al., 1987, J. Neurosci. 7:3341).
SUMMARY OF THE INVENTION
In general, the invention features a method for inhibiting neuronal cell death in a mammal, preferably a human, resulting from a disorder, e.g., a disease or an injury, preferably from a calcium-related disorder of the central or peripheral nervous system, e.g., Alzheimer's disease, Parkinson's disease, Huntington's disease, AIDS dementia, stroke and related ischemic/anoxic events, epilepsy, motor neuron diseases, peripheral nerve degeneration, or head or spinal cord injuries, including administering to the mammal a neuronal cell death inhibiting amount of a preparation comprising any of mepacrine, chloroquine, or hydroxychloroquine, the preparation being essentially free of colchicine.
In preferred embodiments the method includes administering to the mammal a neuronal cell death inhibiting amount of a compound which blocks excitatory amino acid receptors, or which blocks other receptors which mediate calcium entry, e.g., receptor antagonists for angiotensin II or bradykinin, and/or calcium channel antagonists, e.g., flunarizine, verapamil, nimodipine, or nifedipine.
In preferred embodiments, the methods of the invention are useful for preventing cell death occurring in the hippocampus, at cholinergic neurons, in the substantia nigra, in the ventral forebrain, at a neuron that bears a nerve growth factor receptor, in the nucleus basalis of Meynert, at a GABAergic neuron, i.e., a neuron which uses gamma amino butyric acid as a transmitter substance, at dopaminergic neurons, in the basal ganglia, at cortical neurons, in the septum, or at a cell that has been subjected to ischemia, hypoxia, anoxia, or hypoglycemia.
In other preferred embodiments, the treatment of the invention is administered after the onset of the disorder, preferably within one hour after the onset of the disorder.
The treatments of the invention can also be used to inhibit cell death in non-neural tissue, e.g., muscle tissue, e.g., smooth muscle, e.g., cardiac muscle.
A calcium related disorder, as used herein, is a neurological disorder, e.g., a disease or an injury, that is thought to involve calcium sensitive neuronal degeneration, e.g., the neuronal degeneration that results from an alteration in the flow of calcium within or across the cell membrane of a neuronal cell.
Mepacrine (also known as Quinacrine, Merck Monograph number 8053, The Merck Index, 11th Ed., Merck, Rahway N.J., hereby incorporated by reference) was originally developed as a potential antimalarial drug by Mietzsch and Mauss, and is described in Ger. Pats. 553,072 and 571,499 and U.S. Pat. No. 2,113,357. Chloroquine (Merck Monograph number 2163, The Merck Index, 11th Ed., supra) has largely replaced mepacrine for the treatment of malaria due to its lower toxicity. Chloroquine is described in Ger. Pat. 683,692 and U.S. Pat. No. 2,233,970. Hydroxychloroquine (also known as oxychloroquine and oxichlorochine, Merck Monograph number 4748, The Merck Index, 11th Ed., supra), in which one of the N-ethyl substituents of chloroquine is beta-hydroxylated, has been used in the treatment of rheumatoid arthritis and malaria. The uses and pharmacology of mepacrine, chloroquine and hydroxychloroquine have been reviewed in The Pharmacological Basis of Therapeutics, (The Pharmacological Basis of Therapeutics, 5th ed., L. S. Goodman et al., Eds., Macmillan, 1975, pp. 1030-1031; 1049-1053; ibid., 7th ed., L. S. Goodman et al., Eds., Macmillan, 1985, pp. 1032-1035; 1054-1055, hereby incorporated by reference; and in Martindale, The Extra Pharmacopoeia, (29th ed., J. E. F. Reynolds, Ed., pp. 508-514, The Pharmaceutical Press, 1989).
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments, and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings are first described.
FIG. 1 is a graph of the effect of mepacrine on kainate-induced neuronal degeneration in the hippocampus.
FIG. 2 is a graph of the effect of mepacrine on kainate-induced spectrin breakdown in the hippocampus.
FIG. 3 is a graph of the effect of mepacrine on NMDA-induced spectrin breakdown in the hippocampus.
FIG. 4 is a graph of the effect of systemic mepacrine treatment on NMDA-induced spectrin breakdown.
FIG. 5 is a graph of the effect of chloroquine on NMDA-induced spectrin breakdown.
FIG. 6 is a graph of the effect of hydroxychloroquine on NMDA-induced spectrin breakdown.
FIG. 7 is a graph of the effect of mepacrine treatment on ischemia-induced hippocampal damage.
FIG. 8 is a graph of the effect of one hour post-treatment with mepacrine on ischemia-induced hippocampal damage.
FIG. 9 is a graph of the effect of mepacrine treatment on septal NGFr mRNA after fimbria fornix transection.
Treatment with mepacrine, chloroquine or hydroxychloroquine reduces EAA-induced neuronal damage
Intracerebroventricular (icy) treatment with mepacrine significantly reduced both kainate-induced hippocampal damage and kainate-induced spectrin proteolysis in the dorsal hippocampus. Because EAA-induced spectrin proteolysis precedes and appears to be causally related to the subsequent neuronal death produced by EAA (Siman et al., 1989, J. Neurosci., 9:1579), measurement of the proteolytic event can be used to provide an index of neuronal injury and thus of the efficacy of a compound in reducing neuronal injury and subsequent cell death. FIG. 1 shows the effect of mepacrine on kainate-induced neuronal degeneration in the hippocampus. In FIG. 1 cannulated rats received 160 nmol of mepacrine (cross hatched bar), or vehicle (solid bar), by icv infusion, 10 minutes prior to and 3 hours following icv infusion of kainic acid. The rats were killed two weeks later, and damage to the hippocampus was evaluated as described below. Data shown are the mean number of CA-regions of the hippocampus damaged for each group, ±S.E.M. Mepacrine decreased the number of damaged areas within the hippocampus from approximately 2±0.4 (in the absence of mepacrine) to approximately 0.4±0.2 (in the presence of mepacrine). FIG. 2 shows the effect of mepacrine on kainate-induced spectrin breakdown in the hippocampus. In FIG. 2 cannulated rats received 160 nmol of mepacrine (crosshatched bar), or vehicle (solid bar), by icv infusion, immediately prior to icy infusion of kainic acid. Cannulated sham control animals received two infusions of vehicle, but no kainate or mepacrine. All rats were killed 24 hours later, and homogenates of the dorsal hippocampus were analyzed for spectrin breakdown as described below. The magnitude of spectrin proteolysis is expressed as a percent increase in spectrin breakdown products over sham control values. Data shown are the mean percent increase in spectrin breakdown products for each group (sham=100%)±S.E.M. Icv infusion of kainate led to an increase of approximately 95±25% above sham value in the amount of spectrin breakdown products in the dorsal hippocampus. When mepacrine was administered by icy infusion immediately prior to kainate infusion an increase of only approximately 25±25% above the sham value in the amount of spectrin breakdown products was seen.
As shown in FIG. 3, mepacrine was also effective in reducing N-methyl-D-aspartate (NMDA)-induced spectrin breakdown in the dorsal hippocampus. In FIG. 3 rats received 40 mg/kg of mepacrine (crosshatched bar), or vehicle (solid bar), intraperitoneally (ip), immediately following icv infusion of NMDA. Sham control animals received an icv infusion of vehicle, but no NMDA or mepacrine. All rats were killed 24 hours later, and homogenates of the dorsal hippocampus were analyzed for spectrin breakdown, as described below. The magnitude of spectrin proteolysis is expressed as a percent increase in spectrin breakdown products over sham control values. Data shown are the mean percent increase in spectrin breakdown products for each group (sham=100%)±S.E.M. Infusion of NMDA led to a an increase of approximately 140±50% above the sham value in the amount of spectrin breakdown products. When mepacrine was administered intraperitoneally immediately following icv infusion of NMDA, there was an increase of only approximately 50±10% above sham value in spectrin breakdown products.
A separate set of experiments examined the effect of various mepacrine dosages on NMDA-induced spectrin proteolysis in the dorsal hippocampus. As shown in FIG. 4, intraperitoneal injection of either 30 mg/kg or 100 mg/kg of mepacrine substantially reduced NMDA-induced spectrin breakdown. In FIG. 4 the x-axis indicates the mepacrine dosage in mg/kg. The y-axis indicates the level of spectrin breakdown products found in treated animals expressed as a percentage of the level of such products found in sham control animals. i.e., animals which were given vehicle instead of mepacrine and NMDA. As shown in FIG. 4, rats received 10, 30 or 100 mg/kg of mepacrine, or vehicle (0 mg/kg), ip, immediately following icv infusion of NMDA. Sham control animals received an icv infusion of vehicle, but no NMDA or mepacrine. All rats were killed 24 hours later, and homogenates of the dorsal hippocampus were analyzed for spectrin breakdown as described in the text. The magnitude of spectrin proteolysis is expressed as a percent increase in spectrin breakdown products over sham control values. Data shown are the mean percent increase in spectrin breakdown products at each dose (sham= 100%)±S.E.M.
Chloroquine and hydroxychloroquine, two compounds structurally related to mepacrine, were also found to reduce NMDA-induced spectrin breakdown in the dorsal hippocampus. In the study depicted in FIG. 5, infusion of NMDA led to an increase of approximately 260±40% above the sham value in the amount of spectrin breakdown products, while simultaneous icv infusion of chloroquine and NMDA led to an increase of only approximately 140±30% above sham value. As shown in FIG. 5, rats received NMDA and 100 nmol of chloroquine (crosshatched bar), or vehicle (solid bar), icv. Sham control animals received an icv infusion of vehicle, but no NMDA or chloroquine. All rats were killed 24 hours later, and homogenates of the dorsal hippocampus were analyzed for spectrin breakdown as described below. The magnitude of spectrin proteolysis is expressed as a percent increase in spectrin breakdown products over sham control values. Data shown are the mean percent increase in spectrin breakdown products for each group (sham=100%)±S.E.M. In the study depicted in FIG. 6, infusion of NMDA led to an increase of approximately 65±20% above sham value in the amount of spectrin breakdown products; when hydroxychloroquine was administered icy at the same time as the NMDA infusion there was an increase of only approximately 30±10% above sham value in the amount of spectrin breakdown products. As shown in FIG. 6, rats received NMDA and 200 nmol of hydroxychloroquine (cross hatched bar), or vehicle, (solid bar), by icv infusion. Sham control animals received an icv infusion of vehicle, but no NMDA or hydroxychloroquine. All rats were killed 24 hours later, and homogenates of the dorsal hippocampus were analyzed for spectrin breakdown as described below. The magnitude of spectrin proteolysis is expressed as a percent increase in spectrin breakdown products over sham control values. Data shown are the mean percent increase in spectrin breakdown products for each group (sham=100%)±S.E.M.
Kainate infusion regime
The effect of mepacrine on kainate-induced neuronal damage was evaluated as follows. Adult female Sprague Dawley rats (220-250 g) were anesthetized with Nembutal (50 mg/kg, intraperitoneally) and administered mepacrine (160 nmol in 5μl) or vehicle, by icv infusion 10 minutes before and 3 hours following infusion of kainate (2.5 nmol in 1 μl) into the lateral ventricles. Control animals received vehicle instead of kainate and mepacrine. Icv infusions were delivered through cannulae permanently implanted at stereotaxic coordinates: anterior-posterior at bregma, 1.5 mm lateral to bregma, and 4.4 mm ventral from the top of the skull. Results of this treatment protocol were evaluated using the anatomical analysis described below.
In studies to assess the effect of kainate on spectrin proteolysis, rats received an icv infusion of mepacrine (160 nmol in 5 μl) or vehicle immediately prior to icv infusion of kainate. Icv infusions were performed as described above. These rats were killed 24 hours later and subject to biochemical analysis as described below.
NMDA infusion regime
The effect of mepacrine, chloroquine and hydroxychloroquine on NMDA-induced hippocampal damage was evaluated as follows. Female Sprague-Dawley rats (200-250 g) were anesthetized with Nembutal (50 mg/kg, intraperitoneally) and administered NMDA (3 μg in 1 μl) into the hippocampus at stereotaxic coordinates -3.3 mm posterior from bregma, lateral 2.3 mm from the midline, and ventral 4.3 mm from the top of the skull. Mepacrine or vehicle was administered either directly into the hippocampus (20 or 160 nmol in 1 μl) simultaneously with the infusion of NMDA or peripherally (10-100 mg/kg, intraperitoneally) immediately following the intrahippocampal infusion of NMDA. 100 nmol of chloroquine or hydroxychloroquine was coadministered with 3 μg NMDA in 1 μl into the hippocampus at the sterotoxic coordinates given above. Control animals received two infusions of vehicle instead of NMDA and one of the three drugs. In all cases the rats were killed 24 hours later, and homogenates of the dorsal hippocampus were prepared for the biochemical analysis described below.
Anatomical and Biochemical Analyses
Anatomical analysis was performed as follows. Rats were killed by decapitation 2 weeks following treatment, and the brains were rapidly removed and frozen on dry ice. A series of slide-mounted coronal sections from each brain was stained with thionin and examined microscopically. Damage to the hippocampus was quantified by summing the total number of 4 anatomically defined regions of the hippocampus (CA 1-4 according to the classification of Lorente de No, as described by Shepard, 1979, The Synaptic Organization of the Brain, Oxford, p. 310, hereby incorporated by reference), on both left and right sides of the brain, that suffered a loss of pyramidal cells.
Biochemical analysis was performed as follows. Calpain I-sensitive proteolysis of brain spectrin (fodrin) was evaluated in homogenates of the hippocampus using an immunoblot analysis described by Siman et al. (1988, Neuron, 1:279-287, hereby incorporated by reference). Briefly, rats were killed by decapitation 24 hours following treatment, and the dorsal hippocampus was rapidly dissected out of the brain and homogenized in 20 mM Tris-HCl (pH 7.4) containing 0.1 mM phenylmethylsulfonyl-fluoride. Proteins from aliquots of each homogenate were separated by SDS-PAGE, and an immunoblot analysis was used to quantitate the amount of kainate or NMDA-induced spectrin breakdown in each sample.
Treatment With MepaCrine Dramatically Reduces Ischemia-Induced Hippocampal Damage
When gerbils were given repeated, systemic treatments with mepacrine, there was a remarkable reduction in the extent of hippocampal damage sustained after transient cerebral ischemia. As shown in FIG. 7, gerbils treated with mepacrine had approximately 55±10% sparing of CA1 pyramidal cells, while only approximately 4±3% sparing of CA1 pyramidal cells was observed in untreated gerbils. As shown in FIG. 7, gerbils received mepacrine (80 mg/kg, ip) (cross hatched bar), or vehicle (control) (solid bar), immediately prior to, and once a day (40 mg/kg, ip) for 6 days after bilateral occlusion of the carotid arteries. The gerbils were killed on the sixth post-operative day, and damage to the CA1 region of the hippocampus was evaluated as described below. The mean size of the intact (spared) pyramidal cell layer is expressed above as a percentage of the total CA1 pyramidal cell subfield for each group, ±S.E.M. (0%=total neuronal loss; 100%=maximum-possible sparing).
As shown in FIG. 8, gerbils treated with mepacrine one hour after ischemic injury had approximately 80±10% sparing of CA1 pyramidal cells, while only 27±15% sparing of CA1 pyramidal cells was observed in untreated gerbils. Gerbils received mepacrine (80 mg/kg, ip) (crossed hatched bar), or vehicle (control) (solid bar), one hour following, and once a day (40 mg/kg, ip) for 4 days after bilateral occlusion of the carotid arteries. The gerbils were killed on the fourth postoperative day, and damage to the CA1 region of the hippocampus was evaluated as described below. The mean size of the intact pyramidal cell layer is expressed above as a percentage of the total CA1 pyramidal cell subfield for each group,±S.E.M. (0%=total neuronal loss; 100%=maximum possible sparing).
Transient forebrain ischemia was induced under Nembutal anesthesia (50 mg/kg intraperitoneally) in male Mongolian gerbils weighing 50-80 g. An anterior ventral midline incision was made, the right and left common carotid arteries were isolated from the vagus nerve, and suture thread was tied around each artery to achieve total occlusion of blood flow for a period of 5 minutes. At the end of the ischemic period, the suture threads were removed, and the incision was closed with wound clips after ascertaining that blood flow was completely restored to both carotid arteries. The gerbils received mepacrine (80 mg/kg, intraperitoneally) immediately prior to or one hour following ischemia, and once a day (40 mg/kg, intraperitoneally) for 6 or 4 days after the surgery. The gerbils were killed by decapitation and the brains were rapidly removed and frozen on dry ice. A series of slide-mounted coronal sections from each brain was stained with thionin and examined microscopically. The area of pyramidal cell damage in the CA1 subfield of both hippocampi was measured using a Bioquant image analysis system (R and M Biometrics, Nashville, Tenn.). The area of intact CA1 pyramidal cells was expressed as a percentage of the area of the total CA1 pyramidal cell subfield. Five minute bilateral occlusion of the carotid arteries results in a significant induction of spectrin breakdown, and virtually total bilateral destruction of the CA1 pyramidal cell layer in this animal model of stroke.
Treatment with Mepacrine Completely Prevents Degeneration of Septal Neurons After Traumatic Transection of the Fimbria-Fornix
Transection of the fimbria-fornix results in retrograde degeneration of cholinergic neurons in the ventral forebrain. In the human brain, degeneration of these cells is one of the characteristics of Alzheimer's disease and may underlie the memory impairment that is suffered by Alzheimer's victims; as a result, transection of the fimbria-fornix in animals has been used as a model of Alzheimer's disease (Hefti and Weiner, 1986, Ann. Neurol. 20:275). Previous studies have shown that central administration of nerve growth factor (NGF) prevents, or "rescues" septal cholinergic neurons from degeneration following transection of the fimbria fornix (Williams et al., 1986, Proc. Natl. Acad. Sci. USA, 83:9231; Hefti, 1986, J. Neurosci., 6:2155). The survival of septal neurons in this model has previously been confirmed and quantitated by immunocytochemicai detection of the NGF receptor, or messenger RNA for the NGF receptor (NGFr mRNA) using in situ hybridization histochemistry (Springer et al., 1987, J. Neurosci. Res., 17:111, hereby incorporated by reference; Springer et al., 1989, Soc. Neurosci. Abstr., 15:707, hereby incorporated by reference). It was recently found that surgical transection of the fimbria-fornix results in a significant induction of spectrin breakdown in the septum, suggesting a role for CAPA in the retrograde degeneration of septal cholinergic neurons (Roberts-Lewis et al., 1990, Soc. Neurosci. Abstr. 16:983).
As shown in FIG. 9 systemic mepacrine treatment was found to completely prevent the retrograde degeneration of NGFr-bearing septal neurons following surgical transection of the fimbria-fornix in rats.
Female Sprague-Dawley rats (200-250 g) were anesthetized with Nembutal (50 mg/kg, intraperitoneally), and a knife (4 mm wide and 2 mm long) was inserted into the brain at a position approximately -1.0 mm posterior from the bregma, 1 mm lateral from the midline, and 4.5 mm ventral from the top of the skull. The knife was moved several times from side to side and up and down in order to completely transect the fibers of the fimbria. At the time of fimbria-fornix transection, the rats received either a placebo (solid bar in FIG. 9) or 400 mg of mepacrine (cross hatched bar in FIG. 9) subcutaneously, in slow release tablets delivering approximately 20 mg/day (200 mg tablets, Innovative Research of America). The rats were killed 4 days later, and a series of coronal sections from each brain was hybridized with a cRNA probe against nerve growth factor receptor (NGFr) mRNA using in situ hybridization histochemistry with a modification (Baldino et al., 1989, Soc. Neurosc., Abstr., 15:864, hereby incorporated by reference) of the method described by Springer et al. (Springer et al., 1990, Cell. Mol. Neurobiol., 10:33-39, hereby incorporated by reference). The slides were examined microscopically, and positively labelled neurons in the septum ipsilateral to the knife cut were counted and expressed as a percentage of the number of NGFr mRNA-positive neurons in the contralateral (control) septum.
Use
The invention provides a method for the safe, effective treatment of neurological disorders through the use of mepacrine, chloroquine, or hydroxychloroquine. The neurological disorders that may be treated include those neurological disorders thought to involve calcium-sensitive neuronal degradation, including Alzheimer's disease, Parkinson's disease, Huntington's disease, AIDS dementia, stroke and related ischemic/anoxic disorders, epilepsy, motor neuron diseases, peripheral nerve degeneration, and head and spinal cord injuries.
In the practice of the present invention, mepacrine, chloroquine or hydroxychloroquine may be administered orally or parenterally. The mode of administration, dosage, and formulation of these compounds depends upon which neurological disorder is being treated and the general health and level of consciousness of the patient. Appropriate methods of administering these compounds, including dosage and formulation, will be apparent to those skilled in the art, particularly with reference to earlier pharmacological information (e.g., Martindale, The Extra Pharmacopoeia, supra).
Other Embodiments
Other embodiments are within the following claims, e.g., any of mepacrine, chloroquine or hydroxychloroquine may also be provided in combination with other compounds which would be expected to reduce the cellular supply of calcium that activates CAPA, particularly (1) calcium channel blockers (e.g., flunarizine, verapamil, nimodipine, nifedipine); or (2) antagonists of the receptor-mediated entry of calcium, such as antagonists of EAA receptors, or other receptors known to mediate calcium influx (e.g., receptors for angiotensin II or bradykinin). Again, appropriate methods of administering combinations of these compounds, including dosage and formulation, will be apparent to those skilled in the art.
The treatment of the invention can also be used to inhibit cell death from ischemia in non-neural tissues, e.g., in muscle tissue, e.g., smooth muscle, e.g., cardiac muscle.
Chloroquine, mepacrine, and hydroxychloroquine each have an asymmetric carbon at the e position in the N sidechain. The isomers of a racemic mixture of any of these compounds can be separated by methods known to those skilled in the art and the isomeric preparations thus purified tested, by methods known to those skilled in the art, to determine if an isomeric preparation (as opposed to a racemic mixture) is more desirable, e.g., has less toxicity or greater potency, for use in the methods of the invention.
It is understood that various other modifications will be apparent and can readily be made by those skilled in the art without departing from the scope and spirit of the invention. In particular, it will be straightforward to evaluate the neuro-protective activity of derivatives of mepacrine, chloroquine, or hydroxychloroquine by the methods described herein.
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A method for inhibiting neuronal cell death in a mammal resulting from a disorder of the central or peripheral nervous system including administering to the mammal a neuronal cell death inhibitng amount of a preparation including any of mepacrine, chloroquine, or hydroxychloroquine, the preparation being essentially free of colchicine.
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FIELD OF THE INVENTION
[0001] This invention relates to a novel process for the preparation of α-(2,4-disulfophenyl)-N-tert-butylnitrone and pharmaceutically acceptable salts thereof. These compounds have previously been disclosed as being useful as medicaments. Such compounds are alternatively named as 4-[(tert-butylimino)methyl]benzene-1,3-disulfonic acid N-oxide derivatives.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 5,488,145 discloses α-(2,4-disulfophenyl)-N-tert-butylnitrone, pharmaceutically acceptable salts thereof and related pharmaceutical compositions. U.S. Pat. No. 5,475,032 discloses the use of such compositions in the treatment of stroke and of progressive central nervous system function loss conditions. And U.S. Pat. No. 5,508,305 discloses the use of such compositions for ameliorating the side effects caused by oxidative damage resulting from antineoplastic disease treatment. Similar disclosures are also made in WO 95/17876. U.S. Pat. No. 5,780,510 discloses the use of these same compounds in the treatment of concussion.
[0003] Various methods are available for the synthesis of nitrones. The most often used method involves the usually uncatalysed condensation reaction of a hydroxylamine derivative with an aldehyde or ketone (J. S. Roberts in D. H. R. Barton and W. D. Ollis, Comprehensive Organic Chemistry, Volume 2, pages 500-504, Pergamon Press, 1979; R. D. Hinton and E. G. Janzen, J. Org. Chem., 1992, 57, 2646-2651). The utility of this reaction is impaired by its susceptibility to steric hindrance, slow reaction rates, and, in certain cases, by the relative inaccessibility and/or instability of the hydroxylamine starting material. The latter problems can sometimes be overcome by in situ generation of the required hydroxylamine by reduction of a more readily available compound such as the corresponding nitro derivative. This general methodology is employed in the above-described patents where the preparation of α-(2,4-disulfophenyl)-N-tert-butylnitrone is described as involving the reaction of 4-formyl-1,3-benzenesulfonic acid with N-tert-butylhydroxylamine in refluxing methanol for approximately 18 hours.
[0004] α-(2-Sulfophenyl)-N-tert-butylnitrone has been prepared by reaction of 2-formylbenzenesulfonic acid sodium salt with N-tert-butylhydroxylamine in refluxing ethanol for 2 days (E. G. Janzen and R. V. Shetty, Tetrahedron Letters, 1979, 3229-3232).
[0005] A modification of this type of methodology for the manufacture of α-phenyl-N-methylnitrone has been described in French Patent 1,437,188 to E.I. DuPont de Nemours and Co.
[0006] We now disclose a novel process that possesses significant advantages for the preparation of α-(2,4-disulfophenyl)-N-tert-butylnitrone and salts thereof and is also particularly suited to large scale production.
DISCLOSURE OF THE INVENTION
[0007] This invention provides a process for the preparation of a compound of general formula (I)
[0008] wherein each R independently represents SO 3 H or a salt thereof.
[0009] This process involves reaction of an aldehyde of general formula (II)
[0010] wherein R is as defined above,
[0011] with freshly prepared N-tert-butylhydroxylamine (III)
(CH 3 ) 3 CNHOH (III)
[0012] Thus, in one aspect this invention provides an integrated process in which: in a first step, N-tert-butylhydroxylamine (III) free base is prepared by neutralising N-tert-butylhydroxylamine acid addition salt in an organic reaction medium; in a second step the N-tert-butylhydroxylamine free base (III) formed in the first step is reacted under condensation conditions with an aldehyde of general formula (II), thereby forming the nitrone compound of general formula (I); and in a third step the compound (I) is isolated from the condensation reaction mixture.
[0013] In a second aspect, this invention provides an improvement in the condensation of N-tert-butylhydroxylamine (III) with an aldehyde of general formula (II) that comprises conducting the condensation in the presence of an acid catalyst.
[0014] In a third aspect, said acid catalyst is provided by incomplete neutralisation of the N-tert-butylhydroxylamine acid addition salt used as one of the starting materials.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Starting Materials and Products
[0016] In this process, an aldehyde of general formula (II) is reacted with freshly generated N-tert-butylhydroxylamine to form an α-(2,4-disulfophenyl)-N-tert-butylnitrone compound of general formula (I). The compounds of formulae (I) and (II) may be acids or they may be salts.
[0017] Salts of compounds of formula (1) above may be formed by reacting the free acid (wherein R represents SO 3 H), or another salt thereof, with two or more equivalents of an appropriate base, using methods that are well known in the art.
[0018] The salts of compounds of formulae (I) and (II) referred to above will normally be those formed with pharmaceutically acceptable cations. The cation may be a monovalent material such as sodium, potassium, lithium, ammonium, alkylammonium or diethanolammonium. Alternatively, it may be a polyvalent cation such as calcium, magnesium, aluminium or zinc. It may also be a mixed salt formed with a polyvalent cation in combination with a pharmaceutically acceptable monovalent anion such as halide (for example, chloride), phosphate, sulphate, acetate, citrate or tartrate.
[0019] The two R's in those formulas are usually the same. However, they can be independently selected from the possibilities just enumerated.
[0020] It is preferred that the two R's in formulae (I) and (II) above be the same and each represents SO 3 − Na +
[0021] N-tert-Butylhydroxylamine is prepared from a commercially available acid addition salt such as N-tert-butylhydroxylammonium chloride as described below in the section entitled “The Premix Step”.
[0022] The aldehydes of general formula (II) are either commercially available or may be prepared from commercially available materials using methods that are well known in the art. Commercial 4-formyl-1,3-benzenedisulfonic acid disodium salt (II; R=SO 3 − Na + ) typically contains small but significant amounts of the corresponding benzyl alcohol and the corresponding benzoic acid derivatives, and of sodium chloride as impurities. It is preferable, but not essential, that such material is purified before use in the process of the present invention.
[0023] 4-Formyl-1,3-benzenedisulfonic acid disodium salt (II; R=SO 3 − Na + ) is typically associated with varying amounts of water. The proportion of such water generally is not critical to the process of the present invention but generally may be taken into account when determining the overall composition of the compound (I)-forming reaction mixture.
[0024] The Premix Step
[0025] The free base form of N-tert-butylhydroxylamine is relatively unstable, tending in particular to undergo aerial oxidation. This is evidenced by the formation of blue colours, which indicate the presence of the oxidation product, 2-methyl-2-nitrosopropane. The free base of N-tert-butylhydroxylamine cannot therefore be stored as such but should be freshly generated immediately before use. In view of the instability of the free base of N-tert-butylhydroxylamine, it is advisable, particularly for large scale work, to generate the free base in solution and then to use this solution directly in the subsequent reaction rather than attempting to isolate the free base as such.
[0026] A preferred reaction for generating the free base of N-tert-butylhydroxylamine involves reacting in solution N-tert-butylhydroxylamine acid addition salt with a base. Typical acid addition salts include the hydrohalide acid addition salts, with the hydrochloride salt being preferred.
[0027] Bases include the simple inorganic bases such as the alkali metal hydroxides. However, these bases are less soluble in organic solvents. Thus, a preferred group of bases are those that are soluble in organic solvents and that do not yield water as a product of neutralisation. Such materials include alkali metal alkoxides such a sodium or potassium methoxide, ethoxide, isopropoxide and the like.
[0028] Typical solvents for generating the free base include lower alcohols, such as methanol, ethanol, n-propanol and isopropanol, alone, in mixtures or in mixtures with water. Thus, treatment of a solution of commercial N-tert-butylhydroxylamine hydrochloride in methanol with a base such as sodium methoxide yields a methanolic solution of the free base plus sodium chloride.
[0029] The precipitated sodium chloride can be removed by filtration, but the solubility of sodium chloride in methanol is such that significant amounts of sodium chloride remain in solution and are thereby carried forward to become a contaminant of the final product, the nitrone of formula (I). The removal of sodium chloride from compounds of formula (I), particularly the compound wherein R represents SO 3 − Na + , is not a trivial exercise since compounds of formula (I) themselves have very appreciable solubility in solvents such as water. Chloride contamination of the final products (I) can be reduced to acceptable levels by washing with water. This is often at the expense of losing very significant amounts of the desired material (I). In an attempt to overcome this problem, a change of solvent form methanol to isopropanol was investigated. Whilst this approach was successful in terms of reducing the carry over of sodium chloride into the final product, this change of solvent had an unacceptably adverse effect on the rate of the reaction of the aldehyde (II) with N-tert-butylhydroxylamine. Using a solvent mixture comprising methanol 10 to 35% v/v; preferably 20 to 30%; and isopropanol, 90 to 65%, preferably 80 to 70%, in a premix solution, which is filtered, provides a suitable compromise in terms of removing sodium chloride without appreciably increasing the reaction time.
[0030] As previously noted, however, one can use individual alcohols or other mixtures if optimal salt rejection and product recovery is less critical.
[0031] This premix reaction is moderately exothermic. Thus, depending upon the scale of the reaction it can lead to warming of the reaction mixture by as much as 20° C. or more. Agitation can prevent localised heating. Heat can be removed or added as needed to control the reaction temperature into a typical range of about 0° C. up to about 75° C. with mildly elevated temperatures of say 25° C. to 50° C. being most common.
[0032] This reaction is typically carried out with agitation at ambient temperature for a time of from about five minutes up to several hours. Preferably the time is at the shorter end of this range such as from about ten minutes to about fifty minutes.
[0033] Prior to using the neutralisation product of the premix as a feedstock in the condensation reaction, it is advantageous to filter it to remove as much as possible of any salt by-product of the neutralisation. This filtration is generally carried out at 0° C. to 30° C. although this temperature is not seen to be critical.
[0034] While the amount of base used to neutralise the acid addition salt material can be one equivalent of base per equivalent of salt, in practice it is advantageous to use slightly less than one equivalent of base so as to have a minor amount of acid present which then acts as a catalyst for the subsequent condensation reaction. Thus, the amount of base used to form the free base form of N-tert-butylhydroxylamine is from about 0.9 to 1.0 equivalents (basis equivalents of acid addition salt) and preferably from about 0.95 to 1.0 equivalents and especially from about 0.95 to 0.99 equivalents. This provides 0.1 equivalents or less of catalyst, which gives good results.
[0035] The Condensation
[0036] The next step is the condensation of the N-tert-butylhydroxylamine (III) with the aldehyde (II). This reaction is typically conducted in a batch mode with agitation. It could, if desired, be carried out continuously in a flow reaction system.
[0037] In this condensation it is preferred that in general about 1.0 to 1.5 equivalents of N-tert-butylhydroxylamine (III) is used for each equivalent of the aldehyde (II). It is particularly preferred that about 1.05 to 1.3 equivalents of N-tert-butylhydroxylamine (III) is used.
[0038] The condensation is carried out in solution, using a suitable inert solvent in which the starting materials are sufficiently soluble. It is preferred that a suitable polar organic solvent such as an alcohol, or mixture of alcohols, is used as solvent. It is preferred that the solvent is predominantly methanol, and particularly a mixture of methanol and isopropanol. It is further preferred that the reaction mixture contains a suitable percentage of water, generally less than 10% by volume, such as from about 2% to 10% by volume. It is particularly preferred that the solvent contains about 5% by volume of water. It has been found that the presence of a suitable amount of water provides significant advantages, particularly with regards to inhibiting the conversion of the aldehyde (II) into the undesirable acetal side product (IV).
[0039] by reaction with the solvent R 1 OH.
[0040] This side reaction, like the primary condensation reaction, is catalysed by acid and thus is promoted along with the primary reaction by the catalytic amounts of acid present in the hydroxylamine feedstock.
[0041] Overall solvent compositions (by volume) which are preferred include:
methanol 98 to 70%; isopropanol 0 to 30%; water 2 to 10%.
[0042] Especially preferred are:
methanol about 80%; isopropanol about 15%; water about 5%.
[0043] The presence of a suitable amount of water in the solvent also significantly improves the kinetics of the process and allows a more concentrated reaction mixture to be used. The proportion of reaction solvent is typically maintained at about 2 to 10 mL of solvent per gram of nitrone product or greater, with proportions of from especially 4 to 8 mL per gram being preferred.
[0044] The condensation is conducted at a temperature from about ambient temperature to about 150° C.; good results are achieved at a temperature of from about ambient to about 125° C.; with temperatures of from about 40° C. to about 100° C. being preferred. The condensation reaction is carried out substantially to completion. Usually this takes from about 3 hours to about 24 hours, especially about 3 hours to about 8 hours. Longer times are sometimes favoured since the side reaction to form acetal is reversible and prolonged reaction periods drive the equilibrium toward the desired product (I).
[0045] Isolation
[0046] The isolation of the product of formula (I) formed in the above condensation may be achieved by using standard techniques that are well known in the art. It is particularly advantageous that the product be isolated using a suitable crystallisation technique. Thus in a typical isolation, on completion of the reaction of the aldehyde (II) with N-tert-butylhydroxylamine (III), the reaction mixture is cooled to ambient temperature and then filtered in order to remove any insoluble material. The filtrate is then heated at reflux and crystallisation is induced by the gradual addition of a suitable crystallisation agent such as isopropanol or ethyl acetate while water and methanol are removed by distillation. The crystallisation agent is typically an organic liquid that is miscible with the reaction solvent but one in which the nitrone product is less soluble. The agent is also generally a volatile material, such as a material having 5 or less carbon atoms. After cooling once more, the solid product is isolated by filtration and dried. The use of isopropanol as a crystallisation agent is particularly preferred.
[0047] Alternatively, crystallisation may be induced by the addition of a suitable agent such as isopropanol or ethyl acetate without the filtrate having first been heated. Again, the use of isopropanol is particularly preferred.
[0048] The water content of α-(2,4-disulfophenyl)-N-tert-butylnitrone disodium salt obtained using the process of the present invention is dependent on the nature of the methodology used for the isolation of the product and the final drying process that is used. Thus, extensive drying at elevated temperatures and under reduced pressure will yield essentially anhydrous material. Such material is however significantly hygroscopic, forming eventually a trihydrate. Drying of the trihydrate regenerates the anhydrous form. The trihydrate form is obtained directly by crystallisation of α-(2,4-disulfophenyl)-N-tert-butylnitrone disodium salt from hot water, or by passing humidified air over the solid.
[0049] Addition of up to about 5% by volume water to the crystallisation agent can push the product toward the hydrated form and decrease the amount of occluded organic liquids in the crystalline product.
[0050] Water addition can also have the benefit of decreasing the amount of salt and associated by-products, such as aldehyde starting material incorporated into the isolated product (I).
[0051] The invention is illustrated, but is in no way limited, by the following examples:
EXAMPLE 1
[0052] The Synthesis of α-(2,4-disulfophenyl)-N-tert-butylnitrone Disodium Salt Using an Isopropanol/Methanol Premix, Condensation Reaction, Isopropanol Distillation, Water Adjustment, Filtration and Drying Process.
[0053] Sodium methoxide (1012 g) in isopropanol (1.4 L) and methanol (0.36 L) was added to N-tert-butyl-hydroxylamine hydrochloride (2340.3 g) in methanol (1.80 L) and isopropanol (7.5 L), then stirred for 40 minutes. The mixture was filtered and the filtrate then added to a suspension of 4-formyl-1,3-benzenedisulfonic acid disodium salt (4500 g) in methanol (32.0 L) and water (2.10 L) in a 50 L jacketed reactor fitted with reflux condenser and overhead stirrer. The mixture was refluxed for 8 hours to give a solution that was then transferred by peristaltic pump through an in-line filter. The mixture was distilled at such a rate so as to maintain an approximately constant volume while isopropanol:water (99:1) was added. A total of 40 L distillate was collected and 40 L isopropanol:water (99:1) added. The resulting suspension was cooled to 25.2° C. Water (1200 mL) was added and the mixture was stirred for 1.8 hours, then filtered. The white solid was washed with isopropanol (2×8.0 L) then dried in two portions in a fluid bed dryer at 100° C. to give the required product (4183.7 g, 86.8%).
EXAMPLE 2
[0054] The Synthesis of α-(2,4-disulfophenyl)-N-tert-butylnitrone Disodium Salt Using a 100% Methanol Premix, Condensation Reaction, Distillation, Water Adjustment, Filtration and Drying Process.
[0055] Sodium methoxide (186.3 g, 3.45 equiv.) in methanol (2.66 L) was added to N-tert-butylhydroxylamine hydrochloride (461.3 g, 3.65 equiv.) in methanol (2.3 L). An additional 1.15 L of methanol was added and the mixture then stirred for 20 minutes. The mixture was filtered and the filtrate added to a suspension of 4-formyl-1,3-benzenedisulfonic acid disodium salt (1000 g) in methanol (2.65 L) and water (0.45 L) in a 12 L jacketed reactor fitted with reflux condenser and overhead stirrer. The mixture was refluxed for 6 hours to give a solution which was then transferred by peristaltic pump through an in-line filter into a 12 L jacketed vessel, fitted for distillation with a stillhead adapter, condenser and overhead stirrer. The mixture was distilled at such a rate so as to maintain an approximately constant volume while isopropanol:water (99:1) was added. A total of 9 L distillate was collected and 9 L isopropanol:water (99:1) added. The suspension was cooled to ambient temperature. Water (600 mL) was added and the mixture stirred for 2 hours and 20 minutes, then filtered. The white solid was washed with isopropanol (1×800 mL), then dried in a fluid bed dryer at 100° C. for about one hour to give 568 g of the required product (47.2% yield). HPLC (% area): 99.3% α-(2,4-disulfophenyl)-N-tert-butylnitrone disodium salt; 0.13% 4-formyl-1,3-benzenedisulfonic acid disodium salt; 0.05% 4-formyl-1,3-benzenedisulfonic acid disodium salt dimethyl acetal.
EXAMPLE 3
[0056] Preparation of α-(2,4-disulfophenyl)-N-tert-butylnitrone Disodium Salt Using an 100% Isopropanol Premix, Condensation Reaction, Ethyl Acetate Distillation, Water Adjustment, Filtration and Drying Process.
[0057] Sodium methoxide (156.8 g, 2.90 equiv.) in isopropanol (0.5 L) was added to N-tert-butylhydroxylamine hydrochloride (379.2 g, 3.0 equiv.) in isopropanol (2.45 L), then stirred for 20 minutes. The mixture was filtered and the solid then washed with isopropanol (0.5 L). The filtrate and washings were added to a suspension of 4-formyl-1,3-benzenedisulfonic acid disodium salt (814.5 g) in methanol (7.36 L) and water (0.49 L) in a 12 L jacketed reactor fitted with reflux condenser and overhead stirrer. After 7.5 hours reflux, an additional amount of sodium methoxide (15.6 g) in isopropanol (245 mL) was added to N-tert-butylhydroxylamine hydrochloride (37.9 g) in isopropanol (50 mL), mixed and filtered and the filtrate added to the reaction reflux and reflux continued a further 4 hours. The reaction was cooled and sodium methoxide (12.0 g) was added and the reaction mixture then stirred for 20 minutes. The solution was then transferred using a peristaltic pump through an in-line filter into a 12 L jacketed vessel, fitted for distillation with a stillhead adapter, condenser and an overhead stirrer. The mixture was distilled at such a rate to maintain an approximately constant volume while isopropanol:water (99:1) was added. A total of 10 L of distillate was collected and 10 L of isopropanol:water (99:1) was added. The suspension was cooled to ambient temperature. Water (400 mL) was added and the mixture was stirred, then filtered. The white solid was washed with isopropanol (2×200 mL) then dried in a fluid bed dryer at 100° C. for about one hour to give the required product (86% yield). HPLC (% area): 98.3% α-(2,4-disulfophenyl)-N-tert-butylnitrone disodium salt; 0.30% 4-formyl-1,3-benzenedisulfonic acid disodium salt; 0.70% 4-formyl-1,3-benzenedisulfonic acid disodium salt dimethyl acetal; chloride (ISE, w/w): 0.68%.
EXAMPLE 4
[0058] In a 50 L reactor, methanol (32.0 L), water (2.10 L) and 4-formyl-1,3-benzenedisulfonic acid disodium salt (4500.7 g) were stirred and heated at 75° C. while N-tert-butylhydroxylamine [prepared by treating N-tert-butylhydroxylamine hydrochloride (2340.7 g, 18.96 moles) in isopropanol (7.50 L) with sodium methoxide (1012.3 g, 18.74 moles) in isopropanol (3.20 L) and methanol (0.36 L), then removing the sodium chloride by-product by filtration] was added. Additional N-tert-butylhydroxylamine [prepared from treating N-tert-butylhydroxylamine hydrochloride (234.0 g) with sodium methoxide (95.0 g) in isopropanol and methanol (880 mL and 180 mL respectively)] was added after 6 hours reflux. After a total of 11 hours reflux the reaction was complete. The mixture was filtered into a second reactor, sodium methoxide (24.5 g) added, the mixture was heated to distillation and then isopropanol:water (99:1) was added at the same rate at which the distillate was removed. The total distillation time was 24 hours. Water (1200 mL) was added to the stirred suspension, which after cooling to <30° C. was filtered, washed with isopropanol (2×8 L) and dried in a fluid bed dryer to give the required product in 91.7% yield.
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An integrated process for preparing α-(2,4-disulfophenyl)-N-tert-butylnitrone and its salts is disclosed in which N-tert-butylhydroxylamine acid addition salt is incompletely neutralised so as to leave catalytic amounts of acid and the neutralisation product is condensed with an appropriate aldehyde.
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[0001] This is a continuation of U.S. patent application Ser. No. 12/401,137, filed Mar. 10, 2009 (pending), and a continuation-in-part of U.S. patent application Ser. No. 11/860,142, filed Sep. 24, 2007 (pending), which are all incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present application is directed to solar cell manufacturing and, more particularly, to mounting of solar cells on a flexible substrate.
BACKGROUND
[0003] Thin solar cells are fabricated by depositing layers of light absorbing semiconductor material on the surface of a semiconductor wafer and then removing the wafer. The solar cell layer stack is typically bonded to a carrier to provide support during certain manufacturing steps, including removal of the semiconductor wafer. Additional processing can be performed after removal of the semiconductor wafer such as depositing metal wiring and cutting the thin layers of solar cell material into individual solar cell chips. Each solar cell chip can be removed from the support carrier and attached to a solar array device such as a solar panel, collector, etc. The solar cell chips can be made thin enough so that they flex when attached to curved surfaces.
[0004] The layers of solar cell material are typically attached to a carrier support using an adhesive or solder. It is difficult to remove the thin solar cell chips from the support carrier after the semiconductor wafer is removed and processing of the cells is completed. The thin solar cell chips are often damaged during the support substrate removal process, which can require excessively high temperatures and/or mechanical/chemical forces to break the bond formed between the solar cells and the support carrier. Damaging solar cells during the support substrate removal process significantly reduces conventional thin film solar cell manufacturing yields.
SUMMARY
[0005] According to one embodiment, a method of manufacturing a solar cell includes depositing a sequence of layers of semiconductor material forming at least one solar cell on a first substrate; temporarily bonding a flexible film to a support second substrate; permanently bonding the sequence of layers of semiconductor material to the flexible film so that the flexible film is interposed between the first and second substrates; thinning the first substrate while bonded to the support substrate to expose the sequence of layers of semiconductor material; and subsequently removing the support substrate from the flexible film.
[0006] According to another embodiment, a method of manufacturing a solar cell includes depositing a sequence of layers of semiconductor material forming at least one solar cell on a first substrate; attaching a flexible film to a support second substrate with a temporary adhesive; attaching the sequence of layers of semiconductor material to the flexible film with a permanent adhesive so that the flexible film is interposed between the first and second substrates; thinning the first substrate while bonded to the support substrate to expose the sequence of layers of semiconductor material; and subsequently applying an adhesive remover to holes formed through the support substrate to dissolve the temporary adhesive and remove the support substrate from the flexible film.
[0007] According to yet another embodiment, a method of manufacturing a solar cell includes depositing a sequence of layers of semiconductor material forming at least one inverted metamorphic multifunction solar cell on a first substrate; temporarily bonding a flexible film to a support second substrate; permanently bonding the sequence of layers of semiconductor material to the flexible film so that the flexible film is interposed between the first and second substrates; thinning the first substrate while bonded to the support substrate to expose the sequence of layers of semiconductor material; and subsequently removing the support substrate from the flexible film.
[0008] Of course, the present invention is not limited to the above features and advantages. Those skilled in the art will recognize additional features and advantages upon reading the following detailed description, and upon viewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates an exploded perspective view of a solar cell structure temporarily attached to a support substrate according to an embodiment of the present invention.
[0010] FIGS. 2-6 illustrate cross-sectional views of the solar cell structure shown in FIG. 1 being temporarily attached to the support substrate according to an embodiment of the present invention.
[0011] FIGS. 7-9 illustrate cross-sectional views of the solar cell structure shown in FIG. 1 being processing after attachment to the support substrate according to an embodiment of the present invention.
[0012] FIG. 10 illustrates a side perspective view of individual solar cell chips manufactured according to an embodiment of the present invention attached to a surface.
DETAILED DESCRIPTION
[0013] Details of the present invention will now be described including exemplary aspects and embodiments thereof. Referring to the drawings and the following description, like reference numbers are used to identify like or functionally similar elements, and are intended to illustrate major features of exemplary embodiments in a highly simplified diagrammatic mariner. Moreover, the drawings are not intended to depict every feature of the actual embodiment nor the relative dimensions of the depicted elements, and are not drawn to scale.
[0014] With this in mind, the present application is directed to permanently bonding (i.e., bonding with a permanent adhesive) a thin solar cell formed on a growth substrate to one side of a flexible film and temporarily bonding (i.e., bonding with a temporary adhesive) the other side of the flexible film to a support substrate so that the support substrate can be easily removed from the flexible film after processing of the thin solar cell is complete. As used herein, a “temporary adhesive” is an adhesive in which the temporarily bonded layers can be readily separated upon treatment of the temporary adhesive with an organic solvent under conditions that do not damage the semiconductor material. Such conditions typically soften or dissolve the temporary adhesive. In contrast, a “permanent adhesive” as used herein, is an adhesive in which the permanently bonded layers cannot be readily separated upon treatment of the permanent adhesive with a solvent under typical processing conditions for separation of temporarily bonded layers without damaging the semiconductor material. Thin solar cells manufactured in accordance with the embodiments described herein weigh less and are thus well suited for applications where weight is a concern such as space applications. In addition, the solar cells are relatively thin and thus can be readily attached to curved surfaces. Still other advantages of having thin solar cells attached to a flexible film will become readily apparent in view of the detailed description below.
[0015] FIG. 1 shows an exploded perspective view of an embodiment of a sequence of layers of semiconductor material 100 temporarily bonded to a support substrate 110 . The sequence of layers of semiconductor material 100 forms at least one solar cell and is deposited on a growth substrate 120 such as a GaAs wafer, Ge wafer, etc. A flexible film 130 is interposed between the support substrate 110 and the growth substrate 120 . In one embodiment, the flexible film 130 is a polyimide film such as Kapton (manufactured by DuPont.). One side 132 of the flexible film 130 is permanently bonded to the sequence of layers of semiconductor material 100 using a permanent adhesive 140 so that the flexible film 130 cannot be easily removed from the sequence of layers of semiconductor material 100 . The other side 134 of the flexible film 130 is temporarily bonded to the support substrate 110 using a temporary adhesive 150 so that the support substrate 110 can be easily removed from the flexible film 130 without causing damage to the sequence of layers of semiconductor material 100 .
[0016] The support substrate 110 provides support to the sequence of layers of semiconductor material 100 during subsequent processing step(s). This way, the growth substrate 120 on which the sequence of layers of semiconductor material 100 is deposited can be removed after attachment to the support substrate 110 . The sequence of layers of semiconductor material 100 can also be segmented into individual solar cell chips (not shown in FIG. 1 ) when attached to the support substrate 110 without causing damage to the chips. After completing the desired processing step(s), the support substrate 110 is removed from the flexible film 130 . In one embodiment, the support substrate 110 has holes 112 which extend from one surface 114 of the support substrate 110 to the opposing surface 116 as indicated by the dashed lines in the Figures. The support substrate 110 may comprise any suitable material such as sapphire or any other material having suitable chemical and temperature stability and strength. In one embodiment, the support substrate 110 has a thickness of about 40 mils. In one embodiment, the support substrate 110 is removed from the flexible film 130 by applying an adhesive remover to the holes 112 which dissolves the temporary adhesive 150 , leaving the sequence of layers of semiconductor material 100 permanently bonded to the flexible film 130 .
[0017] FIG. 2 shows a cross-sectional view of the growth substrate 120 after the sequence of layers of semiconductor material 100 is deposited on the substrate 120 , e.g. via epitaxial growth. The sequence of layers of semiconductor material 100 can include any number and type of layers of semiconductor material for generating current in response to incident light. In one embodiment, the layers 100 form at least one inverted metamorphic multifunction (IMM) solar cell, e.g., as described in U.S. Patent Application Pub. No. 2010/0122724 A1 (Cornfeld et al.), the contents of which is incorporated herein by reference in its entirety.
[0018] According to one embodiment, the sequence of layers of semiconductor material 100 is deposited on the growth substrate 120 by forming a first solar subcell on the growth substrate 110 having a first band gap and forming a second solar subcell over the first solar subcell having a second band gap smaller than the first band gap. A grading interlayer is formed over the second solar subcell having a third band gap larger than the second band gap. A third solar subcell having a fourth band gap smaller than the second band gap is formed such that the third solar subcell is lattice mismatched with respect to the second solar subcell. In one embodiment, the first solar subcell is composed of an InGaAlP emitter region and an InGaAlP base region and the second solar subcell is composed of an InGaP emitter region and an InGaAs base region. The grading interlayer can be composed of InGaAlAs. Alternatively, the grading interlayer can be composed of a plurality of layers with a monotonically increasing lattice constant. Yet other layers of semiconductor material can be deposited on the growth substrate 120 to form a solar cells which is now ready for attachment to the support substrate 110 .
[0019] FIG. 3 shows a cross-sectional view of the support substrate 110 during bonding to the flexible film 130 . The support substrate 110 is bonded to the flexible film 130 using a temporary adhesive 150 such as Wafer Bond (manufactured by Brewer Science, Inc. of Rolla, Mo.) or any other type of suitable polymer that can be applied by spin coating and has suitable chemical and temperature stability and relatively low curing temperature to produce a temporary bond which can be easily broken without causing damage to the sequence of layers of semiconductor material 100 temporarily attached to the support substrate 110 .
[0020] In one embodiment, the flexible film 130 is vacuum sealed to a chuck (not shown) and the temporary adhesive 150 spun onto the film 130 . The support substrate 110 is then mated with the flexible film 130 while on the chuck. Alternatively, the temporary adhesive 150 can be spun onto the support substrate 110 . According to this embodiment, the holes 112 formed in the support substrate 110 are temporarily plugged so that the adhesive 150 does not escape through the holes 112 . The holes 112 can be plugged by placing tape (not shown) over the side 116 of the support substrate 110 not being bonded to the flexible film 130 . The tape can be removed after the support substrate 110 and flexible film 130 are brought into contact. The support substrate 110 and the flexible film 130 are then bonded together via the temporary adhesive 150 under appropriate heat and/or pressure conditions for curing the temporary adhesive 150 . The growth substrate 120 with the sequence of layers of semiconductor material 100 is also prepared for bonding to the flexible film 130 .
[0021] FIG. 4 shows a cross-sectional view of the growth substrate 120 after the sequence of layers of semiconductor material 100 is deposited thereon. According to one embodiment, the sequence of layers of semiconductor material 100 has a metallized surface 160 . Alternatively, the sequence of layers of semiconductor material 100 does not have a metallized surface. In either case, a permanent adhesive 140 such as benzocyclobutene (BCB) or SU-8 is applied to the surface of the sequence of layers of semiconductor material 100 facing away from the growth substrate 120 . The permanent adhesive 140 can also be applied to the surface 132 of the flexible film 130 not bonded to the support substrate 120 for increased adhesion.
[0022] FIG. 5 shows a cross-sectional view of the two substrates 110 , 120 during the substrate attachment process. The substrates 110 , 120 are brought into contact so that the sequence of layers of semiconductor material 100 can be permanently bonded to one surface 132 of the flexible film 130 via the permanent adhesive 140 and the support substrate 110 can be temporarily bonded to the other surface 134 of the flexible film 130 via the temporary adhesive 150 . In one embodiment, the substrates 110 , 120 are brought into contact under vacuum to prevent air voids in the adhesives 140 , 150 . An appropriate temperature and/or pressure are applied to the substrates 110 , 120 for curing the permanent adhesive 140 . Alternatively, the flexible film 130 can be permanently bonded to the sequence of layers of semiconductor material 100 and then temporarily bonded to the support substrate 110 . In either case, the support substrate 110 is temporarily bonded to the sequence of layers of semiconductor material 100 .
[0023] FIG. 6 shows a cross-sectional view of the two substrates 110 , 120 after the substrates 110 , 120 are bonded together. At this point, the support substrate 110 can be used to support the sequence of layers of semiconductor material 100 during subsequent processing step(s).
[0024] FIG. 7 shows a cross-sectional view of the bonded structure after the growth substrate 120 is removed, leaving only the sequence of layers of semiconductor material 100 and the flexible film 130 bonded to the support substrate 110 . The growth substrate 120 can be removed by grinding, lapping and/or etching. The support substrate 110 prevents the thin sequence of layers of semiconductor material 100 from being damaged during the substrate removal process. Additional processing can be done to the sequence of layers of semiconductor material 100 while temporarily attached to the support substrate 110 .
[0025] FIG. 8 is a cross-sectional view of the bonded structure after the growth substrate 120 is removed and after a metal grid 200 is formed on the exposed surface of the sequence of layers of semiconductor material 100 . The metal grid 200 collects current from across the surface of the cell, and also can be contacted to bring current to the outside world, interconnect adjacent cells, etc. In one embodiment, the metal grid 200 is formed by evaporation and lithographic patterning.
[0026] FIG. 9 is a cross-sectional view of the bonded structure after the sequence of layers of semiconductor material 100 is cut into a plurality of thin solar cell chips 210 . The flexible film 130 interposed between the layers of semiconductor material 100 and the support substrate 110 can also be cut so that each solar cell chip 210 can be easily separated from the support substrate 110 and still have a portion of the flexible film 130 permanently attached thereto. In one embodiment, the solar cell chips 210 are removed from the support substrate 110 by applying an adhesive remover to the holes 112 formed through the support substrate 110 . The adhesive remover travels through the holes 112 and dissolves the temporary adhesive 150 , freeing the solar cell chips 210 and the flexible film 130 from the support substrate 110 without damaging the chips 210 .
[0027] In another embodiment, the support substrate 110 does not have holes 112 formed therein and the temporary adhesive 150 is dissolved by heating the adhesive 150 to a temperature which breaks the temporary bond between the support substrate 110 and the flexible film 130 . The individual solar cell chips 210 each with a layer of the flexible film 130 permanently bonded thereto can then be attached to any type of desirable surface. The solar cell chips 210 are thin and flexible and can be readily attached to flat or curved surfaces. Cover glasses (not shown) and interconnects 200 can be applied to solar cell chips 210 either before or after demounting from the support substrate 110 since the flexible film 130 provides ample support to the chips 210 during this type of processing. The flexible film 130 permanently bonded to the solar cell chips 210 can be sucked down with a vacuum to make the film 130 flat to do cover glassing and welding or soldering.
[0028] FIG. 10 shows a side-view of an embodiment of a solar panel 300 having a curved surface 302 to which the solar cell chips 210 can be attached. The solar cell chips 210 can be permanently or temporarily attached to the solar panel 300 , e.g. via an appropriate type of adhesive.
[0029] Spatially relative terms such as “under”, “below”, “lower”, “over”, “upper”, and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first”, “second”, and the like, are also used to describe various elements, regions, sections, etc and are also not intended to be limiting. Like terms refer to like elements throughout the description.
[0030] As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.
[0031] The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
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According to an embodiment, a method of manufacturing a solar cell includes depositing a sequence of layers of semiconductor material forming at least one solar cell on a first substrate; temporarily bonding a flexible film to a support second substrate; permanently bonding the sequence of layers of semiconductor material to the flexible film so that the flexible film is interposed between the first and second substrates; thinning the first substrate while bonded to the support substrate to expose the sequence of layers of semiconductor material; and subsequently removing the support substrate from the flexible film.
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TECHNICAL FIELD
The present invention relates to an apparatus and method for rolling a metal matrix composite material, and more particularly to an apparatus and method which prevents cracking of the edges of such material during the rolling process.
BACKGROUND ART
Discontinuous fiber reinforced metal matrix composite materials exhibit increased stiffness and strength in comparison to the metal which forms basis thereof, and are formable using standard metal forming equipment. Some of the more popular metal matrix composite materials are various aluminum alloys reinforced with discontinuous fibers of silicon carbide. In the process of making sheet or plate product from metal matrix composite materials, the material is typically hot rolled in several passes from a starting billet, plate or extruded plank. Generally, the rolling mills which are used to roll the metal matrix composite material are those which are also used to roll normal alloys. It has been found that during the rolling process, the resulting rolled sheet or plate of metal matrix composite material is subject to edge cracking, and that such cracking can affect from 15 to 50 percent of the rolled width. The loss of 15 percent or more of the rolled width is a severe cost penalty for the use of a material which has such desirable strength and stiffness properties. Procedures which have been attempted to reduce such edge cracking include extruding the hot pressed billets and then rolling perpendicularly to the extrusion direction. Unfortunately, such procedures have not been too successful and producers and users of metal matrix composite materials have reluctantly accepted a loss of such material due to edge cracking during the rolling process.
Because of the foregoing, it has become desirable to develop an apparatus and a method for eliminating edge cracking of metal matrix composite material during the rolling process.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems associated with the prior art and other problems by providing a frame having an aperture therein for the receipt of a metal matrix composite material so as to constrain same during the rolling process. The frame is interposed between and welded to a bottom plate and a top plate so that the metal matrix composite material is fully "encapsulated" therein. The frame, along with the bottom plate and the top plate, are all formed from a ductile material which deforms as the metal matrix composite material deforms during the rolling process. The frame provides edge restraint to the metal matrix composite material which prevents the edges of the material from cracking.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the present invention.
FIG. 2 is a perspective view of the present invention in an assembled condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings where the illustrations are for the purpose of describing the preferred embodiment of the present invention, and are not intended to limit the invention hereto, FIG. 1 illustrates the apparatus required for this new rolling method. This apparatus includes a frame 10, a top plate 12, a bottom plate 14, and a metal matrix composite core 16 whose thickness is to be reduced by the rolling process.
The frame 10 is metallic and is typically fabricated from 6061 aluminum or a similar ductile material which will deform as the metal matrix composite core 16 deforms. The thickness of the frame 10 is the same as the thickness of the metal matrix composite core 16 prior to rolling. An aperture 18 having dimensions slightly greater than the length and width of the metal matrix composite core 16, prior to rolling, is provided within the frame 10. The size of the frame 10 is such that the location of the aperture 18 therein permits the formation of edge rail areas 20 parallel to the direction of rolling and end rail areas 22 perpendicular to the direction of rolling. The resulting width of the edge rail areas 20 is sufficient to provide the necessary support for the metal matrix composite core 16 during the rolling process. The resulting width of the end rail areas 22 is sufficient to provide a weld free zone, and a heat effect free zone, during the welding process, hereinafter described.
The top plate 12 and the bottom plate 14 are metallic and are typically fabricated from 6061 aluminum or a similar ductile material which will deform as the metal matrix composite core 16 deforms. The length and width of the top plate 12 and the bottom plate 14 are the same as the length and width of the frame 10. The thickness of the top plate 12 and the bottom plate 14 is typically less than the thickness of the frame 10, however, the resulting thickness is determined by the physical properties of the metal matrix composite core 16 and the user's personal preferences. The harder the metal matrix composite core 16 relative to the hardness of the top plate 12 and the bottom plate 14, the thicker the top plate 12 and the bottom plate 14 will have to be. If the material comprising the top plate 12 and the bottom plate 14 is expected to bond to the metal matrix composite core 16 during the rolling process so as to form a laminated construction, the final required thickness of the laminant will dictate the initial thickness of the top 12 and the bottom plate 14. It should be noted that it may be preferable to start with a relatively thick top plate 12 and bottom plate 14 so as to maintain a final assembly thickness at the last rolling station that is greater than the minimum thickness the rolling station can handle with accuracy.
The metal matrix composite core 16 is a discontinuous fiber reinforced metal matrix composite material, such as an aluminum alloy reinforced with discontinuous fibers of silicon carbide to a volume of approximately 20 to 40 per cent. The core 16 can be in the form of a sheet, an extruded plank, or a hot pressed billet. The use of a hot pressed billet eliminates the need for previous rolling operations to the sheet or for the use of the extrusion process on the plank. Whatever approach is used, the resulting length and width of the core 16 is slightly less than the length and width of the aperture 18 within the frame 10, and the thickness of the core 16 is the same as that of the frame 10.
In preparation for the rolling process, the frame 10 is placed on the bottom plate 14, and the core 16 is received within the aperture 18 in the frame 10. The top plate 12 is then placed on top of the frame 10, and the top plate 12 and the bottom plate 14 are welded to the frame 10 at both ends thereof, as shown in FIG. 2. If desired, the sides of the top plate 12 and the bottom plate 14 can also be welded to the frame 10. In any event, unless a vacuum is "pulled" on the completed assembly, gas vents should be provided by not closing the welds at the corners of the top plate 12 and the bottom plate 14.
Because of its ductile properties, the frame 10 deforms as much as the core 16 during the rolling process. The frame 10 provides edge restraint to the core 16 which prevents the edges of the core 16 from cracking. Thus, the core 16 can be "rolled" to the desired thickness without any loss of material due to edge cracking. After the rolling process has been completed, the core 16, which is now in the form of a metal matrix composite sheet, can be easily removed from the frame 10 by cutting inboard of the welds between the top plate 12, the bottom plate 14 and the frame 10. The removal process can be eased by coating the surfaces of the core 16 with a suitable stop-off compound, prior to rolling. The use of such a stop-off compound helps prevent diffusion bonding between the core 16 and the top plate 12, the bottom plate 14 and the frame 10. It should be noted that in some instances the use of a top plate 12 and/or a bottom plate 14 is not necessary. For example, if the rates of thermal expansion of the materials comprising the frame 10 and the core 16 are such that a press fit is maintained between the core 16 and the frame 10 at the rolling temperature, then the option of rolling the assembly without the use of a top plate 12 and a bottom plate 14 is available. However, the use of a top plate 12 and a bottom plate 14 does provide a significant advantage in that it places a ductile material, rather than the core, in direct contact with the rolling mills. This may significantly influence the acceptability of rolling metal matrix composite material at a large number of mills. In addition, control of the surface finish of the resulting metal matrix composite sheet is possible through the use of the top plate 12 and the bottom plate 14.
The foregoing apparatus and method of rolling were used to reduce the thickness of a one-half inch thick plate of 25 percent (volume) silicon carbide particulate reinforced aluminum 6061 alloy plate through hot rolling to a final thickness of one-fourth inch thick plate. The frame was fabricated from 6061-T6 aluminum alloy and had a thickness of one-half inch. The top plate and the bottom plate were similarly fabricated from 6061-T6 aluminum alloy, however, each of the plates was one-eighth inch thick. A stopoff material was applied to the silicon carbide/aluminum plate prior toencasement in the frame assembly. The top plate and the bottom plate were welded, along all four sides thereof, to the frame. The resulting assembly was rolled at 900° F. in two or three heavy passes and one light pass to a final thickness of one-fourth inch for the silicon carbide/aluminum plate. The resulting silicon carbide/aluminum plate exhibited no edge cracking. For comparison purposes, the same silicon carbide/aluminum material was rolled at the same temperature in the same mill to the same resulting thickness, and the resulting plate experienced extensive edge cracking resulting in the loss of about 15 percent of the material comprising the plate.
In addition to eliminating the costly waste of material due to edge cracking, this new apparatus and rolling method permit the rolling of a hot pressed billet directly into a plate without any intermediate production steps, such as extruding the billet into the desired configuration for rolling. Thus, the elimination of such intermediate production steps result in additional economies.
Certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It will be understood that all such improvements and modifications have been deleted herein for the sake of conciseness and readability, but are properly within the scope of the following claims.
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An apparatus and method for rolling metal matrix composite material is disclosed. The material is confined within an aperture in a frame member during the rolling process. The frame member has deformation properties compatible with that of the metal matrix composite material permitting the frame member to be deformed during the rolling process and allowing the surfaces defining the aperture in the frame member to constrain the material during this process, thus eliminating edge cracking of the material. The frame member may be interposed between a top member and a bottom member both having deformation properties compatible with that of the metal matrix composite material so as to "encapsulate" the material during the rolling process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to power transmission units for translating reciprocating to rotary motion.
2. Summary of the Invention
In the power transmission unit of the instant invention a bar having rack teeth on opposite sides thereof is provided for vertical reciprocation and is attached to any vertically reciprocating device. Gears are meshed with rack teeth on opposite sides of the rack bar so as to be rotated as the rack bar reciprocates. The gears are connected through oppositely arranged one-way clutches so as to alternately drive a single gear in one direction only. The single gear is connected through a gear train and/or belts to power any device.
The primary object of the invention is to provide a power transmission for translating reciprocating to rotary motion.
Other objects and advantages will become apparent in the following specification when considered in light of the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the invention;
FIG. 2 is a side elevation of the invention shown partially broken away for convenience of illustration;
FIG. 3 is a fragmentary horizontal sectional view taken along the line 3--3 of FIG. 2, looking in the direction of the arrows;
FIG. 4 is a fragmentary vertical sectional view taken along the line 4--4 of FIG. 3, looking in the direction of the arrows; and
FIG. 5 is a fragmentary transverse vertical sectional view taken along the line 5--5 of FIG. 4, looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, wherein like reference characters indicate like parts throughout the several figures, the reference numeral 10 indicates generally a power transmission unit constructed in accordance with the invention.
The power transmission unit 10 includes a channel shaped base member 11. A generally rectangular housing 12 is secured to the base member 11 and extends upwardly therefrom. A shaft 13 is journalled in the front wall 14 of the housing 12 at one end and in the rear wall 15 at its opposite end. A shaft 16 is arranged parallel to the shaft 13 and is similarly journalled in the front wall 14 and rear wall 15. A shaft 17 is journalled in the front wall 14 and in a block 18 secured to the bottom wall 19 of the housing 12. The housing 12 has a top wall 20 secured by studs 21 to the side walls 22, 23 of the housing 12. A rectangular opening 24 extends through the top wall 21 adjacent the rear wall 15 and a rectangular opening 25 extends through the bottom wall 19 and the channel 11 adjacent the rear wall 15 in aligned relation to the opening 24.
A generally rectangular rack bar 26 having rack teeth 27 on one side thereof and rack teeth 28 on the opposite side thereof, is mounted for vertical reciprocation through the openings 24, 25 as can be clearly seen in FIGS. 3 and 4. An upright slot 29 is formed in the forward face of the rack bar 26 and engages over a tongue 30 on the block 18 in the housing 12.
A gear 31 is keyed for the shaft 13 and meshes with the rack teeth 27 on the bar 26. A second gear 32 is keyed to the shaft 16 and meshes with the rack teeth 28 of the bar 26. A gear 33 is journalled on the shaft 13 and is secured to one-way clutch element 34 also journalled on the shaft 13. A second one-way clutch element 35 is keyed to the shaft 13 and is held in engagement with the one-way clutch element 34 by means of a coil spring 36 encompassing the shaft 13 and extending between the gear 31 and the one-way clutch element 35.
A gear 37 is journalled on the shaft 16 and is rigidly secured to a one-way clutch element 38 also journalled on the shaft 16. A one-way clutch element 39 is keyed to the shaft 16 and is held in engagement with the one-way clutch element 38 by means of a coil spring 40 encompassing the shaft 16 and extending between the gear 32 and the one-way clutch element 39. The one-way clutch elements 35, 39 are mounted for endwise sliding movement on the shafts 13, 16 respectively.
A gear 41 is secured to the shaft 17 intermediate the gears 33, 37 and meshing with the gears 33, 37 to be driven thereby. A shaft 42 is rigidly mounted to the base member 11 and a power take-off shaft 43 is also rigidly mounted to the base 11 in parallel relation to the shafts 42 and 17. A relatively large spur gear 44 is fixed to the shaft 17 and meshes with a relatively small spur gear 45 journalled on the shaft 42 and rigidly secured to a relatively large spur gear 46. A relatively small spur gear 47 is journalled on the shaft 43 and meshes with the spur gear 46. A V-pulley 48 is fixed to the spur gear 47 to revolve therewith.
In the use and operation of the invention the unit 10 is secured in any desired manner with the lower end of the rack bar 26 connected to any vertically reciprocatable device (not shown), to thus cause the rack bar to reciprocate with respect to the housing 12. As the rack bar reciprocates the rack teeth 27 rotate the spur gear 21 and the rack teeth 28 rotate the spur gear 32. As the rack bar moves downwardly with respect to the housing 12, the gear 31 as seen in FIG. 4 rotates in a clockwise direction to thus rotate the one-way clutch element 35 in a clockwise direction driving the one-way clutch element 34 and the gear 33 in a clockwise direction so as to turn the shaft 17 in a counter clockwise direction. As the rack bar 26 reverses its direction and moves upwardly with respect to the housing 12, the one-way clutch elements 34, 35 slip by each other so that no drive occurs to the gear 33. The gear 32 is then rotated in a clockwise direction and through the one-way clutch elements 38, 39 rotates the gear 37 in a clockwise direction to thus rotate the shaft 17 in a counter clockwise direction. The one-way elements 38, 39 slip by each other when the gear 32 is rotated in a counter clockwise direction during downward movement of the rack bar 26 with respect to the housing 12.
The shaft 17 is thus rotated solely in a counter clockwise direction by alternate driving connections to opposite sides of the rack bar 26. The gears 44, 45, 46 and 47 provide a relatively high speed rotary power drive.
Having thus described the preferred embodiment of the invention it should be understood that numerous structural modifications and adaptations may be resorted to without departing from the spirit of the invention.
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A power transmission unit which translates reciprocating motion to one-way rotary motion through a rack and drive gears connected through one-way clutches to a gear train.
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BACKGROUND
[0001] The present invention generally relates to the stimulation of subterranean wells and, in a representatively illustrated embodiment thereof, more particularly relates to specially designed apparatus and methods for inhibiting a screen-out condition in a subterranean well fracturing operation.
[0002] In zone fracturing of subterranean wells one previously proposed method employs a series of tubular sleeves longitudinally spaced apart along a tubular casing of an overall wellbore string. Each sleeve is slidable relative to the casing between a closed position in which the sleeve blocks associated casing side wall ports, and an open position in which the sleeve unblocks such ports to permit exit therethrough of a pressurized fracing slurry which is used to create and prop open subterranean formation fractures through which production fluid may be subsequently delivered through the wellbore string to the surface for recovery. Annular seats are secured to the sliding sleeves for movement therewith relative to the casing and are sized to sealingly receive valve actuating members, such as balls, which are successively dropped through the string. Via the use of packers or other types of seal-off structures interdigitated with the sliding sleeves, a series of fracturing zones are defined externally of the casing—each zone being associated with one of the sliding sleeves.
[0003] In carrying out a typical zone fracturing operation, with the sleeves initially in their closed positions, a ball or other type of valve actuating member is dropped through the string and caused to sealingly engage the seat portion of the lowermost sleeve. Via downward fluid pressure exerted on the dropped ball, its associated sleeve is forced in a downstream direction to its open position in which its previously covered casing ports are opened to permit pressurized frac slurry to be discharged into the formation adjacent the now-opened set of casing ports. When the fracing of this first zone is complete, a second ball is dropped into sealing engagement with the seat of the closed sliding sleeve immediately uphole of the opened first sleeve. Downward fluid pressure is then exerted on the second ball to downwardly slide its sliding sleeve and thereby open a second series of casing ports to permit pressurized fracing fluid to flow outwardly therethrough to thereby frac a second formation zone above the first fraced formation zone while the second ball isolates the fracing fluid from the first dropped ball. This sequence is repeated for each of the upwardly successive closed sliding sleeves until the zone fracturing operation is completed.
[0004] When fracing a well it is desirable to pack as much proppant into a formation as possible to keep the fractures open for production, especially close to the wellbore. A risk exists for plugging a well by packing too much proppant into a specific zone. This plugging is commonly known as a “screen-out” which may be defined as a condition arising when fracture fluids are no longer capable of carrying the proppant or the concentration of proppant becomes too great, causing the proppant to settle out in the piping and not be carried into the subterranean fractures.
[0005] A screen-out condition may cause a severe disruption in well operations and significant cost overruns due to the well known difficulties encountered in eliminating the screen-out. Various techniques have been previously proposed to prevent a screen-out condition from occurring since unplugging a screen-out is quite time consuming and expensive. Each of these known techniques carries with it problems which makes it less than entirely desirable. As but one example, a common screen-out prevention method when initiating fractures upon opening a new zone is to send fluid with no proppant therein to the formation for a period of time, and later add maximum concentrations of proppant to the fluid to place the proppant into the subterranean fractures. Due to the cost of the fluid it is desirable to minimize its use in the fracing operation. This known technique, however, substantially increases the volume of fracing fluid required, thereby materially increasing the overall cost and time needed for the fracing operation.
[0006] As can be seen from the foregoing, a need exists for improved apparatus and methods which eliminate or at least reduce the aforementioned problems created by the occurrence of screen-out conditions in well fracing operations as generally described above. It is to this need that the present invention is primarily directed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional view through a longitudinal portion of a deployed wellbore string with a sliding sleeve assembly therein opened to permit the fracturing of a subterranean formation zone adjacent the opened sliding sleeve assembly;
[0008] FIG. 2 is a view similar to that in FIG. 1 , but with an undesirable screen-out condition having been created within the wellbore string above the opened sliding sleeve assembly;
[0009] FIGS. 3-5 are cross-sectional views through the deployed wellbore string portion and sequentially depict the representative use of improved apparatus and methods of the present invention in inhibiting in the wellbore string portion the creation of the screen-out condition shown in FIG. 2 ; and
[0010] FIG. 6 is an enlarged perspective view of a specially designed valve actuating member embodying principles of the present invention and used in the screen-out inhibiting technique shown in FIGS. 3-5 .
DETAILED DESCRIPTION
[0011] Referring initially to FIGS. 1 and 2 , a longitudinal portion of a downhole-deployed wellbore string 10 is shown which comprises a tubular casing 12 in which a longitudinally spaced apart series of sliding sleeve valve assemblies, including a representative uphole or upstream sleeve valve assembly 14 and a downhole or downstream sleeve valve assembly 16 below it. Packing elements 18 , or some other structures such as cement sections, prevent fluid flow between annular zones 20 disposed between the exterior of the wellbore string 10 and the borehole 21 through which the string 10 extends.
[0012] Each sliding sleeve valve assembly 14 , 16 comprises a coaxial tube 22 that can be positioned over radial holes or ports 24 in an exterior tubing component 26 of the sliding sleeve valve assembly. Sealing structures such as O-rings 28 prevent fluid passage from the interior of the wellbore string 10 to the annular zones 20 . Each sliding sleeve valve assembly 14 , 16 may also have a structure, such as a seat 30 that can be engaged by a valve actuating member, representatively in the form of a ball 32 , to actuate the associated coaxial tube 22 . Most commonly, seats are designed to be engaged by balls of increasing size to selectively open zones with specific ball sizes. The present invention applies to, but is not limited to, systems with ascending ball sizes. Sliding sleeve systems utilizing expandable seats (as opposed to the representatively fixed diameter seats 30 ) can also benefit from principles of the present invention.
[0013] FIG. 1 shows the wellbore string with fracing fluid passing therethrough in the downstream direction 34 to the open downstream sliding sleeve assembly 16 , the fracing fluid comprising a fluid laden with proppant such as sand. The fluid is directed through the opened radial ports 24 of the downstream sliding sleeve valve assembly 16 and into adjacent subterranean formation fractures 36 in the earth. It is desirable to lodge as much proppant as possible in these fractures to allow hydrocarbons to later be able to pass through the fractures 36 for delivery to the surface for recovery. It is also desirable to minimize the use of fluid when delivering the proppant due to the cost of the fluid.
[0014] FIG. 2 , in which principles of the present invention are not utilized, illustrates the wellbore string 10 in a screen-out condition in which proppant 38 has become too dense and impacted within the string 10 to allow fluid to flow to the fractures 36 . The most common time for this screen-out condition to occur is at the point when fractures 36 can no longer accept any more proppant 38 . Another point at which a screen-out condition can occur is when the sliding sleeve assembly 16 is initially opened and fractures 36 have not yet been initiated. A current practice employed to prevent a screen-out condition is to send fluid without proppant therein to the formation for a period of time, and thereafter add proppant to the fluid once the fractures 36 have been created. As previously mentioned herein, this technique is often less than satisfactory due to increased cost and time delay considerations. In a screen-out condition such as that depicted in FIG. 2 , it is not possible to flow a ball down the string 10 and open the upstream sliding sleeve valve assembly 14 since fluid cannot be pumped downwardly through the string 10 due to the proppant-blocked screen-out condition shown in FIG. 2 .
[0015] FIGS. 3-5 sequentially illustrate the representative use of improved apparatus and methods of the present invention in preventing in the depicted portion of the wellbore string 10 the screen-out condition shown in FIG. 2 . With initial reference to FIG. 3 , there is illustrated therein a specially designed valve actuating structure used to create a pressure differential across the seat of the upstream sliding sleeve valve assembly 14 . By way of non-limiting example, the valve actuating structure is a second ball 40 (see also FIG. 6 ) with through-holes 42 (representatively three in number) suitably formed therein and extending along axes 44 so that the ball 40 , when seated on the upstream seat 30 , is not capable of completely plugging fluid flow therethrough to the downstream sliding sleeve valve assembly 16 . The valve actuating ball structure 40 could also function in this method without holes. However, the ability of the ball 40 to pass fluid is desired. In FIG. 3 , ball 40 which is being downwardly forced through the string 10 by pressurized fracing fluid is shown at a point at which the ball 40 initially lands on the upstream seat 30 , but has not yet opened the upstream sliding sleeve assembly 14 .
[0016] As will be appreciated by those of ordinary skill in this particular art, the dropping of the ball 40 takes place after the lower ball 32 has been dropped onto and blocks the downstream seat 30 which is then downwardly shifted by pressurized fracing fluid to open the downstream sliding sleeve valve assembly 16 and create the fractures 36 via pressurized fracing fluid outflow through the uncovered tubing string side wall ports 24 of the downstream sliding valve assembly 16 .
[0017] The ball 40 is made of a suitable material hard enough to actuate the coaxial tube 22 of the upstream sliding sleeve assembly 14 . Upstream coaxial tube 22 (like the downstream coaxial tube 22 ) is representatively held in its closed position by means of shear pins or a shear ring (neither of which is illustrated herein). Upstream and downstream sliding sleeve valve assemblies 14 , 16 are designed to open at a pressure much lower than the pressure at which the formation is fraced. The ball 40 is strong enough to stay supported in the upstream seat 30 and open the upstream sliding sleeve valve assembly 14 , but is not strong enough to remain in the upstream seat 30 at the fracing pressure.
[0018] Ball 40 can have a soft enough modulus to either extrude or shear through the upstream seat 30 . A suitable dissolving material may also be utilized in the construction of the ball 40 since a dissolving material used in downhole force-receiving structures are typically suitable for opening of the upstream sliding sleeve valve assembly 14 , but do not require future milling in the well. When in place upon the upstream seat 30 , the ball 40 only partially blocks the upstream seat 30 , thereby permitting a limited fluid flow downwardly through the upstream seat 30 and creating a downward pressure drop across the upstream seat 30 sufficient to downwardly open the upstream sliding sleeve valve assembly 14 . After the upstream sliding sleeve valve assembly 14 is opened, the ball 40 shears downwardly through the upstream seat 30 and arrives at its FIG. 4 position. The ball 40 is initially dropped onto the upstream seat 30 during a final period of the fracing of the downstream subterranean formation zone associated with the downstream sliding sleeve assembly 16 . Representatively, the fracing fluid pressure is lowered somewhat during the dropping of the ball 40 , and then returned to its full fracing pressure after the ball 40 lands on the upstream seat 30 .
[0019] FIG. 4 shows the well bore string 10 after the second ball 40 has downwardly moved the upstream tube 22 to its open position and then sheared downwardly through the upstream seat 30 . At this point the downstream sliding sleeve valve assembly 16 can still receive proppant concurrently with the upstream sliding sleeve assembly 14 . Since the proppant 38 is denser than its carrier fluid, most of the proppant will pass by the upstream sliding sleeve valve assembly 14 to the downstream sliding sleeve assembly 16 which is desirable at the end of a zone's fracture. This also works to the advantage of the upstream sliding sleeve assembly 14 since a low concentration of proppant will be present as initial fractures 46 are made adjacent the upstream sliding sleeve assembly 14 .
[0020] FIG. 5 depicts the final step in the illustrated representative embodiment of the present invention. A ball 48 (of an imperforate construction like that of the downstream ball 32 ) is sent down the string 10 to plug fluid flow to the downstream sliding sleeve assembly 16 via the upstream seat 30 by landing on and sealingly blocking the upstream seat 30 . Even if the fractures 36 can no longer accept proppant 38 , the ball 48 can still land on the upstream seat 30 to concentrate the fracing fluid to the zone at the upstream sliding sleeve assembly 14 . The method can subsequently continue with a further ball (not shown) opening yet another zone upstream of the open upstream sliding sleeve valve assembly 14 .
[0021] As can be readily seen from the foregoing, principles of the present invention may be utilized to reduce the risk of a screen-out condition during the initiation of a new zone and improves the amount of proppant close to the wellbore of a completed zone by dropping an intermediate plugging member (such as the illustrated perforated ball 40 ) to open the sliding sleeve valve assembly for a new zone while still allowing fracing fluid flow to the nearly completed zone. This uniquely allows two zones to be open for a period of time before dropping a ball to plug fluid from reaching the completed zone and diverting the flow through the most recently opened sliding sleeve assembly. During the period in which both zones are opened, a heavier amount of proppant-laden fluid can be pumped so that a high concentration of proppant surrounds the well bore when the ball serving as a plug closes the completed zone. Having a second zone opened at the time of initiating new fractures in the newly opened sliding sleeve valve assembly's zone also gives time for fractures to form and reduces the risk of a screen-out condition occurring during the initial fracturing stage.
[0022] Principles of the present invention are suitable for use in all sliding sleeve valve applications that are actuated by drop systems, usually utilizing but not exclusive to ball-type plug members. Such principles of the present invention may also be utilized to advantage in both cemented and open-hole applications, with open-hole applications being defined herein as sleeves being partitioned by packing elements (as illustratively depicted in FIGS. 3-5 in which principles of the present invention are utilized). The representatively described screen-out inhibiting process applies to both graduated size ball systems and to systems with seats capable of locking. In the case of locking seat-based systems, the ball sent to actuate the upper sliding sleeve valve assembly (for example, the ball 40 used to open the upstream sliding sleeve valve assembly 14 ) can be of a significantly smaller diameter than the lower ball (for example, the ball 32 ) while still being capable of actuating its associated seat and then passing therethrough at a pressure less than the full fracing pressure.
[0023] 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.
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A subterranean well fracturing system comprises a downhole well string having installed therein initially closed upstream and downstream sliding sleeve valve assemblies each openable to provide fracing fluid discharge outlets through well string side ports to an associated subterranean fracing zone. To inhibit an undesirable screen-out condition during formation fracturing, specially designed apparatus and methods are operative to sequentially (1) block the downstream valve seat, (2) open the blocked downstream valve seat using pressurized fracing fluid, (3) partially block the upstream valve seat, (4) open the partially blocked upstream valve seat using pressurized fracing fluid, a portion of which is flowed through the partially blocked upstream valve seat, and then (5) unblock the partially blocked upstream valve seat to permit a full flow of pressurized fracing fluid therethrough. In this manner, pressurized fracing fluid is simultaneously delivered to two fracing zones to inhibit a screen-out condition in the well string.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and is continuation in part for a now pending U.S. Utility application Ser. No. 14/445,122 filed on 29 Jul. 2014 and a continuation of pending PCT application PCT/US14/72403 filed on 24 Dec. 2014 which claims priority to Provisional Application 2013096110 filed on Dec. 26, 2013 in Singapore and are hereby incorporated by reference in its entireties for all of its teachings.
FIELD OF THE INVENTION
[0002] This disclosure relates generally to an apparatus, system and method for an adaptive kneading technology for a food preparation appliance. More specifically it relates to the apparatus that is controlled by the software to optimize the consistency of the dough while kneading to make a dough ball.
BACKGROUND
[0003] Dough kneading mechanisms are found in food preparation appliances as well as industrial processes for making various dough products. Most of these mixers are top loaded and the final product as a dough is removed from the top when done. However, it is difficult to automate the removal of dough from the mixer in such a setup. These apparatus are good for disparate function where separate equipment is required for each step of cooking or baking goods. Due to this disadvantage that the kneading process is not fully optimized. There are varies types of flour that require different types of water and flour proportions to make a dough but it is human judgment that determines the quantity of both at present. There is a need to automate this process. There is a need for optimized dough making apparatus for an automated use.
SUMMARY OF INVENTION
[0004] The present invention describes an apparatus, system and a method of kneading and optimizing the kneading using adaptive kneading technology is disclosed. The kneading apparatus is a part of the bigger apparatus for making edible flat bread using a compact apparatus. In one embodiment, the kneading apparatus, system and method may be a standalone product that may be used for kneading dough. In one embodiment, the kneading mechanism has a kneading container, a blade assembly and a kneading base. In another embodiment, the kneading container has an open bottom face and the kneading base has a textured surface.
[0005] In another embodiment, the kneading base has a textured surface that may have a grove, protrusion surface, ridge, projection or combination thereof. In one embodiment, the kneading container has a handle and the bottom is open.
[0006] In one embodiment, the blade assembly has a shaft that is spring loaded and is attached to a spring load cell. In another embodiment, the kneading container is detachable and can be washed clean after every use. In another embodiment, the blade is a part of the blade assembly. In another embodiment, the blade has several planar surfaces to mimic the hand motion kneading of the dough to form an optimal dough ball for flattening and cooking.
[0007] In one embodiment the blade assembly is supported by a kneading subsystem. The kneading subsystem comprises of a strain gauge, load cell, engaging gear, motor, spring, and a processor to control the movements. In another embodiment, a processor has a software system that does detection of the hardness of the dough ball, correction if necessary of the hardness using either adding flour or water and recording the ratio for historical values and self-learning management system is done.
[0008] In one embodiment, a method of kneading a dough ball is described. Several steps are used to obtain an optimal viscoelastic consistency dough ball. In one embodiment as a method, receiving a quantity of flour to make a single dough ball from a dough dispenser is performed. In another embodiment, mixing a selected amount of oil and a suitable amount of water to mix with the flour to make one dough ball at a time and optimizing a consistency of the dough ball by using an adaptive kneading process residing in a processor to have an optimal viscoelastic consistency for the single dough ball to be flattened into a flattened dough. In one embodiment, the kneading base is raised upwards to close the kneading container and hold a unmixed flour, oil and water till it forms a dough ball; and a blade assembly is rotated to mix the flour, water and oil is received in a kneading container.
[0009] In one embodiment, as a novel system and method, an upwards pressure is exerted through the blade assembly to determining a strain value to measure the hardness of the dough ball and a correction the consistency of the dough ball is done by adding at least one of a flour and water. In another embodiment, the strain value is recorded three times to determine the consistency of the dough ball as the optimal viscoelastic consistency for a given flour for future use as part of the self-learning process by the processor for a given flour type. Each flour type has its own gluten content and this is important to understand the optimal process steps and the amount for calculation. In one embodiment, the dispensing the dough ball to a transfer base for using it to flatten is done by moving the kneading base and allowing the dough ball to fall into the transfer base.
[0010] In one embodiment, an adaptive kneading technology residing in the processor is applied to create a dough ball and recording a hardness index for the forming the dough ball using a type of flour. In another embodiment, for a method, a strain value of the flour to create the hardness index by the upward force exerted by the blade assembly is measured. In another embodiment, the flour is either added or water is added to correct the hardness index of the flour to obtain an optimal viscoelasticity consistency.
[0011] Other features and advantages will be apparent from the detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the current apparatus and method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
[0013] FIG. 1 shows a perspective view of the blade assembly, in one embodiment
[0014] FIG. 2 shows an enclosure to house the blade assembly, in one embodiment.
[0015] FIG. 3 shows the kneading base for the kneading apparatus, in one embodiment.
[0016] FIG. 4 shows the whole assembly for the kneading apparatus, in one embodiment.
[0017] FIG. 5 shows the gears and wheels attached to the blade shaft, in one embodiment.
[0018] FIG. 6 shows a flow chart for a method of making the dough ball.
[0019] Other features of the present embodiments will be apparent from accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
[0020] Several components for an apparatus, system and method of making a dough ball for flattening it to make a flattened edible are disclosed. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments.
[0021] The adaptive kneading technology residing in the processor is a system for detection, correction and self-learning by the apparatus and all other parts associated with the kneading mechanism. Different flour types or brands have different water absorption capacity, the right proportion of flour and water is essential in achieving the right consistency of dough. Driven primarily by the inputs in the process, flour and water had to be pre-calibrated and is this was done by either human judgment or very expensive laboratory equipment. We have found a novel system to overcome this technological challenge. Innovative design for inducing stress on dough ball coupled with analysis of understanding of change in elasticity as a function of time and stress are inputs into the adaptive kneading technology system. The stress is measured in terms of force exerted on the blade by the developing dough. Constant recording and the adjustment to detect and correct is done till a threshold is reached that is between the golden band for viscoelastic consistency and then the dough ball is purged out to be flattened.
[0022] FIG. 1 shows a perspective view of a blade assembly 110 . The blade assembly is part of a kneading mechanism that will be discussed in the following paragraphs. The blade 110 comprises of a two dimensional and three planar face horizontal blade assembly that has a flat surface 112 , upwards facing angular plane 106 and downwards facing vertical plane 108 . This blade 110 is attached to a cylindrical shaft 102 . The cylindrical shaft has a groove for locking 114 the kneading container 204 . This locking mechanism 114 when unlocked also enables the kneading container to separate from the apparatus and be washed. The groves 102 at the end of the cylindrical shaft allow the whole blade mechanism to attach to an engaging gear and a spring gauge. The three dimensional structure of the blade with its angular planes imitates the hand kneading mechanism to create an optimal viscoelastic consistency dough ball for each flour type. The blade 110 while kneading feels the resistance from the dough ball and is forced upwards. The spring loaded blade shaft 104 which is also in contact with the spring gauge or a load cell registers the strain value in real time. The blade assembly 110 by engaging itself to a strain gauge provides the reading for strain value in real time. In real time a strain vs time graph is created and recorded for self-learning of the adaptive kneading technology that resides in a processor. Typical strain value is between 250-300 units which is the range of optimal viscoelastic consistency value for most flour. Since all flour have its own gluten content and other factors that influence the optimal viscoelastic consistency it is novel to record that in real time and keep that as an intelligent knowledge value to use for given flour when the resistance is encountered the very first time. No other dough kneading equipment has this automated feature for making single dough for any flour.
[0023] FIG. 2 shows the kneading container 204 enclosing the blade assembly 110 . The bottom opening 210 is not covered and the handle 206 enables the kneading container 208 to be dislodged from the machine and be washed properly. There is a lock mechanism 202 to secure the kneading container to the locking mechanism 114 . The extra space inside the container 208 allows the dough ball to rotate without hindrance. The whole kneading container may be made up of transparent material and may be coated with food grade coating so it is not easily contaminated. Preferably, kneading container 204 has a bore at its top surface and blade assembly 102 extends through the bore into kneading container 101 .
[0024] FIG. 3 shows the kneading base 306 . This kneading base has a unique feature because it has a specially designed surface. The base stand 304 enables the user to hold it and get it out so it can be washed. The square surface 304 gives the stability for the round surface to move inside the container without resistance. The square part 304 also enables the food making machine to raise the base up and down the kneading container. The distance between the blade and the kneading base is controlled by the software residing in the processor. The surface is specifically designed so that the dough ball while being formed does not slip and a cohesive dough ball can be made easily. The textured surface 302 is at least one of a protrusion surface, groove, ridge, projection and a combination thereof. The kneading base also provides coverage for the kneading container so that the kneading container can receive the flour, water and oil for mixing to make a dough ball. The kneading base has at least one of a textured surface, made of a material with different frictional properties and a combination thereof, than the blade to support slip free kneading for kneading the dough in to a dough ball.
[0025] This allows the invention for creating a Kneading mechanism 100 comprises kneading container 204 , blade assembly 102 and kneading base 306 . Kneading container 204 is hollow and has an open bottom face. Preferably, kneading container 204 has a bore at its top surface and blade assembly 102 extends through the bore into kneading container 204 . In the figures, textured surface 302 is shown to be protrusions extending radially from the center of kneading base 306 . Textured surface 302 can be any form of protrusion, groove, ridge, projection or the like. What is important is that textured surface 302 applies a counter force to the dough product when it is being kneaded by blade assembly 102 , thereby keeping the dough product in place and from slipping, so that mechanical forces can be effectively applied by blade assembly 102 . Furthermore, textured surface 302 helps prevent the dough product from sticking to kneading base 306 . Once kneading has been completed, kneading base 103 move downwards such that it no longer contacts kneading container 204 , exposing the dough product. The dough product can then be easily transported to the cooking station to be cooked. The advantages are apparent here as the kneading operation disclosed herein can be easily automated.
[0026] FIG. 4 shows the whole assembly of the kneading base 306 with the kneading container handles 206 locked in with a secure clasp 402 and dough ball 406 made and placed between the kneading base and the blade mechanism of the blade assembly 122 . The shaft of the blade assembly 104 is outside the kneading container to be connected with the gear box and motor. The speed of this motor is software controlled using feedback from an encoder.
[0027] FIG. 5 shows the shaft 104 of the blade 110 engaging with the gear box 504 and being attached to the spring 502 . The gear box in turn is connected with the motor 504 . This whole assembly drives the blade assembly and is controlled by the processor.
[0028] FIG. 6 shows the method of making the dough ball. To initiate or start 602 the kneading operation, and before dispensing of water and flour, kneading base 306 moves up to contact 606 kneading container 204 , effectively sealing the open bottom face of kneading container 204 . Water, oil and flour is then dispensed 606 to be received into kneading container 204 . Blade assembly 110 than rotates and stirs and mixes the water and flour mixture to begin kneading 608 . During kneading, kneading base 306 (a kneading base having a textured surface to support slip free kneading for kneading the dough in to a dough ball) can move downwards such that it no longer contacts kneading container 204 . Wherein the textured surface is at least one of a protrusion surface, groove, ridge, projection and a combination thereof. Kneading may be done when adjusting the rotational speed of blade assembly 110 to properly form a dough ball. Kneading may also be done in the event when there is a large quantity of flour, so blade assembly 110 requires more displacement from kneading base 306 to apply sufficient mechanical force to form well kneaded dough. The detection of hardness is done to estimate and optimize the viscoelasticity property of the flour 610 . This is an important step because the dough ball once formed and dispensed cannot be used if it is not of proper consistency and will stick to the flattening surface and the cooking surface and the machine will be halted from further use. Once the hardness of the dough ball is detected the correction may be made in two ways. If the hardness is very less than some more flour may be added while making the dough by kneading and if the hardness is high then water may be added to reduce the hardness and make an optimal viscoelastic property having dough ball. The detection of hardness is done there times to not only average and correct but to record for historical purposes for that particular flour.
[0029] The repetition of the process for correction is shown in process 618 . Once an ingredient is added than the determination of hardness is performed again at step 620 . The formation of the dough ball then takes place 612 . The dough ball is than dispensed out of the kneading container to the transfer base 614 . The transfer base is not shown in this instance specifically as an apparatus but can be seen in the cited prior depended application. Once the machine runs out of flour the process is ended 616 . The novel adaptive kneading technology as described above also has a self-learning process by creating a golden band of strain value for the strain vs time graph for each flour type between 250-300 units.
[0030] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader sprit and scope of the various embodiments. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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The present invention presents a kneading mechanism for a food preparation appliance. The kneading mechanism has a kneading container, a blade assembly and a kneading base. The kneading container has an open bottom face and the kneading base has a textured surface. An adaptive kneading technology which resides in a processor is used to form an optimal viscoelastic dough ball. Since there is variation in the gluten content and the amount of water used makes the dough ball have a viscoelastic nature this technology due to its self-learning mechanism optimizes the kneading of single dough balls using adaptive kneading technology.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/361,840 entitled Rigid Tipped Riblets and having a common assignee with the present application, the disclosure of which is incorporated herein by reference. This application is also copending with U.S. patent application Ser. No. 12/361,882 filed on Jan. 29, 2009 entitled Shaped Memory Riblets and U.S. patent application Ser. No. 12/361,918 filed on Jan. 29, 2009 entitled Amorphous Metal Riblets, both having a common assignee with the present application, the disclosures of which are incorporated herein by reference.
BACKGROUND INFORMATION
1. Field
Embodiments of the disclosure relate generally to the field of surface geometries for aerodynamic improvements to aircraft or surfaces having a flow interface and more particularly to embodiments and fabrication methods for rigid riblets having improved damage resistance.
2. Background
Increasing fuel efficiency in modern aircraft is being accomplished through improvement in aerodynamic performance and reduction of structural weight. Recent advances in the use of microstructures such as riblets on aerodynamic surfaces have shown significant promise in reducing drag to assist in reducing fuel usage. Riblets have various forms but advantageous embodiments may be ridge-like structures that minimize drag on the surface of an aircraft. Riblets may be used in areas of a surface of an aircraft where turbulent regions may be present. Riblets may limit circulation causing a breakup of large scale vortices in these turbulent regions near the surface in the boundary layer to reduce drag.
In certain tested applications, riblets have been pyramidal or inverted V shaped ridges spaced on the aerodynamic surface to extend along the surface in the direction of fluid flow. Riblet structures have typically employed polymeric materials, typically thermoplastics. However in service use such as on an aircraft aerodynamic surface, polymers are relatively soft and thus reducing the durability of the surface. Existing solutions with polymeric tips may readily deform hundreds of percent with fingernail pressure and may be unrecoverable. Such structures may be undesirable in normal service use on an aircraft or other vehicle. Additionally aircraft surfaces are typically required to withstand interactions with various chemicals including Skydrol®, a hydraulic fluid produced by Solutia, Inc. In certain applications elastomers that resist or recover from severe deformation created at the tip may be employed to form the riblets. However, many elastomers and other polymers may not be compatible with Skydrol® or other aircraft fluids or solvents.
The practicality of riblets for commercial aircraft use would therefore be significantly enhanced with a riblet structure providing increased durability and aircraft fluids compatibility.
SUMMARY
Exemplary embodiments provide a multilayer construction having a first layer composed of a material with riblets, the first layer material exhibiting a first characteristic of having long term durability and a second layer composed of a material exhibiting a second characteristic with capability for adherence to a surface. The multilayer construction is employed in exemplary embodiments wherein the riblets are implemented on a vehicle, the riblets having long-term durability due to the rigidity of the first layer.
In various embodiments, the multilayer construction for an array of aerodynamic riblets is created by a plurality of rigid tips with a layer supporting the rigid tips in predetermined spaced relation and adhering the rigid tips to a vehicle surface. In exemplary embodiments, the rigid tips are formed from material selected from the set of nickel, chromium, metal alloy, glass, ceramic, silicon carbide and silicon nitride. Additionally, the supporting layer may be continuously cast with the tips as a surface layer. Alternatively, a polymer support layer is deposited on the surface layer opposite the tips. An adhesive layer deposited on the polymer support layer forms a multilayer appliqué, and provides the capability for adhering the appliqué to the vehicle surface.
In another exemplary embodiment, the supporting layer is an elastomeric layer engaging the tips and a metal foil and a polymer layer are provided intermediate the elastomeric layer and the adhesive layer. The metal foil, polymer layer and adhesive layer may be provided as a preformed appliqué. For exemplary embodiments using the elastomeric layer, the tips each incorporate a base and each base may be embedded in the elastomeric layer.
For greater flexibility in certain applications, each tip is longitudinally segmented.
An aircraft structure may be created by an array of aerodynamic riblets having a plurality of rigid tips formed from material selected from the set of nickel, chromium, metal alloy, glass, ceramic, silicon carbide and silicon nitride and segmented longitudinally at predetermined locations. An elastomeric layer engages bases extending from the rigid tips and a polymer support layer is deposited on the elastomeric layer opposite the tips. An adhesive layer deposited on the polymer support layer to forms a multilayer appliqué. The adhesive layer adheres to a surface of the aircraft.
The embodiments disclosed are fabricated in an exemplary method by forming a master tool having protuberances corresponding to a desired riblet array and forming a complementary tool from the master tool. A plurality of rigid tips is then cast in the master tool using electroforming, casting or other desirable deposition technique. The cast rigid tips are then removed from the complementary tool and adhered to an aerodynamic surface.
In exemplary aspects of the method, resist is applied to the complementary tool for a segregating the rigid tips and removed subsequent to casting the rigid tips. An elastomeric layer is then cast engaging the rigid tips and a multilayer appliqué is applied to the elastomeric layer to form a riblet array appliqué.
In exemplary embodiments of the method, the multilayer appliqué comprises a metal foil, a polymer support layer and an adhesive layer. An adhesive liner covering the adhesive layer and masking covering the riblets may be employed for handling. The riblet array may then be adhered to the aerodynamic service by removing the adhesive liner and applying the riblet array appliqué to the aerodynamic surface and removing the masking.
In an alternative method, casting the plurality of rigid tips includes casting of the plurality of tips and an intermediate surface layer as a cladding. An elastomeric layer is then cast to the cladding.
A method for fabricating an array of aerodynamic riblets for an aircraft surface may be accomplished by diamond machining a form and curing an acrylate film on the form. The acrylate film is then stripped from the form and applied to a roller to form a master tool having protuberances corresponding to a desired riblet array. A silicon complementary web tool is created by impression on the master tool. A metal coating is then sputtered on the complimentary web tool and a plurality of rigid tips is then electroformed in the complimentary web tool. A multilayer appliqué having a metal foil, a polymer support layer and an adhesive layer to the elastomeric layer is applied to form a riblet array appliqué. The rigid tips are then adhered to an aerodynamic surface using the adhesive layer of the applique and the silicone complementary web tool is then stripped from the rigid tips.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of embodiments disclosed herein will be better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is an isometric view of a portion of an aerodynamic surface such as a wing or fuselage skin showing exemplary riblets extending in the flow direction;
FIG. 2A is a lateral section view perpendicular to the flow direction of a first embodiment for rigid tipped riblets;
FIG. 2B is a lateral section view of a modification of the embodiment of FIG. 2A with an additional support layer;
FIG. 2C is a lateral section view of a modification of the embodiment of FIG. 2A with rigid cladding over an elastomer core;
FIG. 2D is a lateral section view of a modification of the embodiment of FIG. 2A without an adhesive layer for direct thermoplastic boding;
FIG. 3 is a lateral section view of a second embodiment for rigid tipped riblets with lateral structural separation of the riblets;
FIG. 4 is a lateral section view of a third embodiment for rigid tipped riblets with reduced cross-section and with lateral separation;
FIG. 5A is a top view of a portion of an aerodynamic surface employing riblets of the first embodiment as shown in FIG. 2B ;
FIG. 5B is a section view comparable to FIG. 2B for reference with the features of FIG. 5A ;
FIG. 6A is a top view of a portion of an aerodynamic surface employing riblets of the second embodiment shown in FIG. 2B with additional longitudinal separation of riblet sections;
FIG. 6B is a section view comparable to FIG. 4 for reference with the features of FIG. 6A ;
FIG. 7A is a flow diagram of processing steps for a first exemplary method of fabrication of rigid tipped riblets of the first embodiment;
FIG. 7B is a flow diagram of processing steps for a second exemplary method of fabrication of rigid tipped riblets of the first embodiment;
FIG. 7C is a flow diagram of roll-to-roll processing for the method shown in FIG. 7B
FIG. 8 is a flow diagram of processing steps for an exemplary method of fabrication of rigid tipped riblets of the second embodiment;
FIG. 9 is a flow diagram of processing steps for an exemplary method of fabrication of rigid tipped riblets of a third embodiment;
FIG. 10 is a flow diagram describing use of the rigid tipped riblets embodiments disclosed herein in the context of an aircraft manufacturing and service method; and
FIG. 11 is a block diagram representing an aircraft employing the rigid tipped riblets with embodiments as disclosed herein.
DETAILED DESCRIPTION
An exemplary embodiment of rigid tipped riblets having a structure as will be described in greater detail subsequently is shown as a portion of an aerodynamic surface for an aircraft is shown in FIG. 1 . “Rigid” as used herein generally refers to a high modulus of elasticity and/or a high load to failure. Many of these materials may have a small strain elastic region. Exemplary embodiments herein employ rigid materials which may have moduli of elasticity up to and larger than about 25×10 6 lbs/in 2 with deformation response essentially all elastic. The aircraft 110 employs a structure with a surface 111 , shown enlarged, having multiple substantially parallel riblets 112 arranged parallel to the flow direction as represented by arrow 114 . For the exemplary embodiment shown, the dimension 116 perpendicular to the surface 111 (as shown in FIGS. 2A and 2B for example) is approximately 0.002 inch while the tip-to-tip spacing 118 between the riblets is approximately 0.003 inch. Spacing may vary depending on the fluid dynamic properties of the air, water or other fluid for which the application of riblets is employed. The aerodynamic surface is typically curved and may be, without limitation, a portion of a wing, an engine nacelle, a control surface, a fuselage or other suitable surface. Therefore flexibility and conformability of the riblets and any structure supporting and affixing the riblets to the surface may be required. While described herein with respect to an aircraft aerodynamic surface the embodiments disclosed herein are equally applicable for drag reduction on surfaces of other aerospace vehicles such as, without limitation, missiles or rockets and other vehicles such as cars, trucks, buses and trains moving in a gaseous fluid, commonly air, or on boats, submarines, hydrofoils, fluid flow conduits or other surfaces exposed to liquid fluid flow.
The embodiments disclosed herein recognize and provide the capability for riblets that may resist various impacts and/or other forces that may reduce riblet durability. Further, certain of the different advantageous embodiments provide a multi-layer structure that may have a support layer and a plurality of riblet tips located on or extending from the support layer. The tips which form the riblets may be fabricated from stiff metals such as nickel (used for the embodiments described herein) or alternative rigid materials such as chromium, other metal alloys, glass, ceramics, Silicon Carbide or Silicon Nitride. The materials of the multilayer structure are flexible and may be formed as an appliqué separately or in combination with the riblets for fastening, bonding, coupling or otherwise attaching to a surface to improve aerodynamics of a vehicle such as an aircraft.
A first embodiment for rigid tipped riblets is shown in FIG. 2A as a multilayer construction. Individual tips 202 of the riblets protrude from a surface layer 204 to provide a first layer 201 of the multilayer construction. The protruding riblets and continuous surface layer are formed by casting or deposition, as will be described in greater detail subsequently, of the rigid material desired for providing a first characteristic of durability. In an exemplary embodiment, nickel is employed. For the embodiment shown in FIG. 2A a second layer 203 created by an adhesive layer 206 is deposited on a bottom 204 a of the surface layer 204 . Exemplary adhesives for use in various embodiment may include, without limitation, acrylic pressure sensitive adhesive, sylilated polyurethane pressure sensitive adhesive; thermoplastic adhesive; heat-reactive adhesive or epoxy adhesive. In alternative embodiments, a supporting polymer layer 207 engages the surface layer 204 intermediate the surface layer and adhesive layer as shown in FIG. 2B as a portion of the second layer. The polymer layer 207 may be, without limitation, a polymer film or other suitable material. In certain embodiments polyetheretherketone (PEEK) is employed as the film. Additionally, a foil or metallic layer 310 as will be described with respect to the embodiment of FIG. 3 may be employed for lightning strike protection, particularly where the riblet tips 202 and surface layer 204 are non-metallic. The polymer, adhesive and/or other elements in the second layer provide a second characteristic of resilience and the ability to adhere to the surface.
FIG. 2C is an additional alternative embodiment wherein the nickel or alternative rigid material is employed as a contoured surface cladding 208 forming the tips 202 ′ and surface layer 204 ′ as the first layer of the multilayer construction. As the second layer, a polymer layer 210 is employed. The polymer layer 210 in certain embodiments as described herein may be an elastomer and may be cast into the cladding 208 or conversely the cladding 208 cast over the polymer layer 210 . The polymer layer 210 provides both a support layer 206 ′ and light weight cores 212 for the tips 202 ′ to maintain the predetermined spaced relation of the tips 202 ′. Exemplary elastomers used in exemplary embodiments may be polyurethane elastomers, polysulfide elastomers, epoxy-based elastomers, silicones, fluoroelastomers, fluorosilicone elastomers, EPDM elastomers, or other polymers with lower strain to yield, for example thermoplastic polyurethanes, PEEK, PEKK or polyamide. This alternative embodiment may allow weight reduction and flexibility of the structure may be further enhanced. The polymer layer 210 may then be adhered to a surface using an adhesive layer 206 or directly as described with respect to FIG. 2D .
In the form shown in FIG. 2A, 2B or 2C , the embodiment may fabricated as a multilayer appliqué 209 , as shown in FIG. 2B , including the tips 202 , surface layer 204 , polymer layer 207 and adhesive layer 206 which can then be adhered to the aerodynamic surface 111 using the adhesive layer 206 .
In alternative embodiments, the surface layer 204 may be directly adhered to or deposited on an aircraft surface 111 . FIG. 2D demonstrates an embodiment similar to that described with respect to FIG. 2C however, no adhesive layer is employed. Elastomeric layer 210 ′ is a thermoplastic cast into the nickel cladding 208 which allows direct bonding to the aircraft surface 111 with application of heat.
Another embodiment for rigid tipped riblets is shown in FIG. 3 . With complex or multiple curved surfaces, it may be desirable in the first layer 301 for the individual riblet tips 302 to be separated from each other perpendicular to the flow direction for greater lateral flexibility. For the embodiment shown individual tips 302 protrude from an elastomeric layer 304 . Tips 302 have an internal angle 303 of approximately 30° for the exemplary embodiment. A base 306 expands from each tip. In certain embodiments the elastomeric layer 304 surrounds the base 306 to provide greater structural continuity. In alternative embodiments a bottom face 308 of the base adheres directly to the exposed surface 304 a of the elastomeric layer 304 .
The second layer 303 is created by a multilayer structure incorporating a screen and/or foil metallic layer 310 such as aluminum, a polymer layer 312 such as PEEK and an adhesive layer 314 supports the elastomeric layer 304 . The polymer layer 312 and adhesive layer 314 may be supplied as a portion of the preformed appliqué as described with respect to FIG. 9 below or directly deposited on the elastomeric layer 304 . The metallic layer 310 provides a conducting material for lightning strike protection in an exemplary aircraft usage of the embodiment. The metallic layer, polymer and adhesive multilayer structure may be comparable to a current lightning strike appliqué (LSA) employed for composite aircraft structural surfaces.
The elastomer layer 304 supporting the riblet tips 302 may provide elastic sideways deformation and recovery for the tips 302 when lateral forces are applied thereby further enhancing the durability of the rigid riblet tips. Additionally, the elastomeric layer 304 flexibility may allow greater ability to conform to complex contour shapes.
FIG. 4 demonstrates a third embodiment for the rigid tipped riblets 112 in FIG. 1 which takes advantage of the structural capability provided by the material from which the riblets 112 are formed to allow a sharper profile of tips 402 . For the embodiment shown in each of the tips 402 extends from a base 406 supported in an elastomer layer 404 . As with the embodiment described with respect to FIG. 3 the base 406 of each tip 402 is surrounded by the elastomer to structurally retain the base 406 within the elastomer layer 404 . In alternative embodiments, the extended bottom surface 408 of the base 406 may be adhered to the surface 404 a of the elastomer layer 404 . The embodiment of FIG. 4 also employs riblet tips 402 separated perpendicular to the flow direction 114 as in the embodiment of FIG. 3 . However, in alternative embodiments a continuous surface layer 204 from which the tips 202 extend as disclosed for the embodiment described with respect to FIG. 2A may be employed.
As also disclosed in FIG. 4 the embodiment employs a supporting polymer layer 410 on which the elastomer layer 404 is adhered or deposited. An adhesive layer 412 extends from the polymer layer opposite the elastomer layer 410 forming a multilayer appliqué 414 .
FIG. 5 shows a top view of the embodiment as disclosed in FIG. 2B . The riblets formed by the tips 202 extend longitudinally along surface layer 204 in the flow direction 114 . The thin surface layer 204 provides for flexibility in adhering to curvature having tangents substantially perpendicular to the riblets. However as previously described, the surface 111 on which the riblets 112 may be employed may have multiple complex curvatures requiring greater flexibility. The embodiments previously described may therefore be adapted as shown in FIG. 6A wherein the individual tips 402 as described with respect to FIG. 4 are laterally separated by spacing 118 substantially perpendicular to the flow direction 114 with bases 406 attached to or captured within an elastomer layer 404 . This provides even greater flexibility for adhering to surfaces with curvatures having tangents (generally shown as represented by arrow 604 ) substantially perpendicular to the riblets 112 . The scale of the drawings herein based on the small riblet dimensions makes the surfaces appear flat even though they may be curved in larger scale. An aluminum foil layer 407 has been added to the embodiment of FIG. 6B for demonstration of an embodiment for lightning strike protection with tips 402 which may be non-metallic. Additionally the individual riblets incorporate longitudinal separation in the flow direction using gaps 602 to segment the riblet to provide greater flexibility for adhering to surfaces having curvatures with tangents substantially parallel to the riblets 112 in the flow direction 114 . For the embodiment shown gaps 602 may be evenly spaced in the riblets 112 at substantially equal longitudinal distances 606 . In alternative embodiments spacing on individual riblets 112 and between riblets 112 may be uneven and chosen in a predetermined manner to accommodate surface curvature as required.
FIG. 7A is a flow diagram showing a first exemplary manufacturing process for a riblet structure as defined in the embodiment described with respect to FIG. 2A . In step 701 a master tool 712 is created using, as an example without limitation, diamond machining of a copper form or other suitable material on which an acrylate film is cured then stripped to define spaced protuberances 714 corresponding to the desired riblet dimensions. The tool 712 as shown in FIG. 7A may be a section of a flat tool, or a roller employed for roll-to-roll web processing. Exemplary details of a web processing format are shown in FIG. 7C . For the embodiment shown in FIG. 7A nickel is employed for the rigid tips 202 . A complimentary tool 716 is created in step 702 by impression, casting or electroforming on the master tool 712 which provides grooves 718 corresponding to the riblet shape. Spacing between the grooves 718 provides a substantially flat intermediate surface 720 corresponding to the dimension 118 desired between the tips 202 . In step 703 , rigid tips 202 and surface layer 204 may be deposited by electro-forming onto the complimentary tool 716 . In certain embodiments, a release compound is applied to the surfaces on the complimentary tool to assist in removal of the cast riblets and surface layer from the tool. Adhesive layer 206 is then applied, in step 704 , to the surface layer 204 opposite the rigid tips 202 . The adhesive layer 206 may be combined with a polymer layer, such as support layer 207 as shown in FIG. 2B and supplied as a preformed appliqué which is then joined with the electroformed surface layer 204 . A removable adhesive liner 722 for handling of the completed appliqué is added as also shown in step 704 . The appliqué, created by surface layer 204 and adhesive layer 206 , is removed from the complimentary tool 716 and a masking layer 724 is applied for handling as shown in step 705 . For exemplary embodiments, the masking employed may be, without limitation, static masking films, masking films with low tack pressure sensitive adhesive, or castable films of silicone. Application to the aircraft surface 726 is accomplished as shown in step 706 by removal of the adhesive liner 722 followed by attachment of the adhesive layer 206 of the appliqué to aircraft surface 726 . Removal of the masking layer 724 completes the riblet appliqué processing.
The complimentary tool 716 may be a “web tool” which may be silicone or polymeric film. Roll-to-roll processing for the steps described subsequently may then be employed as shown in FIG. 7C and the web tool 716 may be left in place as the masking that is removed after installation of the array of riblets 112 on the aircraft surface 726 . As shown in FIG. 7B for a method employing the web tool approach, a master tool 712 is created in step 731 define spaced protuberances 714 corresponding to the desired riblet dimensions. The tool 712 as shown in FIG. 7B may be a section of a flat tool, or a roller employed for roll-to-roll web processing. A complimentary web tool 746 is created in step 732 by roll processing silicone on the master tool 712 which provides grooves 718 corresponding to the riblet shape. Spacing between the grooves provides a flat intermediate surface 720 corresponding to the dimension 118 desired between the rigid tips 202 . A conductive layer, shown as the dashed line designated as element 747 , is then sputtered onto the silicon web tool, in step 733 , providing a conductive surface on the web tool. In step 734 , rigid tips 202 and surface layer 204 are deposited by electro-forming onto the web tool. Adhesive layer 206 is then applied in step 735 to the surface layer 204 opposite the rigid tips 202 . The adhesive layer 206 may be combined with a polymer layer 207 , as shown for the embodiment in FIG. 2B , and supplied as a preformed appliqué 723 which is then joined with the electroformed surface layer 204 . A removable adhesive liner 722 for handling of the completed appliqué 723 is added as also shown in step 735 . Application to the aircraft surface 724 is accomplished by removal of the adhesive liner 722 shown in step 736 followed by attachment of the adhesive layer 206 of the appliqué to aircraft surface 724 in step 737 . Stripping of the silicone web tool 746 exposes the rigid tips 202 of the riblets and completes the riblet appliqué processing.
As shown if FIG. 7C , a roll-to-roll web processing approach may be employed for the methods described. Master tool 712 is created using, as an example, diamond machining of a copper form 742 on which an acrylate film 744 is cured then stripped and applied to a roller 745 to provide the master tool 712 shown in the drawing. Complimentary web tool 746 is then created by impression on master tool 712 . Conductive layer 747 is sputtered onto the web tool 746 using sputtering gun 750 and electroforming of the tips 202 surface layer 204 , as shown for example in FIG. 7B , onto the web tool 746 is accomplished with deposition tool 752 . The adhesive layer 206 is then deposited on the surface layer 204 with deposition tool 754 and the removable adhesive liner 722 attached by application from roll 756 . The multilayer appliqué 725 is then available for attachment to the aircraft surface 724 as shown, for example, in step 737 of FIG. 7B .
FIG. 8 is a flow diagram showing a manufacturing process for a riblet structure as defined in the embodiment described with respect to FIG. 3 . In step 801 a web tool 812 is created as previously described with respect to FIG. 7C to define spaced protuberances 814 corresponding to the desired riblet dimensions. The tool 812 , as shown in FIG. 8 , may be a section of a flat tool or a roll tool employed for web processing. For the embodiment shown in FIG. 8 , nickel is employed for the rigid tips 302 . A complimentary tool 816 is created in step 802 by impression on the web tool 816 which provides grooves 818 corresponding to the riblet shape. Spacing between the grooves provides a substantially flat intermediate surface 820 corresponding to the dimension 118 desired between the riblet tips 302 . In certain embodiments, the complimentary tool 816 may be nickel or a silicon web tool as described with respect to FIG. 7C . In step 803 resist 822 is applied to the flat surfaces 820 on the nickel tool and rigid tips 302 are deposited by electro-forming onto the tool in step 804 . The resist 822 is then removed in step 806 providing the spaced riblets in the tool. For the embodiment shown the bases 306 are placed into relief extending from the tool 816 by the removal of the resist as shown in step 806 . The elastomer layer 304 is then cast over the bases 306 in step 807 . In alternative embodiments electroforming of the rigid tips 302 provides a base substantially flush with the flat surface for direct adherence to the elastomer surface 305 as previously described with respect to FIG. 3 . For the exemplary process shown with respect to FIG. 8 a preformed appliqué 824 comprising the multilayer structure of aluminum foil as a metallic layer 310 , polymer layer 312 and adhesive layer 314 is adhered to the cast elastomer 304 in step 808 . A removable adhesive liner 826 for preservation of the adhesive during further processing is shown as a portion of the preformed appliqué. The multilayer structure is then removed from the complimentary tool 816 creating a multilayer riblet array appliqué 829 and exposing the rigid tips 302 . Masking 828 is applied over the tips 302 and elastomer 304 to assist in handling during additional processing and as also shown in step 808 . The masking 828 in exemplary embodiments may be, without limitation, a solution cast releasable polymer such as silicon or an adhesive film such as Mylar® with a low tack acrylic adhesive applied during roll processing. Alternatively, the complimentary web tool 816 when fabricated from a water/fluid soluble polymer may be employed as masking layer 828 to allow removal of the masking by dissolving with water or other fluid after installation.
The completed multilayer riblet array appliqué 829 may then be applied to an airplane surface 830 by removing the adhesive liner 826 and adhering the adhesive layer 314 to the surface 830 as shown in step 809 . The masking 828 is then removed from the tips 302 and elastomer 304 .
The rigid materials employed for the tips as described in the embodiments and fabrication processes herein allows very fine tip structure having a dimension 307 of around 15 to 25 microns at the base with a dimension 309 at the extreme end of the tips typically on the order of 100 nanometers (0.1 micron) as shown in FIG. 3 . Smaller tips may be obtained with tooling and release process refinement. Even thought the tips are very sharp, the very fine spacing of the tips avoids cuts in normal handling by installation personnel.
FIG. 9 is a flow diagram showing a manufacturing process for a riblet structure as defined in the embodiment described with respect to FIG. 2A . In step 901 a master tool 912 is created. The tool 912 , as shown in FIG. 9 , may be a section of a flat tool or a roller employed for roll-to-roll web processing. For the embodiment shown in FIG. 9 nickel is employed for the cladding 208 which forms the rigid tips 202 ′ and surface layer 204 ′. A complimentary tool 916 is created in step 902 by impression on the master tool 912 which provides grooves 918 corresponding to the riblet shape. Spacing between the grooves provides a substantially flat intermediate surface 920 corresponding to the dimension 118 desired between the riblets tips 202 ′. In step 903 nickel cladding 208 is deposited by electroforming into the complimentary tool 916 to form rigid tips 202 ′ and surface layer 204 ′ in step 903 . In alternative embodiments, the cladding may be cast or roll formed into the complimentary tool. In certain embodiments, a release compound is applied to the surfaces on the complimentary tool 916 to assist in removal of the tips 202 ′ and surface layer 204 ′ from the tool 916 . Polymer layer 210 is then cast into the cladding 208 to provide both a support layer and light weight cores 212 for the tips in step 904 . As previously described the polymer layer 210 may be an elastomer in certain embodiments. Adhesive layer 206 is then applied in step 905 to the polymer layer 210 opposite the rigid tips 202 ′ to create an appliqué 922 . A removable adhesive liner 924 for handling of the completed appliqué 922 is added, the appliqué 922 with adhesive liner 924 is removed from the nickel tool 916 and masking 926 is applied over the tips 202 ′ and surface layer 204 ′ for handling as also shown in step 905 . Application to the aircraft surface 928 is accomplished as shown in step 906 by removal of the adhesive liner 924 followed by attachment of the adhesive layer 206 of the appliqué 922 to aircraft surface 928 . Removal of the masking 926 completes the process.
Referring more particularly to FIGS. 10 and 11 , embodiments of the rigid riblets disclosed herein and the methods for their fabrication may be described in the context of an aircraft manufacturing and service method 1000 as shown in FIG. 10 and an aircraft 1102 as shown in FIG. 11 . During pre-production, exemplary method 1000 may include specification and design 1004 of the aircraft, which may include the riblets, and material procurement 1006 . During production, component and subassembly manufacturing 1008 and system integration 1010 of the aircraft takes place. The riblet appliqués and their manufacturing processes as described herein may be accomplished as a portion of the production, component and subassembly manufacturing step 1008 and/or as a portion of the system integration 1010 . Thereafter, the aircraft may go through certification and delivery 1012 in order to be placed in service 1014 . While in service by a customer, the aircraft 1002 is scheduled for routine maintenance and service 1016 (which may also include modification, reconfiguration, refurbishment, and so on). The riblet appliqués as described herein may also be fabricated and applied as a portion of routine maintenance and service.
Each of the processes of method 1000 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in FIG. 11 , the aircraft 1102 produced by exemplary method 1000 may include an airframe 1118 having a surface 111 , as described with respect to FIG. 1 , and a plurality of systems 1120 and an interior 1122 . Examples of high-level systems 1120 include one or more of a propulsion systems 1124 , an electrical and avionics system 1126 , a hydraulic system 1128 , and an environmental system 1130 . Any number of other systems may be included. The rigid tipped riblets supported by the embodiments disclosed herein may be a portion of the airframe, notably the finishing of skin and exterior surfaces. Although an aerospace example is shown, the principles disclosed by the embodiments herein may be applied to other industries, such as the automotive industry and the marine/ship industry.
Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method 1000 . For example, components or subassemblies corresponding to production process 1008 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 1102 is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 1008 and 1010 , for example, by substantially expediting assembly of or reducing the cost of an aircraft 1102 . Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 1102 is in service, for example and without limitation, to maintenance and service 1016 .
Having now described various embodiments in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present disclosure as defined in the following claims.
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A multilayer construction for aerodynamic riblets includes a first layer composed of a material with protuberances, the first layer material exhibiting a first characteristic having long-term durability and a second layer composed of a material, exhibiting a second characteristic with capability for adherence to a surface.
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BACKGROUND OF THE INVENTION
The invention relates to a method for concentrating solutions containing macromolecules, more particularly solutions of protein molecules, to a defined end volume and a filter for carrying out this method.
In the publication No. 1/130 F of AMICON Division, W.R. Grace & Co - AMICON GMBH Witten, a commercially available disposable ultrafilter is described for the static concentration of small amounts of macromolecular solutions. This ultrafilter has eight separated upright chambers which can be used at different times for different solutions. The chambers are bound by upright membranes with selective permeability. An absorbing material is placed on the back of these membranes. This absorbing material, through capillary action, sucks the liquid phase from the solutions in the chambers and into the absorbing material. The macromolecular constituents are thereby concentrated in the solutions remaining in the chambers. The level of the solutions in the chambers drops. The chambers are provided with marks which indicate the degree of concentration. As soon as the desired mark is reached in a chamber during the concentration, the solution still present with the macromolecules is removed from the chamber. A lower section of the membrane is made impermeable in order to hinder further concentration. In the known concentration method a batch process is worked. This results in a local thickening of a stationary solution by removal of the liquid phase. The process of concentration is restricted by the capacity of the absorbing material. If larger quantities of solution are to be concentrated, the known device leads to an exceptionally complicated method of operation. A degree of concentration of any level cannot be reached. With this method a part of the macromolecules is deposited on the membrane as the liquid phase is sucked through same. These macro molecules remain sticking to the membrane and do not pass into the concentrate as the solution sinks further down. This loss of substance causes the effectiveness of the concentration method to be irreversibly reduced.
U.S. Pat. No. 4,632,761, column 1, lines 37 to 41, it is expressly stated that with the ultrafilter previously described, a complete drying of the filtered constituents is produced by surface tensions which act on the concentrate in the area of the filter section which has been rendered impermeable together with capillary suction forces. The preparation is thereby unusable. This danger of drying out is pointed out by the manufacturer through a warning packed with the ultrafilters.
From U.S. Pat. No. A 4,123,224 a method and device are known for concentrating solutions containing macromolecules. The solution is introduced into a concentration chamber defined by a filter. An absorbent material is placed on the filtrate side of the filter. The concentrate is collected in a concentrate chamber adjoining the concentration chamber and the filter surface becomes smaller towards the concentrate chamber. The concentrate is collected in the concentrate chamber with defined end volume lying screened from the filter leaf.
SUMMARY OF THE INVENTION
The invention is based on the object of providing a method and filter with which solutions can be concentrated with optimum yield up to a predetermined extent up to 15 ul.
An adjustable pressure is advantageously produced in the solution so that amounts of solution are pressed in the concentration chamber through the filter leaf or membrane. The capacity limit which occurs with suction absorption is excluded. By selecting the adjustable pressure and filter material, the filter process can be set for optimum results. In the solution, in advantageous manner through a filtration in a section of the concentrate chamber screened per se from the filter leaf beneath the concentration chamber, a flowing component directed into this chamber is produced through which the filtered-off macromolecular constituents are transported into the chamber. It is not necessary to lower and observe the level of the solution in the concentration chamber for concentrating so that the danger of drying out can also be eliminated. A concentration can be reached, by way of example for carrying out a preparatory work. The concentration can also be carried out however in order to perform associated analytical work where higher concentrations facilitate greater accuracy.
In an advantageous way the concentration can be improved if in the concentration chamber the solution is pressed through the filter leaf in discrete areas which converge radially at a point on the boundary between the concentration and concentrate chambers. A further filtration is carried out locally in the concentrate chamber beneath this point in order to produce the flowing components directed therein.
The method according to the invention brings the advantageous possibility of being able to preconcentrate the solution in at least one pre-filter of greater capacity. The pre concentration can for example also be carried out in a cascade-type pre-filter. In order to screen the concentrate chamber from the filter leaf and render the filter leaf inactive in this area, the partial region of the filter leaf to be deactivated can with advantage be covered by means of a mask.
Since according to the invention the solution is not conveyed through the filter leaf into an absorbent material but is pressed through the filter leaf, there is the advantageous possibility of backflushing the filter leaf in order to loosen the macromolecular constituents from their position adhering to the filter leaf and to return them to the concentrate. A particularly simple method consists in raising in a suitable way the level at which the liquid phase flows out of the filter. This produces a pressure gradient which opposes the filtering pressure gradient.
The invention offers the possibility of producing the adjustable pressure in the solution by means of a spring or weight biassed or pneumatically, hydraulically or motor driven piston or piston pump.
In order to speed up the sedimentation of the filtered-off macromolecules in the concentration chamber--if this is desired or essential--a centrifugal force is exerted with advantage on the solution at least in the concentration chamber. A centrifuge or pendulum can be used for this. The centrifugal force can also with advantage still produce the adjustable pressure in the solution. For this, for example, a suitably dimensioned structural part, more particularly a piston, which produces the pressure in the solution is biassed by a centrifugal force in a dosing apparatus.
An advantageous embodiment of a filter for carrying out the method is designed as a sandwich assembly. The sandwich assembly comprises a filter chamber disc in which a concentration chamber is formed whose outline is hexagonal with two parallel sides and two pairs of converging isosceles sides, wherein the corner formed by the lower side pair is connected to a concentrate channel. Furthermore this sandwich assembly has a mask of hydrophobic material placed on the filter chamber disc wherein this mask has recesses or openings congruent with the outline of the concentration chamber and a section of the concentrate chamber. An ultrafilter leaf or membrane is placed on this mask. Furthermore a filter support disc containing channels for the liquid phase of the solution is placed on the filter chamber disc.
At the lower isosceles side pair of the concentration chamber the material collecting in front of the filter in this chamber can slide further down towards the concentrate channel. The converging isosceles sides connected to the upper ends of the parallel sides of the concentration chamber allows the easy discharge of air or gas bubbles should these form in the concentration chamber.
With particular advantage a peripheral bead is formed on the edge of the hexagonal concentration chamber and the concentrate channel connected therewith and this bead ensures a reliable seal of the concentration chamber and concentrate chamber at the filter leaf.
In order to optimize concentration the depth of the concentration chamber decreases from the filling channel to the concentrate chamber.
So that the outlet tip of a dosing piston, for example a disposable syringe, can be safely accommodated, the filling channel is advantageously provided with a Luer-Look closure. In order to optimize the seal of the concentration chamber, a contact pressure socket is formed on the filter support disc. This contact pressure socket which covers the peripheral bead on the concentration chamber and concentrate channel has at least three parallel open channels in the surface area lying inside the peripheral bead of the concentration chamber. The open channels open by their lower ends into an open channel which is formed in the surface area lying inside the area of the peripheral bead of the concentrate channel and which in turn is connected to a closed discharge outlet formed inside the filter chamber body. When the sandwich assembly is braced together the contact pressure socket presses an inlaid rectangular filter leaf against the peripheral bead in the filter chamber disc to provide a secure seal. To fix the elements, for example the filter leaf and/or mask which are to be placed in the sandwich assembly, at least two fixing pins are formed on the filter chamber disc to engage in suitably aligned bores in the filter support disc.
In a preferred embodiment, the filter chamber disc described above has a parallelepipedic open recess wherein the concentration chamber and concentrate channel are designed in the bottom of the recess. The filter support disc is provided with a parallelepipedic web which fits tight into the recess and which is provided on its surface with the contact pressure socket. This embodiment allows the easiest fitting of the structural elements in the sandwich assembly. Specialized experience or skills are not required for this. To facilitate insertion of the ultrafilter during assembly and the removal of the filter leaf and mask after filtration, a pair of outward curves is provided at the upper end of the parallelepipedic recess in the side walls so that when the filter leaf is inserted, the air located beneath the filter leaf can flow out through these curvatures. Two grooves are formed in the bottom of the parallelepipedic recess at the open end. Auxiliary tools are inserted into these grooves in order to lift the filter leaf and mask out of the recess. In order to hold the composite sandwich assembly in this state, at least two pairs of bores are provided in the filter chamber disc and filter support disc. These pairs of bores are aligned with each other and accommodate a tension device for the sandwich assembly. To insert the above described embodiments of a filter into a centrifuge or other device which produces an additional gravity force, the filter chamber disc and filter support disc are advantageously designed as complementary partial cylinders.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be explained with reference to the drawings in which:
FIGS. 1 and 2 show a plan view and sectional view of an embodiment of the filter chamber disc,
FIGS. 3 and 4 show a side view and side view of a filter support disc which is to be fitted to the filter chamber disc,
FIG. 5 shows a plan view of a mask and
FIG. 6 shows a side view of a tensioned sandwich assembly of a filter.
DETAILED DESCRIPTION
The filter chamber disc or plate 1 illustrated in FIG. 1 has a parallelepipedic recess 45 which is open at the bottom. A concentration chamber 2 having a hexagonal outline is formed in the bottom 46 of this recess 45. The concentration chamber 2 is defined by two parallel sides 26 and 27. The upper ends of these parallel sides 26,27 are adjoined by a pair 28 of isosceles sides. The corner of the concentration chamber 2 formed by these sides 28 is connected to a filling channel 41 which is fitted with a Luer-Lock closure 43. The lower ends of the parallel sides 26,27 of the concentration chamber 2 are adjoined by a pair of isosceles sides 29. Advantageously the length of the sides in this pair 29 is greater than the length of the sides in the diametrically opposite pair 28. The corner of the concentration chamber 2 formed by the downwardly converging pair of sides 29 communicates with a concentrate channel 31 whose lower end is closed off. In the bottom 46 of the recess 45 on either side of the lower side pair 29 of the concentration chamber 2 there are fixing pins 48 for a rectangular ultrafilter leaf (not shown) and a mask.
As shown in FIG. 3, the filter support disc or plate 35 has a parallelepipedic web 53 which can be inserted with a tight fit into the recess 45 of the filter chamber disc 1. On the upper side 54 of the web 53 there is a contact pressure socket 44 which in the assembled state covers the peripheral bead 42 in the filter chamber disc 1. The larger dimensioned outline of this contact pressure socket 44 is designed to conform with the shape of the peripheral bead 42. Three parallel open channels 36,37,38 are formed in this contact pressure socket 44, with their lower ends opening into a channel 39 which in the assembled state lies opposite the concentrate channel 31 and is separated by a filter leaf section and a section of the mask. The channels 36,37,38,39 are open at the top. The channel 39 is connected to a closed discharge outlet 40 which runs in the body of the filter support disc 35.
The filter chamber disc 1 and filter support disc 35 have pairs of bores 50, 51 into which a tension device is inserted when the sandwich assembly is in the assembled state. The tension device presses the filter chamber disc 1 and filter support disc 35 together.
When fitting the sandwich assembly together, first the mask 33, which is made of hydrophobic material to eliminate the capillary force and is shown in FIG. 3, is placed on the peripheral bead 42. This mask 33 has a recess or opening 34 which is congruent with the sides of the concentration chamber 2 and thus congruent with the peripheral bead 42 and has at the lower end a recess or opening 55 which only covers the section 32 of the concentrate channel 31. The difference in length between this recess 55 and the length of the concentrate channel 31 determines the defined volume.
A rectangular ultrafilter leaf or membrane (not shown) is placed on this mask 33 and centered by the fixing pins 48.
The web 53 of the filter support disc 35 is inserted in a simple way to fit into the recess 45 of the filter chamber disc 1 wherein the bores 49 accommodate the fixing pins 48.
The sandwich assembly can now be pressed together by using the pair of bores 50, 51.
The solution is introduced under pressure into the concentration chamber 2 through the Luer-Lock closure 43 and then forced into the channels 36,37,38 through the filter leaf (not shown) which is compressed between the peripheral bead 42 of the filter chamber disc 1 and the contact pressure socket 44 of the filter support disc 35. The macromolecules filtered off in the concentrate chamber 4 of the concentration chamber 2 sink down in the concentration chamber 2 and slide down further along the converging side pair 29. Filtration still takes place in the section 32 of the concentrate channel 31. A flowing component directed into the concentrate channel 31 is thereby produced in the collecting area of the downwardly sinking macromolecules so that these are transported into the concentrate channel 31 through this flowing component in addition to the force of gravity. If during concentration macro molecules become fixed on the filter leaf 8, the outlet level which connects with the discharge outlet 40 can be raised sufficiently to produce an opposing pressure gradient at the filter leaf 8 through which the macromolecules are removed from the filter leaf 8 and returned to the concentration chamber 2 in which they can then sink down.
As shown in FIG. 1, two outward curvatures 61 are provided at the upper end of the recess 45 in the side walls so that the air can escape as the rectangular filter leaf is inserted. At the lower end there are two grooves 57 provided at the bottom 46 of the recess 45. An auxiliary tool inserted into these grooves can lift out the mask and filter leaf at the end of the filtering process.
As shown in FIG. 6, tension pins 60 are inserted into the bores 50, 51 described above. These tension pins support a tension web 58 into which a tightening screw 59 is screwed so the the parts of the sandwich assembly can be pressed together.
At the end of concentration the concentrate is removed from the concentrate channel 31, for example by means of a syringe inserted through the filling channel 41.
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The invention relates to a method for concentrating macromolecular solutions, more particularly of protein molecules, to a defined end volume lying in the ul-range and to a filter for carrying out the method. The liquid phase of any amounts of solutions is pressed through an upright filter leaf. The filtered constituents are directed down through gravity and are collected in a concentrate chamber.
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BACKGROUND OF THE INVENTION
The field of the present invention is a liquid cooling system for liquid cooled motorcycle engines and particularly those having a front leg shield, a step floor and the engine mounted behind the step floor.
Motorcycles and particularly smaller motorcycles such as motor scooters have typically employed air-cooled engines. Air-cooled engines are lighter in weight and require less space than liquid-cooled systems often referred to as water-cooled systems. With liquid cooling, a radiator is required along with a water jacket on the engine and tubing connecting the two. These features add both weight and require additional space. Cooling fluid also adds weight to the system. Furthermore, the radiator must be located in an area of the vehicle experiencing air flow during forward motion. Consequently, special ducting and additional space may be needed to realize proper radiator efficiency.
On smaller motorcycles, compact design is important to aesthetic appearance as well as low wind resistance, reduction in weight and space allocation for the components. Weight and weight distribution of components is also important for performance, efficiency and handling. In smaller motorcycles, added components can effect weight distribution and overall weight disproportionately because of an initial low weight.
In motorcycles and particularly smaller motorcycles such as motor scooters, an arrangement employing a front leg shield, a step floor rearwardly of the front leg shield and an engine driving the rear wheel from a location behind the step floor has been common. One location for the radiator of a liquid cooling system for a motorcycle of this design is at the front leg shield. In such a system, the feed and return lines of the cooling system may extend beneath the step floor. This location dictates that the top of the cooling jacket on the engine is above the lowermost portion of the feed and return lines. Consequently, air may become trapped in the water jacket as any path returning it to the radiator must extend downwardly from the water jacket. The size of the required return line for adequate cooling efficiency and the need to periodically terminate flow below certain cooling temperatures make it difficult to quickly and appropriately discharge the air from the cooling jacket.
SUMMARY OF THE INVENTION
The present invention is directed to a cooling system for a liquid-cooled engine of a motorcycle requiring that the lines extending between a radiator and a water jacket on the engine extend below the top of the water jacket. A bypass line is employed for discharging accumulated gases in the top of the water jacket to the radiator for eventual elimination from the system. In this way, feed and return lines of the cooling system may pass beneath the step floor of such a motorcycle where they are conveniently hidden from view. Additionally, the location of the radiator at the leg shield helps to distribute the weight of a water cooling system on the motorcycle and locates the radiator in a location where substantial air flow may be directed thereto without substantial compromises in weight and overall vehicle size.
In one aspect of the present invention, a flow restriction is introduced to the return line of the cooling system. This is preferably a thermostat which acts, when closed, to force flow through the bypass line. In another aspect of the present invention, the bypass line is substantially smaller than the return line of the cooling system. The size of this bypass line limits the amount of flow therethrough when the thermostat is closed for rapid engine heating. Additionally, with the bypass line having an internal cross sectional diameter in the range of from three millimeters to five millimeters, the air passing into the bypass line will not be allowed to percolate back up into the water jacket but will be forced by the pursuing water to flow to the radiator.
To insure air flow from the water jacket, the bypass line need extend only past the lowest point of the return line on the motorcycle where the bypass line may then be combined with the return line. The air from the bypass line will then flow upwardly to the radiator. This lowest point is generally below the step floor of the motorcycle. However, the bypass line may conveniently extend to the radiator for collection at the head thereof adjacent the pressure cap assembly.
Accordingly, it is an object of the present invention to provide an improved cooling system for a liquid-cooled engine on a motorcycle of the type having a front leg shield, a step floor and an engine mounted behind the step floor where the radiator is mounted at the front leg shield. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique view of a motorcycle of the present invention.
FIG. 2 is a side elevation of a motorcycle of the present invention with the body portion illustrated in phantom for clarity.
FIG. 3 is a plan view of the motorcycle of FIG. 2 with the body portion illustrated in phantom for clarity.
FIG. 4 is a cross-sectional elevation of the engine cooling system of the present invention partially in schematic.
FIGS. 5a, 5b and 5c are used depicting operation of the pressure regulatory valve of a cooling system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, a motorcycle employing a water-cooled engine system is illustrated. The motorcycle is illustrated to be of the scooter type having a front leg shield 10, a step floor 12 and a rear body portion 14. The motorcycle includes front and rear wheels 16 and 18, a seat 20 and a steering and handle grip assembly 22.
With reference to FIG. 2, it can be seen that the motorcycle frame includes a head pipe 24, a down tube 26 and a rear frame member 28. The down tube 26 extends downwardly from the head tube 24 and then rearwardly to meet with the rear frame member 28. The rear frame member extends upwardly and then rearwardly to form a base for the mounting of an engine and drive train assembly 30. The engine and drive train assembly 30 is pivotally mounted at pivot 32 to the rear frame member 28 and is resiliently biased near the rear wheel 18 by cushion assemblies 34.
The cooling system for the engine 30 includes a radiator 36 positioned at the front leg shield 10. Vents 38 are provided through the body of the front leg shield 10 to allow air to flow inwardly through the radiator 36. A fan assembly 40 may be employed to draw air through the radiator 36 as needed. Air exhausted from the radiator 36 may then flow downwardly and out beneath the step floor 12 or through exhaust vents 42 to provide heat to the rider.
Extending from the radiator 36 to the engine 30 is a feedline 44. The feedline extends below the step floor 12 and to a water pump 46. The water pump 46 induces flow to the engine from the feedline 44. A return line 48 extends from the engine 30 to the radiator 36. The return line 48 also extends below the step floor 12. The feedline 44 directs flow from the bottom of the radiator 36 while the return line 48 returns flow to the top of the radiator 36. Furthermore, the water pump 46 directs flow to the lower portion of the engine while the return line 48 returns flow from near the top of the engine 30.
Looking to FIG. 4 for clarity, the engine 30 includes a cylinder 50, a piston 52 and a head 54. A water jacket 56 extends around the cylinder 50 and forms a portion of the head 54. Cooling passages 58 extend around the cylinder 50 and into the head as defined by the cooling jacket 56. A collection chamber 60 is provided at the top of the passage 58 to collect return flow to be directed through an exhaust port 62 to the return line 48. Seated on the engine at the exhaust passage 62 is a thermostat 64. The thermostat provides selective flow restriction to restrict flow through the return line 48. The thermostat 64 generally responds to cooling liquid temperature to aid in the initial heating of the engine.
At the very top of the cooling passage 58 is a collection cavity 66 to which any air contained within the cooling system at the engine 30 will eventually collect. A vent passage 68 extends from the chamber 66 to a bypass line 70. The bypass line 70 extends from the engine at the vent passage 68 to the radiator 36. Conveniently, the bypass line 70 extends to the cap section 72 of the radiator 36.
The location of the chamber 66 and vent passage 68 extending to the bypass line 70 insures the eventual collection of all gases contained within the water jacket portion of the cooling system. The back pressure initially supplied by the thermostat 64 when it is closed and when the engine drives the water pump 46 forces air and liquid coolant through the bypass line 70 to the radiator 36. The air collects in the cap portion 72 of the radiator 36 during this period. Additionally, resistance normally in the return line 48 may result in some flow continuing through the bypass line 70. The bypass line 70 is not required to extend fully to the radiator 36. Rather, the bypass line need only extend passed the lowermost extent of the return line 48. At that point, all trapped air and gases will flow to the radiator with the returning coolant.
The selection of the line size for the bypass line 70 may aid in its operation. By having the line 70 substantially smaller than the return line 48, flow through the bypass line 70 may be restricted. In this way, the thermostat 64 is effective because there is only a small amount of flow bypassing the return line 48. This restricted flow may be brought about by an effective restriction in the bypass line 70 rather than through the use of an entire smaller tube. In this way, the bypass line may be substantially smaller through a restriction rather than through the tube itself.
A further consideration in the selection of the bypass line 70 is the ability of the flow to entrain air into the line. In this regard, a bypass line 70 of from three to five millimeters will result in the air within the bypass line exhibiting plug flow. Thus, the air will not be allowed to flow against the coolant flow direction back to the cooling jacket at the engine.
The radiator cap portion 72 includes a cap 74 connected to a reserve tank 76 by means of a hose 78. The cap 74 is of the pressure regulated valve type including a valve 80 which opens and closes responsive to pressure within the radiator 36 to control communication with the reserve tank 76.
The pressure regulating valve 80 operates in three ways as shown in FIGS. 5a, 5b and 5c, according to the pressure in the radiator 36. FIG. 5a illustrates the normal condition with the pressure in the radiator 36 less than the pressure setting for the valve (normally 0.75 to 1.05 kg/cm 2 ) As a result, the passage to the hose 78 is closed. In FIG. 5b, the pressure in the radiator 36 is higher than the set pressure such that the outer portion of the valve 80 lifts to open the passage to the hose 78. This allows high pressure air and cooling fluid within the radiator 36 to escape to the reserve tank 76. FIG. 5c illustrates the operation of the radiator cap when pressure within the radiator 36 becomes lower than a second set pressure. This results when the engine cools. The center portion of the valve 80 then opens to allow introduction of cooling liquid from the reserve tank 76 into the radiator 36. Naturally, the air within the reserve tank 76 has risen to above the fluid level and only cooling fluid is introduced in the mode illustrated in FIG. 6.
To illustrate the operation of the present system, an initial condition of operation is contemplated with air located within the cooling jacket passage 58 and with the engine in a cold state. When the engine is started, the water pump 46 forces coolant flow into the engine 30. This pressurizes the cooling jacket passages 58 and forces flow through the bypass line 70. The thermostat 64 is cold and in the closed state, preventing flow through the return line 48. Because the outlet of the cooling jacket passage 58 to the bypass line 70 is located at the uppermost portion of the engine, the air contained within the passage 58 is directed through the bypass line 70 followed by cooling fluid driven by the pump 46. Air then collects within the cap portion 72 of the radiator 36.
As the engine warms, the thermostat 64 opens allowing flow through the return line 48. This reduces the level of flow through the bypass line 70 which has previously evacuated all air from the water jacket portion of the engine 30. As the engine and cooling liquid heat, the cooling liquid expands and increases the pressure within the cooling system. Eventually, the valve 80 is forced upwardly to allow some volume within the cooling system to escape to the reservoir 76. Naturally, the entrapped air or other gases are allowed to escape first, filtering through the liquid within the reserve tank 76. In this way, air is purged from the entire cooling system.
With the later cooling of the engine, liquid contained within the reserve tank 76 is drawn back into the radiator 36 through the valve 80 when there is reduced pressure within the cooling system. In this way, liquid replaces the previously entrapped air and gases within the cooling system.
Thus, an improved cooling system for a water-cooled engine is disclosed which aids in the removal of entrapped air and gases. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
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A motorcycle having a liquid-cooled engine with a liquid cooling system. The system includes a radiator, a water jacket about the engine and connecting feed and return lines. The radiator is located in the forward part of the motorcycle while the engine is located in the rear. The cooling lines pass beneath a step floor located intermediate a front leg shield and the rear body of the vehicle. A thermostat is positioned to selectively control flow through the return line while a water pump pumps flow to the engine. A bypass line extends from the uppermost portion of the cooling jacket at the engine to the radiator for extraction of air from the system. A pressure controlled radiator cap provides selective communication with a reserve tank.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device or connector adapter, having a base element, in which contacting units with contacts for making electrical contact with bus bars of a bus bar system are received, and having a holding device for releasable fixation in place of the device adapter with respect of the bus bar system, as well as the use of the adapter.
2. Discussion of Related Art
Device or connector adapters have been known in various designs, such as in connection with bus bar systems with mounting units, such as shown in German Patent References DE 103 00 723 A1, DE 93 06 013 U1 and DE 100 61 939 A1, where the connector and/or snap-in elements are formed in one piece on the bus bar holders, on the platform of the mounting unit and on the device or connector adapters and are only used for mechanically connecting mounting units and device or connector adapters matched to each other. This considerably narrows the range of employment of the adapters. For example, an installed system with a mounting unit laid out in a defined manner cannot be connected to different device or connector adapters.
SUMMARY OF THE INVENTION
It is one object of this invention to provide a device or connector adapter with increased application and variation range, and to disclose an advantageous employment possibility.
This object is attained by a device or connector adapter having characteristics discussed in the specification and the claims. The holding device has various module-like connecting devices and clamping feet which can be attached, at least in part releasably, on the base element, in order to mechanically fix the device adapter in place, selectively on a support device of the bus bar system, or directly on at least one bus bar.
It is thus possible, along with a simple mounting and simple operation, to mechanically connect the adapter having the same base element and simple-to-connect different connecting elements selectively directly with the bus bars, or with a platform receiving the bus bars, wherein a dependable electrical contact is assured.
One advantage of this invention results from the use of such a device or connector adapter in connection with a bus bar system with a mounting unit, which contains several spaced-apart bus bars in insulated bus bar holders, or an insulating platform.
In one embodiment of the adapter, a portion of the connecting device is attached on a narrow side of the elongated and approximately cube-shaped base element, and a further portion of the connecting device is attached on the oppositely located side of the base element, and the connecting device on at least one narrow side has snap-in elements. The connecting device being matched to each other on the two narrow sides of the adapter result in simple manipulation during attachment and a dependable connection.
For a connection, for example on the edges of a trough-shaped receptacle of the platform, the oppositely located connecting device on both narrow sides of the device adapter has connecting sections which are facing each other or away from each other.
Furthermore, in case of different utilization, steps are advantageous for the mounting and operation, wherein the connection device on at least one narrow side of the device adapter is attached to a attachment piece which is or can be releasably connected with the base element.
In this embodiment, for example, in the connected state the at least one attachment piece is snapped together, plugged together and/or screwed together with the base element.
For mounting and manipulating, those steps can be advantageous wherein, on a narrow side of the device adapter, the connecting device is connected in one piece with the base element via a narrow side section formed thereon.
For simple fixation in place on at least one bus bar, the at least one clamping leg in a hook shape is or can be releasably attached for extending behind the associated bus bar, or a section of the same, at the appropriate underside of the base element.
In this case, the connection of the clamping leg can occur in a simple way because the at least one clamping leg is snapped, screwed and/or plugged into a wall attachment formed on the underside of the base element.
A further advantage can be achieved if the wall attachment laterally borders a bus bar receptacle on the underside of the base element.
Those measures contribute to a dependable fixation in place of the adapter on bus bars wherein, for the lateral delimitation of a side of a bus bar to be assigned which is located opposite a side facing the wall attachment, a locking element, which is seated in the base element and which can be displaced or pivoted perpendicularly with respect to the underside of the base element, projects into at least one bus bar receptacle.
Mounting and operation can be favored if the locking element can be removed.
The mechanical fixation in place, as well as the provision of electrical contacts at the bus bars, can be aided if the contacts are resiliently supported in the base element for making an electrical contact with the bus bars.
For the rapid and simple establishment of the mechanical connection when using the adapter, the connecting elements of the device or connector adapters, which are embodied as snap-in elements, can be cushioned in the device or connector adapter and can be adjusted in a limited way parallel with the fastening surface of the mounting unit and perpendicular in relation to the bus bars. The snap-in elements of the device or connector adapter, which are provided with a snap-in ramp and a snap-in tip, snap into a snap-in receptacle of the platform of the mounting unit or snap-in receptacle of the bus bar holder when the device or connector adapter is placed on the mounting unit.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention is explained in view of exemplary embodiments represented in the drawing, wherein:
FIG. 1 is a lateral view of a bus bar system including a mounting unit with a platform and a connection adapter placed on top of the platform and maintained thereon;
FIG. 2 is a lateral view of a bus bar system in accordance with FIG. 1 , wherein the connection adapter is maintained on bus bars;
FIG. 2A is a partial enlarged view of the bus bar system in accordance with FIG. 2 , with a modified locking element and the fixation of the adapter on a bus bar, as well as an attachment on a platform on one side;
FIG. 3 is a top view of the connection adapter in accordance with FIG. 1 ;
FIGS. 4A , 4 B and 4 C each shows a different perspective view of two differently designed adapters in different exploded views; and
FIG. 5 shows an assembled state of each of two differently assembled adapters in accordance with FIGS. 4A to 4C .
DETAILED DESCRIPTION OF THE INVENTION
As the exemplary embodiment of FIG. 1 shows, three spaced-apart bus bars 20 are fixed in place in an insulated manner. In this case, the platform 11 can have a sort of a trough 9 and can extend over an entire length of the bus bars 20 . The platform 11 can also be equipped with several insulating bus bar holders 8 arranged on the trough 9 , or can be replaced by several insulating bus bars, which are spaced apart from each other in the longitudinal direction of the bus bars 20 . Connecting elements 14 and 16 are attached to the sides of the trough, or platform 11 , which extend parallel with the bus bars 20 wherein, facing the device adapter 30 , the connecting elements 14 and 16 terminate in plug elements in the form of holding sections 15 and 17 , which for example are oriented toward the outside parallel with the fastening surface of the trough 9 . In this case, the fixation on a support is provided, for example, via fastening flanges 18 of the connection elements 16 . In a similar way, the holding sections 15 and 17 can also be formed by outwardly angled end sections of the narrow trough edges. In accordance with FIG. 1 , the fastening of the device adapter 30 is provided at the holding sections 15 , 17 on the one side by a hook-like connecting element 40 , and on the other side by a releasable connector or connecting means 50 which, for example, can be snapped in and has a snap-in projection 51 on an attachment piece 35 on the appropriate narrow side of the device adapter 30 , as FIGS. 1 and 3 show.
In the present case, a foot 21 of the bus bars 20 is inserted into receptacles 12 of the bus bar holders 8 or of the platform 11 , wherein filler pieces 13 fill up the receptacles, and cover plates 19 fix the feet 21 and the filler pieces 13 in place. The bus bars 20 project outward by sections 22 and 23 in an L-shape at the top of the mounting unit 10 . On the side facing the mounting unit 10 , the device or connector adapter 30 has three bus bar receptacles 31 , into which the electrical contact elements 32 project. The wall attachments 33 divide the bus bar receptacles 31 and can have removable clamping feet 36 , such as shown in FIG. 2 , which extend behind the end sections 23 of the bus bars 20 . The clamping feet 36 can be snapped into place in the device or connector adapter 30 . In this case, a spring-loaded locking element 37 can project into at least one bus bar receptacle 31 , besides the contact element 32 , as shown in FIGS. 2 , 2 A and 3 . The locking element 37 is placed behind the transition from the end section 23 to the section 22 of the bus bar 20 and assures that the device or connector adapter 30 is maintained on the mounting unit 10 even if no lock or locking means 51 , such as for example the connecting device or connecting means 50 , are provided for securing on the platform 11 or the bus bar holders 8 . If a locking means for securing on the platform 11 is provided, the additional locking element 37 can be omitted, as shown in FIG. 1 . Flat bus bars can also be used.
As the left side of FIGS. 1 and 2 and the enlarged partial view in accordance with FIG. 2A show, following the plug-in movement the plug elements 15 and 17 of the connecting elements 14 and 16 are introduced into the connecting element 40 at the device or connector adapter 30 and a mechanical connection between the mounting element 10 and the device or connector adapter 30 is achieved. In this case, the connecting element 40 can be attached fixedly, or releasably and exchangeably, to the narrow side end 34 of the device or connector adapter 30 . This mechanical connection assures that the device or connector adapter 30 is securely fixed in place with respect to the fastening surface of the mounting unit 10 .
As shown in FIGS. 1 and 3 , the narrow side end of the device or connector adapter 30 located opposite the narrow side, or the narrow side section 34 with the connecting element 40 , supports the attachment piece 35 . As a connector or connecting means, the attachment piece 35 has a snap-in element 50 with a snap-in ramp for deflection during placement, and a snap-in projection 51 for holding in the inserted state. The snap-in element 50 is resiliently seated in the attachment piece 35 and can be displaced in a limited way substantially parallel with respect to the fastening surface of the mounting unit 10 and perpendicularly with respect to the long sides of the bus bars 20 . If the connecting element 40 is placed or hooked on the flange-like holding sections 15 and 17 of the mounting unit 10 by a sideward movement, it is then possible by a pivot movement to deflect the snap-in element 50 on the opposite side over the snap-in element 50 in such a way that the snap-in tip, or snap-in projection 51 , is moved sideways and thereafter the associated holding section 17 is grasped from behind. In that case, the mechanical connection between the device or connector adapter 30 and the mounting unit 10 is assured in a simple manner. It can only be released by setting the snap-in element 50 back.
It still remains that a multitude of embodiment variations regarding the details of the connecting and/or snap-in elements can exist, as well as the releasable and interchangeable connection with the bus bar holders, the mounting unit and the device of connector adapters.
If as shown in FIGS. 2 and 2A , at least one clamping foot 36 is installed, and at least one adjustable locking element 37 is provided, it can be securely fixed in place on bus bars 20 without the connecting and/or snap-in elements 40 , 50 being installed. This results in variable employment possibilities.
FIGS. 4A , 4 B and 4 C show two device adapters 30 embodied in different ways, having connector or connecting means 40 , 50 and clamping feet 36 , in various exploded views, always with the same base element 31 , in a perspective view. FIG. 5 shows the two embodiments of the device adapter 30 in the assembled state, also in a perspective view.
The variations of the device adapter 30 , which can only be fixed in place on the platform 11 , such as with the holding sections 15 , 17 which are outwardly angled on both sides, are here represented in the partial representations a), while the embodiment variations of the device adapter 30 which can be fixed in place on the bus bars 20 are shown in the partial representations b). As FIGS. 4A and 4B show, in particular, the connecting means equipped with the snap-in elements 50 are formed on the attachment piece 35 at its lower section facing the platform, wherein the snap-in element 50 with the snap-in projection 51 is inserted as a separate element into the slit-shaped cutout of the attachment piece 35 and is resiliently seated therein for lateral displacement parallel with the level of the platform 11 for producing and releasing the snap-in connection. In its upper section facing the respective narrow side of the base element 39 , the attachment piece 35 has lateral plug-in pegs 38 , which can be plugged into matched openings in the area of or near the longitudinal side elements of the base element 39 and fixed in place therein, for example snapped in. The narrow side section 34 on the opposite side of the base element 39 is formed as one piece with it and has on an underside the connecting element 40 , also formed on it, with the hook-like plug-in receptacle 41 for the holding section 15 , 16 matched to it. For connecting the device adapter 30 thus equipped on the platform 11 , first the connecting element 40 is suspended on the respective holding section 15 , 17 by a displacement movement in the direction of the level of the platform, and then the snap-in connection is provided on the opposite narrow side of the device adapter 30 at the appropriate holding section 15 , 17 by a pivot movement, wherein the snap-in element 50 is pushed back against the spring force by the snap-in ramp on the snap-in projection 51 , and then snaps into the snapped-in position under the spring force by extending it behind the holding section 15 , 17 .
Longitudinally extending receptacles for contact springs 72 are formed in the base element 39 , which are connected with suitable conductors in connecting pieces 71 and together form a contacting unit 70 . In this case, the connecting pieces 71 are received in matched recesses of the narrow side section 34 , as shown in FIG. 4A and in FIG. 4B , as well as FIG. 4C . A set-up plate 60 is attached to the top of the base element 39 , for which purpose snap-in springs 62 and snap-in hooks are formed on the underside of the set-up plate 60 , which engage matching openings in the top of the base element 39 . Further snap-in hooks 63 are designed so that they work together with the attachment piece 35 . Helical springs on the underside of the set-up plate 60 are supported on the contact elements 32 of the contact springs 72 , so that a dependable contact is provided on the bus bars 20 and during this the mechanical connection possibly made there is also aided. Further connectors or connecting means for receiving devices can be attached to the top of the set-up plate 60 or to strips laterally bordering it.
In connection with the variation of the device adapter 30 designed for attachment to the bus bars 20 in accordance with the partial representations b), the attachment piece 35 is not provided, which is also shown in FIG. 2 . Instead, a cover plate 62 is formed, or removably attached, on the set-up plate 60 which, in place of the attachment pieces 35 , forms a simple closure on the narrow side of the device adapter 30 . This embodiment has the clamping feet 36 for fixation on the bus bars 20 , which are releasably attached to the wall attachments 33 on the underside of the base element 39 , for example snapped in, plugged in or screwed on. The clamping feet 36 can have inserted reinforcement elements. Fixation in place on the bus bars 20 is also reinforced by the helical springs on the contact elements 32 at the contact springs 72 . The wall attachments 33 form lateral borders for received bus bars 20 . At least one bus bar 20 is secured on its longitudinal side located opposite the wall attachment 33 by a locking element 37 , which is seated, perpendicularly displaceable or pivotable in regard to the underside of the base element 39 , and is pressed outward by a spring force. The locking element 37 has various settings for different widths of bus bars and can be displaced inward against the spring force by a handle 37 . 1 in the top of the narrow side section 34 by a pivot movement or a displacement movement parallel with the longitudinal orientation of the base element 30 via a snap-in ramp in order to unlock the adapter 30 . The locking element 37 and, if required also the handle 37 . 1 , can be taken out of the base element, or introduced into it as separate parts.
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A device or connection adapter having a base part, in which contact-making units with connection contacts are accommodated for making electrical contact with busbars of a busbar system, and having a holding apparatus for detachably fixing the device adapter with respect to the busbar system. Given a simple design and simple operation, variable coupling options are provided if the holding apparatus has different, modular connections and clamping feet, at least some of which can be fitted detachably to the base part, in order to mechanically fix the device adapter either to a supporting apparatus of the busbar system or directly to at least one busbar.
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This is a continuation of application Ser. No. 589,308 filed June 23, 1975, now abandoned, which is a division of application Ser. No. 443,678 filed Feb. 19, 1974.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a solderless termination system. In particular, it relates to the type of such systems where a wire is engaged and held by blades or jaws. In further particular, it relates to the type of such systems adapted for insulation piercing as well as engaging and holding a wire.
2. Description of the Prior Art
Electrical termination systems are known in myriad forms and sizes. The type of system of interest in the present description provides, as a means for retaining a wire, a pair of facing blades or jaws which may be, before insertion of a wire, in a contact or appropriately spaced apart. Conventionally, blades are adapted to grip a wire between them for mechanical and electrical contact. Often, a lead-in portion is provided where the contact portion of the blades opens to provide convenient positioning and gradual gripping of the wire. Such structures as are shown in the prior art may also enable the insulation surrounding the wire to be pierced as it is inserted between the blades. Common applications of such termination systems are in splicing wires and in the wire terminating end of connectors.
There are a number of factors and problems important in an acceptable insulation piercing solderless termination system. Some of these factors and problems are more pronounced with regard to so called miniature termination systems or high density systems where elements are quite close together.
One of the most important (if not the most important) performance factors relates to contact resistance. More accurately, this factor relates to the change in contact resistance between the terminated wire and the terminating system after being subject to time and hostile environments.
The physical strength and durability of the connection between the wire and the termination system is also important.
Other factors relate to manufacturability and within that general subject, to the level of confidence found for terminations passing the various acceptance tests. It should be understood that with high volume production, the number of faulty pieces should be small and predictable with high level of confidence.
The termination system described below has been found to perform very well under a variety of physical and electrical performance conditions and to meet the needs for manufacturability. In terms of change in contact resistance, under hostile environments and use tests, excellent results have been obtained.
It is further notable that termination systems of the type herein described have both civilian and military uses and are particularly used in telephone systems. Production and utilization volumes are high and reliability requirements within the performance parameters specified by users are very stringent. In one exemplary application, the criterion set is that, under the defined test conditions, no more than 1 out of 10,000 terminations may exceed a change in contact resistance of 0.25 milliohms at the 95% confidence level.
SUMMARY OF THE INVENTION
The invention comprises an electrical termination system in which the wire receiving portion is defined by spaced apart sides for receiving a wire between them and at least one pair of formed-in jaws in the sides. The jaws are formed opposite each other presenting a narrowed space between them. The formed-in jaws are integral with the sides at each of their lateral extremities. In a further aspect, a lead-in portion is provided by notching the sides at the jaws establishing an angle to the upper edge of the jaws to aid in locating the wire and directing it into the jaws. In the area which contacts the wire, the lead-in edge desirably has a transition portion which comprises a coined edge in order to present to an entering wire a smoothly angled embossing surface. In addition, the jaws may be freed at their lower ends.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the termination system of the invention.
FIG. 2 is a perspective view of another preferred embodiment of the termination system of the invention as embodied in a ribbon type contact element.
FIG. 3 is a perspective view of the contact element of FIG. 2 installed in a high density connector body.
FIG. 4 is a partial top view of the preferred embodiment of the invention.
FIG. 5 is an enlarged partial section end view of the preferred embodiment of the invention through V--V of FIG. 4.
FIG. 6 is a sectional end view through VI--VI of FIG. 4 of the termination system with a wire installed, and illustrating in phantom the wire prior to installation.
FIG. 7 shows a top view of the invention employed for splicing parallel wires.
FIG. 8 shows a top view of the invention employed for butt splicing.
FIG. 9 is a photomicrograph of a longitudinal cross section of 24 gauge wire inserted in a termination system. The insulation does not appear in the picture.
FIG. 10 is a photomicrograph of a right angle cross section view of 24 gauge wire inserted in a termination system. The insulation does not appear in the picture.
FIG. 11 is an enlarged photomicrograph of a longitudinal cross section, as shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, in FIG. 1, the termination system is illustrated without reference to any specific application. In FIGS. 7 and 8 the termination system is schematically illustrated as employed as a splicing means for parallel wires and butting wires, respectively.
In FIGS. 2 and 3, the system is illustrated as employed as a termination or wire receiving end of a ribbon type contact element 1. FIG. 3 shows how such a contact element may be used in a high density connector system.
By this, it should be evident that the invention has wide utility as a terminating system. However, it is emphasized that the greatest advantages are seen when it is used in a miniaturized application where there is required strength, reliability and manufacturability of very small parts made from otherwise relatively weak materials.
Referring to FIG. 1, the termination system illustrated has spaced apart generally parallel sides 2 and a bottom 3 forming an elongated wire receiving channel. Pairs of oppositely facing formed-in jaws 4, 4a are formed-in and integral with each of the sides 2. Two pairs of jaws 4, 4a are shown although one pair or more than two pair could be used. By formed-in, it is meant that the metal of the sides is not cut or otherwise interrupted but is, rather, stretched and/or bent and thereby formed into the continuous curved jaws attached to and integral with the sides 2 at each of its lateral extremities. Thus, the jaws 4, 4a present laterally smoothly curved opposing formations having working faces 5, 5a as shown.
In order to best explain the lead-in portion 6, 6a of the terminating system, it is helpful to describe some of the steps in making the system. Basically, it is punched, bent and formed from flat sheets. The lead-in 6, 6a is preferably made by punching a V-shaped notch prior to the forming-in of the jaws (and also before bending up the sides) so that after the jaw is formed, the upper edge 7, 7a of the sides extends angularly downward and inward following the plan of the jaw and as best seen in FIGS. 4, 5 and 6.
As shown in FIG. 1, slots 8, 8a are formed in the sides 2 in order to free the lower end of the jaws 4, 4a from the sides. As shown in FIGS. 2, 4 and 5 the slot 8, 8a is a piece of the sheet removed at the bend in the channel between the sides 2, 2a and the bottom 3. With the particular embodiment shown here involving a 90° bend and the bottom 3 being very close to the lower end of the jaws, it is very important to free the lower end of the jaws in order to prevent excessive stretching and random formations of the metal. It may be possible, where more free area is available below the jaw, to omit freeing it, although the freeing is still preferred.
As can be seen in the photomicrograph of FIGS. 9 and 11 a substantially smooth continuous distortion of the wire is achieved by this system. Referring to FIG. 5, in order to facilitate such a smooth distortion, the lead-in portion has a transition area 9, 9a to change the angle of the edge to present an angled embossing surface to the wire at the upper edge of the jaw in the working area. It may be formed by a coining operation in the formation of the piece where the edge 7, 7a has its angle changed to follow the shape of the lead-in portion 6, 6a as seen in FIG. 5. This transition area 9, 9a is so designated because it is an area of transition from contact, by a wire being inserted, with the upper edge 7, 7a of the jaw to contact with its working face 5, 5a. Thus, the transition area is formed at the innermost area of the jaw defined by the working face 5, 5a of the jaw. The transition area, presenting an angled embossing surface, tends to cause compressive forces on the wire, aiding in the desirable relatively smooth distortion of the wire when it is eventually fully inserted. Without the transition area, a sharp corner at the upper edge of the jaw over the working faces 5, 5a would be presented to a wire which would tend to shear and sharply shape the wire.
The lead-in area 6, 6a including the coined transition portion is preferably at about a 45° angle to horizontal. It may be preferable to make the transition area present an even steeper angle to a wire between the upper edge and the working face of the jaw in order to enhance its transition effect. Other methods may be employed to form the transition area 9, 9a such as by forming the V notch of the lead-in area with an angled edge instead of a square cut edge. It is intended to define the transition area therefor as effecting a smooth continuation of the upper edge and into transition to the working face of the jaw.
It is for many applications important to provide some strain relief in combination with this termination system. A strain relief means suitable with the present termination system shown at 13 in FIG. 2 and 3. This strain relief is fully described in co-pending application, Ser. No. 443,730, now U.S. Pat. No. 3,902,154.
In the preferred commercial embodiment, such as illustrated in FIGS. 2 and 3 for a ribbon type contact element, the contact element may be formed from 0.006 inch cadmium bronze sheet. The contact will usually be gold plated either in its entirety or selectively on the mating portion, or both fully and selectively plated. In a primary use in telephone systems employing 24 gauge and/or 26 gauge solid insulated wire, the space between the jaws can be about 0.007 inch.
The tab 14 is provided to hold the contact element in place in the insulating connector body. A similar tab 15 is formed up in the butt splicing embodiment of FIG. 8 to hold the part in place in an associated body member.
FIG. 3 shows part of a 50 contact polarized ribbon type connector. This is a type of high density connector commonly used in rack-and-panel and cable-to-cable applications in telephone systems. In an exemplary case, the contact elements are on 0.085 inch centers. The contact elements 1 are mounted in two parallel rows in the insulator 10 between the ribs 11. The contact elements 1 reside in channels defined, at the wire termination end, by ribs 11. The ribs 11 provide support for the sides 2, 2a of the termination systems, serving to rigidly back the sides 2 in order to prevent their spreading apart when a wire is inserted.
To use the connector, the completed connector is held firmly and wires inserted either singly or multiply, one into each contact element.
An exact procedure and means for inserting the wire is more fully described in co-pending application, Ser. No. 502,085, which has been abandoned in favor of pending divisional application Ser. No. 585,308, now U.S. Pat. No. 4,001,931 and pending continuation application Ser. No. 586,453, now U.S. Pat. No. 3,965,558. For the present description, it is sufficient to understand that the wire 12 is positioned as shown in FIG. 6 over the channel and, with a tool designed to do so, evenly pushed down into the channel.
As can be appreciated, the smoothly angled configuration of the upper edge 7, 7a of the jaw will contact the insulation on the wire and, as the wire is pushed downward, will tear through the insulation. As the wire progresses downward and the metal of the wire itself contacts the jaws commencing past the transition area 9, 9a and to the working faces 5, 5a, it will be deformed to eventually mate intimately with the jaw working faces 5, 5a. The primary distortion of the wire is an inward compression or embossing with some upward displacement of metal. The photomicrographs of FIGS. 9 and 10 show the configuration of the jaw and the wire as it resides in place. An intimate, largely compressive contact of the wire with the jaws is evident. In the horizontal direction, as shown in FIG. 9, the metal is distorted inward in a smoothly curved pattern preserving the axially fibrous structure of the wire and avoiding stress concentration points. In the vertical direction, while some upward displacement is seen, nevertheless, the embossing nature of the distortion can be seen.
In an intensive series of tests involving a variety of hostile environments, thermal cycling, thermal shock, thermal aging and physical strength and durability the termination system performed well according to criteria relevant to telecommunications applications.
While the above description relates to certain embodiments now known to and preferred by the inventors, it is possible for persons skilled in the art to make certain additions, changes and modifications. It is intended by the appended claims to cover such additions, changes and modifications as fall within the scope and spirit of the invention.
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A termination element for electrical connectors and method for making the same. The elements have a wire receiving portion defined by spaced-apart sides in which opposing jaws are formed. The jaws are cut and formed from the sidewalls to present a uniform angular lead-in for the wire being inserted and are spaced and coined to facilitate compression and deformation of the wire upon insertion.
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RELATED APPLICATIONS
[0001] The present application is based on, and claims priority from, Japanese Application Number 2009-090490, filed Apr. 2, 2009, the disclosures of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a guided vehicle, specifically to a guided vehicle equipped with rubber tires suspended by means of air springs used as secondary suspensions or a magnetic levitated vehicle, etc.
[0004] 2. Description of the Related Art
[0005] Recent years, a medium capacity transit system, one of so-called new transit systems, in which guided vehicles equipped with rubber tires travel along exclusive guideways, has become widespread, and also development work toward practical use of magnetically-levitated trains is making advances. Full automatic operation of unmanned vehicles is performed in many of these transit systems. In some case the vehicle has guide wheels to guide it along the sidewall of the guideway.
[0006] Many of vehicles used in these new transit system or magnetic levitation system adopt pneumatic suspension as secondary suspensions for the sake of improving ride quality as shown in FIG. 7 . In FIG. 7 , reference numeral 100 is a body of a vehicle, 102 are air springs, 104 are tires, and 106 are guide wheels for guiding the vehicle along a guide rail not shown in the drawing. Left and right tires 104 are connected by an axle covered by an axle housing.
[0007] However, the air spring 102 must be located between the axle housing and the vehicle body 100 , so each of the left and right air springs 102 is located at a position inner side from the left and right tires 104 respectively when tires 104 are used. The air spring 102 is composed of a bellows (or diaphragm) made of multi-plied rubber and reinforcing fiber layers and it can withstand a pressure of about 2.0 MPa, however, operating pressure is limited generally to 0.59 MPa or lower in consideration of durability of the bellows (or diaphragm).
[0008] Further, the bellows (or diaphragm) act as a spring by its expansion and contraction in vertical directions, so it is shaped to be circular in plan view in order to evade occurrence of local stress concentration which tends to occur if it is not circular in plan view. Therefore, when load to be supported by the air spring increases; the outer diameter of the air spring must be increased to increase its effective load area so that inside pressure of the bellows (or diaphragm) does no exceed the limit pressure. With air springs of large outer diameter, distance between the left and right air springs decreases, resulting in decreased rolling stiffness of the vehicle, that is, resistance to rolling of the vehicle decreases and ride quality is deteriorated. Further, in order to manufacture an air spring of large outer diameter unpracticed heretofore, it is needed to make a mold to form constituent parts, which requires fairly large cost.
[0009] Furthermore, with decreased distance between the left and right air springs, tilt adjustment of the vehicle body by adjusting the left and right air spring becomes not easy, and more time is needed to perform tilt adjustment of the vehicle body. It may be thinkable to broaden the tread, i.e. distance between the left and right wheel in order to locate the air springs of increased outer diameter increased to comply with increased vehicle load without decreasing center distance of left and right air spring. However, larger cross-section surface of guideways are required with increased tread of the guided vehicle, a lot of money will be required for provision of infrastructure. As to domestic new transit systems, vehicle width is determined in standardization and cannot be increased by preference.
[0010] As to an art to improve stiffness and damping of rolling of a vehicle equipped with air springs, a rear suspension device of a bus is disclosed for example in a patent literature 1 (Japanese Laid-Open Patent Application No. 2001-47830).
[0011] According to the literature, in a rear suspension device comprising; air springs located just under the straight side members (component members of the chassis frame) at positions front ward and rear ward from the rear axle housing, and shock absorbers located between the rear axle housing and the straight side members to attenuate vibration of the bellows (or diaphragm) of the air springs; the rear shock absorbers are located outer side from the side members, thereby increasing distance between the left and right shock absorbers, and thereby making the distance between the left and right shock absorber of the rear shock absorbers nearly equal to that of the front shock absorbers. By this, stiffness of rolling and damping of the rolling effectuated by the rear shock absorber is improved, and the effects of suppression of rolling by the rear and front shock absorber become nearly balanced.
[0012] In a patent literature 2 (Japanese Laid-Open Patent Application No. 2005-96724) is disclosed a method of controlling tilting of a vehicle body. The invention relates to tilt controlling of the body of a vehicle having front and rear bogies on which the vehicle body is supported by means of air springs.
[0013] Tilt control is performed by controlling supply and drain of air to four air springs located on the front and rear bogies at left and right positions respectively. According to the invention, when the vehicle runs through a curve section of rail road, two air springs of either of the front or rear bogie are communicated with each other so that the vehicle body is supported by apparent three-point support on the bogies. In this state, tilting of the vehicle body is controlled by supplying or draining air only to or from air springs not communicated with each other. In this way, air consumption for body tilt control can be decreased.
[0014] However, the rear suspension device of a bus as disclosed in the patent literature 1 aims to attain low-floor construction of a bus. As rear axle load is two times that of the front axle in the bus, two air springs of the same size are attached at a forward and rearward position from the rear axle housing for each of left and right side of the vehicle. The left and right air springs depart from each other by more than a little distance, and the two air springs are not communicated with each other. Therefore, the rear axle is supported by four separate air springs, and when there is a bias or deviance in distribution of sprung weight among the four rear air springs, height and tilt adjustment of the vehicle by controlling each separate air spring becomes difficult. That is not problematic in the case of trucks and buses, however, in the case of guided vehicles, it is necessary to severely control difference between the platform surface and floor surface of the vehicle to be in a range of ±few millimeters, so that becomes problematic.
[0015] The method and device of controlling tilting of the vehicle body aims only to decrease consumption of air required to tilt the vehicle body when the vehicle runs through a curve section of the rail road by communicating the left and right air spring of either of the front or rear bogie, and can not resolve such a problem that occurs when air springs of increased outer diameter are used in order to comply with increased axle load, i.e. decrease in rolling stiffness due to decreased distance between the left and right air spring.
SUMMARY OF THE INVENTION
[0016] Therefore, the object of the invention is to provide a guided vehicle of air spring suspension, with which decreasing center distance of the left and right air spring in order to mount air springs of increased diameter and increased load carrying capacity, which decreasing of center distance of the left and right air springs induces decrease in rolling stiffness of the vehicle resulting in deteriorated ride quality and also induces difficulty in adjusting vehicle height resulting in spending long time in height adjusting operation, will not be required even when load carrying capacity of air springs is required to be increased in order to comply with increased vehicle load.
[0017] To attain the object, the present invention proposes a guided vehicle for traveling exclusive guideways having air springs to support the vehicle body on axles thereof, wherein the air spring is composed of a plurality of air spring elements connected to one another so that their inside rooms are communicated to one another.
[0018] By connecting a plurality of air spring elements to one another so that their inside rooms are communicated to one another, the outer diameter of each air spring can be decreased, and mounting distance between the left and right air springs can be widened by just that much, so rolling stiffness of the vehicle is increased and the vehicle does not rolls easily and ride quality is improved. Further, by communicating the inside rooms, inside pressure of a plurality of the air springs is always equal, so it does not happen that only one air spring supports the load, and as a plurality of the air springs can be located so that virtual center line thereof coincides with the center line of the axle, superfluous back-and-forth bending force does not exerts on the frame.
[0019] When manufacturing an air spring of a diameter not commercially available, enormous cost is needed because a mold, or pattern is needed to be made. By using air spring elements of size commercially available as being done in the invention, increase of load of the vehicle can be dealt with at a low cost.
[0020] By mounting the air spring such that they are arranged tandem along the longitudinal direction of the vehicle and symmetrically with respect to the center line of the axle of the vehicle, each air spring can be decreased in outer diameter as mentioned before, and by communicating the inside rooms, front and rear air spring elements are always equal in inside air pressure even when the inside pressure fluctuates and the air spring elements work like a single air spring. Therefore, displacements of the left and right air spring elements are always equal and inclination in the anteroposterior direction does not occur, so, vehicle height adjustment is eased as if left and right wheels are suspended respectively by a single air spring. Further, as air spring of smaller diameter are used, it becomes unnecessary to think of widening the width of the vehicle.
[0021] By arranging a plurality of air spring elements such that the centers of the spring elements are on a circle, an air spring further increased in load supporting capacity can be obtained.
[0022] Spring constant K of an air spring is given by the following equation:
[0000] K =γ×( P 0 /V 0 )× A 0 2
[0000] where γ is polytropic index of air, P 0 is inside air pressure, V 0 is inside room volume, and A 0 is effective load area of the air spring respectively.
[0023] As can be recognized from the above equation, spring constant K reduces with increased inside room volume V.
[0024] Therefore, by composing such that a plurality of air spring elements are covered by a common cover-dish, the volume of the common inside room per one element increases, so spring constant can be decreased further, resulting in further improvement of ride quality.
[0025] By connecting a plurality of air spring elements via flexible communicating pipes, flatness of installation face to place each of the air spring elements is of no importance, and each air spring elements is allowed to be mounted on each installation face not level with each other as necessary depending on the construction of the vehicle.
[0026] As has been mentioned above, the guided vehicle of the invention is provided with a plurality of air spring elements with inside rooms thereof communicated to one another, so the outer diameter of each of them can be decreased. Therefore, the mounting distance between the left and right air spring can be decreased by just that much, rolling stiffness of the vehicle can be increased resulting in improved ride quality, and it becomes unnecessary to think of widening vehicle width, which will result in an increased cost.
[0027] Further, by arranging a plurality of air spring elements such that centers of the spring elements are on a circle, an air spring with increased load supporting capacity can be obtained, and further, by composing such that a plurality of air spring elements are covered by a common cover-dish, the volume of the common inside room per one element increases, so spring constant can be decreased, resulting in improvement of ride quality, because spring constant K is inversely proportional to the inside room volume V 0 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1A is a plan view of the first embodiment of an air spring used for the guided vehicle according to the present invention, FIG. 1B is a cross sectional view along line a-a′ in FIG. 1A , and FIG. 1 c is partial cross sectional view along line b-b′ in FIG. 1A .
[0029] FIG. 2A is a diagrammatic front or rear view of the guided vehicle equipped with the air springs of the first embodiment, and FIG. 2B is a diagrammatic partial side view of the vehicle to show the state the axle is suspended via the air springs.
[0030] FIG. 3 is a diagrammatic plan view of the guided vehicle showing location of tires and air springs.
[0031] FIG. 4D is a plan view of the second embodiment of an air springs used for the guided vehicle according to the present invention, FIG. 4E is a cross sectional view along line d-d′ in FIG. 4D , and FIG. 4F is partial cross sectional view along line e-e′ in FIG. 4D .
[0032] FIG. 5G is a plan view of the third embodiment of an air spring used for the guided vehicle according to the present invention, and FIG. 5H is a cross sectional view along line g-g′ in FIG. 5G .
[0033] FIG. 6J is a plan view of the third embodiment of an air spring used for the guided vehicle according to the present invention, and FIG. 6K is a cross sectional view along line j-j′ in FIG. 6J .
[0034] FIG. 7 is a diagrammatic plan view of the conventional guided vehicle showing location of tires and air springs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Preferred embodiments of the present invention will now be detailed with reference to the accompanying drawings. It is intended, however, that unless particularly specified, dimensions, materials, relative positions and so forth of the constituent parts in the embodiments shall be interpreted as illustrative only not as limitative of the scope of the present invention.
The First Embodiment
[0036] FIG. 1A is a plan view of the first embodiment of an air spring used for the guided vehicle according to the present invention, FIG. 1B is a cross sectional view along line a-a′ in FIG. 1A , and FIG. 1 c is partial cross sectional view along line b-b′ in FIG. 1A , FIG. 2A is a diagrammatic front or rear view of the guided vehicle equipped with the air spring set of the first embodiment, and FIG. 2B is a diagrammatic partial side view of the vehicle to show the state the axle is suspended via the air springs, and FIG. 3 is a diagrammatic plan view of the guided vehicle showing location of tires and air springs.
[0037] In FIG. 3 showing a diagrammatic plan view of the guided vehicle of the invention, air springs 10 are located between a front left and right wheel 30 and between a rear left and right wheel 30 . Reference numeral 32 is a vehicle body, and reference numeral 38 indicates guide wheels. A plurality of air spring elements (two in FIG. 3 ) including an outer cover 12 , an inner case 14 and a rubber diaphragm (bellows) 18 are arranged to compose an air spring 10 (as shown in FIG. 1A ) located across the center line connecting the center of the left and right wheel, and the air spring elements of the air spring 10 are communicated so that inside air pressure thereof are always equal.
[0038] By connecting a plurality of air spring elements to one another so that their inside rooms are communicated to one another, the outer diameter of each air spring can be decreased. Therefore, mounting distance between the left and right air springs 10 can be widened by just that much, so rolling stiffness of the vehicle 32 is increased and the vehicle does not rolls easily and ride quality is improved. Further, by communicating the inside rooms, inside pressure of a plurality of the air spring elements is always equal, so it does not happen that only one air spring element supports the load, and as a plurality of the air springs can be located so that virtual center line thereof coincides with the center line of the axle, superfluous back-and-forth bending force does not exerts on the frame.
[0039] Referring to FIGS. 2A and 2B showing respectively a diagrammatic front or rear view of the guided vehicle equipped with the air springs 10 of the first embodiment and a diagrammatic partial side view thereof, reference numeral 30 are wheels, 32 is a vehicle body, 34 is an axle housing, and 40 is left and right suspension frames. A carriage is provided to the vehicle shown in the drawing via the air springs 10 on the lower side of the vehicle body 32 . As shown in FIG. 2B , two air spring elements are arranged tandem along the longitudinal direction of the vehicle and symmetrically with respect to the axle housing 34 that contains the axle of the vehicle. Also, the air spring elements of each air spring 10 are connected via a communicating pipe 26 so that inside air pressure thereof is always equal.
[0040] As shown in FIG. 2B , an end of each of two parallel links 36 is pivotally fixed to the vertical part of each of the left and right suspension frames 40 . The air springs 10 are located between the basal portion of the suspension frame 40 fixed at the bottom part of the vehicle body and the axle housing 34 fixed to the carriage side.
[0041] A first embodiment of the air spring is shown in FIGS. 1A-1C . Each air spring element of the air spring 10 of the first embodiment is comprised of the air spring element including the outer case 12 , the inner case 14 , and the annular rubber diaphragm (bellows) 18 connecting the outer periphery of the inner case 14 and that of the air spring element. The inner periphery of the rubber diaphragm (bellows) 18 is fixed to the outer periphery of the inner case 14 , and the outer periphery of the bellows 18 is clamped to the outer periphery of the air spring element via a circular clamp 28 . Reference numeral 16 is an air inlet, 22 is an outer cover-fixing bolt. The air spring 10 is fixed to the horizontal part of the suspension frame 40 by an outer case-fixing bolt 22 . Reference numeral 20 is a stopper supported by the bottom of the inner case 14 . The stopper 20 restricts vertical movement of the inner dish 14 . Reference numeral 24 is a positioning pin attached to the bottom of the inner case 14 to position of the air spring 10 , and reference numeral 26 is the communication pipe.
[0042] Each of the two air spring elements of the air springs 10 of the first embodiment provided with the inner case 14 located concentrically to the air spring element, and the diaphragm 18 composed of rubber bellows, is connected to each other by the communicating pipe 26 so that inside pressure of both the air spring elements is always equal. The communicating pipe 26 may be a metal pipe or flexible rubber hose. The inner diameter of the communicating pipe 26 is preferably 15φ or larger so that inside pressure of both air springs is always equalized.
[0043] When the communicating pipe 26 is made of flexible pipe such as a rubber hose, evenness or flatness of the face of a flange for mounting the air springs 10 is not a point to take care of, and it is permissible that each flange face for mounting each air spring 10 of the air spring set is not leveled with each other.
[0044] The stopper 20 is to prevent the air spring 10 to be pressed over the shrinkage stroke between the air spring element and the stopper 20 when some weights are added onto the air spring elements. Further, since the diaphragm 18 is actuated from the up and down displacement, the shape of the diaphragm 18 in planar view is circular geometry, and other shapes are not preferred as the deformation of the diaphragm becomes locally uneven causing the durability of the diaphragm decreased.
[0045] Therefore, as clear from FIGS. 1B and 1C , the diaphragm 18 is formed in same form around the inner case 14 . The inner pressure of the air spring is controlled by admitting and releasing the compressed air through the air inlet 16 from a compressed air tank (not shown). Moreover, the air spring is fixed by the outer case fixing bolt 22 and the positioning pin 24 .
[0046] Although in the embodiment, two air spring elements are arranged tandem along the longitudinal direction of the vehicle body and symmetrically with respect to the axle center line, and connected by a communicating pipe, it is also possible to arrange more than two air spring elements along the longitudinal direction of the vehicle body and symmetrically with respect to the axle center line, and connect them with communication pipes.
The Second Embodiment
[0047] A second embodiment of air springs is shown in FIGS. 4D-4F . FIG. 4D is a plan view, FIG. 4E is a section along line d-d′ in FIG. 4D , and FIG. 4F is a partial cross section along line e-e′ in FIG. 4D .
[0048] In the embodiment, the inner case and diaphragm are the same as those of the first embodiment shown in FIG. 1 , and an outer case having a common inside air room as versus providing communication pipe in the case of the first embodiment is provided covering air spring elements to constitute an air spring.
[0049] In FIGS. 4D-4F , reference numeral 50 is an air spring, and reference numeral 52 is an outer case covering the spring elements each of which includes an inner case 54 , an annular diaphragm 58 , a stopper 60 , and these are the same as those of FIG. 1 as can be recognized from the figures. Reference numeral 62 is an outer case fixing bolt, reference numeral 64 is a inner case positioning pin, and reference numeral 68 is a circular clamp.
[0050] By providing the outer case 52 , volume of the closed room (inside volume) formed by the inner case 54 , the diaphragms 58 , and the cover-dish 52 increases as compared with the air spring of FIG. 1 . Therefore, spring constant can be reduced, resulting in improved ride quality. Spring constant K of an air spring is given by the following equation:
[0000] K =γ×( P 0 /V 0 )× A 0 2
[0000] where γ is polytropic index of air, P 0 is inside air pressure, V 0 is inside air room volume, and A 0 is effective load area of the air spring respectively.
[0051] As can be recognized from the above equation, spring constant K is inversely proportional to inside air room volume V 0 , so spring constant of the air spring of FIG. 4 is decreased due to increased inside volume V 0 as compared with the air spring of FIG. 1 , and ride quality is improved.
The Third Embodiment
[0052] When minor decrease in center distance of the left and right air spring by using inner case is permissible for example in an auto truck, etc., improvement of ride quality can be achieved by providing an inner case for more than two air spring elements arranged circularly as shown in FIGS. 5 and 6 , resulting from reduced spring constant caused by increased inside air room volume.
[0053] FIG. 5 shows an air spring 70 consisting of three air spring elements 82 covered by an outer case 72 so that the closed inside room is common for the three air spring elements. Each of the air spring elements 82 includes an inner case 74 , an annular rubber diaphragm 76 , a stopper 78 , and a positioning pin 80 . The three air spring elements are arranged such that the centers thereof are on a circle.
[0054] FIG. 6 shows an air spring 86 consisting of six air spring elements 98 covered by an outer case 88 so that the closed inside room is common for the six air spring elements. Each of the air spring elements 98 includes an inner case 90 , an annular rubber diaphragm 92 , a stopper 94 , and a positioning pin 96 . The six air spring elements are arranged such that the centers thereof are on a circle. By arranging a plurality of air spring elements and covering them with an outer case, the volume of the inside closed air room can be increased as compared with the case in which a plurality of air spring elements are arranged and their inside closed air rooms are communicated, so spring constant can be decreased and ride quantity can be increased. The air spring elements of the invention work as a single air spring because each of the constituent air springs or constituent air spring elements actuate under the same air pressure.
[0055] Further, in order to provide an air spring of large effective load area not commercially viable, it is needed to begin from making a mold for forming constituent parts of the air spring, which will result in high manufacturing cost. By utilizing a plurality of air spring elements of commonly used sizes to compose an air spring of large effective load area, an air spring of very large load carrying capacity can be provided at low cost.
[0056] According to the invention, a guided vehicle equipped with air springs of large load carrying capacity to comply with increased vehicle load and having increased ride quality can be provided.
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In a guided vehicle of air spring suspension for running along exclusive guideways, decreasing of center distance of the left and right air spring to mount air springs of increased dimension and increased load carrying capacity, which decreasing of the center distance induces decrease in rolling stiffness of the vehicle resulting in deteriorated ride quality and also induces difficulty in adjusting vehicle height resulting in spending long time in height adjusting operation, will not be required even when load carrying capacity of air springs is required to be increased in order to comply with increased vehicle load. A plurality of air spring elements are mounted tandem along the longitudinal direction of the vehicle with the air spring elements connected with each other so that air pressure thereof is always equal.
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BACKGROUND OF THE INVENTION
The present invention relates to articles such as items of furniture, packaging elements, lightweight partitions, and the like, comprised of planar parts assembled perpendicularly (or substantially perpendicularly, with the angles between them being unequal supplementary angles).
It has long been known to assemble two pieces each one of which has a slot of length one half that of the piece, whereby after the two slots are mutually engaged the pieces are fitted together from interlocking with their end faces being coplanar.
This trivial assembly is known as a rebated joint (in French, a "half timber joint"). When assembled, each slot is directed toward the solid member of the opposing piece, and the bottoms of the slots are essentially disposed against each other. Refinements of this basic arrangement are also known--in particular, arrangement of the assembled pieces at an angle other than a right angle.
There is also known (PCT OS No. WO-A-84/00024) an assembly which includes locking means for the pieces after they are engaged, such means being namely a rigid "key". The pieces themselves must be flexible so as to be able to elastically deform to enable the rigid key to be forcibly introduced.
Fr. Pat. No. 2,049,386 describes a construction assembly comprised of members having slots of complex shapes, enabling a "rebated joint" assembly with two different orientations, perpendicular or oblique. The slots in these members have openings in them which are disposed in planes parallel to the plane of the corresponding slot. These openings are intended to receive locking pins which are inserted by sliding. These pins must necessarily have a thickness less than that of the aforesaid assembled members, because the pins run parallel to the surface planes of the respective members.
U.S. Pat. No. 1,529,759 describes a structure comprised of crossbeams and of uprights assembled by means very similar to those described in Fr. Pt. No. 2,049,386 discussed supra except that only orthogonal assembly is provided for. What is important to note is that the slots of the classical "rebated joint" assembly according to the U.S. Pat. are associated with openings each of which accommodates a locking rod which must extend in a plane parallel to the surface planes of the respective assembled pieces.
The present invention is entirely different from these concepts, and notably it employs locking keys which may be esthetic as well as utilitarian, which keys are visible in the assembled condition.
SUMMARY OF THE INVENTION
The invention relates to an article such as an item of furniture, which when unassembled comprises at least two pieces having rectilinear slots which engage one another (by mutual insertion) to achieve an orthogonal assembly of the said pieces; characterized in that the said pieces are in the form of panels which are relatively thin with respect the length and width of their two major faces, which panels have openings passing through them from one major face to the other, wherewith the said slots open out into said openings from one side of the latter, whereby after the engagement (mutual insertion) the slots are disposed beyond the openings which they have passed over lit., "they traverse", and each slot is disposed at right angles with and across a solid part of the other piece which solid part is disposed opposite to the slot on the said other piece, i.e. across the respective opening from said slot, and wherewith after said engagement the openings in the two panels are aligned and adapted to receive a locking key having the same height as the openings, which key is to extend in said openings and be supported on the two opposing sides of said openings which sides do not have slots in them, and which key is relatively rigid in its height dimension so as to prevent the slots from being moved back through the said openings, which movement would result in the disengagement of the slots and the separation of the pieces.
According to other characteristics i.e., refinements of the invention:
Each panel may be attached to a plate disposed in the opening, which plate has the same height as the opening and is pivotally mounted on a pivot with an axis parallel to that of the slot, which pivot is disposed outside of said opening, wherewith the said plate itself has a slot which is aligned with the slot of the panel and which extends to the center of the said plate (which is also the center of the said opening);
The locking key may be comprised of an elastically deformable material;
The locking key may be comprised of a central, rigid core which is surrounded by an elastically deformable material such as a synthetic foam material;
The shape of the locking key may be such that the key is rigid in its height dimension and is elastically deformable in directions (planes) perpendicular to the height dimension;
The locking key may be a tubular element comprised of a semi-flexible material, and intended to be placed in the openings with its virtual axis parallel to that of the slots;
The tubular element may have grooves extended to cooperate with the side faces of the slots;
Each opening in the panels may be circular, and the locking key may be in the form of a spherical element which is substantially rigid and which has two rectilinear grooves which are parallel and are symmetrical with respect to a diameter of the spherical element, wherewith the bottoms of the grooves are separated by a distance which is generally equal to the width of one of the slots.
The invention will be better understood with the aid of the following detailed description presented with reference to the attached drawings. The description and drawings are offered only by way of example, and do not limit the scope of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic elevation of an inventive piece, e.g. for furniture, according to a first embodiment;
FIG. 2 is a schematic perspective view of an inventive assembly of two pieces of the type shown in FIG. 1;
FIG. 3 is a schematic perspective view of a locking key which is a variant of that shown in FIG. 2;
FIG. 4 is a schematic elevation of an inventive piece, according to a second embodiment;
FIGS. 5 and 6 are schematic elevations of a locking key adapted for assembling two pieces of the type shown in FIG. 4;
FIG. 7 is a schematic elevation showing an assembly accomplished with two pieces of the type of that of FIG. 3 and with a locking key of the type of FIGS. 4 and 5;
FIG. 8 is a schematic elevation of an inventive piece according to a third embodiment; and
FIG. 9 is a schematic perspective view of an assembly of two pieces of the type shown in FIG. 8.
DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiment illustrated in FIGS. 1 and 2 is an article (such as an item of furniture), or a packaging element, or a partition or the like, which is assembled by interpenetration of at least two pieces (1,2) of the type shown in FIG. 1, which are panels or the like having thickness x which is small in relation to the length y and width z of the major faces of the piece.
Each piece 1-2 has a rectilinear slot 3 which is perpendicular to the planes of the major faces 4 and 5, which slot extends from an edge 6 and opens out in an opening 7 which passes through the piece from one major face 4 to the other major face 5. The opening 7 has a rectangular shape. The two pieces 1 and 2 are assembled by mutually inserting the slots 3 of the two pieces (1,2) into each other, whereby each of said slots passes through the respective other piece's opening 7 and becomes positioned beyond said opening so as to engage the solid parts 8 adjacent to the edge 9 which edge is opposite to the slotted edge 6 which defines the outer end of slot 3.
The openings 7 of the pieces 1 and 2 are aligned at this stage. In order to immobilize them, a locking key is placed in the two openings 7. This key should be rigid with respect to the direction parallel to the axis of the slots 3.
It can be seen from FIG. 2 that such a key may be comprised of a tubular element 10 comprised of an elastically deformable material. Such a tubular element 10 is substantially rigid with respect to its height dimension H parallel to the longitudinal dimension of the slots 3, but is elastically deformable perpendicularly to said dimension. In this way it is possible to insert element 10 laterally into the two aligned openings 7 by necessarily deforming said element 10, since the pieces 1 and 2 are rigid. The key being rigid in its height dimension H, it can be supported against the two opposing nonslotted edges 11 and 12 of the openings 7, with greater or lesser play (depending on the difference between the height H of the key 10 and the distance between the edges 11 and 12 when pieces 1 and 2 are assembled). Thus, key 10 acts in the manner of a wedge or crosspiece to oppose the disengagement of the engaged slots 3 and thereby to prevent the separation of the pieces 1 and 2.
It is noted that the openings 7 are aligned according to the invention, that the slots 3 are disposed at an angle to each other, and that the key 10 is visible over its entire periphery except across the thickness of the pieces 1 and 2. Thus, this key 10 can be made to play a visual role beyond its functional role, whereby it adds esthetically to the appearance of the assembly. In this connection, pieces 1 and 2 may be provided in a certain material and/or color, with the key 10 being of a material and/or color which contrasts with these visually.
The key 10 of the type just described is cylindrical, and can thus be rotated. If, on the other hand, it is desired for the key to be non-rotatable, it may be provided with grooves 13 (Fig. 3) which cooperate with the edges 14 and 15 of the openings 7, which edges are parallel to the slots 3.
It is noted that the grooves 13 also provide substantial holding of pieces 1 and 2 by way of the sides of said grooves, to ensure good perpendicular alignment of said pieces; and said grooves thereby contribute to the rigidity of the assembly.
Since the key 10 of FIG. 3 is tubular and flexible, it is installed in the manner described in connection with FIGS. 1 and 2, namely by deforming it and inserting it laterally into the aligned openings 7.
FIGS. 4 to 7 illustrate an embodiment according to which the pieces 21 and 22 are of the same general type as that illustrated in FIGS. 1 and 2, namely the pieces comprise relatively thin panels having a slot 23 perpendicular to the plane of the major faces 24 and 25. The slots 23 extend from an edge 26 to a circular opening 27.
The pieces are assembled by mutually inserting the slots 23 until each slot is disposed beyond the opening 27 of the other piece, and is disposed spanning the solid part 28 opposite the slot 23.
The assembled pieces 21 and 22 are immobilized by means of a key 30 comprised of a spherical element having two parallel grooves 31 and 32 which are parallel to and symmetrical with respect to a diameter D of the sphere. The bottoms 33 and 34 of grooves 31 and 32 are separated by a distance d which is generally equal to the width L of the slots 23. The width 1 of the grooves 31 and 32 is (except for slight play) equal to the thickness x of the pieces 21 and 22.
For the immobilization of the pieces 21 and 22 after assembly, the key 30 is placed in the opening of one of the pieces, with the grooves 31 and 32 being in a plane perpendicular to that of the large faces 24 and 25. The slot 23 of the second said piece is then engaged with the first said piece, and the second said piece is caused to slide such that the side faces 23a of its slot pass into the grooves 31 and 32 of the key 30. The opening 27 of the second said piece is at that stage disposed across the key 30. The key is then turned so that the grooves 31 and 32 extend perpendicularly to the planes of the two pieces 21 and 22. Thereby one obtains a locking effect, by bracing or wedging means, of the opposed openings 27 of the two engaged pieces 21 and 22.
FIGS. 8 and 9 illustrate a third embodiment, according to which the pieces 41 and 42 are of the same type as that of FIGS. 1 and 2, and have a rectangular opening 47. The essential difference is that the locking key is not separate and independent as described supra, but results from the cooperation of two plates which are pivotably attached to the respective pieces, as will be described infra.
Opening 47 contains a solid plate 44 having a slot 45 and mounted on a pivot 46 mounted in the interior of the piece. It is seen that this mounting enables plate 44 to be pivoted around the pivot 46, with respect to the piece 41 or 42.
In the assembly process, care is taken to place the plate 44 or each piece 41, 42 in the plane of the piece, whereby the slot 45 constitutes a continuation of the slot 43. The slots 43 of the two pieces are inserted one in the other, and the sliding engagement of the said pieces is continued in the slots 45, which also are inserted one in the other, with the openings 47 being eventually aligned vertically. The plates 44 are thus joined together whereby they both pivot around the same axis, since the pivots 46 of the two plates 44 are coaxial. They are then pivoted together, as shown in FIG. 9, arrow F1. This pivoting is carried out through 90 degrees, namely until the plates 44 are again in the planes of the respective pieces (41, 42), with each plate 44 being in the plane of the opposite piece (41, 42), namely the plate 44 attached to piece 41 being in the plane of piece 42, and the plate 44 attached to piece 42 being in the plane of piece 41. In this way retraction and separation of the pieces is rendered impossible. In order to effect retraction of the pieces 41 and 42, the plates 44 must be pivoted by 90 degrees again (clockwise or counterwise), until the plate 44 attached to piece 41 is in the plane of piece 41, and the plate 44 attached to piece 42 is in the plane of piece 42. The slots 45 and 43 of a given piece-and-plate structure are thus again aligned, and the pieces can be slid apart, one with respect to the other.
It is seen in the above description that the key is in the form of a brace or wedge member, and that said key must be substantially rigid in its active direction parallel to the axis of the slots of the pieces. In the transverse plane, the key should be flexible and elastically deformable, if its contour is wider than that of the openings as aligned. Thus, the key may be in the form of a simple blocking rod, which is narrower, than the openings as aligned. But, if one is to take advantage of the presence of the key to provide a decorative element, the rigid key may be invested with a flexible material such as a synthetic foam material. In the case of very high flexibility, the adornment may take on all sorts of shapes, providing a flexibility which is incompatible with prior solutions to the inventive problem.
Whatever the particular embodiment chosen, the key can be given an appearance which contrasts with that of the pieces, in color or in material of manufacture. Thus, in the embodiment of FIGS. 8-9, the plates 44 may be given an appearance different from that of the pieces 41 and 42.
It should be noted that the embodiment of FIGS. 4-7 envisions a key in the form of a spherical body, which can play the role of a hinge means, where, after the assembly is completed, the key is attached to one of the pieces, so that they can pivot with respect to the other piece. The piece attached to the key may be the pivotable piece (e.g. a furniture door), while the other piece remains stationary (e.g. the frame of an item of furniture).
With the embodiment of FIGS. 1 to 3, the tubular key may be provided in transparent or translucent form and may contain a source of light, such as an electric light bulb or tube. The pieces then constitute a lamp body. One may provide zones of the key which create different lighting effects, and then by rotating the key the zone or zones producing the desired effect (e.g., intense lighting, filtered lighting, colored lighting, etc.) may be exposed.
The use of the invention is not confined to the manufacture of furniture (in particular, finished furniture items). The invention may also be used for toys which can be disassembled; for construction assemblies; etc.
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First and second panel members each formed with an elongate slot extending from one edge of the panel member and an enlarged opening into which the slot extends are connected together at an angle by sliding the slot of one of the panel members lengthwise through the slot and opening of the other panel member and into embracing engagement with material of the other panel member beyond the opening therein until the openings of the respective panels are mutually aligned in the lengthwise direction of the slots. A locking key device having substantial rigidity lengthwise of the slots is fitted in the openings when the panels are assembled to prevent their separation. The locking device may be provided in various decorative forms.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority to U.S. provisional application No. 60/895,153, filed Mar. 16, 2007, which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to an integrated single duct silencing terminal unit for HVAC (heating, ventilating, and air conditioning) systems.
BACKGROUND OF THE INVENTION
Commercial HVAC systems have conventionally contained “Single Duct Terminal Units” (“SDTUs”) for the purpose of providing an outlet for commercial ventilation systems into the rooms of a building or other structure equipped with an HVAC system. An SDTU typically consists of the following components: 1) inlet duct, 2) flow sensor, 3) modulation damper, and 4) insulated casing.
In commercial HVAC installations, a “silencer” (or “attenuator”) is often placed downstream of an SDTU in order to attenuate the sound produced by the high-velocity air exiting the SDTU. Such silencers have typically comprised an air duct (typically from three to five feet in length) that is lined internally with insulation to attenuate the noise produced by the air flowing through the SDTU. Such internal insulation is also known as a “baffle” and is usually held in place by perforated sheet metal. The perforations in the metal allow the air traveling through the silencer to interact with the insulation material contained inside the baffle. The attenuation achieved by the silencer is due to the conversion of acoustic energy into heat energy as the air molecules inside the silencer create friction when they collide with the lined insulation.
The noise generated by an SDTU can be separated into two components: 1) noise due to the air disturbance created in the immediate vicinity of the damper blade and 2) aerodynamic noise due to the flow of air that has variable pressure regions interacting with geometry changes in the air stream. The insulation contained in silencers minimizes both sources of noise created by the SDTU,
The noise generated by a given SDTU can vary widely depending on how it is utilized in a particular HVAC system and on the configuration of the HVAC system. Similarly, the acoustic performance of a given silencer can also vary widely depending upon the configuration of the HVAC system in which it is installed. Such unpredictability of the noise that will be generated by an SDTU and the attenuation achieved by a silencer is related to what is known as the “system effect” of the HVAC system in which the SDTU and silencer are installed. For instance, the manner in which the distribution ductwork is organized in a given building installation can affect the turbulence and air pressures created inside the ductwork. This, in turn, can affect the noise level generated by an SDTU and the acoustic performance achieved by a silencer attached thereto.
The unpredictability produced by such system effects creates uncertainty when HVAC installers are selecting SDTUs and silencers for installation in a building. Manufacturers of traditional SDTUs and silencers typically test their products under artificial laboratory conditions and produce specifications as to the noise generated by their SDTUs and the noise attenuation achieved by their silencers. However, these specifications do not take into account the system effects produced by installing their products in an actual HVAC system. Thus, HVAC installers generally have only marginally reliable product specifications on which they can rely and often must utilize trial-and-error methods to choose the appropriate combination of SDTUs and silencers that will meet their needs in a particular HVAC installation.
SUMMARY OF THE INVENTION
The invention (a single duct silencing terminal unit “SDSTU”) involves an apparatus and method for attenuating the sound generated by a single duct terminal unit in a predictable and consistent manner. A further object of the invention is the integration of an SDTU and a silencer into a single unit, without any intervening ductwork connecting them. It is an object of the invention to minimize the total length of the SDSTU in comparison to the combined length of prior art SDTUs, silencers, and connecting ductwork. Another object of the invention is to attenuate sound to a greater degree than is possible with a combination of prior art SDTUs or silencers of a given size.
Embodiments of the invention reduce both the noise due to the air disturbances within the SDSTU and the self-generated aerodynamic noise by the unique internal geometry in the silencing portion of the SDSTU that minimizes both types of noise.
Some embodiments of the invention reduce noise due to the extended discharge length of the silencing portion of the SDSTU.
Some embodiments of the invention contain a wider casing surrounding the silencing portion of the SDSTU than found in prior art silencers.
Some embodiments of the invention include thicker insulation around the plenum of the SDSTU than prior art SDTUs and thus provide superior attenuation properties.
In some embodiments, the length of the “discharge region” following the inlet duct of the SDSTU is longer than in prior art SDTUs. This provides a longer length inside the plenum for the flowing air to transition from the high-pressure, high-velocity ductwork into the SDSTU. This, in turn, allows for less turbulence as the flowing air moves into the silencing portion of the SDSTU.
The plenum portion of the SDSTU is closely coupled to the silencing portion of the SDSTU in some embodiments. This helps minimize turbulence within the SDSTU and minimizes the overall length of the SDSTU in comparison to the prior art combination of an SDTU, silencer, and connecting ductwork.
Further objects, features and advantages will become apparent upon consideration of the following detailed description of the invention when taken in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-sectional view of a prior art SDTU close-coupled with a prior art silencer.
FIG. 2 is a side cross-sectional view of a prior art SDTU connected to a prior art silencer by a three-foot long air duct that is lined internally with insulation.
FIG. 3 is a side cross-sectional view of an SDSTU in accordance with the invention.
FIG. 4 an end view along the line labeled “ 4 ” of FIG. 3 .
FIG. 5 a cross-sectional view along the line labeled “ 5 ” of FIG. 3 .
DETAILED DESCRIPTION
FIG. 1 is an illustration of the close-coupling of a prior art SDTU 101 with a prior art silencer 102 . Such close-coupling of prior art SDTUs and silencers will produce unpredictable results because of the turbulence created when high velocity air exits the inlet duct 103 and enters the silencer 102 . The wide area 104 created where the silencer 102 attaches to the SDTU 101 will create excess turbulence and noise. In addition, the cross-sectional area of the air pathway 105 of a prior art silencer 102 is typically narrower than the cross sectional area of the outlet 106 of the SDTU 101 . Therefore a “nose” 107 is created where the air exiting the outlet 106 collides into the baffles 108 inside the silencer 103 . This too causes added turbulence and increased noise. Such noise greatly exceeds that which would be predicted based on the manufacturer's noise specifications for the SDTU 101 and silencer 102 individually.
FIG. 2 is an illustration of how prior art silencers are typically installed in an HVAC system. Because of the excess noise created by any attempt to closely couple a prior art silencer to an SDTU 201 , installers will usually separate the SDTU 201 and the silencer 203 by a length of lined ductwork 202 , typically one to three feet in length. While reducing the noise generated by the SDTU 201 , this approach has the drawback of increased costs due to the extra ductwork and increased length of the overall unit. In addition, installers must use trial and error techniques to determine an appropriate length for the connecting ductwork 202 . Furthermore, installers cannot generally rely on the manufacturer's noise specifications for the SDTUs or silencers.
FIG. 3 is a side cross-sectional view of an SDSTU 300 in accordance with an embodiment of the invention. The plenum portion 301 of the SDSTU 300 is directly attached to the silencing portion 302 of the SDSTU 300 with no intervening ductwork. This helps to minimize the overall size of the SDSTU 300 .
The internal geometry of the silencing portion 302 of the SDSTU 300 is configured to minimize both the noise due to the air disturbances inside the SDSTU 300 and the self-generated aerodynamic noise of the SDSTU 300 . Specifically, the silencing portion 302 of the SDSTU 300 has an air pathway 303 that is narrower than the inlet 304 into the silencing portion 302 of the SDSTU 300 . The constricted air pathway 303 is configured to permit a maximum of 4500 feet per minute velocity of air flow through the SDSTU 300 . Under optimal conditions, the flow rate through the SDSTU 300 will not exceed 3000 feet per minute.
This 3000 feet per minute velocity rate produces the optimal trade-off in terms of minimizing the combination of air disturbance noise and self-generated aerodynamic noise. Any further constriction of the air pathway 303 would increase self-generated aerodynamic noise more than it would attenuate the air disturbance noise. Conversely, any widening of the air pathway 303 would increase the air disturbance noise more than it would minimize the self-generated aerodynamic noise.
Baffles 309 in the silencing portion 302 of the SDSTU flare outward into a “tail” 305 in some embodiments of the invention. (In other embodiments, the baffles 309 are straight, thus providing a constant cross-sectional area for the air pathway 303 .) This tail 305 allows the expanding air that is traveling down the air pathway 303 to maintain a constant pressure. This is because the increased cross-sectional area of the tail portion 305 of the SDSTU 300 provides additional space for the expanding gas to occupy, thus preventing a buildup of pressure within the SDSTU 300 .
In some embodiments, the length of the silencing portion 302 of the SDSTU 300 is substantially longer than prior art silencers. This allows for greater attenuation of the noise generated at the SDSTU 300 by providing a longer air pathway 303 in which the air molecules flowing through the SDSTU 300 can interact with the baffles 309 of the silencing portion 302 of the SDSTU 300 . The optimal size for such extended discharge length of the silencing portion 302 is up to thirty six inches.
Some embodiments of the invention contain extended casing 306 surrounding the silencing portion 302 of the SDSTU 300 , making the silencing portion 302 wider than the plenum portion 301 of the SDSTU 300 . This feature, not found in prior art silencer/SDTU combinations, allows for increased attenuation due to the additional insulation enclosed in the extended casing 306 . The extended casing 306 can be up to 10 inches in thickness with an optimal thickness of six inches or less.
The plenum portion 301 , in some embodiments of the invention, has thicker internal insulation 307 than prior art SDTUs. Such insulation provides more sound attenuation than the prior art. Such internal insulation can be up to two inches in thickness and up to four pounds in density. The optimal amount of insulation is up to an inch in thickness and up to 1.5 pounds in density.
Certain embodiments of the invention contain a longer plenum 301 than is found in prior art SDTUs. This extension of the plenum 301 provides a longer length of ductwork for the high-velocity, high-pressure air to exit the inlet duct 308 and transition into the lower pressure plenum 301 of the SDSTU 300 before entering the silencing portion 302 of the SDSTU 300 . As a result, the flowing air will have less turbulence as it flows into the silencing portion 302 of the SDSTU 300 . The optimal length of the plenum discharge region from the outlet 310 of the inlet duct 308 to the entrance 311 of the silencing portion 302 of the SDSTU 300 is up to 36 inches in length with an optimal length of 24 inches or less.
FIG. 4 depicts an end view of the silencing portion 302 of the SDSTU 300 and the perforated metal casing 351 that encloses the insulating material 352 of the baffles 309 . FIG. 4 also shows the extended casing 306 surrounding the silencing portion 302 of the SDSTU 300 .
FIG. 5 is a cross-sectional view of the insulating material 352 that comprises the baffles 309 of the silencing portion 302 of the SDSTU 300 .
While this invention has been described with reference to the structures and processed disclosed, it is to be understood that variations and modifications can be affected within the spirit and scope of the invention as described herein and as described in the appended claims.
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An apparatus and method for attenuating the sound generated by a single duct terminal unit in an HVAC (heating, ventilating, and air conditioning) system. The apparatus utilizes internal geometry to minimize noise due to air disturbances and aerodynamic effects within the apparatus.
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BACKGROUND OF THE INVENTION
This invention relates to a power control unit and, more particularly, to a system suitable for multiple channel light control.
There are lighting environments in which it is desirable to have control over the brightness of individual lights or groups of lights. Such control is used for example in theaters, auditoriums, churches and so forth. Accordingly, it is useful to have a control unit in which each control can vary the power to a light or set of lights. An additional useful capability is a master control which can dim or raise the brightness of all the lights simultaneously, as at the beginning and end of acts in a theatrical performance. The present invention provides a power control suited for such installations.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a control system for controlling the connection of an alternating current source to multiple loads. The system includes means responsive to the alternating current source for generating a sinusoidal compensating signal and means also responsive to the alternating current source for generating a synchronizing pulse at the time when the alternating current is zero. There are multiple load channels, each one being associated with a different one of the loads. Each channel includes a capacitor and means for charging the capacitor toward a potential selected for the one channel. In addition the channel includes means responsive to the compensating signal for charging the capacitor with a current that varies as the absolute value of the alternating current. Each channel additionally includes means for connecting the alternating current source to the load associated with the one channel when the voltage on the capacitor reaches a firing potential. Each channel also has means responsive to the synchronizing pulse to discharge the capacitor.
In another aspect of the invention, each channel has means for controlling the phase at which current is connected to the load associated with the one channel. In addition, there is a master control for controlling said phase for all channels simultaneously.
A control unit enclosure according to the invention, has a base sheet shaped to form front, bottom and rear walls, with side walls attached at opposite ends of the base sheet. A cover sheet forming the top wall of the box holds the controls of the unit, which are connected to a circuit board mounted to the underside of the cover sheet. Special mounting pieces allow attachment of the cover sheet to the base sheet.
In a preferred embodiment, without changing the structure of the enclosure, the cover sheet may be installed in either of two orientations to permit tabletop or wall mounted use of the unit.
The present invention provides a versatile, self-contained light control unit. It has features which allow it to be adapted to either horizontal tabletop use or vertical wall mounted use. The particular structure, including special brackets for holding the cover sheet, permits good access to the interior of the unit for maintenance.
There are, in addition, advantageous features of the electrical system. The relationship of the master control and channel controls permits simultaneously changing all brightness levels, while preserving the comparative brightnesses of the individual lights or sets of lights. Whereas certain circuit elements are necessary for each control channel, it has been possible with one means to generate a sinusoidal compensating signal for all channels. In addition, it has been possible to employ one means to generate a synchronizing pulse for all channels. The elimination of the compensating and synchronizing functions from each channel result in a more economical unit.
These and other features and advantages will become apparent from a consideration of the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a control unit according to the invention.
FIG. 2 is an exploded view of the unit of FIG. 1.
FIG. 3 is a detail of a mounting piece shown in FIG. 2.
FIG. 4 is a detail of another mounting piece shown in FIG. 2.
FIG. 5 is a perspective view of the unit of FIG. 1 mounted on a wall.
FIG. 6 is a perspective view of a flush mounted embodiment of a control unit according to the invention.
FIG. 7 is a block diagram of the electrical system of a control unit according to the invention.
FIGS. 8A-8B is a schematic diagram of the system of FIG. 7.
FIGS. 9a-9h is an illustration of waveforms generated in the operation of the electrical system according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a control unit according to the invention, indicated generally by the reference numeral 10. Controls which can be seen in FIG. 1 include a power on/off switch S5 and a master power control R41, which is a slide potentiometer. The unit has four power control channels, each of which has associated with it one of switches S1-S4 and one of slide potentiometers R42-R45. For example, Channel 1 is controlled by switch S1 and potentiometer R42. The switches each have three positions, INDEPENDENT, OFF and MASTERED, as shown in the drawing. The potentiometers slide against a numbered scale. The master and channel controls are used to adjust power flowing to four different loads, as described in detail below.
FIG. 2 shows the construction of the unit 10. A sheet 11 of metal is bent to form a base which has the bottom 12, front wall 13 and rear wall 14 of the control unit box. The rear wall 14 is of a greater height than the front wall 13. There is a group of electrical components which are mounted on the inside of the base sheet 11, including four power receptacles 15 which project through the rear wall 14 to connect with the loads for which unit 10 controls power.
Wooden side walls 16 fit against opposite edges of the base sheet. Brackets 17 are used to connect the sidewalls 16 to the bottom, front and rear walls, preferably with screws.
The top of the control unit box is formed by a cover sheet 18 of metal which has the controls including slide potentiometers R41-R45 on it. A circuit board 19 is mounted with standoffs 20 on the underside of cover sheet 18. A group of electrical components 21 on board 19 is connected to the controls on the cover sheet 18. An electrical cable 22, shown broken away, connects the group of components 21 with the components on the base sheet.
Mounting pieces 23 and 24, used to attach cover sheet 18 to the bottom sheet 12, are shown in greater detail in FIGS. 3 and 4. These pieces can be made by extrusion. In piece 24 (FIG. 3), a first planar element 25 projects from the edge 29 of the piece at an angle so that the element 25 will lie against and beneath the cover sheet 18. A second planar element 26 projects from edge 29 so as to lie against the inside of front wall 13. A third planar element 27 is parallel to element 25 and spaced above it, so that it projects on top of the cover sheet 18. Similarly, a fourth planar element 28 lies against the outside of front wall 13. The elements 25 and 27 form a notch 30 into which the front edge of sheet 18 fits. Likewise, elements 26 and 28 form a notch 31 into which the top edge of front wall 13 fits.
Mounting piece 24 in FIG. 4 has four planar elements 35-38 comparable to elements 25-28 of mounting piece 24. Elements 35 and 37 form notch 40; elements 36 and 38 form notch 41. In piece 23, the angle between planar elements 35 and 36 is acute to match the desired angle between cover sheet 18 and rear wall 14.
In the attachment of the cover sheet 18, the front edge thereof is inserted in notch 30, while the rear edge is inserted in notch 40. Then the cover sheet with mounting pieces 23 and 24 is lowered so that the top edges of front wall 13 and rear wall 14 are inserted in notches 31 and 41, respectively. Screws are then used to attach element 26 to front wall 13 and element 36 to rear wall 14.
FIG. 5 shows how control unit 10 can be used vertically mounted, as on a wall 48. It can be seen in FIG. 5 that in this case the switches S1-S4 are near front wall 13 of unit 10 rather than the rear wall 14 as in FIG. 1. In a table top configuration such as that in FIG. 1, it is generally desirable to have the power receptacles 15 (FIG. 2 only) and AC power cord 44 leading away from the user. However, in the wall mounted arrangement of FIG. 5, it is generally desirable to have the receptacles 15 and power cord 44 extending downward. In addition, it is desirable to have the cover sheet 18 of unit 10 slope upward away from the user, for readability. Since the receptacles 15 and power cord 44 are mounted in the rear wall 14 of unit 10, it is effective to reverse the installation of the cover sheet 18, putting the switches S1-S4 toward front wall 13. To make this possible, cable 22 (FIG. 2) must be made long enough so that cover sheet 18 may be installed either way. It is an advantage of the construction of unit 10 that the cover sheet and circuit board 19 are so easily installed in alternate orientations.
FIG. 6 shows a flush mount embodiment of a control unit according to the invention, indicated generally by the reference numeral 50. In unit 50, the controls are the same as those of unit 10 in FIG. 1, except that a power on/off switch S5 is additionally provided. A cover sheet 52, somewhat larger than sheet 18 of unit 10 is mounted against the wall 48. The remainder of the enclosure for unit 50 can be a five-sided electrical junction or switching box 54. The box 54 has knockouts 56 for power conductors in and out of the box.
The electrical circuit of the control system of the invention is illustrated by the block diagram in FIG. 7 and the detailed schematic diagram in FIG. 8. The blocks in FIG. 7 have been made to correspond closely, even as to position on the page, to subdivisions of the circuit in FIG. 8 enclosed by broken lines. The electrical system is indicated generally by the reference numeral 120.
As can be seen in FIG. 7, the electrical system of the invention has four channels, each controlling power to one of the loads 121-124. The loads are preferably resistive loads, for example, light bulbs. It will become apparent from the description that follows that the system 120 can be designed with any number of control channels.
The "phase control" executed by each channel of the system 120 is illustrated with reference to FIGS. 9a and 9b. In those drawings are shown two alternating current wave forms which can be applied to a load. The hatched portion in each waveform represents an interval during which the alternating current is actually connected to the load by the system 120; during other parts of the cycle, the current is disconnected from the load. In FIG. 9b, current is connected to the load at an earlier time in the cycle; therefore, the load receives more power. Thus, a light bulb being energized according to the phase relation in FIG. 9b would, in general, be brighter than one corresponding to FIG. 9a.
In the system 120, current from the AC line 126 is switched to each of the loads 121-124 by one of triacs Q15-Q18. The triacs are, in turn, controlled by firing circuits 141-144. The firing circuits are of the ramp-and-pedestal type, in which the timing of the firing is controlled by a selectable voltage level. These voltage levels are supplied to the firing circuits by input circuits 151-154 and channel controls 161-164, in conjunction with master control 166.
Each of the firing circuits 141-144 must have its timing synchronized with the AC line 126. Circuit 128 provides a synchronizing pulse for this purpose to each of the firing circuits 141-144. The circuit 130 provides a particular sinusoidal waveform to each of firing circuits to produce a desirable compensating effect.
With reference to FIG. 8, it can be seen that there is connected across the AC line a circuit 131, including a series combination of triac Q15 and receptacle J1, which in use has the load 121 connected thereto. The circuit 131 also has an L section EMI filter made up of inductor L1 and capacitor C6. Identical circuits 132-134 containing triacs Q16-Q18 and receptacles J2-J4 are all connected in parallel with circuit 131. Examining circuit 131, it can be seen that when triac Q15 is nonconducting, the load at receptacle J1 is disconnected from the AC line. Only when a proper trigger pulse is applied to terminal 138, the gate of triac Q15, does the load at receptacle J1 become connected to the line. Thus, it is the object of the control circuitry in system 120 to apply properly timed trigger pulses to the gates of triacs Q15-Q18 to provide power to the receptacles J1-J4 at the selected phasing.
Also connected across the AC line 126, through a circuit breaker 136, is a stepdown transformer T5. The voltage at the secondary 146 of transformer T5 can be, for example, 24 volts peak. This voltage from the secondary 146 is connected to a full wave rectifier 148 comprised of diodes D1-D4, which produces a 24 volt peak full wave rectified potential between terminal 149 and ground. A combination of a diode 156 and a filtering capacitor C1 connected to terminal 149 derives therefrom an unregulated DC potential at the cathode of 156. Regulator circuit 158 produces at its output 159 a regulated 24 volt DC reference potential, derived from the unregulated potential at terminal 157.
The function of the channel controls 161-164, and the circuitry immediately associated with it, is to allow the selection for each channel of a potential that charges a capacitor in the firing circuit for that channel. Thus for example, in Channel 1, a potential at the output 168 of operational amplifier 169 charges capacitor C2 of firing circuit 141. By varying the potential at output 168, the user selects the point in the alternating current cycle, when triac Q15 switches current to the load at receptacle J1.
Circuit 174 provides a DC reference potential for the master control and channel controls. The 24 volt DC reference potential is divided across resistors R1 and R41 to obtain an input to operational amplifier 176. The divided voltage is applied through resistor R2 to the positive input of amplifier 176, which has resistor R3 connected to feedback from the output 178 of the amplifier to the negative input thereof. This configuration serves as a buffer, producing at output 178 a voltage established between resistors R1 and R41. This voltage at output 178 then becomes the control reference voltage applied to the "INDEPENDENT" or "I" terminals of switches S1-S4. The lower reference potential used in the master control 166 and channel controls 161-164 on lead 180, is approximately one volt. This is the sum of the voltages across the diodes D6 and D7 connected in series between lead 180 and ground. The one volt value is used as a lower reference, because the single supply operational amplifiers preferably employed for amplifiers 168-172, 176 and 182 cannot accept inputs going all the way down to ground potential.
The potential applied to the "MASTER" or "M" terminals of switches S1-S4 is set by the use of master control potentiometer R41, which is connected in series with resistor R1 to the 24 volt DC reference potential. The voltage from the wiper of potentiometer R41 is applied through resistor R4 to the positive input of operational amplifier 182, which has resistor R5 connected to feedback from the output 183 of the amplifier to the negative input thereof. The potential derived by potentiometer R41 and buffered by the amplifier 182 configuration is connected from output 183 of the amplifier to each of the "M" inputs of switches S1-S4.
If one of the switches, for example switch S1, is set to the "MASTER" position, then the voltage selected by the master control potentiometer R41 is applied to the potentiometer R42 connected to S1. The fraction of this master potential that is to be applied to the firing circuit of Channel 1, is selected by the setting of potentiometer R42. Thus, for example, when the system 120 is used to control lights, the master setting of switches S1-S4 provides a way to dim or brighten all the lights in Channels 1-4 without disturbing the relative brightness settings between them, selected by potentiometers R42-45.
In the "INDEPENDENT" setting of switches S1-S4, the voltage selected by potentiometers 142-145 is a fraction of the fixed reference potential at point 178. In the "OFF" setting of switches S1-S4 the one volt lower reference potential is applied to the associated one of the control input circuits 151-154.
The potentials from the wipers of potentiometers R42-R45 are applied to buffer amplifier 169-172, respectively. The positive input to operational amplifier 169, for example, is applied through resistor R15. A feedback resistor R16 is connected between the negative input of the amplifier and the output 168 thereof, which is at the same voltage as the wiper of potentiometer R42.
Operational amplifier 184 has connected to the negative input thereof, through resistor R8, the full wave rectifier 148 output, shown in FIG. 9c. The 24 volt DC reference potential is applied through resistor R9 to the positive input of the amplifier. Amplifier 184 has a feedback resistor R10 connected between the output 185 and the negative input thereof. The effect of this operational amplifier configuration is to produce, at its output 185, a subtraction of the waveform in FIG. 9c from 24 volts. The result, shown in FIG. 9d, thus has peaks at 24 volts.
The voltage at the amplifier output 185 is applied to the bases of transistors Q3, Q6, Q9 and Q12. The emitter of, for example transistor Q3, is connected through resistors R18 and R19 to the 24 volt DC supply. Accordingly when the waveform in FIG. 9d is at its peak of 24 volts, there is no base-emitter drive on transistor Q3. As the base voltage decreases in a sinusoidal fashion, transistor Q3 draws a current which is proportional to the difference between 24 volts DC and the emitter voltage. Since the emitter voltage will be similar to that of the base, shown in FIG. 9d, the current through transistor Q3 has the waveform of FIG. 9c. As will be discussed more below, this current is drawn from capacitor C2.
The synchronizing circuit 128 also uses as inputs the 24 volt DC level and the output of the full wave rectifier 148, in this case to generate a synchronizing pulse. The full wave rectified voltage is coupled to the negative input of operational amplifier 188 through R6, which is much smaller than R7 through which the 24 volts DC is connected to the positive input. Thus, the output of amplifier 188 tends to be held negative most of the time. When the full wave rectified signal of FIG. 9c approaches its minimum, the positive input to amplifier 188 becomes predominant and drives the output of the amplifier positive for a brief period.
The output of amplifier 188 is connected through resistor R11 to the base of transistor Q1, which has the emitter thereof connected through resistors R12 and R39 to ground. So long as the output of amplifier 188 is negative, transistor Q1 is off and the voltage at lead 190 between its emitter resistors is zero. When the output of operational amplifier 188 goes positive, transistor Q1 is turned on and, for a brief period, the voltage at lead 190 is high, as shown in FIG. 9e. Thus, there are generated synchronizing pulses on lead 190 which occur at the minimum of the full wave rectified waveform and the zero crossings of the alternating current waveform.
The operation of the firing circuits, of which circuit 141 is descriptive, is a matter of timing the firing of unijunction transistors such as transistor Q4. An interbase voltage is established for Q4 by its connection through potentiometer R20 to the unregulated DC supply lead 157. Capacitor C2, connected to the emitter of unijunction transistor Q4, is charged and discharged by various means. When the potential on capacitor C2 reaches a certain fraction of the interbase voltage of transistor Q4, the transistor fires. When it fires, a pulse is coupled through transformer T1, connected to a base of transistor Q4, to gate terminal 138, triggering triac Q15.
The capacitor C2 begins each half of the alternating current cycle in the discharged condition. Thus, in FIG. 9g, the voltage on capacitor C2 is seen to be driven to zero at times 191. This is because the synchronizing pulse on line 190 is applied to the base of transistor Q5, turning it on and discharging C2. Then, capacitor C2 is rapidly charged, through diode D8 and R17 to a "pedestal" voltage, which is the potential at the output 168 of operational amplifier 169. In FIG. 9g, the "pedestal" can be seen at point 192. It will be recalled that this voltage is selected by the use of the control circuits 161 and 178.
Capacitor C2 is charged at a much slower rate by the current from transistor Q3, forming the "ramp" 194 in FIG. 9g. At point 196 on the waveform of that drawing, the voltage on capacitor C2 has increased sufficiently to fire the unijunction transistor Q4. From an examination of FIG. 9g, it can be understood that if the pedestal 192 were adjusted higher, then the transistor Q4 would fire earlier, turning on current to the load at receptacle J1 earlier in the alternating current cycle. FIG. 9f shows how long the firing is delayed, when the pedestal voltage is zero. FIG. 9h shows the use of a high pedestal voltage, which switches power to the load very early in the alternating current cycle.
In both of FIGS. 9g and 9h, it can be seen that capacitor C2 is discharged by the firing of the unijunction transistor Q4, then capacitor C2 again charges to the firing point. Subsequent firing of unijunction transistor Q4 does not affect the operation of the triac, which remains on after the first triggering, until the line voltage passes through zero.
The current from transistor Q3 charging capacitor C2 has the waveform of FIG. 9c. This is for the purpose of giving the ramp voltage the shape seen in FIG. 9f, with a steeper slope during that portion 198 of the cycle when the AC line voltage is at its peak. When firing is being controlled by portion 198 of the ramp, a given increment in the pedestal voltage produces a smaller change in the phase of firing than it would, say, near the zero crossing of the alternating current waveform. This then compensates for the fact that a given increment in the phase of firing near the line voltage peak results in a greater change in the power delivered to the load than the same phase increment would if made near the zero crossing of the line voltage.
Another form of compensation results from the use of the unregulated DC potential at potentiometer R20 to bias unijunction transistor Q4. If the line voltage fluctuates upward, then switching it to the load at the same phase, results in greater power to the load. However, if the line voltage increased, the unregulated DC potential biasing unijunction transistor Q4 would also increase. Thus, the voltage on capacitor C2 would take a little longer to reach the firing level, thereby compensating for the increased line voltage.
In the use of the system 120, the individual channel controls 161-164 are adjusted to control the power to their respective loads 121-124. When the switches S1-S4 are in the "MASTER" position, master control 166 can be used to raise and lower the power to all loads 121-124 simultaneously.
Relating the block diagram of FIG. 7 to the construction of the control unit 10 in FIG. 2, channel controls 161-164 and part of master control 166 are on the control panel of cover sheet 18. Transformer 146, and triacs Q15-Q18 are mounted on the bottom of base sheet 12. The other circuits are on circuit board 119, including firing circuits 141-144, synchronizing circuit 128 and compensating circuit 130.
Each of the channels includes a firing circuit, circuitry for selecting a pedestal voltage supplied to the firing circuit, and a triac to switch current to the load. However some functions which are common to all channels are performed by only one circuit for all the channels. Thus, the system 120 of the present invention is able to provide a pulse synchronized with the AC line to all channels, using only the circuit 128. Likewise, a sinusoidal waveform for charging the firing circuit capacitors C2-C5 in a compensating fashion is produced for all channels, using the circuit 130. In this fashion, there is avoided the redundancy of requiring these functions for each channel, resulting in a lower cost.
Although preferred embodiments of the invention have been described in detail, it is to be understood that various changes, substitutions and alterations can be made therein, without departing from the spirit and scope of the invention as defined by the appended claims.
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A unit is disclosed for individually controlling power to multiple loads, such as lights. The unit has multiple phase control channels, each having thyristor control of current to the load, triggered by a ramp-and-pedestal firing circuit employing a unijunction transistor with a capacitor at its emitter. The system has a circuit providing a pulse to all of the firing circuits to discharge the capacitor synchronous with the AC line. Another circuit generates a sinusoidal compensating signal for all of the firing circuits.
Each of the load channels has its own power control. In addition, a master control allows the power on all channels to be changed together, with the proportion of power in each channel set by its individual control.
The unit is housed in a box having a base sheet shaped to form front, bottom and rear walls, with side walls attached at opposite edges of the base sheet. A cover sheet forming the top wall of the box holds the controls of the unit, which are connected to a circuit board mounted to the underside of the cover sheet. Special mounting pieces allow attachment of the cover sheet to the base sheet. Without changing the structure, the cover sheet may be installed in either of two orientations to permit table top or wall mounted use of the unit.
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RELATED APPLICATIONS
[0001] This application is a continuation of PCT/AU2003/001010, filed Aug. 8, 2003, which claims priority to AU 2002950813, filed Aug. 9, 2002, the disclosures of which are incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a modular decking tile, and temporary decking made from modular decking tiles.
BACKGROUND OF THE INVENTION
[0003] Exploration for mineral resources such as natural gas and oil often takes place in regions remote from civilization. Such exploration sites are often located in remote jungles in tropical climates of high rainfall, in mountainous areas, or in areas of particular environmental sensitivity. When a mining organization selects a site for drilling, one of the initial tasks is to clear a working area of native vegetation, and to construct a working platform on top of the cleared earth on which equipment, buildings and drilling hardware can be assembled. The conventional foundation for this platform requires transportation of gravel or concrete and in many cases timber felled for the cleared site, from the surrounding forests. In many cases the working platform area is of considerable size, so large amounts of timber are required. Not only is this process labor intensive and high risk, it is also destructive to a broad perimeter of vegetation surrounding the actual working area and can be regarded as an environmentally unsound practice. Once drilling operations cease, the cut timber is not of economic value so it is left in situ and gravel and timber are required to be excavated and removed from the location. Despite any restoration works to the area, the native flora is likely to take decades to regenerate and recover.
[0004] In mining locations where there is no local supply of forest timber from which to make a suitable working platform, companies have been known to airlift in loads of gravel for foundations, clearly at considerable expense. Again, although material is generally not recovered for re-use after the site is abandoned, it may need to be excavated and removed.
[0005] Mining operations place high demands on the working platform. The platform must be stable when heavy machinery is driven over it. It must be capable of stabilizing the earth upon which it is laid because mining sites are frequently in high rainfall areas where erosion can otherwise occur. These platforms are often required to be used as helicopter landing sites, and must be capable of being safely secured in place so that when helicopters are landing or taking off, the turbulent rotor downwash does not dislodge parts of the platform which could otherwise fly out to injure personnel or damage the aircraft.
[0006] Accordingly, there is a need for a modular platform or decking with inherent mechanical attributes which can be installed at a desired site which may be accessible only by aircraft, can be assembled in a wide variety of configurations, can be safely secured to the ground to withstand high loads, traffic and wind forces such as helicopter rotor downwash, and which can be easily dismantled and removed for reuse. There is also a need for modular decking tiles that can easily be cut into alternative shapes yet retain its load bearing strength.
SUMMARY OF THE INVENTION
[0007] The present invention provides a modular decking tile and modular decking formed from such tiles that satisfy one or more of the above requirements. It will be convenient to refer to the invention in relation to use for oil and gas, mining and remote area exploration applications, although it will be appreciated that the invention may have wider application where a modular heavy-duty temporary ground cover is required.
[0008] According to one aspect of the present invention there is provided a tile for forming a modular deck with like-configured tiles, where the tile may have a planar polygonal upper surface and a lower surface, a web strengthening structure on said lower surface and a plurality of peripheral edges, where at least one of said edges includes a male connecting portion including a lateral tongue extending from said peripheral edge, and at least one of said edges includes a female connecting portion defining a lateral recess in said peripheral edge, whereby at least three of said peripheral edges include either of said male connecting portions or female connecting portions and such that the male connecting portion of one tile may be located into the lateral recess of the female connecting portion of an adjacent tile by lateral relative sliding movement of said tiles.
[0009] The tile may have a planar polygonal upper surface. The upper surface forms the surface of the deck that is subjected to downward and lateral forces from traffic including pedestrian and vehicular traffic when in use. The upper surface may include friction-enhancing means such as a textured or roughened surface treatment, and/or a plurality of raised lugs such as a chequerplate pattern so as to reduce the risk of slipping on the upper surface. The upper surface may be a regular polygonal shape such as a triangle, square, pentagon or octagon, but preferably is hexagonal in shape. It is considered that a hexagonal shape allows the greatest degree of versatility in deck configuration and also provides lo optimal rigidity and interfile connection to create the deck structure. This is because each tile within the deck structure is held in place by six adjacent tiles.
[0010] The web is preferably a continuous web that doesn't allow passage of water or air from the upper surface to the lower surface, although it may optionally be of a mesh configuration or have openings for drainage or ventilation if desired.
[0011] The lower surface of the web has a web strengthening and reinforcing structure for mechanical integrity to enable the web to withstand downward and lateral loads. The reinforcing web may be a plurality of webs perpendicular to the plane of the upper surface. Preferably the webs of the reinforcing structure are made from the same material as the web and are formed integrally therewith. The reinforcing webs may form box-like or triangular reinforcing structures, triangular reinforcing structures or circular reinforcing structures or combinations of these. In a preferred embodiment, the tile has one or more severing lines, preferably which run between opposite and or adjacent corners of the polygonal shape. These are so that the tile can be cut into shapes different from the shape of a full tile so irregular decking arrangements can be made. Preferably a plurality of reinforcing webs are provided proximate to and substantially parallel with such severing lines although other reinforcing webs may be provided which do lie on said severing lines which would be cut if the tile is cut along that severing line. In one embodiment, such webs are provided alternately on either side of such severing lines.
[0012] The tile may have a plurality of peripheral edges that abut corresponding edges of complementary tiles when in use. Preferably the edges are substantially linear except for the connection portions, which are described below. The edges preferably each have a continuous edge face, which is perpendicular or slightly angular to the plane of the upper surface.
[0013] In one embodiment, at least one of the edges includes a male connecting portion that comprises a lateral tongue. The tongue may extend from and along a central part of the peripheral edge laterally and substantially perpendicular to the plane of the peripheral edge. Most preferably the male connecting portion includes a cutaway section that extends into the upper surface beyond the line of the edge so that a recess exists in the upper surface. This is so that the tongue does not just extend from the edge of the tile, but extends from a region within the edges of the tile.
[0014] In one embodiment, at least one of the edges includes a female connecting portion which defines a lateral recess in the peripheral edge. Preferably the female connecting portion consists of an upper flange and a lower flange that extend beyond the edge and the recess between the upper and lower flanges which extends into the tile beyond the edge of the tile.
[0015] Preferably the tile is hexagonal and three of the six edges have a male connecting portion and each of the three other edges has a female connecting portion. Preferably the male and female connecting portions are equally and alternately spaced around the edges of the tile (i.e., each edge with a female connecting portion has on either side an edge with a male connecting portion, and vice versa, so that going around the tile the edges have male, then female, then male, then female, etc connection portions). The male and female connecting portions are of complementary shape so that the male portion may be snugly accommodated in the female portion of an adjacent tile with little relative movement possible between the tiles when so joined. Each of the male and female connecting portions may include a bore in a position where the bores of joined male and female portions are coaxial so as to allow insertion of a securing rod therethrough. Female connecting portions preferably include a recess proximate said bore adapted to receive a head of said securing rod so that the head of the securing rod can be recessed below the plane of said upper surface. More preferably the recess is located in the upper flange of the female connecting portion.
[0016] Additionally tiles may include a bore in a central region or any other region of the upper surface through which a securing rod may be passed. Such a bore preferably has a recess adapted to receive the head of a securing rod, and may have additional recesses proximate the first recess to facilitate removal of a securing rod.
[0017] In another aspect of the invention there is provided a modular deck comprising a plurality of like-configured modular tiles as previously defined, wherein male connecting portions of tiles are inserted into female connecting portions of adjacent tiles such that tiles resist lateral, upward and downward movement relative to adjacent tiles. In yet another preferred embodiment the modular decking may further include a plurality of securing rods located through the bores of joined male and female connecting portions, and wherein the securing rods have heads located in recesses in the female connecting portions. In another aspect of the invention there may be provided a modular deck as previously defined consisting of a first layer of assembled tiles and a second layer of assembled tiles, wherein the edges of the first layer of tiles are offset from the edges of the second layer of tiles and where bores of tiles in the first layer are coaxial with bores of the second layer so that a securing rod may be passed through both layers of tiles to secure said deck in position. Additionally, any number of layers of tiles can be achieved so that a securing rod can be passed through all layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] It will now be convenient to describe the invention with particular reference to the preferred embodiments. It will be appreciated that the drawings related to a preferred embodiment only and are not to be taken as limiting the invention.
[0019] FIG. 1 shows a top view of a modular decking tile according to one embodiment of the present invention;
[0020] FIG. 2 shows a bottom view of a modular decking tile according to the present invention;
[0021] FIG. 3 shows a perspective view of a female connector portion of the present invention;
[0022] FIG. 4 shows a perspective view of a male-connector portion of the present invention;
[0023] FIG. 5 shows a top plan of a modular deck made up from two layers of modular decking tiles of the present invention; and
[0024] FIG. 6 shows a perspective view of a fixing peg of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In FIG. 1 , modular decking tile 1 has a planar hexagonal upper surface 3 bearing a pattern of raised friction lugs 5 to provide grip to upper surface 3 . Lugs 5 are shown in a chequer plate configuration designed to ensure that wheels of vehicles or footwear of pedestrian traffic does not slip on upper surface 3 , particularly when upper surface 3 is wet or muddy. The surface area of upper surface 3 may be up to approximately 3 m 2 although smaller or larger versions may be made if desired. Peripheral edges 7 , 7 a and & 7 b each have a female connector portion 9 , 9 a and 9 b typically shown in more detail in FIG. 3 .
[0026] Peripheral edges 11 , 11 a and 11 b each have male connector portions 13 , 13 a and 13 b typically shown in more detail in FIG. 4 .
[0027] Upper surface 3 has recessed lines 15 and 15 a which are reduced slightly below the plane of upper surface 3 . Recessed lines 15 and 15 a may accommodate an adhesive marking tape (not shown) for clearly outlining desired areas of a decking made up of modular decking tiles 1 , for example. The marking tape may define a landing zone for helicopters, or a walkway or vehicle pathway bordered by tape or other marking means in the recessed lines 15 and 15 a of one or more modular decking tiles 1 .
[0028] Securing openings are provided in various locations through the modular decking tile. Securing openings 16 , 16 a and 16 b are shown in female connector portions 9 , 9 a and 9 b and securing openings 18 , 18 a and 18 b are shown in male connector portions 13 , 13 and 13 b . Central securing opening 20 is shown in the center of modular decking tile 1 and has a head recess 22 . The securing openings are adapted to receive a fixing peg shown in FIG. 6 .
[0029] In FIG. 2 , the underside of modular decking tile 1 is shown. Under-side 17 comprises a multitude of structural reinforcing web members typically shown as 19 , 19 a and 19 b . These webs are perpendicular to the plane of upper surface 3 and give the modular decking tile 1 structural and torsional rigidity and load bearing capability for loads applied to upper surface 3 . Webs are generally lo arranged in a square or rectangular arrangement shown typically as 21 and 21 a , with additional webs forming concentric circular reinforcing structures 23 , 23 a and 23 b.
[0030] Two severing lines 25 and 25 a are shown where webs are positioned and aligned on either side of these lines. This is so that the modular decking tile 1 can easily be cut or sawn along either of severing lines 25 or 25 a to form alternative polygonal shapes. These may be required to fill certain spaces in a modular deck that cannot be filled with a full sized decking tile, particularly along edges or corners of such a deck. The severing line 25 extends between opposite corners 29 and 29 a and severing line 25 a extends between adjacent corners 27 and 27 a . Webs falling along the severing lines 25 and 25 a are preferably spaced less than about 20 mm from their respective severing line. This is so that if the modular decking tile is cut, the ingress of water, soil, insects, or other things into recesses created by cutting the modular decking tile are minimized at the same time maintaining the strength and integrity of the tile even though the tile has been cut.
[0031] In FIG. 3 female connector 9 consists of an upper flange 31 , which extends from and is continuous with upper surface 3 and a lower flange 33 of corresponding shape to upper flange 31 . Upper flange 31 and lower flange 33 define a recess 35 that receives a male portion, which is shown in more detail in FIG. 4 . Recess 35 extends into the body of modular decking tile 1 at least as deep as the extent to which flanges 31 and 33 extend beyond edge 37 .
[0032] Upper flange 31 includes a pair of access slots 39 and 39 a to assist with peg removal, a fixing peg head recess 41 and a securing opening 18 , and lower flange 33 includes a securing opening (not shown) coaxial with securing opening 18 . Access slots 39 and 39 a are provided to allow a tool to be hooked underneath the head of a “T” shaped fixing peg so as to withdraw the fixing peg from securing opening 18 . The head of the fixing head is located within the confines of head recess 41 so that it does not project into upper surface 3 to present a hazard. Recess 35 may be offset from the centerline of edge 37 (i.e., upper flange 31 may be thicker than lower flange 33 ).
[0033] In FIG. 4 male connector portion 13 consists of a tongue 43 which projects beyond edge 45 . Tongue 43 is of a complementary shape to recess 35 and is of slightly smaller dimensions so it can be snugly located within recess 35 . Male connector portion also includes cut away region 47 of upper surface 3 and cut away region 50 of under-side 17 .
[0034] The design of the connector portions shown in FIGS. 3 and 4 is such that when the female connector portion of one modular decking tile is coupled with the male connector portion of another modular decking tile, the mating engagement provides for a very secure fit which minimizes the risk of progressive loosening and separation of the joined tiles, particularly after repetitive traffic movement over the modular deck. Male connector portion 13 also includes a securing opening 49 in a position corresponding to that in the female connector portion of FIG. 3 . This is so that a fixing peg can be inserted through the securing openings of both male and female connector portions when assembled to more securely fix the decking in position.
[0035] In FIG. 5 three upper tiles 51 , 51 a and 51 b are shown laid in an offset arrangement over four lower tiles 53 , 53 a , 53 b and 53 c . This offset arrangement provides a highly stable platform with high load bearing capacity. Fixing pegs, typically shown as 55 , are provided where male and female connector portions of upper tiles 51 and 51 b are joined, which is in register with where male and female connector portions of lower tiles 53 and 53 b are joined. The single fixing peg thus secures four tiles into position in three ways. First it secures all four tiles in position relative to the ground on which they lie. Secondly, it secures each pair of tiles whose male and female portions are coupled relative to each other. Thirdly, it secures the upper layer relative to the lower layer to prevent the upper layer from sliding over the lower layer.
[0036] Fixing pegs, typically shown as 55 a , are provided where the center of a tile ( 51 b ) in the upper layer is in register with where the male and female connector portions of tiles 53 c and 53 b are joined. The resultant platform has an extremely high degree of stability to resist the downward loads, lateral shearing and uplifting forces which are encountered while in use.
[0037] In FIG. 6 , fixing peg 56 is substantially “t” shaped and consists of an elongate shank 57 and a head 59 connected thereto. Elongate shank 57 is of suitable strength to be driven into the ground to secure decking tiles in position and is of a diameter slightly less than the diameter of openings 16 , 18 and 20 , so it can easily be inserted through them. Head 59 is of suitable strength and is affixed to the shank 57 so as to withstand hammering to drive shank into the ground and being pulled to withdraw the fixing peg when the modular deck is dismantled. Head 59 is of a size and shape to enable it to fit within head recess 22 or 41 , so that it does not protrude beyond the top of the deck surface.
[0038] To assemble a modular decking of the present invention on a cleared ground, a pair of modular decking tiles are positioned so that the male connector portion of one decking tile is positioned close to the female connector portion of an adjacent decking tile. The male and female connector portions are then fully engaged so that the cooperation of the two connector portions prevents both lateral and vertical relative movement of the two modular decking tiles along their abutting edge. Further decking tiles are added to those already assembled so as to build up the desired decking area.
[0039] If the decking arrangement requires a space to be filled into which a whole modular decking tile will not fit, a decking tile may be cut by suitable means along either or both of the cutting lines described above. The cut piece is then fitted into the decking in the same manner as for whole modular decking tiles.
[0040] If only light or moderate loads and forces are likely to be applied to the modular decking, a single layer of modular decking tiles may be adequate. If high loads and forces are likely, a second layer or multiple layers of modular decking tiles may be assembled on top of the first layer. Preferably this is done in an offset manner as shown in FIG. 5 . In this configuration, the center of a modular decking tile in the upper layer is positioned directly above the joined male and female connector portions of the underlying modular tiles.
[0041] Fixing pegs may be used to additionally secure the modular decking into position if desired. Fixing pegs may be inserted through either center openings in modular tiles or through the openings in joined male and female connector portions and hammered home so that the head of the peg is located in the recess at the opening. This latter arrangement ensures that the male and female connector portions stay engaged and greatly enhances the structural integrity of the modular decking. It will not generally be necessary to insert a fixing peg through each pair of joined connector portions because when other adjacent modular decking tiles are assembled, they will tend to resist movement of other tiles in the array. However, it may be desirable to use more fixing pegs in high traffic areas to further reduce the risk of movement of the modular tiles.
[0042] Disassembly of the modular deck is essentially the reverse of assembly. First, a fixing peg removal tool is used. This tool has one or preferably two prongs which are inserted into slots adjacent the head recess and the tool is hooked under the head of the fixing peg. The fixing peg can then be drawn vertically from the ground into which it is driven and removed from the openings. Adjacent modular tiles are then separated one by one, commencing at the periphery of the modular deck. The individual tiles are then optionally cleaned, stacked and transported for reuse.
[0043] The modular decking tiles may be made from any suitable material, for example thermoplastic polymers such as virgin or recycled polyethylene or polypropylene, with or without various stabilizers and/or modifiers, or metals such as aluminum or steel, and may be made by any suitable method such as injection molding, rotary molding or casting. Preferably the modular decking tiles are made from polyethylene, although depending on the demands of the modular decking, modular tiles of different materials but of complementary dimensions may be employed together. Tiles may be provided in a range of colors so that selected areas of decking may be colored. For example, red tiles may be used in high danger areas to warn workers of hazard areas.
[0044] Finally, the decking tiles may be made in any sizes suitable for easy handling and rapid installation.
[0045] It is to be understood that various modifications, additions and/or alterations may be made to the arrangements previously described without departing from the ambit of the present invention.
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A tile for forming a modular deck with like-configured tiles, the tile having a web having a planar polygonal upper surface and a lower surface, a web strengthening structure on said lower surface, and a plurality of peripheral edges, where at least one of the edges includes a male connecting portion having a lateral tongue extending from the peripheral edge, and at least one of the edges includes a female connecting portion defining a lateral recess in the peripheral edge. In one embodiment, at least three of the peripheral edges include either of the male connecting portions or the female connecting portions.
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FIELD
[0001] The subject matter relates to underground formation investigation, and more particularly, apparatus and methods for formation testing and fluid sampling within a borehole.
BACKGROUND
[0002] The oil and gas industry typically conducts comprehensive evaluation of underground hydrocarbon reservoirs prior to their development. Formation evaluation procedures generally involve collection of formation fluid samples for analysis of their hydrocarbon content, estimation of the formation permeability and directional uniformity, determination of the formation fluid pressure, and many others. Measurements of such parameters of the geological formation are typically performed using many devices including downhole formation testing tools.
[0003] During drilling of a wellbore, a drilling fluid (“mud”) is used to facilitate the drilling process and to maintain a pressure in the wellbore greater than the fluid pressure in the formations surrounding the wellbore. This is particularly important when drilling into formations where the pressure is abnormally high: if the fluid pressure in the borehole drops below the formation pressure, there is a risk of blowout of the well. As a result of this pressure difference, the drilling fluid penetrates into or invades the formations for varying radial depths (referred to generally as invaded zones) depending upon the types of formation and drilling fluid used. The formation testing tools retrieve formation fluids from the desired formations or zones of interest, test the retrieved fluids to ensure that the retrieved fluid is substantially free of mud filtrates, and collect such fluids in one or more chambers associated with the tool. The collected fluids are brought to the surface and analyzed to determine properties of such fluids and to determine the condition of the zones or formations from where such fluids have been collected.
[0004] One feature that all such testers have in common is a fluid sampling probe. This may consist of a durable rubber pad that is mechanically pressed against the rock formation adjacent the borehole, the pad being pressed hard enough to form a hydraulic seal. Through the pad is extended one end of a metal tube that also makes contact with the formation. This tube is connected to a sample chamber that, in turn, is connected to a pump that operates to lower the pressure at the attached probe. When the pressure in the probe is lowered below the pressure of the formation fluids, the formation fluids are drawn through the probe into the well bore to flush the invaded fluids prior to sampling. In some prior art devices, a fluid identification sensor determines when the fluid from the probe consists substantially of formation fluids; then a system of valves, tubes, sample chambers, and pumps makes it possible to recover one or more fluid samples that can be retrieved and analyzed when the sampling device is recovered from the borehole.
[0005] It is important that only uncontaminated fluids are collected, in the same condition in which they exist in the formations. Often the retrieved fluids are contaminated by drilling fluids. This may happen as a result of a poor seal between the sampling pad and the borehole wall, allowing borehole fluid to seep into the probe. The mudcake formed by the drilling fluids may allow some mud filtrate to continue to invade and seep around the pad. Even when there is an effective seal, borehole fluid (or some components of the borehole fluid) may “invade” the formation, particularly if it is a porous formation, and be drawn into the sampling probe along with connate formation fluids.
[0006] Additional problems arise in Drilling Early Evaluation Systems (EES) where fluid sampling is carried out very shortly after drilling the formation with a bit. Inflatable packers or pads cannot be used in such a system because they are easily damaged in the drilling environment. In addition, when the packers are extended to isolate the zone of interest, they completely fill the annulus between the drilling equipment and the wellbore and prevent circulation during testing.
[0007] There is a need for an apparatus that reduces the leakage of borehole fluid into the sampling probe, and also reduces the amount of borehole fluid contaminating the fluid being withdrawn from the formation by the probe. Additionally, there is a need for an apparatus that reduces the time spent on sampling and flushing of contaminated samples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a system for testing and drilling operations as constructed in accordance with at least one embodiment.
[0009] FIG. 2 illustrates a wireline system for drilling operations as constructed in accordance with at least one embodiment.
[0010] FIG. 3 illustrates a probe as constructed in accordance with at least one embodiment.
[0011] FIG. 4 illustrates a probe as constructed in accordance with at least one embodiment.
[0012] FIG. 5 illustrates a probe as constructed in accordance with at least one embodiment.
[0013] FIG. 6 illustrates a side view of a probe as constructed in accordance with at least one embodiment.
[0014] FIG. 7 illustrates a side view of a probe as constructed in accordance with at least one embodiment.
[0015] FIG. 8 illustrates a side view of a probe as constructed in accordance with at least one embodiment.
[0016] FIGS. 9-16 illustrates an example of a retractable wiper for a probe as constructed in accordance with at least one embodiment.
DESCRIPTION
[0017] In the following description of some embodiments of the present invention, reference is made to the accompanying drawings which form a part hereof, and in which are shown, by way of illustration, specific embodiments of the present invention which may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
[0018] FIG. 1 illustrates a system 100 for drilling operations. It should be noted that the system 100 can also include a system for pumping operations, or other operations. The system 100 includes a drilling rig 102 located at a surface 104 of a well. The drilling rig 102 provides support for a down hole apparatus, including a drill string 108 . The drill string 108 penetrates a rotary table 110 for drilling a borehole 112 through subsurface formations 114 . The drill string 108 includes a Kelly 116 (in the upper portion), a drill pipe 118 and a bottom hole assembly 120 (located at the lower portion of the drill pipe 118 ). The bottom hole assembly 120 may include drill collars 122 , a′ downhole tool 124 and a drill bit 126 . The downhole tool 124 may be any of a number of different types of tools including measurement-while-drilling (MWD) tools, logging-while-drilling (LWD) tools, etc.
[0019] During drilling operations, the drill string 108 (including the Kelly 116 , the drill pipe 118 and the bottom hole assembly 120 ) may be rotated by the rotary table 110 . In addition or alternative to such rotation, the bottom hole assembly 120 may also be rotated by a motor that is downhole. The drill collars 122 may be used to add weight to the drill bit 126 . The drill collars 122 also optionally stiffen the bottom hole assembly 120 allowing the bottom hole assembly 120 to transfer the weight to the drill bit 126 . The weight provided by the drill collars 122 also assists the drill bit 126 in the penetration of the surface 104 and the subsurface formations 114 .
[0020] During drilling operations, a mud pump 132 optionally pumps drilling fluid, for example, drilling mud, from a mud pit 134 through a hose 136 into the drill pipe 118 down to the drill bit 126 . The drilling fluid can flow out from the drill bit 126 and return back to the surface through an annular area 140 between the drill pipe 118 and the sides of the borehole 112 . The drilling fluid may then be returned to the mud pit 134 , for example via pipe 137 , and the fluid is filtered.
[0021] The downhole tool 124 may include one to a number of different sensors 145 , which monitor different downhole parameters and generate data that is stored within one or more different storage mediums within the downhole tool 124 . The type of downhole tool 124 and the type of sensors 145 thereon may be dependent on the type of downhole parameters being measured. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, radiation, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc.
[0022] The downhole tool 124 further includes a power source 149 , such as a battery or generator. A generator could be powered either hydraulically or by the rotary power of the drill string. The downhole tool 124 includes a formation testing tool 150 , which can be powered by power source 149 . In an embodiment, the formation testing tool 150 is mounted on a drill collar 122 . The formation testing tool 150 includes a probe that engages the wall of the borehole 112 and extracts a sample of the fluid in the adjacent formation via a flow line. The probe includes one or more inner channels and one or more outer channels, where the one or more outer channels captures more contaminated fluid than the one or more inner channels. As will be described later in greater detail, the probe samples the formation and, in an option, inserts a fluid sample in a container 155 . In an option, the tool 150 injects the carrier 155 into the return mud stream that is flowing intermediate the borehole wall 112 and the drill string 108 , shown as drill collars 122 in FIG. 1 . The container(s) 155 flow in the return mud stream to the surface and to mud pit or reservoir 134 . A carrier extraction unit 160 is provided in the reservoir 134 , in an embodiment. The carrier extraction unit 160 removes the carrier(s) 155 from the drilling mud.
[0023] FIG. 1 further illustrates an embodiment of a wireline system 170 that includes a downhole tool body 171 coupled to a base 176 by a logging cable 174 . The logging cable 174 may include, but is not limited to, a wireline (multiple power and communication lines), a mono-cable (a single conductor), and a slick-line (no conductors for power or communications). The base 176 is positioned above ground and optionally includes support devices, communication devices, and computing devices. The tool body 171 houses a formation testing tool 150 that acquires samples from the formation. In an embodiment, the power source 149 is positioned in the tool body 171 to provide power to the formation testing tool 150 . The tool body 171 may further include additional testing equipment 172 . In operation, a wireline system 170 is typically sent downhole after the completion of a portion of the drilling. More specifically, the drill string 108 creates a borehole 112 . The drill string is removed and the wireline system 170 is inserted into the borehole 112 .
[0024] FIG. 2 illustrates the formation testing tool 150 in greater detail. As mentioned above, the formation testing tool 150 can be included on the wireline system 170 or a drilling system, for example. It should be noted the formation testing tool 150 can be included on other tools, including, but not limited to tools that lower themselves into the borehole. In FIG. 2 , an example of the wireline system is shown with formation testing tool 150 .
[0025] A portion of a borehole 201 is shown in a subterranean formation 207 . The borehole wall is covered by a mudcake 205 . The formation tester body 171 is connected to a wireline system 170 leading from a rig at the surface ( FIG. 1 ). The formation tester body 171 is provided with a mechanism, denoted by 210 , to clamp the tester body at a fixed position in the borehole. In an option, the clamping mechanism 210 is at the same depth as a probe 152 . Other mechanisms for engaging the probe 152 with the borehole include, but are not limited to inflatable packers.
[0026] In an example, a clamping mechanism 210 and a fluid sampling pad 213 are extended and mechanically pressed against the borehole wall. The fluid sampling pad 213 includes a probe 152 that has one or more outer channel 156 , and one or more inner channel 154 . The inner channel(s) 15 is disposed within at least a portion of the outer channel(s) 156 . In an option, the inner channel(s) 154 is extended from the center of the pad, through the mud cake 205 , and pressed into contact with the formation. For instance, the inner channel(s) 156 is connected by a hydraulic flow line 223 a to an inner channel sample chamber 227 a . In another option, the fluid sample pad 213 is extended via extendable members 211 ( FIGS. 6 and 7 ), and the inner and outer channels 154 , 156 can contact the formation. In an option, flow lines 223 a , 223 b for the inner and/or outer channels 154 , 156 extend through the extendable members 211 , and to their respective channels. In a further option, the probe 152 is an articulating probe, where the probe can hinge at one or more locations 184 ( FIG. 8 ) to contact the surface of a formation and borehole more readily.
[0027] The outer channel(s) 156 has one or more openings 158 ( FIG. 3 ) therealong, the openings being hydraulic connected with the formation thru the channel. Optionally the outer channel(s) can be directly contacting the formation. All of the openings can be connected to one or more hydraulic lines with in the body of the tool. In an option, the outer channel(s) 154 is connected by its own hydraulic flow line, 223 b , to an outer channel sample chamber, 227 b . Because the flow line 223 a of the inner channel(s) 154 and the flow line 223 b of the outer channel(s) 156 are separate, the fluid flowing into the outer channel(s) 156 does not mix with the fluid flowing into the inner channel(s) 154 . The outer channel(s) can 156 isolate the flow into the inner channel(s) 154 from the borehole beyond the pad 213 . In a further option, the inner channel flow line 223 a and/or the outer channel flow line 223 b extend through extendable members 204 ( FIGS. 6 and 7 ).
[0028] The hydraulic flow lines 223 a and 223 b are optionally provided with pressure transducers 211 a and 211 b . In an option, the pressure maintained in the outer channel flowline 223 b is the same as, or slightly less than, the pressure in the inner channel flowline 223 a . In another option, the pressure ratio maintained in the inner channel flowline 223 a to the outer channel flowline 223 b is about 2:1 to 1:2. In another option, the flow rates of the inner channel(s) 154 and the outer channel(s) 156 are regulated. For example, the flow rate ration of the inner channel(s) 154 to the outer channel(s) 156 is about 2:1 to 1:2. With the configuration of the pad 213 and the outer channel(s) 156 , contaminated borehole fluid that flows around the edges of the pad 213 is drawn into the outer channel(s) 156 , and diverted from entry into the inner channel(s) 154 .
[0029] The flow lines 223 a and 223 b are optionally provided with pumps 221 a and 221 b , or other devices for flowing fluid within the flow lines. The pumps 221 a and 221 b are operated long enough to substantially deplete the invaded zone in the vicinity of the pad 213 and to establish an equilibrium condition in which the fluid flowing into the inner channel(s) 154 is substantially free of contaminating borehole filtrate.
[0030] The flow lines 223 a and 223 b are also provided with fluid identification sensors, 219 a and 219 b . This makes it possible to compare the composition of the fluid in the inner channel flowline 223 a with the fluid in the outer channel flowline 223 b . During initial phases of operation, the composition of the two fluid samples will be the same; typically, both will be contaminated by the borehole fluid. These initial samples are discarded. As sampling proceeds, if the borehole fluid continues to flow from the borehole towards the inner channel(s) 154 , the contaminated fluid is drawn into the outer channel(s) 156 . Pumps 221 a and 221 b discharge the sampled fluid into the borehole. At some time, an equilibrium condition is reached in which contaminated fluid is drawn into the outer channel(s) 156 and uncontaminated fluid is drawn into the inner channel(s) 154 . The fluid identification sensors 219 a and 219 b are used to determine when this equilibrium condition has been reached. At this point, the fluid in the inner channel flowline is free or nearly free of contamination by borehole fluids. Valve 225 a is opened, allowing the fluid in the inner channel flowline 223 a to be collected in the inner channel sample chamber 227 a . Similarly, by opening valve 225 b , the fluid in the outer channel flowline 223 b is collected in the outer channel sample chamber 227 b . Alternatively, the fluid gathered in the outer channel(s) can be pumped to the borehole while the fluid in the inner channel flow line 223 a is directed to the inner channel sample chamber 227 a . Sensors that identify the composition of fluid in a flowline can also be provided, in an option.
[0031] FIGS. 3-5 illustrate additional variations for the probe 152 . The probe 152 is defined by a height 180 and a width 182 . In an option, the probe has an elongate shape and the height 180 is greater than the width 182 . This allows for the probe 152 to contact a greater number of laminates. In another option, the probe 152 has an overall oval shape.
[0032] As discussed above, the probe 152 includes inner and outer channels 154 , 156 , and the inner and outer channels 145 , 156 include a number of openings 158 or ports therein, where fluid flows through the openings 158 . The number of flow ports, in an option, in the outer channel(s) 156 is different than in the inner channel(s) 154 . In an option, the outer channels 156 have an overall oval, elongate shape and/or encircle with inner channel(s) 154 . While an elongate or oval shape are discussed, it should be noted other shapes for the probe or outer channels can be used. Furthermore, the area of the outer channel(s) 156 relative to the area of the inner channel(s) 154 can be varied, for example, as seen in FIGS. 3 and 4 . In another option, the outer channel(s) 156 do not completely encircle the inner channel(s) 154 , as shown in FIG. 5 . For example, the outer channel(s) 156 are disposed on one or more sides of the inner channel(s) 154 .
[0033] In a further option, the probe 152 includes an outer sealing member such as a seal 162 that encircles the outer channel(s) 156 , as shown in FIG. 3 . In further option, the probe 152 includes a seal 164 disposed between the outer channel(s) 156 and the inner channel(s) 154 , where the seal 164 is optionally retractable within the probe 152 . The seals 162 , 164 seal against the bore hole wall to enclose a contact surface therein. The seals can be made of elastomeric material, such as rubber, compatible with the well fluids and the physical and chemical conditions expected to be encountered in an underground formation.
[0034] The probe 152 can be operated, cleansed, or kept cleansed in a number of manners. For example, the probe 152 includes one or more screens 166 over the openings 158 . In an option, the one or more screens 166 are retractable to promote flow. Although only one screen 166 is shown in FIG. 3 , the screens 166 can be disposed over one or more of the openings 158 for the inner channel(s) 154 and/or the outer channel(s) 156 . In another option, the probe further includes at least one wiper that excludes or assists in excluding mud entry into the inner or outer channels.
[0035] In another example, fluid can be pumped through the probe 152 in various manners, such as out of the inner and/or outer channels 154 , 156 or into the inner and/or outer channels 145 , 156 . For instance, fluid is pumped through the probe 152 clearing the inner channel(s) 154 including pumping fluid out of the inner channel(s) 154 while optionally pumping into the outer channel(s) 156 . In a further option, fluid is pumped through the probe 152 clearing the outer channel(s) 156 including pumping fluid out of the outer channels) 156 while optionally pumping into the inner channel(s) 154 . In another option, fluid pump through the probe 152 is a selected fluid, such as a fluid that is capable of dissolving material that can clog formation pores near the probe. The fluid can be stored in a collection chamber that can be prefilled, or empty.
[0036] In yet another option, mud cake can be displaced, including removed, adjacent the seals, the inner channel member, or the outer channel member. For example, a wiper assembly as shown in FIG. 9-16 can be included with the above-discussed probe 152 . The wiper assembly includes a retractable wiper. The wiper can be used to remove or exclude mud cake from the probe as the pad sets.
[0037] Advantageously, the formation samples with low levels of contamination can be collected more quickly using the formation tester. Furthermore, the probe can be self cleaning without having to remove the probe from the borehole. This can increase the efficiency of the pumping or drilling operations. Furthermore, the probe allows for a thin layer or fracture to be identified because the probe can capture a layer or fracture by spanning vertically along the well bore.
[0038] Reference in the specification to “an option,” “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the options or embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances of “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments.
[0039] Although specific embodiments have been described and illustrated herein, it will be appreciated by those skilled in the art, having the benefit of the present disclosure, that any arrangement which is intended to achieve the same purpose may be substituted for a specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
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Apparatus and methods for downhole formation testing including use of a probe having inner and outer channels adapted to collect or inject injecting fluids from or to a formation accessed by a borehole. The probe straddles one or more layers in laminated or fractured formations and uses the inner channels to collect fluid.
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BACKGROUND
[0001] The invention relates to a base interlining, a method for producing it as well as roofing membranes comprising a base interlining.
[0002] Base interlinings for producing roofing membranes have to meet a wide variety of requirements. In particular, base interlinings must have sufficient mechanical stability, such as good perforation strength and good tensile strength, which appear during further processing, for example, such as bituminization or laying. In addition, there is a need for high resistance to thermal stress, for example during bituminization, or to radiant heat and spreading fire. Many efforts have therefore been made to improve the existing base interlinings.
[0003] For instance, it is already known, to combine non-woven fabrics on the basis of synthetic non-wovens with reinforcing fibers, for example glass fibers, in order to improve their mechanical stability. Examples of such sealing membranes can be found in GB-A-1,517,595, DE-Gbm-77-39,489, EP-A-160,609, EP-A-176-847, EP-A-403,403 and EP-A-530,769. According to this state of the art, the fiber mat and reinforcing fibers are joined together by gluing by means of an adhesive agent or by needling the layers composed of different materials.
[0004] It is further known to produce composite materials by knitting or stitch bonding technologies. Examples thereof can be found in DE-A-3,347,280, U.S. Pat. No. 4,472,086, EP-A-333,602 and EP-A-395,548.
[0005] From DE-A-3,417,517 a textile interlining having anisotropic properties and a method for producing it is known. Said interlining consists of a substrate having a surface which melts below 150 DEG C and reinforcing filaments connected thereto which melt above 180° C. and are fixed to this surface in a parallel arrangement. According to one embodiment, said substrate may be a non-woven fabric on the one surface of which are arranged melt bonding fibers or melt bonding filaments that are provided to produce an adhesive bond between the parallel arranged reinforcing fibers and the non-woven fabric.
[0006] From U.S. Pat. No. 4,504,539 a combination of reinforcing fibers in the form of bicomponent fibers and non-woven fabrics on the basis of synthetic fibers is known.
[0007] From EP-A-0,281,643 a combination of reinforcing fibers in the form of a network of bicomponent fibers and non-woven fabrics on the basis of synthetic fibers is known, wherein the weight proportion of the network of bicomponent fibers is at least 15% by weight.
[0008] From JP-A-81-5879 a composite which is provided with a net-shaped reinforcing material is known.
[0009] From GB-A-2,017,180 a filter material composed of inorganic non-woven fabric and metal wires is known, which is used for the exhaust air purification at high temperatures (higher than 300 DEG C).
[0010] DE-Gbm-295 00 830 describes the reinforcement of a glass mat with synthetic monofilaments. These reinforcing monofilaments do not substantially contribute to the reference force at low elongation in the water-proof sheeting. They present, however, a sensibly higher elongation at maximum tensile force than the glass mat. Thus, the two-dimensional connection of the water-proof sheeting is ensured, even when it is subjected to deformations which may lead to the fracture of the glass mat. The shrinkage of the synthetic monofilaments is higher than the shrinkage of the glass mat and may result in waviness in the water-proof sheeting.
[0011] DE-A-3,941,189 likewise discloses a combination of reinforcing fibers in the form of a thread chain with non-woven fabrics on the basis of synthetic fibers which can be connected to each other in a great many ways. In this application, it is emphasized that the Young's modulus of the reinforced base interlining does not change compared with an unreinforced basic non-woven fabric.
[0012] From EP-A-0,806,509 and EP-A-0,806,510, there are known base interlinings comprising a textile fabric and a reinforcement which absorb the acting force already at a low elongation. Although such base interlinings have good application properties, the further improvement of these products is a permanent task.
[0013] Furthermore, it was known from the state of the art that the spunbonded non-wovens are subjected to a mechanical consolidation after their production. To this end, the spunbonded non-woven is usually subjected to a needling process. To reach a sufficient delamination stability, needle densities of 20 to 100 stitches/cm 2 are required. Even though needling is done by means of needles whose kick-up, preferably the sum of kick-up and barb depth, is smaller than the diameter of the reinforcing filaments, damages to the reinforcing filaments are unavoidable. Such damages may lead to problems with respect to the dimensional stability.
[0014] The base interlinings known from the state of the art are usually provided with a coating. To this end, the base interlinings are, depending on their intended use, passed through corresponding immersion baths, for example with bitumen, or provided with a coating product. By doing so, the open structure which constitutes a—more or less—large part of the void volume is filled. Due to the large air volume in the base interlining, a considerable volume of impregnating bitumen is required in order to completely replace the air by bitumen.
[0015] If the saturation by impregnating bitumen is insufficient, the properties which are important for subsequent use, such as delamination and moisture absorption, are considerably affected or not obtained at all.
[0016] Therefore, according to the state of the art, a complete preimpregnation of the base interlining is carried out in which the base interlining is passed through a preimpregnation bath, for example with highly viscous, generally unfilled bitumen, in order to eliminate the existing air in the base interlining.
[0017] The processing operations known in the state of the art which are used to obtain a finished roofing membrane are costly and complicated and require several process steps to achieve a sufficient saturation of the base interlining with the impregnating compound. Due to the high costs of special bitumens for filling the base interlining and the additional process steps which lead to a further considerable cost increase of the process, a new approach for the production of coated base interlinings is desirable.
[0018] Consequently, there is still a considerable need for products which properties of the finished base interlining are adversely affected or laying gets costlier.
[0019] Thus, it was the object of the present invention to provide improved base interlinings which can be cheaply produced in commercial quantities, and on the other hand can be provided with a coating in known but simplified processes.
SUMMARY
[0020] Subject-matter of the present invention is thus a base interlining comprising a textile fabric with the following parameters:
a) the weight per unit area of the textile fabric is between 20 and 500 g/m 2 ; b) the air permeability of the textile fabric is between 250 and 1000 l/m 2 sec, measured according to EN-ISO 9237; c) the thermal dimensional stability of the textile fabric is max. 0.9% in the longitudinal direction and max. 0.75% in the transverse direction, measured in conformity with DIN 18192; d) the maximum tensile force lengthwise/crosswise is >500/>300 N/5 cm in conformity with DIN 29073, part 3; e) the perforation resistance is >1200 N in conformity with DIN 54 307.
[0026] Furthermore, the base interlining of the invention may have reinforcements as well as additional textile fabrics, preferably textile fabrics which are different from the first textile fabric.
BRIEF DESCRIPTION OF THE FIGURE
[0027] FIG. 1 represents the improvement of the thermal dimensional stability of the base interlining of the invention compared with base interlinings without the calendering process of the invention.
DETAILED DESCRIPTION
Reinforcement of the Base Interlining
[0028] In a preferred embodiment of the invention, the base interlining has at least one reinforcement. This reinforcement is designed so as to absorb a force so that in the force-elongation-diagram (at 20 DEG C), the reference force of the base interlining with reinforcement compared to the base interlining without reinforcement differs in the range between 0 and 1% elongation at least at one location by at least 10%.
[0029] In another embodiment, the reinforcement of the base interlining can be incorporated in such a way that, due to the reinforcement, forces are only absorbed at higher elongations.
[0030] The good mechanical properties of the base interlining of the invention are in particular achieved by reinforcement filaments and/or reinforcement yarns whose Young's modulus is at least 5 Gpa, preferably at least 10 Gpa, most preferably at least 20 Gpa. The reinforcement filaments mentioned above, that is, the monofilaments as well as the yarns, have a diameter of between 0.1 and 1 mm or 10-400 tex, preferably 0.1 and 0.5 mm, particularly 0.1 and 0.3 mm, and have an elongation at fracture of 0.5 to 100%, preferably 1 to 60%. It is particularly advantageous that the base interlinings of the invention have an elongation reserve of less than 1%.
[0031] Elongation reserve signifies the elongation which acts on the base interlining before the acting force is deviated to the reinforcing filaments, that is, an elongation reserve of 0% would mean that tensile forces acting on the base interlining would immediately be deviated to the reinforcing filaments. This means that forces acting on the non-woven fabric do not cause an alignment or orientation of the reinforcing filaments first but are directly deviated to the reinforcing filaments, so that damages of the textile fabric can be avoided. This is particularly evident in a sharp increase of the force to be applied at small elongations (force-extension diagram at room temperature). In addition, the maximum tensile force of the base interlining can be considerably increased by means of appropriate reinforcing filaments having a high elongation at fracture. Appropriate reinforcing filaments are, for example, monofilaments or multifilaments made from polyester.
[0032] Multifilaments and/or monofilaments on the basis of aramids, preferably so-called high-modulus aramid fibers, carbon, glass, glass rovings, mineral fibers (basalt), high strength polyester monofilaments or multifilaments, high strength polyamide monofilaments or multifilaments, as well as so-called hybrid multifilament yarns (yarns containing reinforcing fibers and lower melting binding fibers) or wires (monofilaments) composed of metals or metal alloys are preferably used as reinforcing filaments.
[0033] For economic reasons, preferred reinforcements consist of glass multifilaments in the form of essentially parallel yarn sheets or scrims. Mostly the reinforcement is done in the longitudinal direction of the non-woven fabrics by essentially parallel running yarn sheets.
[0034] The reinforcing filaments may be used as such or in the form of a discrete textile fabric, for example as a woven fabric, a scrim, a knitted fabric, a warp-knitted fabric or a non-woven fabric. Reinforcements with reinforcing yarns running parallel to each other, that is, warp sheets, as well as scrims or woven fabrics are preferred.
[0035] The yarn density can vary in wide limits depending on the desired properties profile. Preferably, the yarn density is between 20 and 250 yarns per meter. The yarn density is measured perpendicular to the grain of the yarn. The reinforcing filaments are preferably fed during the spunbonded non-woven is produced and thus embedded in the spunbonded non-woven. Also preferred is a deposition of the non-woven fabric on the reinforcement or a subsequent formation of layers of reinforcement and non-woven fabric by assembly beaming.
[0036] Preferred base interlinings of the invention have at least one reinforcement and show in the force-elongation diagram (at 20 DEG C) that the reference force of the base interlining with reinforcement compared to the base interlining without reinforcement differs in the range between 0 and 1% elongation at least at one location by at least 10%, preferably by at least 20%, most preferably by at least 30%.
[0037] For a number of applications, however, a high modulus at small elongations even at room temperature is desired. This high modulus improves handling, in particular in the case of lightweight non-woven fabrics.
[0038] The reference force of the reinforced base interlining at small elongations can be distributed in varying proportions on the textile fabric or the reinforcements, depending on the requirements profile and also depending on cost factors.
[0039] The measurement of the reference force is carried out in conformity with EN 29073, part 3, on 5 cm wide samples at a restraint length of 200 mm. Here, the numerical value of the pretension, given in centinewton, equals the numerical value of the area mass of the sample, given in gram per square meter.
[0040] The reinforcement of the base interlining can be carried out by installing the reinforcements in the textile fabric, on at least one side of the textile fabric or at any location of the base interlining, in particular in further textile fabrics which are different from the first textile fabric or as a discrete textile fabric.
Textile Fabric
[0041] In the context of this description, the term “textile fabric” must be understood in its broadest sense. It can mean any structure composed of fibers which is made according to a technique for producing two-dimensional fabrics. The fiber-forming materials are natural fibers and/or fibers composed of synthesized polymers. Examples of such textile fabrics are woven fabrics, yarn sheets, knitted fabrics and preferably non-woven fabrics.
[0042] Among the non-woven fabrics composed of fibers, spunbonded non-wovens, also known as spunbonds, which are produced by random deposition of freshly melt-spun filaments, are preferred. They consist of continuous synthetic fibers composed of melt-spinnable polymer materials. Suitable polymer materials include, for example, polyamides, such as polyhexamethylenediadipamide, polycaprolactam, wholly or partly aromatic polyamides (“aramids”), aliphatic polyamides, such as nylon, partly or wholly aromatic polyesters, polyphenylene sulfide (PPS), polymers having ether and keto groups, such as polyetherketones (PEKs) and polyetheretherketone (PEEK), polyolefines, such as polyethylene or polypropylene, or polybenzimidazoles.
[0043] The spunbonded non-wovens preferably consist of melt-spinnable polyesters. The polyester material can, in principle, be any known type suitable for the fiber production. Such polyesters consist predominantly of components derived from aromatic dicarboxylic acids and from aliphatic diols. Commonly used aromatic dicarboxylic acid components are bivalent residues of benzenedicarboxylic acids, especially of terephthalic acid and of isophthalic acid; commonly used diols have 2 to 4 carbon atoms, wherein ethylene glycol is particularly suitable. Spunbonded non-wovens which consist of at least 85 mole % polyethylene terephthalate are particularly advantageous. The remaining 15 mole % are composed of dicarboxylic acid units and glycol units, which act as so-called modifying agents and which enable the person skilled in the art to influence the physical and chemical properties of the produced filaments in a targeted manner. Examples of such dicarboxylic acid units are the residues of isophthalic acid or of aliphatic dicarboxylic acid, such as glutaric acid, adipic acid, sebacic acid; examples of modifying diol residues are those of diols having longer chains, for example of propanediol or butanediol, of di- or triethylene glycol or, if present in a small amount, of polyglycol having a molecular weight of about 500 to 2000.
[0044] Particular preference is given to polyesters containing at least 95 mole % of polyethylene terephthalate (PET), especially those composed of unmodified PET.
[0045] In the case that the base interlinings of the invention shall additionally have a flame retardant effect, it is of advantage if they are spun from flame retardant modified polyesters. Such flame retardant modified polyesters are known. They contain additions of halogen compounds, in particular bromine compounds, or, which is particularly advantageous, they contain phosphorous compounds which are contained in the polyester chain as condensed units.
[0046] It is particularly preferred that the spunbonded non-wovens contain flame retardant modified polyesters having structural groups of the formula (I)
[0000]
[0000] wherein R represents alkylene or polymethylene having 2 to 6 carbon atoms, or phenyl, and R 1 represents alkyl having 1 to 6 carbon atoms, aryl or aralkyl, which are contained in the chain as condensed units. In this formula (I), R preferably represents ethylene, and R 1 preferably represents methyl, ethyl, phenyl or o-, m- or p-methyl-phenyl, in particular methyl. Such spunbonded non-wovens are described in DE-A-39 40 713, for example.
[0047] The polyesters contained in the spunbonded non-wovens preferably have a molecular weight corresponding to an intrinsic viscosity (IV) of 0.6 to 1.4, measured in a solution of 1 g polymer in 100 ml dichloroacetic acid at 25 DEG C.
[0048] The filament titer of the polyester filaments in spunbonded non-wovens is between 1 and 16 dtex, preferably 2 to 8 dtex.
[0049] In another embodiment of the present invention, the textile surface or the spunbonded non-woven can also be a non-woven fabric which has been consolidated by means of a melt binder, said non-woven fabric containing substrate fibers and melt bonding fibers. Said substrate fibers and melt bonding fibers can be derived from any thermoplastic filament-forming polymers. Beyond that, substrate fibers can be derived from non-fusing filament-forming polymers. Such spunbonded non-wovens which have been consolidated by means of a melt binder are described, for example, in EP-A-0,446,822 and EP-A-0,590,629.
[0050] Examples of polymers from which the substrate fibers can be derived are polyacrylonitrile, polyolefins, such as polyethylene or polypropylene, essentially aliphatic polyamides, such as nylon 6.6, essentially aromatic polyamides (aramids), such as poly-(p-phenylene terephthalate) or copolymers containing a proportion of aromatic m-diamine units to improve the solubility, or poly-(m-phenylene isophthalate), essentially aromatic polyesters, such as poly-(p-hydroxybenzoate) or preferably essentially aliphatic polyesters, such as polyethylene terephthalate.
[0051] The relative proportion of the two fiber types can be selected within wide limits, making sure that the proportion of the melt bonding fibers is selected sufficiently high to ensure that the non-woven fabric reaches a strength sufficient for the desired application by bonding the substrate fibers to the melt bonding fibers. The proportion of the hot-melt adhesive in the non-woven fabric originating from the melt bonding fibers is usually less than 50% by weight, relative to the weight of the non-woven fabric.
[0052] Modified polyesters having a melting point which, compared to the raw non-woven fabric, is reduced by 10 to 50 DEG C, preferably by 30 to 50 DEG C, are particularly suitable as hot melt adhesive. Examples of such a hot melt adhesive are polypropylene, polybutylene terephthalate, or polyethylene terephthalate modified by the condensation of longer-chain diols and/or isophthalic acid or aliphatic dicarboxylic acids.
[0053] The hot melt adhesives are preferably incorporated into the non-woven fabrics in fibrous form.
[0054] The substrate fibers and melt bonding fibers are preferably made up of one class of polymers. This means that all fibers used are selected from one class of substances so that they can be recycled without any problems after the non-woven fabric has been used. If the substrate fibers are composed of polyester, for example, the melt bonding fibers will likewise be of polyester or a mixture of polyesters, for example as a bi-component fiber with PET in the core and a polyethylene terephthalate copolymer having a lower melting point as an envelope. In addition, however, bi-component fibers which are made up of different polymers are also possible. Examples thereof are bi-component fibers of polyester and polyamide (core/envelope).
[0055] The monofilament titer of the substrate fibers and melt bonding fibers can be selected within wide limits. Examples of common titer ranges are 1 to 16 dtex, preferably 2 to 6 dtex.
[0056] If the base interlinings of this invention having flame retardant properties are additionally bonded, they preferably include flame retardant hot melt adhesives. The laminated sheet of the invention may include, for example, a polyethylene terephthalate modified by incorporation of chain members of the above-indicated formula (I) as a flame retardant hot melt adhesive.
[0057] In a preferred embodiment of the invention, the textile fabric has been subjected to a mechanical and/or chemical consolidation. Such a consolidation improves the application properties of the base interlining.
[0058] The consolidation may be carried out as individual steps or in combination, wherein care has to be taken, in particular in the presence of reinforcements, to ensure that a possibly present reinforcement will not be damaged or only slightly be damaged. The consolidation is carried out by means of known methods. Possible suitable methods include, without being limited to, mechanical methods, such as needling, in particular hydrodynamic consolidation, as well as chemical and/or thermoplastic methods.
[0059] If the consolidation is done mechanically by needling, it is carried out with stitch densities of 20 to 100 stitches/cm 2 , preferably at 40 stitches/cm 2 .
[0060] The hydrodynamic consolidation is preferably a water jet needling technique. The pressure applied during the water jet needling process is preferably between 5 and 600 bar, in particular between 50 and 450 bar, most preferably between 100 and 300 bar.
[0061] The nozzle diameter is between 0.05 and 0.25 mm, preferably between 0.07 and 0.2 mm. The nozzles are arranged in the form of so-called beams. The number of nozzles is between 10 and 60 nozzles per inch, preferably between 20 and 40 nozzles per inch.
[0062] Instead of water, other liquid media can also be used, and the water jet needling process can be carried out in several individual steps. The water jet needling process can be executed by means of a continuous water jet or by means of a pulsed water jet, wherein the pulse frequency is not subject to special restrictions. The water jet needling technique is particularly preferred in the presence of reinforcements.
[0063] If the textile fabrics do not contain binding fibers capable of thermal consolidation or only a few binding fibers capable of thermal consolidation, said textile fabrics are impregnated or additionally impregnated with a binder, preferably with one or more chemical binders. Chemical binders on the basis of acrylates or styrenes are particularly suitable for this purpose. Besides the chemical binders, also binders on the basis of starches can be used. The binder content is advantageously up to 30% by weight, preferably 2 to 25% by weight. The precise choice of binder is made according to the specific requirements of the subsequent processor. Hard binders permit high processing speeds during impregnation, especially bituminization, whereas a soft binder provides particularly high values of tear and nail pullout resistance.
[0064] In a further embodiment, also flame-retardant modified binders can be used.
[0065] The filaments or staple fibers from which the non-woven fabrics are prepared may have a virtually round cross section or have other forms, such as dumbbell-like, kidney-like, triangular or tri- or multilobal cross sections. It is also possible to use hollow fibers and bicomponent or multicomponent fibers. Furthermore, the melt binding fiber can also be used in the form of bicomponent or multicomponent fibers.
[0066] The textile fabric may have a single-layer or multilayer structure.
[0067] The fibers constituting the textile fabric may be modified by customary additives, for example by antistatics, such as carbon black.
[0068] The weight per unit area of the textile fabric, in particular of the spunbonded non-woven, is between 20 and 500 g/m 2 , preferably 40 and 400 g/m 2 , in particular 120 and 300 g/m 2 . In the case that binders are used, the aforementioned weight per unit areas refer to fabrics with binders.
[0069] The textile fabric present in the base interlining of the invention has been subjected to a special calendering process.
[0070] By means of the calendering technique, the textile fabric is consolidated. If the density before calendering is in the range of about 0.1 to 0.2 g/cm 3 , the density of the textile fabric after calendering is preferably at least 0.22 g/cm 3 , in particular at least 0.25 g/cm 3 , most preferably at least 0.3 g/cm 3 . The density is preferably increased by at least 50%, most preferably by at least 70%. The above specifications refer to textile fabrics on the basis of polyesters and have to be adjusted according to the density ratio of polyester versus another material if textile fabrics composed of other materials are used. These variations are accessible to persons skilled in the art without inventive effort, and are encompassed by the present invention.
[0071] The thickness of the textile fabric reduces by the calendering process preferably by at least 30%, particularly by at least 40%, most preferably by at least 45%. If the thickness before calendering is in the range of about 1 to 2 mm, the thickness of the textile fabric after calendering is preferably less than 1 mm, particularly less than 0.8 mm, most preferably 0.75 mm and less. The above specifications refer to textile fabrics on the basis of polyesters and have to be adjusted accordingly if textile fabrics composed of other materials are used. These variations are accessible to persons skilled in the art without inventive effort, and are encompassed by the present invention.
[0072] By means of the compressive calendering technique, the air permeability is adjusted to a value between 250 and 1000 l/m 2 sec (measured in conformity with EN-ISO 9237), preferably between 300 and 900 l/m 2 sec, particularly between 350 and 750 l/m 2 sec, so that the textile fabric permits a reduced uptake of impregnating compound or impregnating bitumen during the subsequent coating process or bituminization of the base interlining of the invention. Also when using other coating compounds for coating, it can be noted that pre-saturation can be omitted, at least partially. The use of the base interlining of the invention results in a reduction of the production costs and the materials used.
[0073] The calendaring process is preferably carried out at a linear load of 100 to 150 daN/cm, particularly 125 to 140 daN/cm. The surface temperature of the calendar-rolls is preferably between 180 and 260 DEG C, particularly between 225 and 250 DEG C. The above specifications refer to textile fabrics on the basis of polyesters and have to be adjusted accordingly if textile fabrics composed of other materials are used. These variations are accessible to persons skilled in the art without inventive effort, and are encompassed by the present invention.
[0074] Calendering, in particular calendering by means of S-calendering, that is, by means of an enlacement in S-shape, additionally increases the thermal dimensional stability of the textile fabric. In the longitudinal direction, an improvement of the dimensional stability of at least 20% (related to the dimensional stability before calendering), preferably of at least 25% is determined, and in the transverse direction, an improvement of the dimensional stability of at least 30% (related to the dimensional stability before calendering), preferably of at least 35% is determined. TDS is measured in conformity with DIN 18192.
[0075] In a preferred embodiment, no additional tensile forces other than those common to S-calendering processes are applied during the aforementioned calendering process.
[0076] In a preferred embodiment of the invention, the thermal dimensional stability of the textile fabric is up to max. 0.9% in the longitudinal direction and up to max. 0.75% in the transverse direction, preferably 0.3 to 0.5%. TDS is measured in conformity with DIN 18192.
[0077] In another preferred embodiment of the invention, the textile fabric, after having been calendared, is coated or impregnated with a binder, preferably with one or more chemical binders, and then consolidated. The binder content is between 10 and 25% in weight [related to the overall weight of the textile fabric]. Furthermore, it is of advantage to use a binder, in particular a chemical binder or binder system, which is compatible to coatings applied at a later time. The binders can naturally contain fillers.
[0078] The use of highly compressed textile fabrics enables a sensible reduction of impregnating compound, in particular impregnating bitumen.
[0079] Moreover, thanks to the smaller thickness of the textile fabric and the smaller thickness of the base interlining resulting thereof, considerably higher roll lengths of coated base interlinings can be reached. By means of the present invention, the overall thickness of the coated sheet can be reduced by at least 10%, so that considerably longer sheets are possible without changing the roll thickness. This leads to a reduction of the transportation costs and an improved handling during processing.
Further Textile Fabrics
[0080] The base interlining of the invention may comprise further textile fabrics besides the textile fabrics already described. These further textile fabrics are preferably different from the textile fabrics mentioned first, that is, they are made of another material or have other textures.
[0081] If the textile fabric is made up of synthetic polymers, it may be necessary to install further textile fabrics in the base interlining of the invention in order to optimize the application properties.
[0082] Besides the additional textile fabrics mentioned above, the base interlining of the invention may be equipped with further functional layers. This means steps or functional layers which increase the resistance to penetration of roots of the base interlining, for example. Said steps and functional layers are also the subject-matter of the invention.
[0083] The production of the base interlining of the invention comprises the following steps:
a) generation of a textile fabric and consolidation thereof; b) calendering of the textile fabric and increasing the density of the textile fabric by at least 50%; c) applying a binder and consolidation of the binder.
[0087] The generation of the textile fabric is carried out by means of known measures. Preferably, the generation of a textile fabric described under a) is done by producing a spunbonded non-woven by means of spinning apparatus known per se.
[0088] For this purpose, the molten polymer is supplied with polymers by several series-connected rows of spinning nozzles or groups of spinning nozzle rows. If a spunbonded non-woven consolidated by means of a melt binder shall be produced, feeding is alternately done with polymers which constitute the substrate fibers and the melt bonding fibers. The freshly spun polymer flows are stretched in a manner known per se and deposited in a dispersed texture on a conveyor belt, for example using a rotating deflecting plate.
[0089] The consolidation is also carried out by means of known methods.
[0090] The installation of the possibly present reinforcement is done during or after the generation of the textile fabric. If the reinforcement shall absorb the applied forces already at low elongations of the base interlining, the installation of the reinforcement is done after the calendering process of step b) or after step c).
[0091] The feeding of a further textile fabric which is possibly to install is done after the calendering process of step b) or after step c). In this context, it is of advantage to install the reinforcement which is possibly to install together with the further textile fabric or previous to it. In the latter case, the reinforcement is sandwiched between the two textile fabrics. The feeding of the reinforcement and any thermal treatment during the production process of the base interlining is preferably carried out under tension, in particular under longitudinal tension.
[0092] The calendering process of step b) is preferably carried out at a linear load of 100 to 150 daN/cm, in particular 125 to 140 daN/cm. The surface temperature of the calendar-rolls is preferably between 180 and 260 DEG C, in particular between 225 and 250 DEG C. The above specifications refer to textile surfaces on the basis of polyesters and have to be adjusted accordingly to if textile fabrics composed of other materials are used. These variations are accessible to persons skilled in the art without inventive effort, and are encompassed by the present invention.
[0093] The calendering process of the textile fabric of step b) causes a consolidation. If the density before calendering is in the range of about 0.1 to 0.2 g/cm 3 , the density of the textile fabric after calendering is preferably at least 0.22 g/cm 3 , particularly at least 0.25 g/cm 3 , most preferably at least 0.3 g/cm 3 . It is particularly preferred that the density is increased by at least 70%. The above specifications refer to textile surfaces on the basis of polyesters and have to be adjusted according to the density ratio of polyester versus another material if textile fabrics composed of other materials are used. These variations are accessible to persons skilled in the art without inventive effort, and are encompassed by the present invention.
[0094] The thickness of the textile fabric decreases by calendering preferably by at least 30%, particularly by at least 40%, most preferably by at least 45%, and reduces to the thicknesses stated at the beginning.
[0095] The calendering process is preferably carried out by means of an S-calendering technique, that is, by means of an enlacement of the textile fabric in S-shape. It causes an improvement of the dimensional stability of the textile fabric. In the longitudinal direction, an improvement of the dimensional stability of at least 20% (related to the dimensional stability before calendering), preferably of at least 25% is determined, and in the transverse direction, an improvement of the dimensional stability of at least 30% (related to the dimensional stability before calendering), preferably of at least 35% is determined.
[0096] In a preferred embodiment, no additional tensile forces other than those common to S-calendering processes are applied during the aforementioned calendering process.
[0097] The application process of the binder according to step c) is also carried out by means of known methods. The applied layer of binder is between 10 and 25% per weight. The used binder is preferably compatible with the coating applied by the customer.
[0098] Drying and solidification of the binder are also executed by means of methods known to persons skilled in the art.
[0099] The individual procedure steps on their own are known. In the combination and order of the invention, however, they are patentable.
[0100] The base interlining of the invention can be used to produce coated sarking membranes, roofing membranes and sealing membranes, preferably to produce bituminized sarking membranes, roofing membranes and sealing membranes.
[0101] The latter are also the subject-matter of the present invention. During the production, the carrier material is treated in a manner known per se with the compound used for coating, in particular bitumen, and subsequently strewed with a granular material, for example with sand, if required. The sarking membranes, roofing membranes and sealing membranes thus produced distinguish themselves by good processability.
[0102] Besides bitumen, also other materials, such as polyethylene or polyvinyl chloride, polyurethane, EPDM or TPO (polyolefins) are used as coating compounds for the coated sarking membranes, roofing membranes and sealing membranes.
[0103] The bituminized sheets contain at least one support sheet or base interlining as described above which is embedded in a bitumen matrix, wherein the weight proportion of the bitumen related to the weight per unit area of the bituminized roofing membrane is preferably 60 to 97% by weight and that of the spunbonded non-wovens is 3 to 40% by weight. Due to the small thickness of the base interlining, the overall thickness is reduced by at least 10% with the same layer of coating compound. The advantages resulting thereof have already been described at the beginning. With a base interlining of the invention (on the basis of polyester) having an weight per unit area of about 180 g/m 2 , the proportion of required impregnating bitumen reduces from about 550 g/m 2 to about 300 g/m 2 .
Example
[0104] A spunbonded non-woven on the basis of polyethylene terephthalate (PET) is produced and consolidated by needling. The weight per unit area is 180 g/m 2 . Subsequently, a calendering (S calendering) process is carried out at 225 DEG C and a linear load of 135 daN/cm, resulting in a reduction of the thickness of the non-woven fabric from 1.25 mm to 0.7 mm.
[0105] The thermal dimensional stability (TDS) improves from −1.15% to −0.85% (in longitudinal direction; MD) and from −0.9% to −0.5% (in transverse direction, CD), corresponding to an improvement by >25% and by >40%, respectively. The TDS is measured in conformity with DIN 18192.
[0106] The air permeability of the lining produced according to the invention reduced from 1275 l/m 2 sec to 544 l/m 2 sec (measured in conformity with EN-ISO 9237) and is determined as the average value of 10 measurement points.
[0107] The following table 1 shows die air permeability of the interlining produced according to the invention before and after calendering.
[0000]
TABLE 1
Permeability
Permeability
Measurement
[l/m 2 sec]
[l/m2 sec]
1
1200
700
2
1250
650
3
1350
550
4
1300
500
5
1250
550
6
1300
500
7
1300
400
8
1250
390
9
1300
550
10
1250
650
Average value
1275
544
max
1350
700
min
1200
390
[0108] Table 2 shows the influence of the calendering process on the thickness and the density of the base interlining of the invention.
[0000] TABLE 2 Areal Δ Δ Δ Δ weight Thickness Density Thickness 1 Density 1 Thickness Thickness Density Density [g/m 2 ] [mm] [g/cm 3 ] [mm] [g/cm 3 ] [mm] [%] [g/cm 3 ] [%] 180 1.25 0.144 0.7 0.257 −0.550 −44.0% 0.113 78.6 140 1 0.140 0.55 0.255 −0.450 −45.0% 0.115 81.3 200 1.3 0.154 0.75 0.267 −0.550 −42.3% 0.113 73.3 300 1.8 0.167 1 0.300 −0.800 −44.4% 0.133 80.0
wherein:
thickness is the thickness before calendering; thickness 1 is the thickness after calendering;
density is the density before calendering; density 1 is the density after calendering.
[0109] FIG. 1 represents the improvement of the TDS of the base interlining of the invention (032/180 SC) compared with base interlinings without the calendering process of the invention (033/180) and (032/180). The abbreviation MD means Main Direction (longitudinal direction); the associated values [%] can be obtained from the labels of the left axis, wherein the upper curve (circular symbols) has to be considered. The abbreviation CD means Cross Direction (transverse direction); the associated values can be obtained form the labels of the right axis, wherein the lower curve (square symbols) has to be considered.
[0110] While various embodiments have been described, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and scope of the claims appended hereto.
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The invention relates to a new base interlining for producing roofing membranes which have to meet a wide variety of requirements. The new base interlining provides a sufficient mechanical stability, good perforation strength, good tensile strength and a high resistance to thermal stress, inter alia required for base interlining during bituminization. In addition, the new base interlining requires a considerable reduced volume of impregnating bitumen when producing bituminized roofing materials and therefore high costs of special bitumens for filling the base interlining can be avoided. Beside the new base interlining, a method for producing it as well as roofing membranes comprising the base interlining are subject matter of this invention.
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This is a divisional of copending application Ser. No. 629,275, filed on Dec. 18, 1990, which is a divisional of application Ser. No. 435,257, filed Nov. 13, 1989, now U.S. Pat. NO. 4,981,660.
BACKGROUND OF THE INVENTION
This invention relates to a method and means for treating sludge.
It has been found that waste sludge can be treated by mixing cement kiln dust, lime, or other alkaline materials with the sludge in such a manner as to produce a disentegrable, friable product which can be applied to land as a soil conditioner. Examples of these methods are shown in U.S. Pat. Nos. 4,781,842, and 4,554,002 issued to N-Viro Energy Systems, Ltd.
While these patents show the desirability of mixing cement kiln dust or other alkaline materials with the sludge, these patents do not disclose the apparatus or methods for accomplishing the mixing. Waste sludge is a difficult material to handle. It can come in a highly liquid form, or it can come in a dewatered form which has a mud-like consistency. It is essential that the cement kiln dust be mixed with the sludge as thoroughly as possible.
Therefore, a primary object of the present invention is the provision of an improved method and means for treating sludge.
A further object of the present invention is the provision of a method and means for treating sludge which comprises mixing cement kiln dust or other alkaline materials with the sludge in an elongated auger mixer.
A further object of the present invention is the provision of a method and means for treating sludge which permits the easy adjustment of the ratios of kiln dust or alkaline materials relative to the amount of sludge being treated.
A further object of the present invention is the provision of a method and means for treating sludge which is economical to manufacture, durable in use, and efficient in operation.
SUMMARY OF THE INVENTION
The present invention utilizes an auger mixer similar to the auger mixers which have been used in the prior art for mixing cement and cement aggregate. The auger mixer comprises an elongated cylindrical housing having an upper wall formed from rigid metal, and having a lower arcuate wall formed from a flexible elastomeric material such as rubber. Within the auger housing is an elongated auger. The housing includes an inlet end and a discharge end.
The present invention utilizes an additive hopper having an additive conveyor for conveying material from the additive hopper to the inlet end of the mixer housing. Similarly, the present invention utilizes a conveyor for conveying the waste sludge to the inlet end of the auger mixer. The auger mixer conveys the additive and the sludge from the inlet end of the mixer housing to the discharge end of the mixer housing. The auger also cooperates with the flexible wall of the mixer housing to cause the additive and the sludge to be mixed together thoroughly.
A control system is connected to the two conveyors for conveying the sludge and the additives to the mixer housing. The control system includes a pair of rotary pulse generators connected to the additive conveyor and the sludge conveyor for sensing the rate with which the two conveyors deliver sludge and additive to the inlet end of the mixer housing. The rotary pulse generators are connected to two display panels which display the relative rates and totals of delivery of the additive and of the sludge. The control system includes means for controlling the rates and totals of delivery of the additive and the sludge so that the desired ratio of mixture can be achieved.
The preferred rotary pulse generators for use with the present invention are manufactured by Red Line Controls, 20 Willow Spring Circle, R. D.#5, York, Pa. 17402, under the model designation "Model RPGC".
The preferred control system comprises a six-digit, presetable counter/rate or dual counter indicator manufactured by Red Line Controls, 20 Willow spring Circle, R. D.#5, York, Pa. 17402, under the trade designation Gemini 4100. These controllers are capable of receiving the information from the pulse generators, and for displaying digitally the rate at which the various ingredients are being delivered. The controllers are also programmable so that the desired rotational speeds can be set and controlled automatically.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one form of the machine of the present invention.
FIG. 1A--1A is a sectional view taken along line 1A--1A of FIG. 1.
FIG. 2 is an elevational view showing the location of the various augers schematically.
FIG. 3 is a schematic view of the hydraulic circuitry of the present invention and connection of the controller to the hydraulic circuitry.
FIG. 4 is a perspective view of a modified form of the present invention.
FIG. 5 is a side elevational view of the machine shown in FIG. 4, showing the augers schematically.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-3, a sludge treating machine is generally designated by the numeral 10. Machine 10 includes a sludge hopper 12, an additive hopper 14, a sludge conveyor 16, an additive conveyor 18, a mixing hopper 20, and a mixer 22.
Mixer 22 comprises a mixer housing 24 which has a flexible upper half 26 and a flexible lower half 28. Housing 24 is made of an elastomeric material such as rubber or any other flexible material capable of yielding and moving slightly in response to internal pressures. The upper half 26 of housing 22 is free to bend with respect to the lower half 28 for hinged movement about reinforcing rib 30 (FIG. 1A). A latch rib 32 is connected to one edge of upper half 26 and mates with a support rib 34 on flexible member 28. A latch 36 locks the upper half 26 to the lower half 28.
Mixer 22 includes an inlet opening 38 and a discharge opening 40. Within the mixer housing 24 is an elongated mixer auger 42 which is driven by a hydraulic mixer motor 44. The inlet end of mixer 22 is hinged to a hinge support 46 for pivotal movement about a horizontal hinge axis 48. A lift cylinder 50 is connected at its lower end 54 to the mixer 22 and is connected at its upper end to an upper cylinder mount 52. During operation of the mixer, the mixer is held in a slightly inclined orientation as shown in FIG. 2 so that the auger 42 is required to move the material being mixed upwardly within mixer 22.
The structure of mixer 22 has been utilized in the prior art for mixing cement with aggregate and water. Normally, cement, water, and aggregate are introduced to the inlet end, and the auger rotates to mix the cement aggregate and water and discharge fully mixed concrete from the discharge end 40. However, the particular mixer 22 has not heretofore been used to treat sludge or to mix any materials with sludge. Furthermore, mixer 22 has not been used in the prior art in combination with a sludge hopper and conveyor or a sludge additive hopper and conveyor.
Mounted within the lower end of sludge hopper 12 is an elongated sludge auger 62 which is driven by a sludge auger motor 64 through a chain and drive box 66. Auger 62 is exposed in the lower end of hopper 12, but extends forwardly therefrom through a sludge conveyor tube 56 which has a rear end 58 adjacent hopper 12 and a forward end 60 in communication with the interior of mixing hopper 20. A sludge rotary pulse generator 68 is connected to the shaft of auger 64 for sensing the rotational speed of sludge auger 62.
Rotation of sludge auger 62 causes the sludge within sludge hopper 12 to be conveyed by sludge auger 12 through sludge conveyor tube 56 into the mixer hopper 20 and thence downwardly through inlet opening 38 into the mixer 22.
Mounted within the lower end of additive hopper 14 is an additive auger 70. Auger 70 is driven by a chain drive 72 which is connected to a hydraulic additive motor 76. Additive auger 70 extends forwardly into an additive tube 74 which is in communication with a downwardly extending spout 80 which empties into mixing hopper 20. An additive rotary pulse generator 78 is connected to the shaft of additive auger 70 so as to sense the rotational speed of additive auger 70.
Additive hopper 14 preferably should include cement kiln dust, fly ash, or other alkaline materials, or any combinations of the aforementioned materials.
A control unit 82 is provided for controlling the operation of the various moving parts. Control unit 82 includes a sludge controller 84 having a sludge display 86 thereon (FIG. 3). An additive controller 88 is also provided and includes an additive display 90. As explained previously, the sludge controller 84 and the additive controller 88 are preferably the Gemini 4100 model six digit, presetable counter/rate or dual counter indicator identified above. Controller 88 also includes a sludge conveyor switch 92, an additive conveyor switch 94, a mixer auger switch 96, a hoist switch 98, and a water switch 100.
Sludge controller 84 is connected to rotary pulse generator 68, and additive controller 88 is connected to rotary pulse generator 78. The pulse generators 68, 78 sense the rotational speeds of the sludge auger and the additive auger respectively, and register the rate of flow on the digital displays 86, 90 respectively. Control of the rate of flow of sludge and additive is provided by changing manual adjustments (not shown) on the pressure compensated flow control valves 102, 106 shown in FIG. 3 so as to cause the hydraulic motors 68, 76 to be driven at predetermined speeds. Valves 102, 106 are manually adjusted until the desired rates of flow are registered on display 86, 90. The sludge switch 92 is movable to an on/off position which causes opening or closing of valve 104 to motor 68, position or is also movable to an automatic position which is used when the sludge motor 68, the additive motor 76, and the mixer 44 are all operating in unison. Similarly, the additive switch 94 can be placed in an on./off position to open or close valve 108, or can be placed in an automatic position during operation of all motors 68, 76, 44 at once.
In the hydraulic circuitry for mixer motor 44 are a pressure compensated flow control valve 110 and an on/off valve 112. Mixer switch 96 has an on/off position which controls mixer valve 112, and an automatic position for simultaneous operation of hydraulic motors 68, 76, and 44.
Cylinder 50 is connected in series to a pressure compensated flow control valve 114 and an on./off valve 116. Hoist switch 98 controls hoist valve 116 which is connected to the cylinder 50 for raising and lowering mixer 22.
A water pump 122 (shown schematically only) is connected to water switch 100, water pump pressure compensated flow control valve 118, and water valve 120 and is adapted to pump water from a water source (not shown) for cleaning the mixer 22.
The hydraulic circuitry includes a plurality of check valves 124, a hydraulic pump 128, and a reservoir 126. Pump 128 is driven by an electric drive motor 130 (FIG. 1).
In operation, the sludge hopper 12 is filled with sludge, and the additive hopper 14 is filled with an additive such as cement kiln dust, fly ash, or other alkaline materials, preferably in a powdered form. The control unit 82 is used to actuate and rotate augers 62, 70 so as to carry sludge and additive to the mixer hopper 20 where the combined materials fall by gravity into the inlet end 38 of the mixer 22. The mixer auger 42 within the mixer 22 rotates and causes the additive to be mixed thoroughly with the sludge and conveyed upwardly to the discharge end 40 where the mixed material is discharged. It has been found that the use of the present machine provides very thorough mixing of the additive and the sludge, and results in the sludge being treated in such a manner that it can be readily converted into a material which can be deposited on soil for fertilization purposes. Machine 10 will work well with a highly viscous form of sludge, having a consistency much the same as mud.
Referring to FIGS. 4 and 5, a modified form of the device is shown for use with waste sludge which is in a substantially liquid state. The device of FIG. 4 is referred to generally by the numeral 136, and includes an additive hopper 138, an additive auger 140 driven by chain and sprocket 142 and additive motor 144. Additive auger 140 extends forwardly into an additive tube 148 which is connected to an additive spout 150 extending downwardly into a mixing hopper 152. A rotary pulse generator 146 may be connected to additive auger 140 and used in combination with a controller 164 in much the same manner as described for additive controller 88 shown in FIG. 3. A sludge spout 154 is in communication with mixing hopper 152 and is adapted to be connected to a source of liquid waste sludge. This source can include a hose or pipe which can be coupled to sludge spout 154 and which may lead from a lagoon or other source of liquid sludge.
A sludge pump 170 is provided and includes an inlet opening 172 which can be connected to a lagoon or other source of liquid sludge. An outlet conduit 174 leads from pump 170 and can be connected to spout 154. Thus, it is possible to connect the source of sludge directly to spout 154 if a pump is present at the sludge source, or, in the alternative, pump 170 can be connected to the sludge source.
An electric motor 156 drives a hydraulic pump 158 which is used for the hydraulic circuitry of the device. The mixer 22 is the same as the mixer shown in FIGS. 1-3, and therefore, corresponding numerals are shown. A water tank 162 includes water for cleaning the mixer 22 after it has been used. Air is for vibrators and air diffusion pad.
The method and means described above for treating waste water sludge is very efficient and thorough in mixing the cement kiln dust or other alkaline materials with the sludge. The result of the use of this machinery is that the sludge is quickly and easily treated and made ready for deposit as a soil additive in agricultural areas. The machinery and method of the present invention permit the continuous treatment of the sludge in a very efficient manner. Thus, it can be seen that the device accomplishes at least all of its stated objectives.
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The method and apparatus of the present invention comprise an elongated auger housing having a rotatable auger therein. Augers are provided for delivering sludge and an additive such as cement kiln dust to the intake end of the mixer housing. An auger within the mixer housing conveys the material to the discharge end of the housing, and at the same time mixes the materials together.
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This is a division of application Ser. No. 444,181 filed Nov. 24, 1982 now U.S. Pat. No. 4,479,107 issued Oct. 23, 1984.
DESCRIPTION
1. Technical Field
This invention relates to a linear potentiometer sensor in which the active element of the potentiometer is constructed on a flexible electrically inert substrate. The resistance path of the potentiometer is a laser sculptured, precisely configured construction having a uniform cross section, so that the potentiometer sensor has virtually instrument-precision capability. The sensor can be readily constructed of various sizes.
2. Background Art
A position responsive linear sensor of potentiometric configuration is quite old in the art. An example of this is U.S. Pat. No. 4,284,969 entitled "Potentiometer," inventor Victor Carbonneau, issued Aug. 18, 1981. In these prior art constructions, there is typically a slider having a contactor, the contactor engaging a resistance path and a conductor path. A change in voltage output is dependent upon a change in slider position relative to these paths. In each instance, the potentiometer acts as a mechanical transducer providing a change in voltage output as a function of change of slider position. Thus, a mechanical means and its operation provides a variable voltage output value. The different embodiments provided in the past, while serving to an extent the needs of the art, have nevertheless incorporated many shortcomings such as insufficient accuracy in the resistance path. In other words, the prior art overlooked the criticality of the resistance path and thus produced resistance paths nonuniform in cross section and outline so that it was difficult to accurately equate slider position and change of slider position with a change in potentiometric voltage output. If change in slider position is equated with change in voltage output and the resistor path itself varies in resistance value along its length when engaged by the wiper component of a slider, there will not be a uniform change in voltage output corresponding to a change in slider position. Moreover, it is highly desirable to provide different potentiometer sensors having a variation of sensitivities, i.e. for a given range of linear movement the contactor and resistor should effect a constant rate of change of voltage, but the slope in the rate of change should be a matter of design variability. Thus, the designer should have available a sensor in which the range of potentiometric sensor movement is variable. Frequently, changing the effective travel length for the slider necessitates a change in length for the housing. Such changes necessitate retooling which is undesirable. With a single set of tooling, it should be possible to change the effective range of movement of the slider and the sensitivity of the potentiometer while at the same time providing near instrument accuracy in position responsiveness to equate a change of position to a linear change in voltage output.
In addition to the foregoing needs of the prior art, there is a further need for an improved method of assembly and construction of a potentiometric linear position sensor in which the electrical element may consist of a flexible substrate such as Kapton or the like, electrically inert and serving as a substrate for a uniform coating of resistance material.
DISCLOSURE OF THE INVENTION
The present invention comprises a potentiometric linear position sensor. The sensor comprises a housing of extruded aluminum that may be constructed of variable length and cut to dimension. The active elements of the potentiometer are formed on an electrically inert substrate. The substrate may consist, by way of example, of Kapton. The Kapton is uniformly coated with a resistance material, the coating being developed by a mier rod application and after this uniform coating is developed, a laser beam is directed toward the uncoated side of the substrate to burn off linear paths and sculpting the surface of the resistance layer into two electrically isolated pathways, one the resistance and return path, and the second a collector. After these two "islands" are formed, conductive portions may be screened-on to provide for electrical connection of the resistive path to a terminal, define the collector path at a very low resistance value and provide for connection of the collector path to an output terminal, and further provide a low resistance electrical path as a return path for connection to an output terminal. Alternatively, the conductive portions may be applied prior to the laser sculpting.
The substrate with electrically isolated islands is inserted longitudinally into a housing of narrower width than the substrate so that the edges of the substrate curl upwardly along the interior side walls of the housing and are captured within longitudinal slots of the housing. The central portion of the Kapton element is forced to lie flatly against the interior base of the housing because of the force developed by the curled edges. The housing is enclosed except at its ends. A slider is disposed within the housing and has a contactor engaging the resistance and collector paths so that the position of the contactor determines the potentiometric linear position sensor voltage output. An extension spring may be used to return the slider to its initial position when biasing effort, which displaces the slider, is relieved.
The ends of the housing are sealed by a first closure member which includes terminals and by another closure which provides a slideable bearing for an externally operated rod operatively connected to the slider.
One of the important features of the present invention is that the Kapton substrate is flexible and variations in its width and in housing width are readily compensated for by flexing the substrate edges from a flat position to curled positions as they are fitted into the longitudinal internal slots of the housing. The main portion of the substrate which constitutes the central portion carrying the pathways, lies flat against the confronting internal flat surface of the housing. Variations in substrate and housing widths are readily accommodated for by either a large radius or small radius of flexed substrate sides force fitted into the longitudinal slots. Thus, the device, while highly accurate in its electrical functions, may be constructed of components which are not critical in their dimension, except the all important feature of having a highly uniform resistance path of uniform thickness and sculpted of precisely outlined dimensions.
Instead of being mechanically operative, the device can have its ends sealed and the slider magnetically coupled through the side walls of the housing with a magnetic slide actuator which moves longitudinally on the housing serving as a carrier for the magnetic slide actuator. All of the described functions contribute to a variability of design in the construction, provide a substantial range of voltage sensitivity, obviate extensive tooling for changes, and above all produce an instrument level accuracy in voltage output precisely reflective of change in position of the slider.
The described improvement in the method of assembly also offers substantial economies in the construction and usage of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric exploded detail view of the potentiometer and illustrates the components of the potentiometer;
FIG. 2 is a longitudinal section view taken along the longitudinal center line of the device;
FIG. 3 is a section view taken along lines 3--3 of FIG. 2 and illustrating one dimension for the Kapton substrate;
FIG. 4 is the same section view as illustrated in FIG. 3 but with a Kapton substrate of less width than that illustrated in FIG. 3;
FIGS. 5, 6 and 7 illustrate progressive views showing how the substrate in FIG. 5 is first coated with a uniform lamination of resistance material by a mier rod application; FIG. 6 illustrates the beginning of the sculpting of the "islands" that are electrically insulated from each other by the substrate and developed by linear "burning" away of the resistance material by a laser beam; FIG. 7 illustrates the completed sculpting of the "islands" and with screened-on conductive paths for the resistance path, the collector path, and the return path, respectively;
FIG. 8 illustrates in longitudinal cross section the magnetic polarities of a multipole slider displaceable by means of a multipole magnetic actuator mounted on the housing and movable longitudinally along the housing while magnetically coupled through the housing walls with the slider, and;
FIG. 9 is a section view along view line 9--9 of FIG. 8.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring now to FIGS. 1-4, there is illustrated a housing 10 having a base 12, side walls 14 and 16, and upper wall 18. The housing forms an enclosure on four sides with the ends 20 and 22 being open. Within the housing side walls are two ribs 24 and 26 which form slots 28 and 29 extending the length of the housing. The active element of the potentiometer is designated generally by reference numeral 30 and consists of a Kapton substrate 32 which is electrically inert and has on its surface a uniform coating 34 (FIGS. 5-7) of resistance material obtained by meir rod application. The characteristic of this coating 34 is a uniformity of thickness from one end of the substrate to the other and from side to side. This is an important feature of the present invention as will be seen from a later part of this description. After the uniform coating 34 is applied to the substrate and conductive laminations applied to portions of the coating, the resistance coating 34 is sculpted by means of a laser 36 wherein a laser beam 38 is directed against the uncoated side 40 of the substrate 32 to burn away linear sections commencing in the manner designated by reference numeral 44 in FIG. 6. The final sculptured lines 45 are illustrated in FIG. 7.
Referring to FIG. 7, it can be seen that the laser beam described two continuous lines 45, the effect of which is to separate the resistance coating 34 into two distinct "islands" isolated one from the other by the transparent Kapton substrate. One sculpted island consititutes the resistance path 48 and the return path 55, and the second path a collector 51. Because the laser 36 can describe an island of precise formation, it should be noted that the island constituting the resistance path 48 has a precise dimension, i.e. its width is carefully dimensioned and precisely defined and this, together with the uniform thickness of the coating, produces a change in resistance that is linearly related to the position of a contactor member in slideable connection therewith (FIG. 2).
A conductor path 57 with path end 58 is screened onto resistance path 48 and connected electrically with terminal 62 in end cap 60 (FIG. 1). The end 31 of the element 30 is bent upwardly and fits within recess 66 of the end cap 60 (FIG. 1). A screened-on conductor lamination 50 provides a substantially resistance-free conductive path which forms the collector path 51 and the path end 53 is electrically connected to terminal 68 in end cap 60. The screened-on conductive 55 forms the return path and path end 56 is connected to terminal 70 in end cap 60. These conductive laminations may be applied to the uniform coating 34 of the resistance material either before or after the laser sculpting described above. It is preferable to apply the conductive laminations to the uniform coating 34 prior to laser sculpting so that no further printing is necessary after the sculpting.
Of the two described island, the resistive path 48 and the collector path 51 are engaged by a contactor 77 (FIG. 2) secured to the undersurface 78 of a slider 76.
Slider 76 has two longitudinal mounting slots 80, 82 interfitted with coacting ribs 84 and 86 of the housing 10 to provide free sliding movement for the slider (see FIG. 1).
End 20 of housing 10 is sealed by an end cap 90 having a mounting boss 92 fitting within open end 20 and notches 94 embracing the ribs 84, 86. The outer circumference of boss 92 is press fitted into the interior of the open end 20 until shoulder 96 encloses end 20. Within end cap 90 is a stepped recess 100 (FIG. 2) which captures the large end coil 102 of extension spring 104 and the smaller or reduced end coil 108 is captured over the conical end 117 of a shaft 116. Shaft 116 is journalled in bearing 120 disposed in end recess 100. The reduced end 119 of the shaft 116 is fitted into an opening 79 of the slider 76 so that the slider together with its contactor 77 can be advanced to the right in FIG. 2 by forcing the external shaft 116 to the right and concurrently stretching the spring 104. It has been found than an extension spring is superior to a compression spring in that loading the spring by stretching obviates kinking of the coils which commonly occurs with a long excursion compression spring. Additionally, a compression spring underload develops sideways or lateral forces on the slider to impede its movement. With an extension spring, the slider is advanced without any lateral forces exerted thereon and thus no sideways distortion factor is introduced, which minimizes side loading forces on the bearings.
ALTERNATIVE EMBODIMENT
Instead of mechanically advancing and retracting the slider 76, the ends 20 and 22 of the housing can be sealed and the slider magnetically coupled with a multipole magnetic actuator 134 (FIGS. 8 and 9) mounted on the housing 10. Thus, as the magnetic actuator 134 with multipole magnet 135 is moved to the right and to the left on the housing (see FIG. 8) which serves as a track for the magnetic actuator, the magnetically coupled slider 176, also having a multipole magnet 177, is caused to move concurrently with the magnetic actuator 134, thus accomplishing the same functional results as if the slider 76 were mechanically coupled with rod 116 in the manner previously described.
METHOD OF FABRICATION
The housing 10 starts out as extruded aluminum stock of whatever length is desired (as illustrated by dashed lines 15 in FIG. 1) and then is cut to length, without need for changing the tooling or fixtures with change in length of housing. It should be understood that the housing can be made of other materials such as plastics. Also, the range of resistance can be readily changed by simply varying the length or the volumetric resistance of the uniform coating 34 of resistance material 32 and thereby varying the sensitivity of the sensor.
The sensor has a high degree of accuracy because even though there may be a variation in voltage input, the change of voltage output, which is the parameter measured, is a function of the change of location of the contactor 77 on the resistance path 48. There is virtually no change in the thickness dimension of the resitance film 34 along the path of movement of the contactor 77. The width of the resistance path 48 is the same along the entire length of the path, thus the change in voltage is alwyas proportional to the change of position of the contactor relative to the resistance path 48. This is achieved because of the precision in forming the outline for the resistance path, and because of the remarkably uniform thickness of the resistance material forming the resistance path. The change in voltage output is virtually instrument grade in spit of the fact that the device is manufacturable in variable size by such a ready manner.
The characteristics that contribute to and effect this degree of accuracy obtainable from production line techniques, are the flexible electrically inert substrate in the form of Kapton and the initial resistance coating applied by mier rod in the manner illustrated in FIG. 5, and the subsequent sculpting in the manner illustrated in FIG. 6 to produce the precise configurations of the resistance path, the collector path, and the return path. The assembly of the device is also readily achieved in that the flexible Kapton subcoating is drawn into position either by roller means or by other means, and any variation of substrate and housing widths is easily accommodated as illustrated in FIGS. 3 and 4 by either curling the substrate edges along a small diameter as shown in FIG. 3, or by effecting a larger radius if the Kapton substrate is narrower as in FIG. 4. In either event, the edges of the Kapton substrate are caused to curl and are captured within slots 28, 29 formed at the side walls of the housing 10.
Another important advantage of the present invention is that the central portion of the Kapton substrate 32, regardless of width variations, lies flat against the inner surface 13 of the base 12 as illustrated in FIGS. 3 and 4, because the curled edges bias the central portion into such engagement. Once the Kapton substrate, together with its active functional surfaces, is disposed in such flat condition, this provides the opportunity for the contactor to make a positive and flat surface-to-surfaced contact.
OPERATION
In operation, the shaft 116 is displaced toward the right (FIG. 2), stretching the spring 104 and displacing the slider 76 toward the right. As this occurs, contactor 77 moves along the surfaces of the resistance path 48 and collector path 51. Such change in position causes a change in voltage output, the voltage change occurring in a linear manner. That is, the change in voltage as a function of a change in position, is a linear relationship which is at all times proportional. The voltage change can occur along a linear path with a steep slope which indicates enhanced sensitivity; also, the rate of change can extend over a short stroke length or a substantial stroke length for the shaft 116 and its attached slider, depending upon the particular application.
In any event, the method of assembly together with the variability of length for the extruded aluminum housing which can be cut to a particular design, all combine to produce a sensor that is relatively inexpensive to fabricate, is readily adaptable to particular designs and applications, and above all has such accuracy in its response that it approaches, if not equals, instrument quality.
CONCLUSION
Although the present invention has been illustrated and described in connection with example embodiments, it will be understood that these are illustrative of the invention, and by no means restrictive thereof. It is reasonably to be expected that those skilled in the art can make numerous revisions and additions to the invention and it is intended that such revisions and additions will be included within the scope of the following claims as equivalents of the invention.
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A potentiometric linear position sensor including a housing (10) made of extruded aluminum which may be cut to preferred lengths (15). The sensor includes a Kapton film substrate (32) having first a uniform coating of resistive material (34) disposed thereon, and then distinct islands formed by laser sculpting. Conductive material (50, 53, 55, 56, 57, 58), screen printed upon the resistive material before or after the laser sculpting, is connected to terminals (62, 68, 70) for the respective electrical elements (48, 51, 55). The flexible Kapton film substrate (32) is inserted endwise into the housing (10) with the side edges of the substrate curled upwardly and captured within longitudinal housing slots (28, 29) disposed along opposite housing walls (14, 16). The housing (10) is sealed by end closures (60, 90), one closures (60) having the terminations (62, 68, 70) connected to conductive paths (53, 56, 60) disposed on the respective electrical elements (48, 51, 55), and the other end closure (90) providing securement for an extension spring (104) and journalling for a shaft (116) attached to a combination slider-and-contactor (76, 77) disposed within the housing. Displacement of the shaft (116) stretches the extension spring (104) and effects a corresponding longitudinal movement of the contactor (77) along the resistive element (48) and collector path (51). An alternative embodiment includes an exterior magnetic actuator (134) located exteriorly of the housing (10) and coupled magnetically with the interiorly disposed slider (176) for movement therewith.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device that enables persons of limited mobility to wash and wipe their perineal areas, in order to meet basic needs of hygiene and comfort, and to avoid medical complications such as skin rashes and infections. Examples of persons with limited mobility include arthritic patients, who may experience difficulties in reaching or squeezing with their hands, or in performing wiping motions; bed-confined patients, for whom reaching or cleaning their perineal areas may be difficult because of surgeries, accidents, or other medical conditions; mutilated patients; and overweight persons, whose physical sizes may make it difficult or impossible to reach and clean their genital and anal areas. These users need a device that can be employed safely and conveniently, without concerns about contacts with unsanitary areas or about uncontrolled flow of cleaning liquid during use.
Care providers also need a device that will make patients of limited mobility as self-supporting as possible, that can be easily stored and assembled at the time of use, that can be employed effectively and as contact-free as possible, and that does not require costly and time-consuming sterilization procedures. With the graying of our population, the need for auxiliary cleaning devices is expected to increase significantly over time.
The present invention achieves cleaning of the perineum through a directed stream of liquid droplets that is sprayed through calibrated nozzle holes. The perineal area is successively wiped with a paper or fabric tissue that is gripped, securely held, and eventually released by a tissue holder, which is part of this cleaning device.
2. Description of the Related Art
Cleaning of the perineum not only satisfies a basic desire for hygiene and for comfort, but also meets a basic health requirement by preventing adverse skin reactions and the spreading of infections. Different devices are available today that provide either a stream of cleaning liquid to the perineum, or that, alternatively, hold and extend the reach of cleaning tissue, but no device achieves both functions simultaneously and effectively.
In addition, existing devices are generally larger than the present invention, exhibit more complex mechanical features, and are designed to be reusable, requiring repeated sterilizations. Moreover, such devices usually require the exertion of pressure (for instance, to push a start button) beyond the level of comfort, or even beyond the physical capability, of certain users, such as users with arthritic joints.
U.S. Pat. No. 5,097,540, issued to Lovitt on May 24, 1992, discloses a re-usable hand-held bidet with a spray function, activated by a pump, either mechanical or electric, and without a hygienic tissue holder.
U.S. Pat. No. 5,377,364, issued to Cabrera on Jan. 3, 1995, discloses a portable toilet assembly that includes a bidet-like washing device. Such device is mounted on the portable toilet assembly and is not hand-held nor disposable.
U.S. Pat. No. 5,409,167, issued to Borod on Apr. 25, 1995, discloses a re-usable hygienic spray bottle that dispenses liquid through a L-shaped spray tube and that is pressurized by a pump.
U.S. Pat. No. 5,858,010, issued to Berry on Jan. 12, 1999, discloses a personal washing device for douching the female pelvic or genital areas. Such device exhibits two different configurations of the washing head, but neither appears suitably configured for the anal area nor for male patients, and does not include a tissue holder.
U.S. Pat. No. 5,864,895, issued to Ota on Feb. 2, 1999, discloses a hand-held body washer with a retractable nozzle. This device includes a pump which is housed in a separate container and which is attached to the liquid reservoir, is re-usable, and does not include a cleaning tissue holder.
U.S. Pat. No. 6,145,154, issued to Blair on Nov. 14, 2000, discloses a hygienic tissue or fabric holder for reaching and wiping body parts. Such device is reusable and involves a complex design, requiring a level of dexterity that may be uncomfortable or impossible for arthritic patients.
U.S. Pat. No. 6,190,366, issued to Tani on Feb. 20, 2001, discloses a disposable liquid container made of plastic film, which is connected to a tube and a spray nozzle. A liquid stream is generated by squeezing the liquid container with a movement that may be difficult or impossible for arthritic or bed-confined patients.
U.S. Pat. No. 6,269,516, issued to Saatjian on Aug. 7, 2001, discloses a device for removing human waste that is essentially a remotely-activated spoon with a cover.
U.S. Pat. No. 6,272,716, issued to Thornton on Aug. 14, 2001, disclosed a re-usable device for wiping body parts, activated by pushing a button that opens a pair of longitudinal jaws and that grips the cleaning tissue.
Other prior art discloses mechanical devices that prevent leakage or backflow in hygienic spray bottles.
Japanese Patent 09-028611, issued to Shibagaki Kazuyuki on Jul. 13, 1995, discloses a valve that controls the flow of liquid from a spray bottle to the discharge tube.
Japanese Patent 09-238865, issued by Chugenji Hiroshi on Sep. 16, 1997, discloses a hygienic cleaning bottle with a retractable nozzle, out of which water leakage is prevented during transport by sealing the bottle cap with the nozzle tip, when pushed in the retracted position.
BRIEF SUMMARY OF THE INVENTION
The present invention consists of a device through which fecal or other bodily matter is removed by spraying the perineum with a calibrated stream of cleaning liquid, such as warm water or a medicated solution, which is generated by squeezing a container with gentle pressure. The perineum is then wiped with a paper or fabric tissue that is gripped, securely held and eventually released through a tissue holder which is also part of the device.
The present invention comprises a liquid reservoir; a reservoir cap that closes and seals the liquid reservoir, and to which a discharge tube is attached; a nozzle that is attached to the discharge tube; and a tissue holder that is securely fastened to the liquid reservoir, and that comprises a stem and a clamp to grip, hold and release a cleaning tissue.
The spray nozzle is designed to generate a liquid stream which becomes a flow of liquid droplets that travels through the air in a basically straight line. This provides the user with the comfort of a mist but also with the effectiveness of a directed stream that facilitating removal of fecal or other deposits, and at the same time reducing wetting of patient clothing or bed which is common with continuous liquid streams.
When the reservoir is filled but not in use, and is laid on one side or held with the discharge tube pointing downwards, gravity-related liquid outflows from the nozzle are prevented by nozzle holes of a diameter small enough to generate a combination of surface tension and liquid pressure at the nozzle holes that is less than ambient air pressure. That prevents an undesired dripping of cleaning liquid.
If the reservoir is accidentally squeezed while the tissue holder is used for wiping, the accidental liquid spray is directed away from the user because the nozzle holes are designed to point in a direction opposite to that of the tissue clamp. In one embodiment, the risk of accidental spraying is further reduced by positioning the discharge hole on the reservoir cap off the center of the cap, in a position opposite to where the liquid would tend to flow due to gravity when the reservoir is tilted during wiping.
The present invention is intended for a limited number of uses and is disposable. The materials employed allow for sanitary disposal through incineration; in particular, the device can be shipped, used and incinerated together with a disposable bedpan. During storage and before use, the device can rest on the cylindrical base of the liquid reservoir opposite to the filling cap, with the tissue holder disassembled and locked into a semi-circular ring built into the reservoir cap.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings provide a further understanding of the invention and are incorporated in, and constitute part of, this specification.
FIG. 1 illustrates the disposable perineum cleaning device in accordance to a first embodiment of the invention.
FIG. 2 illustrates the liquid reservoir in accordance to a first embodiment of the invention.
FIG. 3 illustrates the depression on the closed end of the liquid reservoir.
FIG. 4 illustrates the combination of reservoir cap, discharge tube and spray nozzle in accordance to a first embodiment of the invention.
FIG. 5 illustrates the tissue holder, including the stem portion, the clamp portion and the connecting structure.
FIG. 6 illustrates the base of the stem portion of the tissue holder, including protruding pins and spring clip.
FIG. 7 illustrates a cross-section of the depression on the closed end of the liquid reservoir, including a groove with detents and the recess for the spring clip.
FIG. 8 illustrates a cross-section of the reservoir cap in accordance to a first embodiment of the invention, including grooves, keyways and the semicircular extension which holds the stem portion of the tissue holder.
FIG. 9 illustrates a cross-section of the stem portion of the tissue holder in accordance to a first embodiment of the invention.
FIG. 10 illustrates the clamp portion of the tissues holder, including the upper and lower halves of the clamp, the connecting structure to the stem portion, and the lever opening said clamp portion.
FIG. 11 illustrates a second embodiment of the clamp portion of the tissue holder, which includes protruding teeth along the arrow-shaped profile of the upper half of the clamp portion and matching tooth-shaped depressions along the V-shaped profile of the lower half of the clamp portion.
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of the invention follows, which is merely representative, because the various components may be embodied in a variety of forms. The details described here are deemed to represent the best embodiment for the purpose of disclosure, and to provide a basis for the claims which define the scope of the present invention. The invention, however, is capable of other embodiments, and the phraseology and terminology employed here are only for the purpose of description, and should not be regarded as limiting.
Referring to FIGS. 1 and 4 , the disposable perineum cleaning device is shown in a first embodiment, which comprises reservoir 4 , reservoir cap 3 , discharge tube 2 , nozzle 1 , and tissue holder 5 . Typically, the device is supplied to the user in three disassembled pieces, namely, reservoir 4 ; tissue holder 5 ; and the pre-assembled combination of reservoir cap 3 , discharge tube 2 , and nozzle 1 .
In the preferred embodiment, reservoir 4 is made of polypropylene. Other resilient materials may be employed that retain their shape regardless of whether the reservoir is empty or full, but that can also be squeezed with gentle pressure returning to their original shape after squeezing pressure is released.
Referring to FIGS. 2 and 4 , reservoir 4 has a cylindrical configuration, of a diameter that can be comfortably held in a human hand. The volume of reservoir 4 is such that, when reservoir 4 is not squeezed and is combined with discharge tube 2 and nozzle 1 , the combination of surface tension and maximum liquid pressure at holes 6 of nozzle 1 withstands one bar atmospheric pressure. In the preferred embodiment, reservoir 4 has a circular cross-section of 2″ diameter, 4.5″ height, and 0.060″ wall thickness, and nozzle holes 6 have a 0.020″ diameter.
Other embodiment have different reservoir and nozzle holes dimensions, but achieve the same design objectives of fitting within a human hand and of avoiding undesired liquid outflow while not in use.
Reservoir 4 exhibits an external surface that is smooth. In other embodiments, the external surface is corrugated for better grip, or carries ergonomic impressions for lodging a human hand comfortably.
Referring further to FIGS. 3 , 6 and 7 , end 7 of reservoir 4 is closed, and carries a depression 8 of a roughly circular shape, that is the housing for base 9 of stem 10 of tissue holder 5 . Base 9 is slid and securely locked in depression 8 at the time tissue holder 5 is used. Depression 8 has two keyways 13 , 14 and recessb 15 extending from its roughly circular shape. Two pins 11 and 12 protruding from base 9 of stem 10 slide into keyways 13 and 14 and further slide into grooves 16 and 17 that are located on the inner wall of depression 8 . Pairs of detents 37 extending from grooves 16 and 17 lock pins 11 and 12 in place when tissue holder 5 is turned clockwise. Recess 15 further locks base 9 in place after stem 10 is turned, due to spring clip 18 that is also located on base 9 and that compresses against base 9 when inserted into depression 8 . Spring clip 18 then springs back into its released position when, after being turned into position, it meets matching keyway 15 .
Further referring to FIGS. 2 and 8 , circular end 19 of reservoir 4 is open, and is designed to be closed and sealed through reservoir cap 3 . Wall 20 of reservoir 4 , in the proximity of end 19 , has a recessed surface 21 with three protruding pins 22 , which are designed to match and slide into three keyways 23 on reservoir cap 3 , leading to three spiral grooves 24 on the inner wall of reservoir cap 3 .
Both grooves 16 and 17 inside depression 8 of reservoir 4 , and grooves 24 on the inner wall of reservoir cap 3 , are designed so to orient spray nozzle 1 and clamp 25 of tissue holder 5 in directions opposite to each other, in order to have the liquid spray away from the patient, if the patient inadvertently squeezes reservoir 4 while using tissue holder 5 .
It is to be understood that the reservoir in the present invention is not restricted to the above described modes, and that modifications and variations of the reservoir that do not depart from the spirit and scope of the present invention are encompassed within this invention.
Further referring to FIG. 5 , tissue holder 5 comprises two main portions, stem 10 and clamp 25 , which are linked by connecting structure 26 . In the preferred embodiment, tissue holder 5 consists of a single, integrally molded piece made of a high performance synthetic material such as polypropylene, acetal, nylon or ABS.
As shown in FIG. 9 , in the preferred embodiment, stem 10 of tissue holder 5 has a solid, X-shaped cross-section 39 along its length and with a solid cylindrical section at base 9 . Other embodiments include a profile of stem 10 with a tubular profile, or with different cross-section profiles. Stem 10 in the preferred embodiment has a straight shape. Other embodiments include different lengths and shapes of stem 10 , such as hook-shaped, J-shaped, or arched.
Stem 10 of tissue holder 5 is joined to tissue clamp 25 via connecting structure 26 that comprises parallel arms 27 and 28 joined by perpendicular flexing wall 38 . Arm 28 connects upper half 30 of clamp 25 to lever 31 , which causes flexing wall 38 to bend when lever 31 is depressed, and clamp 25 to open, and which further causes flexing wall 38 to return to its straight position, and clamp 25 to close, when lever 31 is released. Lever 31 is ergonomically designed to fit the fore part of a human thumb and requires a pressure low enough to be comfortable for arthritic users. Lower arm 27 of connecting structure 26 joins stem 10 to lower half 29 of tissue clamp 25 . In the preferred embodiment, connecting structure 26 is integrally molded with stem 10 and clamp 25 .
With further reference to FIG. 10 , upper half 30 of clamp 25 has an arrow-shaped contour matching lower half 29 , which instead exhibits a V-shaped contour. This arrow-and-V design makes clamp 25 extremely effective in gripping and securely holding the cleaning tissue. With reference to FIG. 11 , in one embodiment, two parallel, tooth-shaped protrusions 31 run along the arrow-shaped contour of upper half 30 , while the V-shaped contour of lower half 29 contains matching tooth-shaped depressions 32 , so to increase grip on the cleaning tissue when clamp 25 is closed.
The front part of clamp 25 exhibits an outer surface that is rounded and smooth, in order to increase comfort to the user and to prevent adhesion of fecal matter. Size and movement of clamp halves 29 and 30 resemble human fingers, both in the gripping and in the wiping motions. In the preferred embodiment, ergonomics of the tissue holder is enhanced through a 65 degrees angle between the clamp and the stem.
Reservoir cap 3 is removable and locks securely onto reservoir 4 . With further reference to FIG. 8 , in the preferred embodiment, reservoir cap 3 has a round opening 32 in the center, in which discharge tube 2 is press-fit. In a different embodiment, opening 32 is positioned off-center, on the same side of the longitudinal axis of the device as tissue clamp 25 , in order to improve flow of liquid to discharge tube 2 when reservoir 4 is held at an angle with discharge tube 2 pointing downwards, and, during wiping, to decrease flow of liquid to discharge tube 2 and to minimize risk of undesired spraying if reservoir 4 is inadvertently squeezed.
Three keyways 23 leading to three spiral grooves 24 are located on the inner cylindrical wall of reservoir cap 3 , and match pins 22 on recessed area 21 of reservoir 3 . A protruding wall 34 creates a depression 36 on the inner surface of reservoir cap 3 and generates a tight seal between the recessed area 21 of reservoir 4 and reservoir cap 3 .
A semi-circular extension 33 is integrally molded into the external side of reservoir cap 3 , and is designed to house and lock in place stem 10 of tissue holder 5 , when tissue holder 5 is not attached to depression 8 of reservoir 4 . In the preferred embodiment, reservoir cap 3 is manufactured from polypropylene. In other embodiments, other types of plastic such as polyethylene and nylon can be employed.
Discharge tube 2 is essentially rigid, achieving a limited degree of bending when pressed against the perineal surface, in order to facilitate spraying of hard-to-reach body parts. Discharge tube 2 is also resilient, returning to its original shape after a slight bending. In the preferred embodiment, discharge tube 2 is made from polypropylene, but can be made from other plastic materials such as polyethylene or nylon. The shape of discharge tube 2 is straight in the preferred embodiment, without internal reinforcing walls. Other embodiments include discharge tubes 2 that are hook-shaped, J-shaped or curved.
Nozzle 1 is located at the free end of discharge tube 2 , and generates a liquid spray that turns into a directed stream of liquid droplets during travel in the air. Three parallel nozzle holes 6 , perpendicular to nozzle face 35 and spaced 0.086″ apart, are positioned in a triangular pattern on the face of nozzle 1 and produce a liquid stream that maintains an essentially triangular configuration during travel in the air. While traveling, due to the combination of hole diameter, air friction and surface tension, the liquid stream becomes a stream of liquid droplets that produces the comfort of a mist and reduces the wetting of linens that is common with directed liquid streams. In another embodiment, nozzle holes 6 are not parallel but directed outwards at an angle from nozzle face 35 , for instance, an 85 degree angle.
In the preferred embodiment, nozzle 1 is J-shaped, with face 35 angled at 35 degrees from stem 10 . This generates a liquid stream at 55 degrees from stem 10 for optimal user ergonomics. The external surface and edges of nozzle 1 are curved and smooth, in order to minimize friction with the body of the user and to reduce adhesion of fecal matter.
In the preferred embodiment, nozzle 1 is made of polypropylene, but can be manufactured from other synthetic materials such as polyethylene, nylon or ABS.
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The present invention relates to a hand-held device that enables persons of limited mobility to clean their perineal areas, and comprises a liquid reservoir that can be squeezed with gentle pressure, a spraying portion that generates a directed stream of liquid droplets towards the patient, and a tissue holder portion through which the user can grab, use and dispose of cleaning tissue.
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CROSS REFERENCE TO RELATED APPLICATION
The application is related to the following applications: Phrase Identification in an Information Retrieval System, application Ser. No. 10/900,021, filed on Jul. 26, 2004, now U.S. Pat. No. 7,580,921; Phrase-Based Indexing in an Information Retrieval System, application Ser. No. 10/900,055, filed on Jul. 26, 2004, now U.S. Pat. No. 7,536,408; Phrase-Based Searching in an Information Retrieval System, application Ser. No. 10/900,041, filed on Jul. 26, 2004, now U.S. Pat. No. 7,599,914; Phrase-Based Personalization of Searches in an Information Retrieval System, application Ser. No. 10/900,039, filed on Jul. 26, 2004, now U.S. Pat. No. 7,580,929; Automatic Taxonomy Generation in Search Results Using Phrases, application Ser. No. 10/900,259, filed on Jul. 26, 2004, now U.S. Pat. No. 7,426,507; and Phrase-Based Detection of Duplicate Documents in an Information Retrieval System, application Ser. No. 10/900,012, filed on Jul. 26, 2004, now U.S. Pat. No. 7,711,629 all of which are co-owned, and incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to an information retrieval system for indexing, searching, and classifying documents in a large scale corpus, such as the Internet.
BACKGROUND OF THE INVENTION
Information retrieval systems, generally called search engines, are now an essential tool for finding information in large scale, diverse, and growing corpuses such as the Internet. Generally, search engines create an index that relates documents (or “pages”) to the individual words present in each document. A document is retrieved in response to a query containing a number of query terms, typically based on having some number of query terms present in the document. The retrieved documents are then ranked according to other statistical measures, such as frequency of occurrence of the query terms, host domain, link analysis, and the like. The retrieved documents are then presented to the user, typically in their ranked order, and without any further grouping or imposed hierarchy. In some cases, a selected portion of a text of a document is presented to provide the user with a glimpse of the document's content.
Direct “Boolean” matching of query terms has well known limitations, and in particular does not identify documents that do not have the query terms, but have related words. For example, in a typical Boolean system, a search on “Australian Shepherds” would not return documents about other herding dogs such as Border Collies that do not have the exact query terms. Rather, such a system is likely to also retrieve and highly rank documents that are about Australia (and have nothing to do with dogs), and documents about “shepherds” generally.
The problem here is that conventional systems index documents based on individual terms, than on concepts. Concepts are often expressed in phrases, such as “Australian Shepherd,” “President of the United States,” or “Sundance Film Festival”. At best, some prior systems will index documents with respect to a predetermined and very limited set of ‘known’ phrases, which are typically selected by a human operator. Indexing of phrases is typically avoided because of the perceived computational and memory requirements to identify all possible phrases of say three, four, or five or more words. For example, on the assumption that any five words could constitute a phrase, and a large corpus would have at least 200,000 unique terms, there would approximately 3.2×10 26 possible phrases, clearly more than any existing system could store in memory or otherwise programmatically manipulate. A further problem is that phrases continually enter and leave the lexicon in terms of their usage, much more frequently than new individual words are invented. New phrases are always being generated, from sources such technology, arts, world events, and law. Other phrases will decline in usage over time.
Some existing information retrieval systems attempt to provide retrieval of concepts by using co-occurrence patterns of individual words. In these systems a search on one word, such as “President” will also retrieve documents that have other words that frequently appear with “President”, such as “White” and “House.” While this approach may produce search results having documents that are conceptually related at the level of individual words, it does not typically capture topical relationships that inhere between co-occurring phrases.
Accordingly, there is a need for an information retrieval system and methodology that can comprehensively identify phrases in a large scale corpus, index documents according to phrases, search and rank documents in accordance with their phrases. Additionally, there is a need in such a system to allow users to provide additional phrase information to the system and to capture and integrate the resulting semantic knowledge.
SUMMARY OF THE INVENTION
An information retrieval system and methodology uses phrases to index, search, rank, and describe documents in the document collection. The system is adapted to identify phrases that have sufficiently frequent and/or distinguished usage in the document collection to indicate that they are “valid” or “good” phrases. In this manner multiple word phrases, for example phrases of four, five, or more terms, can be identified. This avoids the problem of having to identify and index every possible phrase resulting from all of the possible sequences of a given number of words.
The system is further adapted to identify phrases that are related to each other, based on a phrase's ability to predict the presence of other phrases in a document. More specifically, a prediction measure is used that relates the actual co-occurrence rate of two phrases to an expected co-occurrence rate of the two phrases. Information gain, as the ratio of actual co-occurrence rate to expected co-occurrence rate, is one such prediction measure. Two phrases are related where the prediction measure exceeds a predetermined threshold. In that case, the second phrase has significant information gain with respect to the first phrase. Semantically, related phrases will be those that are commonly used to discuss or describe a given topic or concept, such as “President of the United States” and “White House.” For a given phrase, the related phrases can be ordered according to their relevance or significance based on their respective prediction measures.
An information retrieval system indexes documents in the document collection by the valid or good phrases. For each phrase, a posting list identifies the documents that contain the phrase. In addition, for a given phrase, a second list, vector, or other structure is used to store data indicating which of the related phrases of the given phrase are also present in each document containing the given phrase. In this manner, the system can readily identify not only which documents contain which phrases in response to a search query, but which documents also contain phrases that are related to query phrases, and thus more likely to be specifically about the topics or concepts expressed in the query phrases.
The use of phrases and related phrases further provides for the creation and use of clusters of related phrases, which represent semantically meaningful groupings of phrases. Clusters are identified from related phrases that have very high prediction measure between all of the phrases in the cluster. Clusters can be used to organize the results of a search, including selecting which documents to include in the search results and their order, as well as eliminating documents from the search results.
Websites typically have anywhere from a few pages to potentially hundreds or thousands of pages. Thus, phrase information generated by the information retrieval system can be used to determine a list of top phrases for each website, such as the most representative phrases for the website. This can be done by examining the related phrase information for the phrases that appear in documents on the website. Further, phrase information may be later supplemented and refined by capturing changes made to the top phrase list by administrators or other authorized users and integrating the resulting semantic knowledge into the phrase information already contained within the system. An administrator can associate additional related phrases with any of the top phrases for the website. The related phrase information for the top phrases for which additional related phrases have been received is then updated to include information pertaining to the additional related phrases, and the additional related phrases are also updated to include information from the top phrases. This operates to treat the additional phrases as if they were present in the website. In addition, the additional related phrases can be updated to use the related phrase information for the top phrases.
The present invention has further embodiments in system and software architectures, computer program products and computer implemented methods, and computer generated user interfaces and presentations.
The foregoing are just some of the features of an information retrieval system and methodology based on phrases. Those of skill in the art of information retrieval will appreciate the flexibility of generality of the phrase information allows for a large variety of uses and applications in indexing, document annotation, searching, ranking, and other areas of document analysis and processing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is block diagram of the software architecture of one embodiment of the present invention.
FIG. 2 illustrates a method of identifying phrases in documents.
FIG. 3 illustrates a document with a phrase window and a secondary window.
FIG. 4 illustrates a method of identifying related phrases.
FIG. 5 illustrates a method of indexing documents for related phrases.
FIG. 6 illustrates a method of retrieving documents based on phrases.
FIGS. 7 a and 7 b illustrate relationships between referencing and referenced documents.
FIG. 8 illustrates a method of obtaining and integrating phrase information input from users.
FIG. 9 illustrates a sample user interface for displaying top phrases and allowing users to input changes.
The figures depict a preferred embodiment of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
DETAILED DESCRIPTION OF THE INVENTION
I. System Overview
Referring now to FIG. 1 , there is shown the software architecture of an embodiment of a search system 100 in accordance with one embodiment of present invention. In this embodiment, the system includes a indexing system 110 , a search system 120 , a presentation system 130 , and a front end server 140 .
The indexing system 110 is responsible for identifying phrases in documents, and indexing documents according to their phrases, by accessing various websites 190 and other document collections. The front end server 140 receives queries from a user of a client 170 , and provides those queries to the search system 120 . The search system 120 is responsible for searching for documents relevant to the search query (search results), including identifying any phrases in the search query, and then ranking the documents in the search results using the presence of phrases to influence the ranking order. The search system 120 provides the search results to the presentation system 130 . The presentation system 130 is responsible for modifying the search results including removing near duplicate documents, and generating topical descriptions of documents, and providing the modified search results back to the front end server 140 , which provides the results to the client 170 . The system 100 further includes an index 150 that stores the indexing information pertaining to documents, and a phrase data store 160 that stores phrases, and related statistical information.
In the context of this application, “documents” are understood to be any type of media that can be indexed and retrieved by a search engine, including web documents, images, multimedia files, text documents, PDFs or other image formatted files, and so forth. A document may have one or more pages, partitions, segments or other components, as appropriate to its content and type. Equivalently a document may be referred to as a “page,” as commonly used to refer to documents on the Internet. No limitation as to the scope of the invention is implied by the use of the generic term “documents.” The search system 100 operates over a large corpus of documents, such as the Internet and World Wide Web, but can likewise be used in more limited collections, such as for the document collections of a library or private enterprises. In either context, it will be appreciated that the documents are typically distributed across many different computer systems and sites. Without loss of generality then, the documents generally, regardless of format or location (e.g., which website or database) will be collectively referred to as a corpus or document collection. Each document has an associated identifier that uniquely identifies the document; the identifier is preferably a URL, but other types of identifiers (e.g., document numbers) may be used as well. In this disclosure, the use of URLs to identify documents is assumed.
II. Indexing System
In one embodiment, the indexing system 110 provides three primary functional operations: 1) identification of phrases and related phrases, 2) indexing of documents with respect to phrases, and 3) generation and maintenance of a phrase-based taxonomy. Those of skill in the art will appreciate that the indexing system 110 will perform other functions as well in support of conventional indexing functions, and thus these other operations are not further described herein. The indexing system 110 operates on an index 150 and data repository 160 of phrase data. These data repositories are further described below.
1. Phrase Identification
The phrase identification operation of the indexing system 110 identifies “good” and “bad” phrases in the document collection that are useful to indexing and searching documents. In one aspect, good phrases are phrases that tend to occur in more than certain percentage of documents in the document collection, and/or are indicated as having a distinguished appearance in such documents, such as delimited by markup tags or other morphological, format, or grammatical markers. Another aspect of good phrases is that they are predictive of other good phrases, and are not merely sequences of words that appear in the lexicon. For example, the phrase “President of the United States” is a phrase that predicts other phrases such as “George Bush” and “Bill Clinton.” However, other phrases are not predictive, such as “fell down the stairs” or “top of the morning,” “out of the blue,” since idioms and colloquisms like these tend to appear with many other different and unrelated phrases. Thus, the phrase identification phase determines which phrases are good phrases and which are bad (i.e., lacking in predictive power).
Referring to now FIG. 2 , the phrase identification process has the following functional stages:
200 : Collect possible and good phrases, along with frequency and co-occurrence statistics of the phrases.
202 : Classify possible phrases to either good or bad phrases based on frequency statistics.
204 : Prune good phrase list based on a predictive measure derived from the co-occurrence statistics.
Each of these stages will now be described in further detail.
The first stage 200 is a process by which the indexing system 110 crawls a set of documents in the document collection, making repeated partitions of the document collection over time. One partition is processed per pass. The number of documents crawled per pass can vary, and is preferably about 1,000,000 per partition. It is preferred that only previously uncrawled documents are processed in each partition, until all documents have been processed, or some other termination criteria is met. In practice, the crawling continues as new documents are being continually added to the document collection. The following steps are taken by the indexing system 110 for each document that is crawled.
Traverse the words of the document with a phrase window length of n, where n is a desired maximum phrase length. The length of the window will typically be at least 2, and preferably 4 or 5 terms (words). Preferably phrases include all words in the phrase window, including what would otherwise be characterized as stop words, such as “a”, “the,” and so forth. A phrase window may be terminated by an end of line, a paragraph return, a markup tag, or other indicia of a change in content or format.
FIG. 3 illustrates a portion of a document 300 during a traversal, showing the phrase window 302 starting at the word “stock” and extending 5 words to the right. The first word in the window 302 is candidate phrase i, and the each of the sequences i+1, i+2, i+3, i+4, and i+5 is likewise a candidate phrase. Thus, in this example, the candidate phrases are: “stock”, “stock dogs”, “stock dogs for”, “stock dogs for the”, “stock dogs for the Basque”, and “stock dogs for the Basque shepherds”.
In each phrase window 302 , each candidate phrase is checked in turn to determine if it is already present in the good phrase list 208 or the possible phrase list 206 . If the candidate phrase is not present in either the good phrase list 208 or the possible phrase list 206 , then the candidate has already been determined to be “bad” and is skipped.
If the candidate phrase is in the good phrase list 208 , as entry g j , then the index 150 entry for phrase g j is updated to include the document (e.g., its URL or other document identifier), to indicate that this candidate phrase g j appears in the current document. An entry in the index 150 for a phrase g j (or a term) is referred to as the posting list of the phrase g j . The posting list includes a list of documents d (by their document identifiers, e.g. a document number, or alternatively a URL) in which the phrase occurs.
In addition, the co-occurrence matrix 212 is updated, as further explained below. In the very first pass, the good and bad lists will be empty, and thus, most phrases will tend to be added to the possible phrase list 206 .
If the candidate phrase is not in the good phrase list 208 then it is added to the possible phrase list 206 , unless it is already present therein. Each entry p on the possible phrase list 206 has three associated counts:
P(p): Number of documents on which the possible phrase appears;
S(p): Number of all instances of the possible phrase; and
M(p): Number of interesting instances of the possible phrase. An instance of a possible phrase is “interesting” where the possible phrase is distinguished from neighboring content in the document by grammatical or format markers, for example by being in boldface, or underline, or as anchor text in a hyperlink, or in quotation marks. These (and other) distinguishing appearances are indicated by various HTML markup language tags and grammatical markers. These statistics are maintained for a phrase when it is placed on the good phrase list 208 .
In addition the various lists, a co-occurrence matrix 212 (G) for the good phrases is maintained. The matrix G has a dimension of m×m, where m is the number of good phrases. Each entry G(j, k) in the matrix represents a pair of good phrases (g j , g k ). The co-occurrence matrix 212 logically (though not necessarily physically) maintains three separate counts for each pair (g j , g k ) of good phrases with respect to a secondary window 304 that is centered at the current word i, and extends +/−h words. In one embodiment, such as illustrated in FIG. 3 , the secondary window 304 is 30 words. The co-occurrence matrix 212 thus maintains:
R(j,k): Raw Co-occurrence count. The number of times that phrase g j appears in a secondary window 304 with phrase g k ;
D(j,k): Disjunctive Interesting count. The number of times that either phrase g j or phrase g k appears as distinguished text in a secondary window; and
C(j,k): Conjunctive Interesting count: the number of times that both g j and phrase g k appear as distinguished text in a secondary window. The use of the conjunctive interesting count is particularly beneficial to avoid the circumstance where a phrase (e.g., a copyright notice) appears frequently in sidebars, footers, or headers, and thus is not actually predictive of other text.
Referring to the example of FIG. 3 , assume that the “stock dogs” is on the good phrase list 208 , as well as the phrases “Australian Shepherd” and “Australian Shepard Club of America”. Both of these latter phrases appear within the secondary window 304 around the current phrase “stock dogs”. However, the phrase “Australian Shepherd Club of America” appears as anchor text for a hyperlink (indicated by the underline) to website. Thus the raw co-occurrence count for the pair {“stock dogs”, “Australian Shepherd”} is incremented, and the raw occurrence count and the disjunctive interesting count for {“stock dogs”, “Australian Shepherd Club of America”} are both incremented because the latter appears as distinguished text.
The process of traversing each document with both the sequence window 302 and the secondary window 304 , is repeated for each document in the partition.
Once the documents in the partition have been traversed, the next stage of the indexing operation is to update 202 the good phrase list 208 from the possible phrase list 206 . A possible phrase p on the possible phrase list 206 is moved to the good phrase list 208 if the frequency of appearance of the phrase and the number of documents that the phrase appears in indicates that it has sufficient usage as semantically meaningful phrase.
In one embodiment, this is tested as follows. A possible phrase p is removed from the possible phrase list 206 and placed on the good phrase list 208 if:
a) P(p)>10 and S(p)>20 (the number of documents containing phrase p is more than 10, and the number of occurrences of phrase p is more then 20); or
b) M(p)>5 (the number of interesting instances of phrase p is more than 5).
These thresholds are scaled by the number of documents in the partition; for example if 2,000,000 documents are crawled in a partition, then the thresholds are approximately doubled. Of course, those of skill in the art will appreciate that the specific values of the thresholds, or the logic of testing them, can be varied as desired.
If a phrase p does not qualify for the good phrase list 208 , then it is checked for qualification for being a bad phrase. A phrase p is a bad phrase if:
a) number of documents containing phrase, P(p)<2; and
b) number of interesting instances of phrase, M(p)=0.
These conditions indicate that the phrase is both infrequent, and not used as indicative of significant content and again these thresholds may be scaled per number of documents in the partition.
It should be noted that the good phrase list 208 will naturally include individual words as phrases, in addition to multi-word phrases, as described above. This is because each the first word in the phrase window 302 is always a candidate phrase, and the appropriate instance counts will be accumulated. Thus, the indexing system 110 can automatically index both individual words (i.e., phrases with a single word) and multiple word phrases. The good phrase list 208 will also be considerably shorter than the theoretical maximum based on all possible combinations of m phrases. In typical embodiment, the good phrase list 208 will include about 6.5×10 5 phrases. A list of bad phrases is not necessary to store, as the system need only keep track of possible and good phrases.
By the final pass through the document collection, the list of possible phrases will be relatively short, due to the expected distribution of the use of phrases in a large corpus. Thus, if say by the 10 th pass (e.g., 10,000,000 documents), a phrase appears for the very first time, it is very unlikely to be a good phrase at that time. It may be new phrase just coming into usage, and thus during subsequent crawls becomes increasingly common. In that case, its respective counts will increases and may ultimately satisfy the thresholds for being a good phrase.
The third stage of the indexing operation is to prune 204 the good phrase list 208 using a predictive measure derived from the co-occurrence matrix 212 . Without pruning, the good phrase list 208 is likely to include many phrases that while legitimately appearing in the lexicon, themselves do not sufficiently predict the presence of other phrases, or themselves are subsequences of longer phrases. Removing these weak good phrases results in a very robust likely of good phrases. To identify good phrases, a predictive measure is used which expresses the increased likelihood of one phrase appearing in a document given the presence of another phrase. This is done, in one embodiment, as follows:
As noted above, the co-occurrence matrix 212 is an m×m matrix of storing data associated with the good phrases. Each row j in the matrix represents a good phrase g j and each column k represented a good phrase g k . For each good phrase g j , an expected value E(g j ) is computed. The expected value E is the percentage of documents in the collection expected to contain g j . This is computed, for example, as the ratio of the number of documents containing g j to the total number T of documents in the collection that have been crawled: P(j)/T.
As noted above, the number of documents containing g j is updated each time g j appears in a document. The value for E(g j ) can be updated each time the counts for g j are incremented, or during this third stage.
Next, for each other good phrase g k (e.g., the columns of the matrix), it is determined whether g j predicts g k . A predictive measure for g j is determined as follows:
i) compute the expected value E(g k ). The expected co-occurrence rate E(j,k) of g j and g k , if they were unrelated phrases is then E(g j )*E(g k );
ii) compute the actual co-occurrence rate A(j,k) of g j and g k . This is the raw co-occurrence count R(j, k) divided by T, the total number of documents;
iii) g j is said to predict g k where the actual co-occurrence rate A(j,k) exceeds the expected co-occurrence rate E(j,k) by a threshold amount.
In one embodiment, the predictive measure is information gain. Thus, a phrase g j predicts another phrase g k when the information gain I of g k in the presence of g j exceeds a threshold. In one embodiment, this is computed as follows:
I ( j,k )= A ( j,k )/ E ( j,k )
And good phrase g j predicts good phrase g k where:
I(j,k)>Information Gain threshold.
In one embodiment, the information gain threshold is 1.5, but is preferably between 1.1 and 1.7. Raising the threshold over 1.0 serves to reduce the possibility that two otherwise unrelated phrases co-occur more than randomly predicted.
As noted the computation of information gain is repeated for each column k of the matrix G with respect to a given row j. Once a row is complete, if the information gain for none of the good phrases g k exceeds the information gain threshold, then this means that phrase g j does not predict any other good phrase. In that case, g j is removed from the good phrase list 208 , essentially becoming a bad phrase. Note that the column j for the phrase g j is not removed, as this phrase itself may be predicted by other good phrases.
This step is concluded when all rows of the co-occurrence matrix 212 have been evaluated.
The final step of this stage is to prune the good phrase list 208 to remove incomplete phrases. An incomplete phrase is a phrase that only predicts its phrase extensions, and which starts at the left most side of the phrase (i.e., the beginning of the phrase). The “phrase extension” of phrase p is a super-sequence that begins with phrase p. For example, the phrase “President of” predicts “President of the United States”, “President of Mexico”, “President of AT&T”, etc. All of these latter phrases are phrase extensions of the phrase “President of” since they begin with “President of” and are super-sequences thereof.
Accordingly, each phrase g j remaining on the good phrase list 208 will predict some number of other phrases, based on the information gain threshold previously discussed. Now, for each phrase g j the indexing system 110 performs a string match with each of the phrases g k that is predicts. The string match tests whether each predicted phrase g k is a phrase extension of the phrase g j . If all of the predicted phrases g k are phrase extensions of phrase g j , then phrase g j is incomplete, and is removed from the good phrase list 208 , and added to an incomplete phrase list 216 . Thus, if there is at least one phrase g k that is not an extension of g j , then g j is complete, and maintained in the good phrase list 208 . For example then, “President of the United” is an incomplete phrase because the only other phrase that it predicts is “President of the United States” which is an extension of the phrase.
The incomplete phrase list 216 itself is very useful during actual searching. When a search query is received, it can be compared against the incomplete phase list 216 . If the query (or a portion thereof) matches an entry in the list, then the search system 120 can lookup the most likely phrase extensions of the incomplete phrase (the phrase extension having the highest information gain given the incomplete phrase), and suggest this phrase extension to the user, or automatically search on the phrase extension. For example, if the search query is “President of the United,” the search system 120 can automatically suggest to the user “President of the United States” as the search query.
After the last stage of the indexing process is completed, the good phrase list 208 will contain a large number of good phrases that have been discovered in the corpus. Each of these good phrases will predict at least one other phrase that is not a phrase extension of it. That is, each good phrase is used with sufficient frequency and independence to represent meaningful concepts or ideas expressed in the corpus. Unlike existing systems which use predetermined or hand selected phrases, the good phrase list reflects phrases that actual are being used in the corpus. Further, since the above process of crawling and indexing is repeated periodically as new documents are added to the document collection, the indexing system 110 automatically detects new phrases as they enter the lexicon.
2. Identification of Related Phrases and Clusters of Related Phrases
Referring to FIG. 4 , the related phrase identification process includes the following functional operations.
400 : Identify related phrases having a high information gain value.
402 : Identify clusters of related phrases.
404 : Store cluster bit vector and cluster number.
Each of these operations is now described in detail.
First, recall that the co-occurrence matrix 212 contains good phrases g j , each of which predicts at least one other good phrase g k with an information gain greater than the information gain threshold. To identify 400 related phrases then, for each pair of good phrases (g j , g k ) the information gain is compared with a Related Phrase threshold, e.g., 100. That is, g j and g k are related phrases where:
I ( g j ,g k )>100.
This high threshold is used to identify the co-occurrences of good phrases that are well beyond the statistically expected rates. Statistically, it means that phrases g j and g k co-occur 100 times more than the expected co-occurrence rate. For example, given the phrase “Monica Lewinsky” in a document, the phrase “Bill Clinton” is a 100 times more likely to appear in the same document, then the phrase “Bill Clinton” is likely to appear on any randomly selected document. Another way of saying this is that the accuracy of the predication is 99.999% because the occurrence rate is 100:1.
Accordingly, any entry (g j , g k ) that is less the Related Phrase threshold is zeroed out, indicating that the phrases g j , g k are not related. Any remaining entries in the co-occurrence matrix 212 now indicate all related phrases.
The columns g k in each row g j of the co-occurrence matrix 212 are then sorted by the information gain values I(g j , g k ), so that the related phrase g k with the highest information gain is listed first. This sorting thus identifies for a given phrase g j , which other phrases are most likely related in terms of information gain.
The next step is to determine 402 which related phrases together form a cluster of related phrases. A cluster is a set of related phrases in which each phrase has high information gain with respect to at least one other phrase. In one embodiment, clusters are identified as follows.
In each row g j of the matrix, there will be one or more other phrases that are related to phrase g j . This set is related phrase set R j , where R={g k , g j , . . . g m }.
For each related phrase m in R j , the indexing system 110 determines if each of the other related phrases in R is also related to g j . Thus, if T(g k , g i ) is also non-zero, then g j , g k , and g i are part of a cluster. This cluster test is repeated for each pair (g i , g m ) in R.
For example, assume the good phrase “Bill Clinton” is related to the phrases “President”, “Monica Lewinsky”, because the information gain of each of these phrases with respect to “Bill Clinton” exceeds the Related Phrase threshold. Further assume that the phrase “Monica Lewinsky” is related to the phrase “purse designer”. These phrases then form the set R. To determine the clusters, the indexing system 110 evaluates the information gain of each of these phrases to the others by determining their corresponding information gains. Thus, the indexing system 110 determines the information gain I(“President”, “Monica Lewinsky”), I(“President”, “purse designer”), and so forth, for all pairs in R. In this example, “Bill Clinton,” “President”, and “Monica Lewinsky” form a one cluster, “Bill Clinton,” and “President” form a second cluster, and “Monica Lewinsky” and “purse designer” form a third cluster, and “Monica Lewinsky”, “Bill Clinton,” and “purse designer” form a fourth cluster. This is because while “Bill Clinton” does not predict “purse designer” with sufficient information gain, “Monica Lewinsky” does predict both of these phrases.
To record 404 the cluster information, each cluster is assigned a unique cluster number (cluster ID). This information is then recorded in conjunction with each good phrase g j .
In one embodiment, the cluster number is determined by a cluster bit vector that also indicates the orthogonality relationships between the phrases. The cluster bit vector is a sequence of bits of length n, the number of good phrases in the good phrase list 208 . For a given good phrase g j , the bit positions correspond to the sorted related phrases R of g j . A bit is set if the related phrase g k in R is in the same cluster as phrase g j . More generally, this means that the corresponding bit in the cluster bit vector is set if there is information gain in either direction between g j and g k .
The cluster number then is the value of the bit string that results. This implementation has the property that related phrases that have multiple or one-way information gain appear in the same cluster.
An example of the cluster bit vectors are as follows, using the above phrases:
Monica
purse
Cluster
Bill Clinton
President
Lewinsky
designer
ID
Bill Clinton
1
1
1
0
14
President
1
1
0
0
12
Monica
1
0
1
1
11
Lewinsky
purse
0
0
1
1
3
designer
To summarize then, after this process there will be identified for each good phrase g j , a set of related phrases R, which are sorted in order of information gain I(g j , g k ) from highest to lowest. In addition, for each good phrase g j , there will be a cluster bit vector, the value of which is a cluster number identifying the primary cluster of which the phrase g j is a member, and the orthogonality values (1 or 0 for each bit position) indicating which of the related phrases in R are in common clusters with g j . Thus in the above example, “Bill Clinton”, “President”, and “Monica Lewinsky” are in cluster 14 based on the values of the bits in the row for phrase “Bill Clinton”.
To store this information, two basic representations are available. First, as indicated above, the information may be stored in the co-occurrence matrix 212 , wherein:
entry G [row j, col. k]=(I(j,k), clusterNumber, clusterBitVector).
Alternatively, the matrix representation can be avoided, and all information stored in the good phrase list 208 , wherein each row therein represents a good phrase g j :
Phrase row j=list [phrase g k , (I(j,k), clusterNumber, clusterBitVector)].
This approach provides a useful organization for clusters. First, rather than a strictly—and often arbitrarily—defined hierarchy of topics and concepts, this approach recognizes that topics, as indicated by related phrases, form a complex graph of relationships, where some phrases are related to many other phrases, and some phrases have a more limited scope, and where the relationships can be mutual (each phrase predicts the other phrase) or one-directional (one phrase predicts the other, but not vice versa). The result is that clusters can be characterized “local” to each good phrase, and some clusters will then overlap by having one or more common related phrases.
For a given good phrase g j then the ordering of the related phrases by information gain provides a taxonomy for naming the clusters of the phrase: the cluster name is the name of the related phrase in the cluster having the highest information gain.
The above process provides a very robust way of identifying significant phrases that appear in the document collection, and beneficially, the way these related phrases are used together in natural “clusters” in actual practice. As a result, this data-driven clustering of related phrases avoids the biases that are inherent in any manually directed “editorial” selection of related terms and concepts, as is common in many systems.
3. Indexing Documents with Phrases and Related Phrases
Given the good phrase list 208 , including the information pertaining to related phrases and clusters, the next functional operation of the indexing system 110 is to index documents in the document collection with respect to the good phrases and clusters, and store the updated information in the index 150 . FIG. 5 illustrates this process, in which there are the following functional stages for indexing a document:
500 : Post document to the posting lists of good phrases found in the document.
502 : Update instance counts and related phrase bit vector for related phases and secondary related phrases.
504 : Annotate documents with related phrase information.
506 : Reorder index entries according to posting list size.
These stages are now described in further detail.
A set of documents is traversed or crawled, as before; this may be the same or a different set of documents. For a given document d, traverse 500 the document word by word with a sequence window 302 of length n, from position i, in the manner described above.
In a given phrase window 302 , identify all good phrases in the window, starting at position i. Each good phrase is denoted as g i . Thus, g 1 is the first good phrase, g 2 would be the second good phrase, and so forth.
For each good phrase g i (example g 1 “President” and g 4 “President of ATT”) post the document identifier (e.g., the URL) to the posting list for the good phrase g i in the index 150 . This update identifies that the good phrase g i appears in this specific document.
In one embodiment, the posting list for a phrase g j takes the following logical form:
Phrase g j : list: (document d, [list: related phase counts] [related phrase information])
For each phrase g j there is a list of the documents d on which the phrase appears. For each document, there is a list of counts of the number of occurrences of the related phrases R of phrase g j that also appear in document d.
In one embodiment, the related phrase information is a related phase bit vector. This bit vector may be characterized as a “bi-bit” vector, in that for each related phrase g k there are two bit positions, g k −1, g k −2. The first bit position stores a flag indicating whether the related phrase g k is present in the document d (i.e., the count for g k in document d is greater than 0). The second bit position stores a flag that indicates whether a related phrase g l of g k is also present in document d. The related phrases g l of a related phrase g k of a phrase g j are herein called the “secondary related phrases of g j ” The counts and bit positions correspond to the canonical order of the phrases in R (sorted in order of decreasing information gain). This sort order has the effect of making the related phrase g k that is most highly predicted by g j associated with the most significant bit of the related phrase bit vector, and the related phrase g l that is least predicted by g j associated with the least significant bit.
It is useful to note that for a given phrase g, the length of the related phrase bit vector, and the association of the related phrases to the individual bits of the vector, will be the same with respect to all documents containing g. This implementation has the property of allowing the system to readily compare the related phrase bit vectors for any (or all) documents containing g, to see which documents have a given related phrase. This is beneficial for facilitating the search process to identify documents in response to a search query. Accordingly, a given document will appear in the posting lists of many different phrases, and in each such posting list, the related phrase vector for that document will be specific to the phrase that owns the posting list. This aspect preserves the locality of the related phrase bit vectors with respect to individual phrases and documents.
Accordingly, the next stage 502 includes traversing the secondary window 304 of the current index position in the document (as before a secondary window of +/−K terms, for example, 30 terms), for example from i−K to i+K. For each related phrase g k of g i that appears in the secondary window 304 , the indexing system 110 increments the count of g k with respect to document d in the related phrase count. If g i appears later in the document, and the related phrase is found again within the later secondary window, again the count is incremented.
As noted, the corresponding first bit g k −1 in the related phrase bit map is set based on the count, with the bit set to 1 if the count for g k is >0, or set to 0 if the count equals 0.
Next, the second bit, g k 2 is set by looking up related phrase g k in the index 150 , identifying in g k 's posting list the entry for document d, and then checking the secondary related phrase counts (or bits) for g k for any its related phrases. If any of these secondary related phrases counts/bits are set, then this indicates that the secondary related phrases of g j are also present in document d.
When document d has been completely processed in this manner, the indexing system 110 will have identified the following:
i) each good phrase g j in document d;
ii) for each good phrase g j which of its related phrases g k are present in document d;
iii) for each related phrase g k present in document d, which of its related phrases g l (the secondary related phrases of g j ) are also present in document d.
a) Determining the Topics for a Document
The indexing of documents by phrases and use of the clustering information provides yet another advantage of the indexing system 110 , which is the ability to determine the topics that a document is about based on the related phrase information.
Assume that for a given good phrase g j and a given document d, the posting list entry is as follows:
g j : document d: related phrase counts:={3,4,3,0,0,2,1,1,0}
related phrase bit vector:={11 11 10 00 00 10 10 10 01}
where, the related phrase bit vector is shown in the bi-bit pairs.
From the related phrase bit vector, we can determine primary and secondary topics for the document d. A primary topic is indicated by a bit pair (1,1), and a secondary topic is indicated by a bit pair (1,0). A related phrase bit pair of (1,1) indicates that both the related phrase g k for the bit pair is present in document d, along the secondary related phrases g l as well. This may be interpreted to mean that the author of the document d used several related phrases g j , g k , and g l together in drafting the document. A bit pair of (1,0) indicates that both g j and g k are present, but no further secondary related phrases from g k are present, and thus this is a less significant topic.
b) Document Annotation for Improved Ranking
A further aspect of the indexing system 110 is the ability to annotate 504 each document d during the indexing process with information that provides for improved ranking during subsequent searches. The annotation process 506 is as follows.
A given document d in the document collection may have some number of outlinks to other documents. Each outlink (a hyperlink) includes anchor text and the document identifier of the target document. For purposes of explanation, a current document d being processed will be referred to as URL 0 , and the target document of an outlink on document d will be referred to as URL 1 . For later use in ranking documents in search results, for every link in URL 0 , which points to some other URLi, the indexing system 110 creates an outlink score for the anchor phrase of that link with respect to URL 0 , and an inlink score for that anchor phrase with respect to URLi. That is, each link in the document collection has a pair of scores, an outlink score and an inlink score. These scores are computed as follows.
On a given document URL 0 , the indexing system 110 identifies each outlink to another document URL 1 , in which the anchor text A is a phrase in the good phrase list 208 . FIG. 7 a illustrates schematically this relationship, in which anchor text “A” in document URL 0 is used in a hyperlink 700 .
In the posting list for phrase A, URL 0 is posted as an outlink of phrase A, and URL 1 is posted as an inlink of phrase A. For URL 0 , the related phrase bit vector is completed as described above, to identify the related phrases and secondary related phrases of A present in URL 0 . This related phrase bit vector is used as the outlink score for the link from URL 0 to URL 1 containing anchor phrase A.
Next, the inlink score is determined as follows. For each inlink to URL 1 containing the anchor phrase A, the indexing system 110 scans URL 1 , and determines whether phrase A appears in the body of URL 1 . If phrase A not only points to URL 1 (via a outlink on URL 0 ), but also appears in the content of URL 1 itself, this suggests that URL 1 can be said to be intentionally related to the concept represented by phrase A.
FIG. 7 b illustrates this case, where phrase A appears in both URL 0 (as anchor text) and in the body of URL 1 . In this case, the related phrase bit vector for phrase A for URL 1 is used as the inlink score for the link from URL 0 to URL 1 containing phrase A.
If the anchor phrase A does not appear in the body of URL 1 (as in FIG. 8 a ), then a different step is taken to determine the inlink score. In this case, the indexing system 110 creates a related phrase bit vector for URL 1 for phrase A (as if phrase A was present in URL 1 ) and indicating which of the related phrases of phrase A appear in URL 1 . This related phrase bit vector is then used as the inlink score for the link from URL 0 to URL 1 .
For example, assume the following phrases are initially present in URL 0 and URL 1 :
Anchor
Phrase
Related Phrase Bit Vector
Australian
blue
red
agility
Document
Shepherd
Aussie
merle
merle
tricolor
training
URL0
1
1
0
0
0
0
URL1
1
0
1
1
1
0
(In the above, and following tables, the secondary related phrase bits are not shown). The URL 0 row is the outlink score of the link from anchor text A, and the URL 1 row is the inlink score of the link. Here, URL 0 contains the anchor phrase “Australian Shepard” which targets URL 1 . Of the five related phrases of “Australian Shepard”, only one, “Aussie” appears in URL 0 . Intuitively then, URL 0 is only weakly about Australian Shepherds. URL 1 , by comparison, not only has the phrase “Australian Shepherd” present in the body of the document, but also has many of the related phrases present as well, “blue merle,” “red merle,” and “tricolor.” Accordingly, because the anchor phrase “Australian Shepard” appears in both URL 0 and URL 1 , the outlink score for URL 0 , and the inlink score for URL 1 are the respective rows shown above.
The second case described above is where anchor phrase A does not appear in URL 1 . In that, the indexing system 110 scans URL 1 and determines which of the related phrases “Aussie,” “blue merle,” “red merle,” “tricolor,” and “agility training” are present in URL 1 , and creates an related phrase bit vector accordingly, for example:
Anchor Phrase Related Phrase Bit Vector Australian blue red agility Document Shepherd Aussie merle merle tricolor training URL0 1 1 0 0 0 0 URL1 0 0 1 1 1 0
Here, this shows that the URL 1 does not contain the anchor phrase “Australian Shepard”, but does contain the related phrases “blue merle”, “red merle”, and “tricolor”. This approach has the benefit of entirely preventing certain types of manipulations of web pages (a class of documents) in order to skew the results of a search. Search engines that use a ranking algorithm that relies on the number of links that point to a given document in order to rank that document can be “bombed” by artificially creating a large number of pages with a given anchor text which then point to a desired page. As a result, when a search query using the anchor text is entered, the desired page is typically returned, even if in fact this page has little or nothing to do with the anchor text. Importing the related bit vector from a target document URL 1 into the phrase A related phrase bit vector for document URL 0 eliminates the reliance of the search system on just the relationship of phrase A in URL 0 pointing to URL 1 as an indicator of significance or URL 1 to the anchor text phrase.
Each phrase in the index 150 is also given a phrase number, based on its frequency of occurrence in the corpus. The more common the phrase, the lower phrase number it receivesorder in the index. The indexing system 110 then sorts 506 all of the posting lists in the index 150 in declining order according to the number of documents listed phrase number of in each posting list, so that the most frequently occurring phrases are listed first. The phrase number can then be used to look up a particular phrase.
III. Search System
The search system 120 operates to receive a query and search for documents relevant to the query, and provide a list of these documents (with links to the documents) in a set of search results. FIG. 6 illustrates the main functional operations of the search system 120 :
600 : Identify phrases in the query.
602 : Retrieve documents relevant to query phrases.
604 : Rank documents in search results according to phrases.
The details of each of these of these stages is as follows.
1. Identification of Phrases in the Query and Query Expansion
The first stage 600 of the search system 120 is to identify any phrases that are present in the query in order to effectively search the index. The following terminology is used in this section:
q: a query as input and receive by the search system 120 .
Qp: phrases present in the query.
Qr: related phrases of Qp.
Qe: phrase extensions of Qp.
Q: the union of Qp and Qr.
A query q is received from a client 190 , having up to some maximum number of characters or words.
A phrase window of size N (e.g., 5) is used by the search system 120 to traverse the terms of the query q. The phrase window starts with the first term of the query, extends N terms to the right. This window is then shifted right M-N times, where M is the number of terms in the query.
At each window position, there will be N terms (or fewer) terms in the window. These terms constitute a possible query phrase. The possible phrase is looked up in the good phrase list 208 to determine if it is a good phrase or not. If the possible phrase is present in the good phrase list 208 , then a phrase number is returned for phrase; the possible phrase is now a candidate phrase.
After all possible phrases in each window have been tested to determine if they are good candidate phrases, the search system 120 will have a set of phrase numbers for the corresponding phrases in the query. These phrase numbers are then sorted (declining order).
Starting with the highest phrase number as the first candidate phrase, the search system 120 determines if there is another candidate phrase within a fixed numerical distance within the sorted list, i.e., the difference between the phrase numbers is within a threshold amount, e.g. 20,000. If so, then the phrase that is leftmost in the query is selected as a valid query phrase Qp. This query phrase and all of its sub-phrases is removed from the list of candidates, and the list is resorted and the process repeated. The result of this process is a set of valid query phrases Qp.
For example, assume the search query is “Hillary Rodham Clinton Bill on the Senate Floor”. The search system 120 would identify the following candidate phrases, “Hillary Rodham Clinton Bill on,” “Hillary Rodham Clinton Bill,” and “Hillary Rodham Clinton”. The first two are discarded, and the last one is kept as a valid query phrase. Next the search system 120 would identify “Bill on the Senate Floor”, and the subsphrases “Bill on the Senate”, “Bill on the”, “Bill on”, “Bill”, and would select “Bill” as a valid query phrase Qp. Finally, the search system 120 would parse “on the senate floor” and identify “Senate Floor” as a valid query phrase.
Next, the search system 120 adjusts the valid phrases Qp for capitalization. When parsing the query, the search system 120 identifies potential capitalizations in each valid phrase. This may be done using a table of known capitalizations, such as “united states” being capitalized as “United States”, or by using a grammar based capitalization algorithm. This produces a set of properly capitalized query phrases.
The search system 120 then makes a second pass through the capitalized phrases, and selects only those phrases are leftmost and capitalized where both a phrase and its subphrase is present in the set. For example, a search on “president of the united states” will be capitalized as “President of the United States”.
In the next stage, the search system 120 identifies 602 the documents that are relevant to the query phrases Q. The search system 120 then retrieves the posting lists of the query phrases Q, and intersects these lists to determine which documents appear on the all (or some number) of the posting lists for the query phrases. If a phrase Q in the query has a set of phrase extensions Qe (as further explained below), then the search system 120 first forms the union of the posting lists of the phrase extensions, prior to doing the intersection with the posting lists. The search system 120 identifies phrase extensions by looking up each query phrase Q in the incomplete phrase list 216 , as described above.
The result of the intersection is a set of documents that are relevant to the query. Indexing documents by phrases and related phrases, identifying phrases Q in the query, and then expanding the query to include phrase extensions results in the selection of a set of documents that are more relevant to the query then would result in a conventional Boolean based search system in which only documents that contain the query terms are selected.
In one embodiment, the search system 120 can use an optimized mechanism to identify documents responsive to the query without having to intersect all of the posting lists of the query phrases Q. As a result of the structure of the index 150 , for each phrase g j , the related phrases g k are known and identified in the related phrase bit vector for g k . Accordingly, this information can be used to shortcut the intersection process where two or more query phrases are related phrases to each other, or have common related phrases. In those cases, the related phrase bit vectors can be directly accessed, and then used next to retrieve corresponding documents. This process is more fully described as follows.
Given any two query phrases Q 1 and Q 2 , there are three possible cases of relations:
1) Q 2 is a related phrase of Q 1 ;
2) Q 2 is not a related phrase of Q 1 and their respective related phrases Qr 1 and Qr 2 do not intersect (i.e., no common related phrases); and
3) Q 2 is not a related phrase of Q 1 , but their respective related phrases Qr 1 and Qr 2 do intersect.
For each pair of query phrases the search system 120 determines the appropriate case by looking up the related phrase bit vector of the query phrases Qp.
The search system 120 proceeds by retrieving the posting list for query phrase Q 1 , which contains the documents containing Q 1 , and for each of these documents, a related phrase bit vector. The related phrase bit vector for Q 1 will indicated whether phrase Q 2 (and each of the remaining query phrases, if any) is a related phrase of Q 1 and is present in the document.
If the first case applies to Q 2 , the search system 120 scans the related phrase bit vector for each document d in Q 1 's posting list to determine if it has a bit set for Q 2 . If this bit is not set in for document d in Q 1 's posting list, then it means that Q 2 does not appear in that document. As result, this document can be immediately eliminated from further consideration. The remaining documents can then be scored. This means further that it is unnecessary for the search system 120 to process the posting lists of Q 2 to see which documents it is present in as well, thereby saving compute time.
If the second case applies to Q 2 , then the two phrases are unrelated to each other. For example the query “cheap bolt action rifle” has two phrases “cheap” and “bolt action rifle”. Neither of these phrases is related to each other, and further the related phrases of each of these do not overlap; i.e., “cheap” has related phrases “low cost,” “inexpensive,” “discount,” “bargain basement,” and “lousy,” whereas “bolt action rifle” has related phrases “gun,” “22 caliber”, “magazine fed,” and “Armalite AR-30M”, which lists thus do not intersect. In this case, the search system 120 does the regular intersection of the posting lists of Q 1 and Q 2 to obtain the documents for scoring.
If the third case applies, then here the two phrases Q 1 and Q 2 that are not related, but that do have at least one related phrase in common. For example the phrases “bolt action rifle” and “22” would both have “gun” as a related phase. In this case, the search system 120 retrieves the posting lists of both phrases Q 1 and Q 2 and intersects the lists to produce a list of documents that contain both phrases.
The search system 120 can then quickly score each of the resulting documents. First, the search system 120 determines a score adjustment value for each document. The score adjustment value is a mask formed from the bits in the positions corresponding to the query phrases Q 1 and Q 2 in the related phrase bit vector for a document. For example, assume that Q 1 and Q 2 correspond to the 3 rd and 6 th bi-bit positions in the related phrase bit vector for document d, and the bit values in 3 rd position are (1,1) and the bit values in the 6 th pair are (1,0), then the score adjustment value is the bit mask “00 00 1100 00 10”. The score adjustment value is then used to mask the related phrase bit vector for the documents, and modified phrase bit vectors then are passed into the ranking function (next described) to be used in calculating a body score for the documents.
2. Ranking
a) Ranking Documents Based on Contained Phrases
The search system 120 provides a ranking stage 604 in which the documents in the search results are ranked, using the phrase information in each document's related phrase bit vector, and the cluster bit vector for the query phrases. This approach ranks documents according to the phrases that are contained in the document, or informally “body hits.”
As described above, for any given phrase g j , each document d in the g j 's posting list has an associated related phrase bit vector that identifies which related phrases g k and which secondary related phrases g l are present in document d. The more related phrases and secondary related phrases present in a given document, the more bits that will be set in the document's related phrase bit vector for the given phrase. The more bits that are set, the greater the numerical value of the related phrase bit vector.
Accordingly, in one embodiment, the search system 120 sorts the documents in the search results according to the value of their related phrase bit vectors. The documents containing the most related phrases to the query phrases Q will have the highest valued related phrase bit vectors, and these documents will be the highest-ranking documents in the search results.
This approach is desirable because semantically, these documents are most topically relevant to the query phrases. Note that this approach provides highly relevant documents even if the documents do not contain a high frequency of the input query terms q, since related phrase information was used to both identify relevant documents, and then rank these documents. Documents with a low frequency of the input query terms may still have a large number of related phrases to the query terms and phrases and thus be more relevant than documents that have a high frequency of just the query terms and phrases but no related phrases.
In a second embodiment, the search system 120 scores each document in the result set according which related phrases of the query phrase Q it contains. This is done as follows:
Given each query phrase Q, there will be some number N of related phrases Qr to the query phrase, as identified during the phrase identification process. As described above, the related query phrases Qr are ordered according to their information gain from the query phrase Q. These related phrases are then assigned points, started with N points for the first related phrase Qr 1 (i.e., the related phrase Qr with the highest information gain from Q), then N−1 points for the next related phrase Qr 2 , then N−2 points for Qr 3 , and so on, so that the last related phrase QrN is assigned 1 point.
Each document in the search results is then scored by determining which related phrases Qr of the query phrase Q are present, and giving the document the points assigned to each such related phrase Qr. The documents are then sorted from highest to lowest score.
As a further refinement, the search system 120 can cull certain documents from the result set. In some cases documents may be about many different topics; this is particularly the case for longer documents. In many cases, users prefer documents that are strongly on point with respect to a single topic expressed in the query over documents that are relevant to many different topics.
To cull these latter types of documents, the search system 120 uses the cluster information in the cluster bit vectors of the query phrases, and removes any document in which there are more than a threshold number of clusters in the document. For example, the search system 120 can remove any documents that contain more than two clusters. This cluster threshold can be predetermined, or set by the user as a search parameter.
b) Ranking Documents Based on Anchor Phrases
In addition to ranking the documents in the search results based on body hits of query phrases Q, in one embodiment, the search system 120 also ranks the documents based on the appearance of query phrases Q and related query phrases Qr in anchors to other documents. In one embodiment, the search system 120 calculates a score for each document that is a function (e.g., linear combination) of two scores, a body hit score and an anchor hit score.
For example, the document score for a given document can be calculated as follows:
Score=0.30*(body hit score)+0.70*(anchor hit score).
The weights of 0.30 and 0.70 can be adjusted as desired. The body hit score for a document is the numerical value of the highest valued related phrase bit vector for the document, given the query phrases Qp, in the manner described above. Alternatively, this value can directly obtained by the search system 120 by looking up each query phrase Q in the index 150 , accessing the document from the posting list of the query phrase Q, and then accessing the related phrase bit vector.
The anchor hit score of a document d a function of the related phrase bit vectors of the query phrases Q, where Q is an anchor term in a document that references document d. When the indexing system 110 indexes the documents in the document collection, it maintains for each phrase a list of the documents in which the phrase is anchor text in an outlink, and also for each document a list of the inlinks (and the associated anchor text) from other documents. The inlinks for a document are references (e.g. hyperlinks) from other documents (referencing documents) to a given document.
To determine the anchor hit score for a given document d then, the search system 120 iterates over the set of referencing documents R (i=1 to number of referencing documents) listed in index by their anchor phrases Q, and sums the following product:
R i .Q.Related phrase bit vector*D.Q.Related phrase bit vector.
The product value here is a score of how topical anchor phrase Q is to document D. This score is here called the “inbound score component.” This product effectively weights the current document D's related bit vector by the related bit vectors of anchor phrases in the referencing document R. If the referencing documents R themselves are related to the query phrase Q (and thus, have a higher valued related phrase bit vector), then this increases the significance of the current document D score. The body hit score and the anchor hit score are then combined to create the document score, as described above.
Next, for each of the referencing documents R, the related phrase bit vector for each anchor phrase Q is obtained. This is a measure of how topical the anchor phrase Q is to the document R. This value is here called the outbound score component.
From the index 150 then, all of the (referencing document, referenced document) pairs are extracted for the anchor phrases Q. These pairs are then sorted by their associated (outbound score component, inbound score component) values. Depending on the implementation, either of these components can be the primary sort key, and the other can be the secondary sort key. The sorted results are then presented to the user. Sorting the documents on the outbound score component makes documents that have many related phrases to the query as anchor hits, rank most highly, thus representing these documents as “expert” documents. Sorting on the inbound document score makes documents that frequently referenced by the anchor terms the most high ranked.
IV. Top Phrases and Phrase Information Refinement
The phrase information refinement system 130 uses the per-document phrase information generated by the indexing system 110 to determine additional phrase information for individual websites (or other limited document collections), and uses any modifications made by users to this additional information to refine the existing generated phrase information stored in index 150 . FIG. 8 illustrates the main functional operations of the phrase information refinement system 130 :
800 : Determine the top phrases associated with a given website
810 : Receive additional related phrases for top phrases
820 : Update related phrases of top phrase with additional related phrases
830 : Update additional related phrases with information from existing related phrases.
1. Determining Top Phrases
In addition to determining the documents in which particular phrases and related phrases occur, as already accomplished by the indexing system 110 , the phrase information refinement system 130 is configured to determine the a set of representative or significant phrases for a particular web site or other limited document collection; these representative phrases can be generally referred to as “top phrases.” The “top phrases” for a website are useful indicators of the queries for which the website is likely to be relevant, and thus provide a mechanism for improved search efficiency.
For a given website, the phrase information refinement system 130 processes 800 each document within the website to determine the top phrases per page, and then aggregates these per-page top phrases to determine the top phrases of the document collection as a whole.
(a) Per-Document Processing
For each document in the website, the phrase information refinement system 130 determines the phrases that appear in the document, from index 150 . For each identified phrase, an importance score is calculated based on the related phrases. In one embodiment, the importance score for a phrase is a function of the summed frequency of occurrence of each of the related phrases in the document. This is readily accomplished by examining the posting list of the document, created earlier by the indexing system 110 , since lists of related phrases and the frequencies of each related phrase in the document are stored within the posting list for a given phrase and document. This determination means that phrases with the most numerous related phrases will be considered to be the most representative of the given document.
(b) Determining Top Phrases for a Website
With the top phrases for each document in the website determined, the phrase information refinement system 130 now uses this per-document information in order to determine the top phrases of the website as a whole. In one embodiment, the scores of each top phrase are summed across the documents in the website, and a number N (e.g., 10) of the phrases with the highest aggregate scores are chosen to be the top phrases for the website. In another embodiment, the scores of top phrases for a document are weighted according to their positions in the document collection. For example, in a document collection consisting of website pages, pages with shorter paths to the root of the site are given a higher weighting than pages with longer paths, on the assumption that pages closer to the root are more important than pages nested deep in the page hierarchy. The top phrases for the website are then stored in a data structure indexed by document identifier for the home page for the website.
The top phrases for the website can be recomputed on periodic basis, or on demand from the website administrator. In one embodiment, on each update the scores for a previous set of top phrases can be decayed and combined with the scores for the current set of top phrases, then the final scores determined, and sorted to identify the new top phrases. For example, the final score can be a weighted combination of 75% of the current score and 25% of a previous score. This (or other linear or non-linear) decay function enables the site to gradually change its most important phrases.
2. Receive Replacement Top Phrases for Current Top Phrases
The phrase information refinement system 130 also provides an interface that allows the administrators of document collections, such as webmasters, to view the top phrases and to manually change them to phrases deemed more representative of the site content. Allowing administrators to make such changes confers the dual benefits of updating the top phrase lists with more representative phrases so that the documents in the collection will be deemed relevant to a broader range of queries, and of providing additional, reliable semantic information, as discussed below.
FIG. 9 illustrates schematically a simplified web-based user interface designed for this purpose. Webmasters or other authorized administrators first enter the appropriate identifying information, such as a username and password created during an earlier registration process and identifying them as having authority for the web site. Upon authentication of this identifying information, the phrase information refinement system 130 then displays a page such as the user interface of FIG. 9 . The top phrases for the site are presented in text fields 902 . The administrator can provide a different replacement phrase for any of the top phrases, and submit these replacement phrases to the system 130 , with buttons 904 . For example, administrators could specify that the top phrase “working dog” 906 be replaced with a more representative top phrase, such as “dog sports.”
3. Updating Existing Phrase Information
Changes made by administrators represent particularly reliable knowledge about the relationships of phrases, since they are manually entered by an administrator who has authority for the document collection, and who is therefore presumably highly knowledgeable about what concepts the document collection represents. Thus, it is very valuable to capture this additional knowledge, using it to supplement the existing phrase information automatically determined by the indexing system 110 and creating a richer and more representative understanding of phrase relationships.
Initially, the phrase information refinement system 130 updates the phrase information, noting using the change of a current top phrase TP old to a new, administrator-specified replacement top phrase TP new as the basis of the update. Responsive to the top phrase change, a series of actions is performed, the order of which need not be performed in the particular order set forth below. Rather, the order of the actions may vary greatly in different embodiments, while still accomplishing the same result. The effect of the updating step 820 is to treat each replacement top phrase “as if” it was already present in the website. In general, this is done by adding the website to the posting list of the replacement phrase, and then updating the related phrase data for the replacement top phrase with related phrase data from the old top phrase, and other top phrases. This process is now described in more detail.
First, the root document for the website, such as the base URL of the web site, is added to the posting list for the replacement top phrase TP new . This in effect associates TP new with the site, treating it as if it appeared on home page of the site. This is reasonable since top phrases represent the entire document collection, rather than any particular document thereof, and thus the home page serves as a proxy for a location on the site for an occurrence of the replacement top phrase.
Another action is to add the current top phrase TP old to the related phrase list of the replacement related phrase TP new , and to likewise add TP new to the related phrase list of TPold. This action is appropriate since the administrator has expressly indicated that the phrases are related by providing the new phrase as a replacement for the old one. This feature thus allows the system to capture the semantic relationship between the two phrases. This is done by accessing the posting list for each of the phrases TP old and TP new , further accessing the entry for the root document of the document collection, such as the base URL for a web site, and then updating this entry to reflect the presence of the other phrase as a related phrase.
A further action is to determine which related phrases TP old and TP new have in common. Since the bits of the related phrase bit vectors of one phrase do not correspond to those of another phrase, the intersection of the related phrases cannot be determined simply by intersecting the related phrase bit vectors of two phrases. Rather, the set of actual related phrases corresponding to the bit vector bits is determined for each of TP old and TP new , and then the two sets are intersected, the result being the phrases that are related to both TP old and TP new . In one embodiment, intersecting (i.e., common) related phrases have their counts in the posting list for TP new set to the counts of TP old , which serves to give TP new a copy of the counts for TP old for their common related phrases.
For example, if the related phrases of TP old are “blue merle,” “red merle,” and “Aussie,” and the related phrases of TP new are “agility training,” “red merle,” and “working dog,” then the related phrase “red merle” is in the intersection. Thus, in the posting list for TP new , the entry for the root document of the collection is accessed and the count for the related phrase “red merle” is incremented.
It is expected that some webmasters and administrators will attempt to provide a replacement phrase for a top phrase to which it is not actually semantically related; this may be done either accidentally or intentionally, for example in order to attack search results to the page. This problem can be avoided by ensuring that a replacement phrase TP new has a minimal degree of semantic relationship to the TP old which it is to replace. In one embodiment then, TP new cannot be substituted for TP old unless there is some degree of relatedness of the two phrases, e.g. at least one phrase in common in their respective primary related phrases or their secondary related phrases. Further, in this embodiment, the phrase information refinement system 130 may additionally penalize an attempt to substitute an unrelated phrase by decrementing the counts of the related phrases of TP new with respect to the website. A “decrement penalty” serves to deter an administrator from entering popular but spurious top phrases in order to attract users to the site.
Still another action is to increment the counts in the related phrase list for TP new for related phrases that are also top phrases of the website. This incrementing reflects the fact that the top phrases are either already present somewhere in the document collection (in the case of automatically determined top phrases) or are at least considered to be effectively, if not actually, present (in the case of manually specified top phrases). For example, assume the top phrases in a website for cooking recipes are “baked chicken,” “chicken salad,” “vegetable stew” and “roast beef”, and further assume that new top phrase “chicken dishes” is being used to replace for old top phrase “baked chicken.” Assume as well that the related phrases of “baked chicken” are “roast chicken,” “broiled chicken” and “chicken salad”. Since “chicken salad” is both an existing top phrase in the website and is a related phrase of the replacement phrase “chicken dishes”, the entry for “chicken salad” in the related phrase list of the phrase “chicken dishes” is incremented.
The effect of these various updating actions is to update the data structures with information as if the administrator-specified replacement phrase TP new were itself present in the website and related to other phrases as indicated by its posting list related phrase entries. Even though TP new may not actually be present, the fact that an administrator stated it to be a top phrase of the document collection means that such “simulated” relationship data has a strong semantic foundation and is a valuable addition to the phrase data tracked by the system 100 .
With the updates to the top phrases using replacement phrases, during the search process described above, the website will be returned in response to queries that correspond to replacement phrases (and their related phrases).
The present invention has been described in particular detail with respect to one possible embodiment. Those of skill in the art will appreciate that the invention may be practiced in other embodiments. First, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other programming or structural aspect is not mandatory or significant, and the mechanisms that implement the invention or its features may have different names, formats, or protocols. Further, the system may be implemented via a combination of hardware and software, as described, or entirely in hardware elements. Also, the particular division of functionality between the various system components described herein is merely exemplary, and not mandatory; functions performed by a single system component may instead be performed by multiple components, and functions performed by multiple components may instead performed by a single component.
Some portions of above description present the features of the present invention in terms of algorithms and symbolic representations of operations on information. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. These operations, while described functionally or logically, are understood to be implemented by computer programs. Furthermore, it has also proven convenient at times, to refer to these arrangements of operations as modules or by functional names, without loss of generality.
Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Certain aspects of the present invention include process steps and instructions described herein in the form of an algorithm. It should be noted that the process steps and instructions of the present invention could be embodied in software, firmware or hardware, and when embodied in software, could be downloaded to reside on and be operated from different platforms used by real time network operating systems.
The present invention also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored on a computer readable medium that can be accessed by the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, application specific integrated circuits (ASICs), or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus. Furthermore, the computers referred to in the specification may include a single processor or may be architectures employing multiple processor designs for increased computing capability.
The algorithms and operations presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may also be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will be apparent to those of skill in the, along with equivalent variations. In addition, the present invention is not described with reference to any particular programming language. It is appreciated that a variety of programming languages may be used to implement the teachings of the present invention as described herein, and any references to specific languages are provided for disclosure of enablement and best mode of the present invention.
The present invention is well suited to a wide variety of computer network systems over numerous topologies. Within this field, the configuration and management of large networks comprise storage devices and computers that are communicatively coupled to dissimilar computers and storage devices over a network, such as the Internet.
Finally, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
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An information retrieval system uses phrases to index, retrieve, organize and describe documents, analyzing documents and storing the results of the analysis as phrase data. Phrases are identified that predict the presence of other phrases in documents. Documents are the indexed according to their included phrases. Related phrases and phrase extensions are also identified. Changes to existing phrase data about a document collection submitted by a user is captured and analyzed, and the existing phrase data is updated to reflect the additional knowledge gained through the analysis.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to a motorized vehicle for pulling shopping carts, and more particularly to a cart pulling vehicle with dual cable drums and dual torsion springs.
II. Discussion of the Prior Art
In the past, collection of shopping carts from parking lots was done by manual pushing of a string of carts by a store employee. As these carts were retrieved, the line of carts being pushed would grow longer and more difficult to maintain control. Two workers were required, one at the rear of the string to push and one at the front to steer. Therefore, the number of carts that were retrieved at one time was comparatively limited. Not only was this manual process time-consuming and manpower intensive, it was also a strenuous activity requiring physical strength and agility.
In response to the difficulty experienced in retrieving shopping carts, several motorized devices began to be utilized. One such device is disclosed in U.S. Pat. No. 6,220,379. This device is basically a small electrically powered cart which can be either driven or operated by remote control. The device uses a pushing from the rear technique.
Another, more closely related, prior art design uses a rope extending from a motorized vehicle to the last cart in a line to pull the carts in a train-like fashion. These prior pulling machines generally have two rope play-out and take-up drums on a common shaft and a single torsion reaction spring with a single lock mechanism. The lock mechanism is controlled by switch when the handle is placed in working position. A rope extends from one drum out the rear of the machine to a rope pull and is returned to the drum on the other side of the machine. This device allows the rope to be free to extend or retract when the lock is engaged. Unfortunately, this design has a substantial number of problems. Because the single torsion spring is attached to both drums, tension is only provided to the side with the tightest length of rope. Often the other length of rope does not have enough tension to keep it from dragging on the ground, especially when rounding corners. While this problem is intended to be addressed with the pulleys, they prove to be only marginally effective due to friction and rotational resistance. The lack of tension on one side often causes the rope on that side to unspool from its drum. Torsion spring life also is a problem due to limited space on the machine, the fact that the spring is on a common shaft with the drums, and the large number of extend/retract cycles to which the machine and spring are subjected. Finally, the rope used is also a problem because the rope is heavy and bulky to withstand the load exerted by the carts and is vulnerable to the negative effects of rubbing.
Therefore, what is needed is the cart pulling vehicle of the present invention which effectively eliminates the requirements of physical strength and agility without the tension, torsion spring life, and rope problems of the past.
SUMMARY OF THE INVENTION
The present invention provides for a cart pulling vehicle for use in parking lots everywhere. The cart pulling vehicle is made up of a hand-operated, motor-driven base which pulls shopping carts with a cable that is retractably mounted on the base and stretches to surround the line of carts being pulled. This cable is wrapped around a pair of cable drums at its opposite ends. Separate dual torsion springs for each drum place torque on the cable drums which, in turn, exert tension on the length of cable spanning each side of the string of shopping carts. A lock mechanism prevents the cable from unreeling when the vehicle is in motion while the tension of each side cable pulls the carts in a train-like fashion. When the vehicle is stopped, a lock disengages the cable tension and the cable is able to be pulled from the drums so that additional shopping carts can be added to the already assembled string of carts.
These and other objects, features, and advantages of the present invention will become readily apparent to those skilled in the art through a review of the following detailed description in conjunction with the claims and accompanying drawings in which like numerals in several views refer to the same corresponding parts.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the cart pulling vehicle of the present invention;
FIG. 2 is a perspective view of the internal components of the cart pulling vehicle;
FIG. 3 is a top view of the cable routing layout and unassembled cable pull handle;
FIG. 4 is a side view of the cable pull handle;
FIG. 5 is a perspective view of the cart hitch used to couple the vehicle to the lead shopping cart;
FIG. 6 is a cross-sectional frontal view of the internal machine layout;
FIG. 7 is a partial side view of the internal machine parts;
FIG. 8 is a partial side view of the internal machine parts;
FIG. 9 is a cross-sectional view of the spring shaft assembly; and
FIG. 10 is a cross-sectional view of the drum shaft assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention represents broadly applicable improvements for cart pulling vehicles. The embodiments herein are intended to be taken as representative of those in which the invention may be incorporated and are not intended to be limiting.
Referring first to FIG. 1 , there is shown a side view of the cart pulling vehicle along with a string of nested carts to be transported by the vehicle. The assembly itself is indicated generally by numeral 10 . It includes a motor-driven base 12 , a cable reel cover 14 , a steering arm 16 , a vehicle motor control box 18 , a cart hitch assembly 20 , a cable 22 , cable routing pulleys 24 , cable guides 26 , a pull handle 28 , handle and guide storage bracket 30 , visibility flags 32 , and visibility beacon 34 .
With reference to FIG. 2 , the cart pulling vehicle is seen in a perspective view with its cable cover 14 lifted, allowing a more detailed examination of the vehicle's internal features. The cable reel cover 14 is flipped open about a hinge and the internal components are exposed. The internal components include cable drums 36 and 38 , cable springs 40 and 42 , a first drum shaft 44 for the drum 36 , large sprockets 46 , outer sprockets 48 , and brackets 50 . All of these features are mounted above the motor-driven base 12 and contained within the cable reel cover 14 . In that the present invention is not directed to the dc motor drive for the vehicle's wheels, there is no need to describe these features.
Generally, the cable 22 wraps around the center spindle 52 of one of the drums 36 , extends out from opening 53 in the back of cover 14 , loops through pulley 24 on the vehicle's base, stretches around the collected shopping carts in a manner described more particularly below, back under the cover 14 , and around the center spindle 54 of drum 38 . The cable springs 40 and 42 are principally responsible for producing independent torque on each of the cable drums 36 and 38 , thus causing simultaneous tension pulling on both ends of the cable 22 . A more complete explanation of the working of these components will be discussed in detail later.
It is also possible to view some of the components of the motor-driven base 12 in FIG. 2 , including its conventional battery, motor, wiring etc., although, as mentioned, these will not be discussed in detail.
FIG. 3 shows a top view of the cable routing layout and unassembled cable pull handle. This figure is intended to disclose a schematic of the locations where the cable 22 interacts with the various elements of the device. The cable 22 is preferably aircraft cable made of steel, but coated in plastic to reduce damage caused by the cable. The two looped and clamped ends 56 of cable represent the location where the cable ends mount on the flat side faces of the cable drums 36 and 38 before they are wound around the center spindles of the drums. Next, is a cable travel stop and limiter 58 which provides a contact point to stop the cable motion before the end of the cable is reached. The cable 22 then extends out from underneath the cable reel cover 14 and around the two pulleys 24 which are mounted near the bottom edge of motor-driven base 12 . Next, the cable wraps around the perimeter of the carts using the holes 60 in the two cable guides 26 to direct the cable's path. The cable guides 26 are mounted longitudinally across the open basket of a shopping cart near the cart's handle pushed by the consumer. These two guides can be placed on any carts which would enable a more effective path around the cart perimeter. (See FIG. 1 .)
The cable guides 26 are each comprised of a solid, metal rod which is roughly bent into a U-shape. The ends of the rod are curled back into loops 62 on both sides through which the cable 22 passes. Adjacent to the loops 62 , the ends extend up at an angle before straightening and bending at a right angle over the open basket of the shopping cart. When the rod approaches the center, it extends up into a further long and narrow U-shaped bend 64 . This design effectively fits over a shopping cart basket with a stable, yet easily movable, set of guides for cables stretching along the perimeter of a line of carts.
The cable 22 completes the loop around the perimeter of the carts by extending through a pull handle 28 that is adapted to be hooked to the handle on the rearmost shopping cart. This pull handle 28 , shown in exploded form in FIG. 3 , comprises edge plates 66 , u-shaped couplers 68 , a handle member 70 , a bottom plate 72 , and pulleys 74 .
The pull handle 28 generally is a latching mechanism enabling the cable 22 to connect with the carts without significant frictional resistance. The pull handle 28 allows the cable to move from left to right to equalize tension. The pulleys 74 act as low friction bearings to ensure minimal movement of the cable. The pull handle 28 is attached to the last shopping cart in a line of pulled carts by hooking the curved couplers 68 over the shopping cart's handle. Because most forces will be directed contrary to this interaction, the curved coupler 68 typically bears most of the load directed by the carts. Between the curved couplers 68 is a large handle 70 . This handle enables the user to easily add carts to the end of the line, then to quickly move the pull handle 28 to the handle of the last shopping cart in the string. L-shaped edge plates 66 are also attached to the sides of the pull handle 28 so that it will not slide off the cart handle due to side-to-side forces. These forces can be caused during the moving of carts when a turn is made by the cart string. During turns, the extra cable required at the outside of the turn is pulled through the inside pulley of the pull handle 28 . The pulleys 74 of the pull handle 28 are placed at the front edges of the panel bottom plate 72 . On the top of the cable pull handle 28 is a visibility flag 32 ( FIG. 1 ) which is mounted by an angled bracket. This flag is intended to make the string of carts more easily recognizable to motorists in the parking lot.
FIG. 4 shows a side view of the pull handle assembly 28 . It is important to note that the cable 22 will extend around the pulleys 74 which are mounted within the front portion of the handle. Also observed here is the shape and configuration of the edge plates 66 , couplers 68 , handle 70 , and bottom plate 72 .
With reference to FIG. 5 , a perspective view of a cart hitch 20 is shown. This hitch is generally a triangular-shaped piece of metal containing two C-shaped hooks 76 looping up from the sides of the base of the triangular metal piece. The apex of the triangle has a hole 78 through which a spring mounted bolt passes to an angled bracket 80 secured on the motor-driven base 12 . There is a second sheet metal piece 82 that forms a latch or detent. It is bolted to the middle of the hitch at a hole 84 . It angles up from its attachment before bending downward to form a blocking panel 86 . This panel is perpendicular to an opening 88 in the triangular piece and may be pushed down against the force of a return spring (not shown) positioned between the triangular plate and the detent 82 . When the blocking panel 86 is pushed down, the bottom bar of the first shopping cart in a line can be slid into the c-shaped hooks 76 . When the blocking panel 86 is released, the bottom bar of the shopping cart will be prevented from moving outside the confines of the c-shaped hooks 76 . The action of holding the first cart allows steering of the other carts as long as each cart in the string remains nested into the cart preceding it. The cart hitch 20 is spring loaded by axially mounting a spring 90 on a bolt 91 extending through angle plate 80 and hole 78 in the triangular plate. This allows the cart to be slightly above or below the hitch connection to the pulling machine during driving over uneven ground.
Also, seen in FIG. 5 is a more detailed perspective of the pulleys 24 which are used to route the cable 22 as it comes out from underneath the cable reel cover 14 . Routing the cable downward from the cable drums 36 and 38 and around pulleys 24 helps to prevent lifting of the drive wheels of the cart pulling vehicle. Directing the forces downward in this way provides greater traction than if the cable were routed directly from the drums 36 and 38 to the pull handle.
FIG. 6 shows a cross-sectional frontal view of the internal machine layout. In the figure, mounting brackets 50 are bolted to each side of the motor-driven base 12 . These brackets are roughly U-shaped pieces of sheet metal with legs which bolt to the base 12 and have a hole 92 centrally located. Bearings 94 are placed within holes 92 of the mounting brackets 50 . Axially mounted though the bearings 94 , on each side of the assembly, are drum shafts 44 . The two drum shafts 44 are axially aligned, although each shaft extends about one-third of the width of the assembly with a gap in between. (See FIG. 10 ) The shafts are additionally supported on bearings 96 , which are held in place by another set of brackets 98 . Shafts 44 contain square keys which protrude slightly out from their circumference. This feature allows for a locked connection with the sprockets 100 and drums 36 and 38 which are axially engaged around the keyed shaft 44 .
Sprockets 100 and cable drums 36 and 38 are axially mounted on the drum shaft 44 between the bearings 94 and 96 . The sprockets 100 have a plurality of teeth and are critical components of the locking mechanism of the assembly. (See FIG. 7 .) The cable drums 36 and 38 comprise a pair of circular flanges on each side of a spindle 52 , 54 on which the cable 22 is wound. The outside flat surface flanges of the drums contain a bolt 102 onto which the ends of the cable 22 are secured. One end of the cable is affixed to the outside of the first cable drum 36 and the other end mounted on the outside of the second cable drum 38 . The center hole of these cable drums and sprockets 100 are all adapted to axially engage around the keyed drum shafts 44 . (see FIG. 7 )
Looking again at FIG. 6 , a smaller diameter sprocket 104 is mounted on each of the drum shafts 44 , just inside the location of the cable drums 36 and 38 . These sprockets 104 have a keyed center mount and are transversely aligned with sprockets 106 . A drive chain 108 (not shown) is engaged around both sprocket 104 and sprocket 106 . (see FIG. 8 )
Sprockets 106 are both part of the spring shaft assembly. These sprockets 106 are located on opposite sides of the assembly from one another and are displaced vertically from one another. Sprockets 106 have keyed center holes 110 . It is important to note that while the center axis of the two holes 110 are simply vertically displaced from one another, these are both vertically and horizontally displaced from the axis that runs through the center of drum shaft 44 (see FIG. 8 ). Sprockets 106 serve to rotate spring shafts 112 . These spring shafts 112 span the gap between the two brackets 98 and are rotationally mounted within bearings 114 in each side of bracket 98 . Inside the confines of the brackets 98 , there are hub 116 and 118 on each side of the shaft 112 . The hubs each contain a hole into which an end of the spring 40 or 42 is fit. The hub 116 , on the side furthest from the sprocket 106 , is bolted into place and remains non-rotatable. The hub drive 118 , nearest the sprocket 106 has its center hole keyed to the spring shaft 112 and is capable of being rotated, causing the shaft 112 to rotate when the sprocket 106 is driven. This serves to store energy in the spring. There is a hollow spring support tube 120 extending between the ends of the hub drives 116 and 118 . Springs 40 and 42 encircling the spring support tubes 120 . These springs are the mechanisms responsible for generating the required tension in the cable 22 for securing the shopping carts. (See FIG. 9 )
Also seen in FIG. 6 are braces 122 and 124 , which generally are metal bars that run longitudinally between the brackets 98 near the top and bottom of the spring shaft assembly. These braces 122 and 124 are attached with bolts through their angled ends. They generally provide increased stability and support to the assembly.
Now referring to FIG. 7 , a partial inside side view of internal machine parts is shown. This figure discloses a excellent perspective of the cable attachment to drum 36 and cable routing under the cable reel cover 14 and around pulley 24 . This figure also shows the outline of one of the brackets 50 upon which the drum shaft 44 is centrally mounted. A cable drum lock 126 , used to engage with the sprocket 100 to halt cable movement when the vehicle is in motion is seen here as well. This cable drum lock 126 is solenoid controlled by an electric motor driver that provides a signal which the circuit uses to control the lock and unlock action of a locking pawl.
Now referring to FIG. 8 , a partial inside side view of internal machine parts is shown. This figure discloses a cross-section of parts seen if one were to hypothetically remove the nearest cable drum and support bracket of FIG. 7 . This is a useful cross-section denoting the locations of the axis of both spring shafts 112 as well as the drum shaft 44 and the chain linking the two. A side view of bracket 98 is also disclosed. The bracket 98 contains three shaft openings for the spring and drum shafts. The openings for the spring shafts are rounded horizontal slots into which shafts are inserted, and the drum shaft opening is a centrally located hole.
FIG. 9 shows a cross-sectional view of the spring shaft assembly. The figure discloses a shortened spring 40 which enables view of the end fittings. Also seen here is how the end of the shaft nearest the hub drive 118 uses a square key fitting 128 . In the actual assembly of the cable drum and tensioning mechanism, there are two spring shaft assemblies of the type illustrated in FIG. 9 . One of these assemblies is turned 180 degrees and is mounted above the other. Because the spring assemblies are on discrete shafts that overlap in spanning the width dimension of the vehicle, the vehicle can be of a reduced width allowing it to be no wider than the shopping carts being pulled. This allows easier passage through doors of the commercial establishment. Where a wider cart profile can be tolerated, the cable springs 40 and 42 can be mounted on the same shaft as an associated drum 36 and 38 . That is, spring 42 can be mounted on shaft 44 on which drum 36 is offered the shaft supporting cable spring 40 . In this way, the chains and sprockets can be eliminated.
FIG. 10 is a cross-sectional view of the drum shaft assembly. In this device there are two drum shaft assemblies like the one shown. One is turned 180 degrees from the one shown in FIG. 10 , but the axis of both of the drum shaft assemblies are aligned axially.
The operation of the cart pulling vehicle with dual cable drums and dual torsion springs is as follows. First, an operator first moves the cart pulling vehicle into the parking lot to the location of a shopping cart using the handle controls 18 which lead to the motor that drives the cart. The pull handle and cable guides are initially held on the handle guide and storage bracket 30 . The first cart is attached by inserting the cart's lower bar in the c-shaped hooks 76 of the cart hitch 20 . All additional carts are stacked into a line by partially nesting the basket of one into the cart in front of it. Next, the cable pull handle 28 is extended and hooked on the handle of the last cart in the line. Cable guides 26 are placed across the baskets of some of these carts to ensure the cable encircles the carts with a minimum of contact with the sides of the carts. Once the propelling machine has surrounded a variable number of carts with a cable 22 , the vehicle control is activated by the operator to move the vehicle. The locking solenoid device 126 locks the drums 36 and 38 , preventing playout of the cable 22 as the machine moves the carts to a new location. Once the machine has stopped, the solenoid latch 126 is released to allow the cable to be pulled from the drums so that carts can be added or removed. The operator has the ability, at any time the machine is not moving, to move the cable in or out with little effort based upon the spring design. The attachment and design of the cable guide 26 and cable pull handle 28 allows addition of carts without moving the cable pull handle 28 until after the carts have been added. Additional controls allow locking the cable so that the cable drum lock does not disengage when the machine has stopped. This feature provides additional control of the cart motion for the operator when moving the machine, device and carts from the collection area of the parking lot to the use or storage areas.
This invention has been defined herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself
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A cart pulling vehicle for use in parking lots made up of a hand operated motor-driven base which pulls shopping carts. The device utilizes a cable that is retractably mounted on the base and stretches to surround the line of carts pulled. This cable is retracted by a pair of cable drums at its ends which are driven by torsion springs. These separate dual torsion springs place torque on the cable drums which, in turn, exert tension on each half of the cable. When the cart pulling vehicle is in motion, a lock arrangement prevents additional cable from unreeling which the tension on each side cable pulling the carts in a train-like fashion. When the vehicle is stopped, a lock is released and the cable is able to extend to surround additional carts.
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TECHNICAL FIELD
[0001] The present disclosure relates to fabrication of fin-type field effect transistors (FinFETs) with epitaxially grown source/drain regions. The present disclosure is particularly applicable to devices for the 14 nanometer (nm) technology node and beyond.
BACKGROUND
[0002] In current processes of forming cavities for epitaxial growth of source/drain regions, non-vertical cavity sidewalls are formed, and conventional source/drain implantations result in non-uniform doping profiles. Consequently, a non-conformal junction is formed which in turn leads to threshold voltage non-uniformity along the fin height. During the device operation, the non-conformal junction will prevent the fin active region from full utilization, and it also degrades channel resistance and spreading resistance. Besides, the junction invasion at the fin tip worsens short channel effects.
[0003] FIG. 1A illustrates a desired cavity sidewall. FIG. 1B illustrates an implant profile after source/drain implantation, which includes a sloped sidewall (at 101 ). Adverting to FIG. 1C , after all thermal processes, the resulting dopant profile forms a gradient with a decreasing concentration from 103 to 113 . As illustrated in FIG. 2A , conventional low energy and heavy dose source/drain implantation after epitaxial growth aimed for ohmic contact will introduce excessive dopant at the fin tip region 201 . If a moderate energy source/drain implantation is employed, the middle to bottom effective gate length Leff is slightly reduced, but the junction over all is degraded at regions 203 in FIG. 2B and the junction profile is not straightened. A high energy implantation will cause serious tailing, as illustrated at 205 in FIG. 2C .
[0004] The conventional extension implantation techniques cannot straighten the junction. As illustrated in FIG. 3A , for FinFETs with fins 301 having a pitch 303 between 20 and 40 nm, extension implantation 305 is tilted with respect to the fins 301 to cover the entire fin sidewall. However, as illustrated in FIG. 3B , the resultant implantation 307 is non-conformal and non-uniform, and it will also cause both causes fin damage and junction uniformity issues. Thus, conventional implantation before or right after source/drain epitaxial growth will cause a graded junction, undesired junction tailing, a non-conformal junction, and fin damage.
[0005] A need therefore exists for methodology enabling formation of both a conformal junction and a high epi surface dopant concentration in a FinFET and the resulting device.
SUMMARY
[0006] An aspect of the present disclosure is a method of forming a source/drain region including partially epitaxially growing the source/drain region, doping the partially grown source/drain region, and epitaxially growing the remainder of the source/drain region with in situ doping, and doping the remainder of the region.
[0007] Another aspect of the present disclosure is a FinFET device having abrupt, vertical and conformal junction.
[0008] Additional aspects and other features of the present disclosure will be set forth in the description which follows and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present disclosure. The advantages of the present disclosure may be realized and obtained as particularly pointed out in the appended claims.
[0009] According to the present disclosure, some technical effects may be achieved in part by a method including: forming a gate electrode over and perpendicular to a semiconductor fin; forming first spacers on opposite sides of the gate electrode; forming second spacers on opposite sides of the fin; forming a cavity in the fin adjacent the first spacers, between the second spacers; partially epitaxially growing source/drain regions in each cavity; implanting a first dopant into the partially grown source/drain regions; epitaxially growing a remainder of the source/drain regions in the cavities, in situ doped with a second dopant; and implanting a third dopant in the source/drain regions.
[0010] Aspects of the present disclosure include implementing a rapid thermal anneal (RTA) between implanting the first dopant and implanting the third dopant. Other aspects include partially epitaxially growing the source/drain regions includes growing the source/drain regions to a height of 0 to 80% of the depth of the cavity. Further aspects include implanting the first dopant with a dose of 1e14 cm −3 to 1e16 cm −3 and at an energy of 1 kiloelectron Volt (keV) to 10 keV. Another aspect includes implementing the RTA at a high temperature greater than 800° C. to repair fin damage, activate implanted dopants, and drive the dopants diffusing into the fin bottom region. Other aspects include in situ doping the second dopant with a concentration of 1e19 cm −3 to 1e21 cm −3 . Additional aspects include implanting the third dopant with a concentration of 1e14 cm −3 to 1e16 cm 3 and at an energy of 0.5 keV to 2 keV. Another aspect includes implanting the first dopant in a direction perpendicular to a top surface of the partially epitaxially grown source/drain regions. Additional aspects include implanting the third dopant with zero degrees of rotation and with a maximum tilt with respect to the fin.
[0011] Another aspect of the present disclosure is a device including: a gate electrode over and perpendicular to a semiconductor fin; first spacers on opposite sides of the gate electrode; second spacers on opposite sides of the fin; an epitaxially grown source/drain region in the fin adjacent the first spacers, between the second spacers, the epitaxially grown source/drain region having a bottom portion and a top portion; a first dopant implanted in the bottom portion; a second dopant in situ doped in the top portion; and a third dopant implanted in the top portion, wherein the source/drain region has an abrupt, vertical and conformal junction boundary.
[0012] Aspects include the bottom portion having a height of 0 to 80% of the height of the eptiaxially grown source/drain region. Other aspects include the first dopant having a dose of 1e14 cm −3 to 1e16 cm −3 and being implanted at an energy of 1 kiloelectron Volt (keV) to 10 keV. Further aspects include the second dopant having a concentration of 1e19 cm −3 to 1e21 cm −3 . Additional aspects include the third dopant having a concentration of 1e14 cm −3 to 1e16 cm 3 and being implanted at an energy of 0.5 keV to 2 keV. Another aspect includes the epitaxially grown source/drain region including eSiGe and the first, second, and third dopants including BF 2 . Further aspects include the epitaxially grown source/drain regions including SiP and the first, second, and third dopants including arsenic.
[0013] Another aspect of the present disclosure is a method including forming first and second parallel semiconductor fins on a substrate; forming a gate electrode over and perpendicular to the first and second semiconductor fins; forming first spacers on opposite sides of the gate electrode; forming a first mask over the first fin; forming second spacers on opposite sides of the second fin; forming a first cavity in the second fin adjacent each first spacer, between the second spacers; partially epitaxially growing eSiGe source/drain regions to a height of 0 to 80% of the depth of the first cavity in each first cavity; implanting a first BF 2 into the partially grown eSiGe; epitaxially growing eSiGe for a remainder of the source/drain regions in the first cavities, in situ doped with a second BF 2 ; removing the mask; forming a second mask over the second fin; forming third spacers on opposite sides of the first fin; forming a second cavity in the first fin adjacent each first spacer, between the third spacers; partially epitaxially growing SiP source/drain regions to a height of 0 to 80% of the depth of the second cavity in each second cavity; implanting a first arsenic into the partially grown SiP; epitaxially growing SiP for a remainder of the source/drain regions in the second cavities, in situ doped with a second arsenic; removing the second mask; implanting a third BF 2 in the eSiGe source/drain regions; and implanting a third arsenic in the SiP source/drain regions.
[0014] Aspects include implementing a rapid thermal anneal (RTA) subsequent to implanting the first BF 2 and/or subsequent to implanting the first arsenic, the RTA having a peak temperature higher than 800° C. and for a duration longer than 1 second. Other aspects include implanting the first arsenic and the first BF 2 with a dose of 1e14 cm −−3 to 1e16 cm −3 , at an energy of 1 keV to 10 keV, and in a direction perpendicular to a top surface of the partially epitaxially grown source/drain regions. Further aspects include in situ doping the second arsenic and the second BF 2 with a concentration of 1e19 cm −3 to 1e21 cm −3 . Other aspects include implanting the third arsenic and the third BF 2 with a concentration of 1e14 cm 3 to 1e16 cm −3 , at an energy of 0.5 keV to 2 keV and at maximum tilt angle with respect to a plane perpendicular to the first and second fins and with zero rotation.
[0015] Additional aspects and technical effects of the present disclosure will become readily apparent to those skilled in the art from the following detailed description wherein embodiments of the present disclosure are described simply by way of illustration of the best mode contemplated to carry out the present disclosure. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the present disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present disclosure is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawing and in which like reference numerals refer to similar elements and in which:
[0017] FIG. 1A schematically illustrates a desired cavity sidewall;
[0018] FIG. 1B schematically illustrates an implant profile after source/drain implantation;
[0019] FIG. 1C schematically illustrates an implant profile after all thermal processes;
[0020] FIGS. 2A through 2C schematically illustrate implant profiles after conventional low energy, moderate energy, and high energy implantations, respectively;
[0021] FIG. 3A schematically illustrates a tilted extension implantation for a FinFET with multiple fins;
[0022] FIG. 3B schematically illustrates the implant profile resulting from the implantation shown in FIG. 3A ; and
[0023] FIGS. 4A through 7A and FIGS. 4B through 7B and 8 schematically illustrate a three-dimensional view and a cross-sectional view, along the length of a fin and across the fin, of a process flow, in accordance with an exemplary embodiment.
DETAILED DESCRIPTION
[0024] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of exemplary embodiments. It should be apparent, however, that exemplary embodiments may be practiced without these specific details or with an equivalent arrangement. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring exemplary embodiments. In addition, unless otherwise indicated, all numbers expressing quantities, ratios, and numerical properties of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”
[0025] The present disclosure addresses and solves the current problems of graded junctions, undesired junction tailing, non-conformal junctions, and fin damage attendant upon performing source/drain implantation right after source/drain epitaxial growth. In accordance with embodiments of the present disclosure, source/drain regions are partially epitaxially grown followed by a high dose, low energy implantation to straighten the junction at the middle-to-bottom region. An optional RTA can be implemented to repair the damage and further drive the dopant into the fin middle-to-bottom region. Next, the remainder of the source/drain region is epitaxially grown with a low concentration of in situ dopant to prevent aggressive dopant diffusion at the fin tip. Last, a high dose, low energy source/drain implantation is performed for ohmic contact.
[0026] Methodology in accordance with embodiments of the present disclosure includes forming a gate electrode over and perpendicular to a semiconductor fin and forming first spacers on opposite sides of the gate electrode. Then second spacers are formed on opposite sides of the fin, and a cavity is formed in the fin adjacent the first spacers, between the second spacers. Source/drain regions are partially epitaxially grown in each cavity, and a first dopant is implanted into the partially grown source/drain regions with an optional RTA thereafter. A remainder of the source/drain regions is epitaxially grown in the cavities and is in situ doped with a second dopant. Last, a third dopant is implanted in the source/drain regions.
[0027] Still other aspects, features, and technical effects will be readily apparent to those skilled in this art from the following detailed description, wherein preferred embodiments are shown and described, simply by way of illustration of the best mode contemplated. The disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
[0028] FIGS. 4A through 7A and FIGS. 4B through 7B and 8 schematically illustrate a three-dimensional view and a cross-sectional view, along the length of a fin and across the fin, respectively, of a process flow, in accordance with an exemplary embodiment. Adverting to FIGS. 4A and 4B , silicon fins 401 and 403 are shown on a substrate 405 . A gate electrode 407 is formed over and perpendicular to fin 401 , with gate sidewall spacers 409 on opposite sides of the gate electrode. The gate electrode and gate sidewall spacers are also formed over and perpendicular to fin 403 , but is not shown for illustrative convenience. FIN 403 , for example for a PFET, is covered with a mask 411 during processing of fin 401 , which is, for example, for an NFET. Once fin 403 is masked off, spacers 413 are formed on opposite sides of fin 401 .
[0029] As illustrated in FIGS. 5A and 5B , a cavity 501 is etched in fin 401 . between spacers 413 for a source/drain region. A corresponding cavity is formed on the opposite side of the gate electrode, but is not shown for illustrative convenience. The cavity is formed to a depth of 80% to 125% of the fin height.
[0030] Next, silicon phosphide (SiP) 601 is partially grown in the cavities to a height of 0 to 80% of the depth of the cavities 501 , for example 50%. Arsenic 603 is implanted in SiP 601 with a low energy and a high dose, with zero tilt, to straighten the junction at the middle- to-bottom region. For example, arsenic may be implanted at an energy of 1 kiloelectron volt (keV) to 10 keV and a dose of 1e14 cm −3 to 1e16 cm −3 , though “low energy” depends on the thickness of the SiP. An optional RTA can be implemented to further drive the implanted dopant into the fin lower part region. The RTA may have a peak temperature higher than 800° C. and last for a duration longer than 1 second. Then the upper surface of SiP is surface cleaned.
[0031] Adverting to FIGS. 7A and 7B , SiP 701 is grown in the remainder of the cavity, with in situ doping having a lighter concentration than arsenic 603 . For example, arsenic is implanted in situ in SiP 701 with a dosage of 1e19 to 1e21 cm 3 . The light concentration of dopant prevents aggressive dopant diffusion at the fin tip region.
[0032] Next, mask 411 is removed and a new mask (not shown for illustrative convenience) is formed over fin 401 to protect fin 401 during processing of fin 403 . The steps described above for processing of fin 401 are then substantially repeated for fin 403 , substituting embedded silicon germanium (eSiGe) for the SiP and born difluoride (BF 2 ) for the dopant. In other words, spacers 803 are formed, and a cavity is etched in fin 403 on each side of the gate electrode to a depth of 80% to 125% of the fin height. eSiGe 803 is then partially grown in the cavity to a height of 0 to 80% of the depth of the cavities, for example 50%. BF 2 is implanted in eSiGe 803 with a low energy and a high dose, with zero tilt, e.g. an energy of 1 keV to 10 keV and a dose of 1e14 cm −3 to 1e16 cm −3 . An optional RTA may be implemented to further drive the implanted dopant into the fin lower part region. The RTA may have a peak temperature higher than 800° C. and last for a duration longer than 1 second. The epitaxial surface is surface cleaned and eSiGe 805 is grown in the remainder of the cavity, in situ doped with BF 2 with a lighter concentration, for example with a dosage of 1e19 to 1e21 cm 3 , resulting in the structure shown in FIG. 8 .
[0033] After both the NFET and PFET source/drain regions are both epitaxially grown, each is implanted with a dopant with a high dose, for example 1e14 cm −3 to 1e16 cm −3 , and low energy, for example 0.5 keV to 2 keV, e.g. 1 keV, for ohmic contact. The dopant for the NFET is arsenic and for the PFET is BF 2 . The last high dose source/drain implantation is performed across the fin, at an angle of 0 to 25° with respect to a surface perpendicular to the fin. An RTA and a laser spike anneal (LSA) then drive the dopants into the source/drain regions.
[0034] The embodiments of the present disclosure can achieve several technical effects, such as an improved junction without an extra mask, reduced effective gate length in the mid-to-bottom region of the source/drain region without implantation tailing, reduced dopant diffusion at the fin tip region, reduced dopant in the channel, and a conformal junction. Devices formed in accordance with embodiments of the present disclosure enjoy utility in various industrial applications, e.g., microprocessors, smart phones, mobile phones, cellular handsets, set-top boxes, DVD recorders and players, automotive navigation, printers and peripherals, networking and telecom equipment, gaming systems, and digital cameras. The present disclosure therefore enjoys industrial applicability in any of various types of highly integrated FinFET semiconductor devices, particularly for the 14 nm technology node and beyond.
[0035] In the preceding description, the present disclosure is described with reference to specifically exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the present disclosure, as set forth in the claims. The specification and drawings are, accordingly, to be regarded as illustrative and not as restrictive. It is understood that the present disclosure is capable of using various other combinations and embodiments and is capable of any changes or modifications within the scope of the inventive concept as expressed herein.
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A method of forming a source/drain region with an abrupt, vertical and conformal junction and the resulting device are disclosed. Embodiments include forming a gate electrode over and perpendicular to a semiconductor fin; forming first spacers on opposite sides of the gate electrode; forming second spacers on opposite sides of the fin; forming a cavity in the fin adjacent the first spacers, between the second spacers; partially epitaxially growing source/drain regions in each cavity; implanting a first dopant into the partially grown source/drain regions with an optional RTA thereafter; epitaxially growing a remainder of the source/drain regions in the cavities, in situ doped with a second dopant; and implanting a third dopant in the source/drain regions.
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BACKGROUND AND SUMMARY OF THE INVENTION
Nacre (also known as Pearl Powder, Concha Margarita, Amber Poria Pearl, Concha Margaritaferae, marine calcium, and Mother of Pearl) is an excellent source of calcium and has been used by generations of Chinese to soothe restlessness, anxiety, and stress. It has been used with children, even newborn infants, to calm or cure seizures, epileptic episodes, and brain functions. It is also used with adults for these same conditions and also for senile memory problems.
Western laboratory sciences have tracked neurotransmission to the molecular level of electron exchanges. Calcium is central in receiving and sending signals from one nerve cell to another. The balance of calcium within the nerve cell is crucial to maintaining the health of the cell, the life or death of the cell. Calcium helps maintain the electrical energy capacity within the appropriate range for the specific nerve cells and helps absorb and eject toxins when they enter a cell. It is not surprising, then, that the health of the calcium transport system at the cellular level in nerve cells both reflects the health of the body as whole and affects the capacity of the body to withstand injury, invasion and stress. In 1993, Chinese laboratory research found memory improved because acetylcholinesterase activity was inhibited with nacre based formulae.
Calcium utilization, however, is low compared with calcium intake in the normal U.S. diet. Until recent identification of the preference of amino acids for nacre over other sources of calcium there has been no satisfactory explanation for this. One likely reason amino acids prefer nacre as their source of calcium was identified in Chinese laboratory research which identified amino acids as proportionately high in nacre. This makes it easy for alien amino acids to be attached to and to utilize nacre as a source of calcium and is an advantage other inorganic calcium sources cannot provide.
In the late 1960s Western psychiatry made a significant breakthrough with the discovery that lithium can combat uni-polar depression and, later, bipolar disease. This turned attention to the possibility that many psychological, emotional, behavioral problems are related to metabolism and, in particular, to metabolism of a few elements in the brain and central nervous system. While lithium is an effective treatment for various neurochemical imbalances and their psychological symptoms, it also affects other systems of the body, placing a strain on kidneys and other organs. For this reason, exploration of elements with similar chemical interactions as possible replacements for or alternatives to lithium began. Calcium has been the primary element which shares many of the chemical affinities of lithium, produces similar psychological correction of imbalances and has fewer negative side-effects than lithium. There is, then, a consensus of opinions that from Western psychiatric research and oriental treatment practices that calcium, and partly calcium in the form of nacre, has effects of restoring metabolic balance, calming the restless and hyperactive, healing at the cellular and systemic levels of the central nervous system, and facilitating sending and receiving of nerve impulses.
In traditional Chinese medicine, nacre has also been used in formulae for bone disorders and the healing of fractures and for insomnia, as well as in formulae for the treatment of hyperactivity, seizures, childhood epilepsy, senility, and symptoms of aging. It is believed that calcium is involved in neurotransmission on the molecular level of electron exchanges. The balance of calcium within the nerve cell is crucial to maintaining the health of the cell, in maintaining the electrical energy capacity within a specific range and in absorbing and rejecting toxins. The health of the calcium transport system reflects the ability to withstand injury, invasion, and stress. Memory has been found to improve as acetylcholinesterase activity is inhibited with nacre-based formulae. (See Peterson, Christine. Nov. 21, 1992. Changes in Calcium's Role as a Messenger during Aging in Neuronal and Non neuronal Cells. Annals New York Academy of Sciences, Volume 663, pp. 279-293.) Aging and/or stress induced alterations in calcium homeostasis are suspected in the disruption of several hippocampal processes that correlate with learning and memory. In patients with Alzheimers, total cell calcium levels are markedly elevated. It has been suggested that free radical levels resulting from oxidative stress is responsible for many age-related degenerative changes due to increased intracellular calcium levels.
According to the present invention, nacre is used as the primary constituent in a number of different formulas which are specific to improving the functionality of various human body parts, as well as providing relief for a number of different ailments and conditions, such as insomnia and anxiety. The formulations according to the present not only take advantage of nacre's ability to facilitate and maintain human health, but provide important additional constituents and functions which enhance the effectiveness of nacre for performing its intended functions and/or dealing with other aspects of the ailments or conditions to be corrected. The formulations according to the present invention are basically herbal in nature, have few or no side effects, and can be taken for long periods of time if necessary. They are also relatively simple and easy to produce and utilize.
According to one aspect of the present invention a formula is provided which is pharmacologically active in the relief of insomnia, anxiety, pain, and muscular tension, improving the quality of sleep in general. Such a formulation can have significant practical benefits for large segments of the population.
The number of people with chronic sleep deprivation has dramatically increased over the last two decades; in fact recent estimates suggest that as many as 40 million people in the U.S. may suffer from chronic or intermittent sleep disorders. Lack of sleep lowers the immune system and negatively affects brain functioning. During the 1990s the second leading cause of traffic accidents in the United States has been drivers falling asleep at the wheel. Lowered immunity increases the number and severity of minor illnesses as well as increasing susceptibility to major illnesses. In the last four years, studies have linked sleep cycle disruptions with a number of cancers. Physiologically, the causes of simple insomnia are primarily neurological. Lack of sleep quickly results in lowered brain function and altered brain chemistry.
The sleep facilitating formula according to the present invention has its basis in regulating calcium metabolism through the use of nacre. Calcium is a core mechanism through which nerve cells communicate. Calcium's metabolism is altered under stress, neurodegenerative diseases and in the aging process. Aging and/or stress-induced alterations in calcium homeostasis are suspected to disrupt processes in the hippocampus region of the brain. Nacre's effect parallels drugs that promote calcium uptake (calcium channel blockers), partially reversing deficits in calcium dependent processes.
The sleep facilitating formulation according to the present invention has nacre as the primary constituent thereof, typically between about 65-75% by weight (e.g. about 70% by weight). Two other ingredients are also provided. Sclerotium Poriae cocos is used to calm the mind and to regulate urination and edema. It assists in the actions of promoting sleep. Succinum is used as a second assistant to nacre for insomnia and also acts as a tranquilizing agent. Succinum and Sclerotium Poriae cocos are each preferably provided in the amount of about 13-17%, preferably about 15% by weight.
Another formulation according to the present invention is provided primarily to increase bone density, for preventing osteoporosis, and like disorders. However this formulation also relieves anxiety, pain, and muscular tension when administered in a pharmacologically effective amount for increasing bone density, and because of its nacre base can also improve the quality of sleep.
Currently, 25 million women in the United States are affected by osteoporosis. Osteoporosis leads to 1.5 million fractures each year. Annual medical care costs for fractures among older adults ranged from $7 to $10 billion in 1986 to $13.8 billion in 1995. The cost of osteoporosis is growing rapidly in human, medical and financial terms, especially in countries with aging populations. The number of persons 65 and older is projected to increase from 32.0 million to 51.5 million during 1990-2020. The formulation according to the invention is an alterative to current treatments, including controversial hormone replacement therapy (HRT), expensive drugs with serious side effects such as Fosamex, and calcium supplementation. Most forms of calcium are not well-utilized by the body; most of the calcium is simply excreted. The nacre-based formulation according to the invention is found to be most utilized by amino acids, the means by which the body metabolizes calcium. Nacre, when grafted on broken bones, stimulates new bone growth with the nacre matrix nearly indistinguishable from the matrix of human bone. Collagen is also necessary for bone growth. Sources of collagen in the typical American diet are few. It occurs in bones, sharks, a few ocean animals, and some plants not normally part of the U.S. diet. The formula of the invention thus desirably contains plant and animal based collagen.
The bone density increasing formulation according to the present invention has nacre as the primary constituent thereof, preferably between about 65-75% (e.g. about 71 %) by weight. Preferably at least about 5% collagen is also provided, about 4-6% of which is animal collagen such as Gelatinum asini, and about 1.5-2.5% of which is plant collagen, e.g. kudzu. Other ingredients are also provided.
Of the other ingredients in the bone formulation according to the invention besides nacre, the following beneficial affects can be expected: Angelicae sinensis radix nourishes the blood and promotes blood circulation. Gelatinum asini (a collagen source), glue made from ass's skin, also nourishes the blood and, in experiments on animals, was able to increase the absorption and utilization of calcium carbonate. Drynariae rhizoma, aka Rhizoma Gusuibu, assists and promotes the mending of sinews and bones (the Chinese name translates to "Mender of Shattered Bones"). Carthami tinctorii flos is also used as an agent to promote blood circulation. Paeonea rubrae radix (kudzu) is another agent for vitalizing the blood, i.e. a source of collagen. Psoraleae corylifoliae fructus is used for weakness of the back (the Chinese name translates to "Resin that Tonifies the Bone"). Puerariae radix is used to loosen tightness in the upper back and neck. Radix Panacis Quinqueofolii, aka American Ginseng, is used as a stimulant to the central nervous system; that is it is used in stress syndromes and helps promote calcium absorption.
According to another aspect of the present invention a skin formula is provided which has specifically beneficial affects on the health and appearance of hair, skin and nails. Because nacre is the majority component thereof it also has the effect of relaxing upper body tension (especially in the neck, shoulders, face and head) and has a calming affect on both the nervous and muscular systems. Nacre has historically been used in Chinese preparation, both topical and oral, for acne and other skin problems, and the composition according to the present invention contains kudzu and Radix Notoginseng to have a wide variety of beneficial affects for skin problems, including reducing inflammation, causing rashes to reduce in size or disappear, moistening skin, and relieving itching.
Another formulation according to the present invention contains nacre as a significant component, but not a majority component, thereof, and is useful for anxiety disorders. This "anxiety" formulation was originally developed for withdrawal symptoms encountered by persons going through rehabilitation of cocaine or heroin addiction. However it has now been found to be pharmacologically effective in relieving anxiety disorders and related problems.
Anxiety disorders are quite common, affecting from 5% to 10% of the general population. Many psychological, emotional and behavioral problems are related to the metabolism of a few elements in the central nervous system (CNS). Calcium metabolism has been under study in its effect on psychological well-being and correction of neurochemical imbalances. There is a growing consensus of Western psychiatric research and Chinese herbal treatment practices that calcium, particularly calcium in the form of nacre, has the effect of restoring metabolic balance, calming the CNS, and healing at the cellular level.
The anxiety formula according to the present invention has "Adaptogens" which help the body deal with stress. By harmonizing body functions the formulation helps with symptoms of irritability, forgetfulness, and general malaise. A smooth muscle relaxer is also included for digestive problems and for constriction in the chest.
The major ingredients of the anxiety formula according to the present invention, and their usefulness in the formulation are: Fructus Schisandrae Chinensis: Acts as a tranquilizer. It is useful for chronic cough, dream disturbed sleep, and insomnia. Nacre: In this formula it is used to sedate the mind when fright or anger is easily provoked. Cortex Acanthopanais Gracilistyli: This is used when the normal flow of energy and blood are obstructed, especially in the treatment of long term illness. Pericarpium Citri Reticulatae: This is effective in the loss of appetite, fatigue, and tightness in the chest.
According to the present invention there thus are provided a number of highly desirable nacre-based formulations that can effectively treat a wide variety of human ailments or conditions.
According to one aspect of the present invention a method of increasing human bone density in a human in need of treatment is provided. The method comprises the step (a) of administering to the human in need of treatment an ingestible material that primarily comprises nacre, and also includes at least about 5% by weight of a source of animal, plant, or both animal and plant, collagen, in an amount effective to increase bone density. Step (a) is typically practiced by administering a formulation comprising about 65-75% nacre, about 4-6% of a source of animal collagen, and about 1.5-2.5% of a source of plant collagen. That is step (a) is practiced by administering a complex formulation comprising a pharmacologically effective mixture of the following, which may have the indicated percentages (expressed in weight percent):
______________________________________Margaritaferae, concha (nacre) 65-75% (e.g. about 70%)Angelicae sinensis radix 5-7% (e.g. about 6%)Gelatinum asini (aka Corii asini 4-6% (e.g. about 5%)gelatinum)Rhizoma Gusuibu (aka Drynariae 3-5% (e.g. about 4%)Rhizoma)Carthami tinctorii flos 3-5% (e.g. about 4%)Paeonea rubrae radix 3-5% (e.g. about 4%)Psoraleae corylifoliae fructus 1.5-2.5% (e.g. about 2%)Puerariae radix (kudzu) 1.5-2.5% (e.g. about 2%)Panacis quinquefolii radix 1.5-2.5% (e.g. about 2%)(aka American Ginseng)______________________________________
According to another aspect of the present invention there is provided a pharmacologically effective composition comprising a mixture of Margaritaferae, concha (nacre), Angelicae sinensis radix, Gelatinum asini (aka Corii asini gelatinum), Rhizoma Gusuibu (aka Drynariae Rhizoma), Carthami tinctorii flos, Paeonea rubrae radix, Psoraleae corylifoliae fructus, Puerariae radix (kudzu), and Panacis quinquefolii radix (aka American Ginseng), in a pharmacologically effective amount. The percentages of the components therein preferably are as set forth above.
According to another aspect of the present invention there is provided a pharmacologically effective composition comprising at least 65% by weight nacre, and at least 5% by weight animal, plant, or animal and plant collagen.
According to another aspect of the present invention a method of eliminating or ameliorating skin conditions including inflammation, rashes, itching, and/or swelling in a human patient in need of treatment, comprising the step (a) of administering to the human patient in need of treatment an ingestible material that comprises a pharmacologically effective mixture of nacre, kudzu and radix notoginseng, in a pharmacologically effective amount. Step (a) may be practiced by administering a formulation having the active composition, expressed in approximate weight percent, consisting essentially of:
______________________________________Concha Margaritaferae (nacre) 65-75% (e.g. about 70%)Radix Pseudoginseng 17-23% (e.g. about 20%)Radix Puerariae (kudzu) 8-12% (e.g. about 10%).______________________________________
The invention also relates to a pharmacologically effective composition comprising a mixture of Concha Margaritaferae (nacre), Radix Notoginseng, and Puerariae radix (kudzu), in a pharmacologically effective amount (preferably in the percentages as set forth above).
According to another aspect of the present invention there is provided a method of substantially eliminating or ameliorating insomnia or other sleeping disorder in a human patient, comprising the step (a) of administering to the human patient in need of treatment an ingestible material having active ingredients consisting essentially of: Concha Margaritaferae, Sclerotium Poriae cocos, and Succinum, in a pharmacologically effective amount. Step (a) is preferably practiced by administering a complex having the following active composition (and consisting essentially of the components listed):
______________________________________Concha Margaritaferae (nacre) 65-75% (e.g. about 70%)Sclerotium Poriae cocos 12-18% (e.g. about 15%)Succinum 12-18% (e.g. about 15%)______________________________________
The invention also relates to a pharmacologically effective composition comprising a mixture of (e.g. consisting essentially of) Concha Margaritaferae (nacre), Sclerotium Poriae cocos, and Succinum, in a pharmacologically effective amount. The percentage contributions of each of the active ingredients preferably are set forth above.
According to still another aspect of the present invention a method of substantially eliminating or ameliorating an anxiety disorder in a human patient is provided, comprising the step (a) of administering to the human patient in need of treatment an ingestible material, in a pharmacologically effective amount, having active ingredients consisting essentially of Fructus Schisandrae Chinensis, Concha Margaritaferae (nacre), Cortex Acanthopanais Gracilistyli, and Pericarpium Citri Reticulatae. Step (a) is typically practiced by administering a complex consisting essentially of the following and having the following composition in weight percent: Fructus Schisandrae Chinensis 35-50% (e.g. about 42%)
______________________________________Fructus Schisandrae Chinensis 35-50% (e.g. about 42%)Concha Margaritaferae (nacre) 20-30% (e.g. about 24%)Cortex Acanthopanais Gracilistyli 13-19% (e.g. about 16%)Pericarpium Citri Reticulatae 14-22% (e.g. about 18%)______________________________________
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Nacre, forming the iridescent inner layer of mollusk shells, is a highly ordered microlaminate composite of crystals and biopolymers with a strength and fracture resistance far exceeding the mineral crystals themselves. Nacre's composite biomaterials consist of calcium carbonate (CaCO 3 ) in a matrix of proteins and glycoproteins with calcium binding properties. Because of the organic matrix in which nacre is formed, similar to the matrix of human bone, this form of calcium is more bioavailable than other sources. Nacre's calcium is preferentially taken up by amino acids in living systems. Nacre also is commonly referred to as Pearl Powder, Mother of Pearl, Amber Poria Pearl, Concha Margarita, marine calcium, and Concha Margaritaferae.
One of the nacre based formulations according to the present invention is a formulation that is particularly useful, in a pharmacologically effective amount, for improving the quality of sleep. The formulation relieves insomnia, anxiety, pain, and muscular tension. The preferred formulation according to the invention is as follows (expressed in weight percent):
______________________________________Concha Margaritaferae (nacre) 65-75% (about 70%)Sclerotium Poriae cocos 12-18% (about 15%)Succinum 12-18% (about 15%)______________________________________
Sclerotium Poriae cocos is used to calm the mind and to regulate urination and edema. It assists in the actions of promoting sleep. Succinum is used as a second assistant to nacre for insomnia and also acts as a tranquilizing agent.
Clinical data indicating the usefulness of the sleep improving formulation according to the present invention is indicated in Table I. Each capsule used in the data reported in Table I had about 300 mg of active ingredient, consisting essentially of about 70% nacre, and about 15% each of Succinum and Sclerotium Poriae cocos.
TABLE I__________________________________________________________________________CLINICAL DATALog Patient Age & Treatment Presenting ResultantNumber #Gender Dosage Duration Symptoms Effects Side Effects__________________________________________________________________________10 36 years male 2 capsules, 1 month insomnia improved none evening sleep14 12 years 1 capsule, 3 weeks insomnia, within 3 days continued usefemale evening trouble getting she was caused to sleep sleeping much grogginess better17 17 years 2 capsules, 1 month sleep decrease in nonefemale evening interrupted by frequency and hot flashes intensity of hot flashes, sleep significantly deeper and more restful__________________________________________________________________________
The bone formulation according to the present invention increases bone density. It also relieves anxiety, pain and muscular tension. The preferred formulation is as follows (listed in weight percent):
______________________________________Margaritaferae, concha (nacre) 65-75% (e.g. about 71%)Angelicae sinensis radix 5-7% (e.g. about 6%)Gelatinum asini (aka Corii asini 4-6% (e.g. about 5%)gelatinum)Rhizoma Gusuibu (aka Drynariae 3-5% (e.g. about 4%)Rhizoma)Carthami tinctorii flos 3-5% (e.g. about 4%)Paeonea rubrae radix 3-5% (e.g. about 4%)Psoraleae corylifoliae fructus 1.5-2.5% (e.g. about 2%)Puerariae radix (kudzu) 1.5-2.5% (e.g. about 2%)Panacis quinquefolii radix 1.5-2.5% (e.g. about 2%)(aka American Ginseng)______________________________________
Angelicae sinensis radix nourishes the blood and promotes blood circulation. Gelatinum asini, glue made from ass's skin, also nourishes the blood and, in experiments on animals, was able to increase the absorption and utilization of calcium carbonate (it is a source of animal collagen). Drynariae rhizoma, aka Rhizoma Gusuibu, assists and promotes the mending of sinews and bones (the Chinese name translates to "Mender of Shattered Bones"). Carthami tinctorii flos is also used as an agent to promote blood circulation. Paeonea rubrae radix (kudzu) is another agent for vitalizing the blood, being a source of plant collagen. Psoraleae corylifoliae fructus is used for weakness of the back (the Chinese name translates to "Resin that Tonifies the Bone"). Puerariae radix is used to loosen tightens in the upper back and neck. Radix Panacis Quinqueofolii, aka American Ginseng, is used as a stimulant to the central nervous system; that is it is used in stress syndromes and helps promote calcium absorption.
The kudzu is particularly useful as a source of collagen, as is the gelatinum asini, comprising plant and animal sources of collagen, respectively. The total amount of collagen, from these or related or equivalent sources, is at last 5% preferably about 6-9%.
The skin formulation according to the present invention has numerous beneficial affects on the health and appearance of hair, skin, and nails. For example it can reduce inflammation, promote hair and nail growth, make the skin more moist, relieve itching, and the like. It also relaxes upper body tension, especially in the neck, shoulders, face and head. The desirable constituents according to the invention are (in approximate weight percent):
______________________________________Concha Margaritaferae (nacre) 65-75% (e.g. about 70%)Radix Pseudoginseng 17-23% (e.g. about 20%)Radix Puerariae (kudzu) 10-12% (e.g. about 10%).______________________________________
Utilizing the formulation according to the invention, containing about 70% nacre, about 10% kudzu, and about 20% radix pseudo ginseng, with each capsule containing approximately 300 mg of active ingredient, the clinical data in Table II has been gathered:
TABLE II__________________________________________________________________________CLINICAL DATALog Patient Agent Treatment Presenting ResultantNumber #& Gender Dosage Duration Symptoms Effects Side Effects__________________________________________________________________________100 53 years 2 capsules, 3 months sympathetic reduced inflammation; nonefemale 2 bid dystrophy of hair and nails growing the hand faster; skin more moist103 64 years 2 capsules, 2 months neck reduced inflammation nonefemale 2 bid inflammation of neck; improvement with pain with aches, pain, stiffness, and swelling106 42 years 2 capsules, 2 months stiff neck and stiff neck and nonefemale 2 bid shoulder; shoulders "released"; muscular sleep is fine tightness in legs; difficulty sleeping107 44 years 1 capsule, 2 3 months stiff neck; stiff neck is gone; nonefemale bid headaches; headaches do not last skin rash on as long and are much back of arms less intense110 7 years male 2 capsules, 1 month neurodermatitis this has been the only none 2 bid thing that has helped with the itching__________________________________________________________________________
An anxiety formulation according to the present invention also has been developed, which can be used as a tea or in capsules. A preferred formulations according to the present invention is (expressed in weight percent):
______________________________________Fructus Schisandrae Chinensis 35-50% (e.g. about 42%)Concha Margaritaferae (nacre) 20-30% (e.g. about 24%)Cortex Acanthopanais Gracilistyli 13-19% (e.g. about 16%)Pericarpium Citri Reticulatae 14-22% (e.g. about 18%)______________________________________
This formulation harmonizes body functions, helps with symptoms of irritability, forgetfulness, and general malaise, and provides a smooth relaxer for digestive problems and for constriction in the chest. Schisandrae acts as a tranquilizer. It is useful for chronic cough, dream disturbed sleep, and insomnia. Nacre, in this formula, is used to sedate the mind when fright or anger is easily provoked. Cortex Acanthopanais Gracilistyli is used when the normal flow of energy and blood are obstructed, especially in the treatment of long term illness. Pericarpium Citri Reticulatae is effective in the loss of appetite, fatigue, and tightness in the chest. The formulation is particularly effective when given in a pharmacologically effective amount to one with an anxiety disorder.
Utilizing the formulation according to the invention, containing about 42% Fructus Schisandrae Chinensis, about 24% nacre, about 16% Cortex Acanthopanais Gracilistyli, and about 18% Pericarpium Citri Reticulatae administered in the form of a tea, the clinical data in data in Table III has been gathered:
TABLE III__________________________________________________________________________CLINICAL DATALog Patient Age & Treatment Presenting ResultantNo. #Gender Dosage Duration Symptoms Effects Side Effects__________________________________________________________________________407 49 years 1 package of 9 days pain in arms reduced stress nonefemale tea, daily and hands; level; insomnia; improved "stressed out"; sleep; anxious improved energy level; reduced pain; better able to focus405 40 years 1 package of 3 months muscle worked nonefemale tea, as contractions of wonderfully; needed the upper improved back, neck palpitations; and shoulder; keeps energy chest tightness level good and and steady; palpitations; relieved jaw problems, muscular rashes, nerve tightness in pain/neuralgia the upper body;__________________________________________________________________________
In all of the formulations discussed above the nacre is preferably in the form of a fine powder.
For all of the formulations according to the invention in addition to the nacre and active herbal (or related) ingredients, the complexes utilized according to the present invention may have any number of substantially inert ingredients which will vary depending upon the particular form by which the complex will be administered. Normally the complexes are administered in the form of ingestible tablets or capsules which are swallowed with water, although the complex active ingredients may be mixed with food or beverage items and eaten or drunk, may be in the form of a tea, or in extreme cases may be introduced directly into the bloodstream using a hypodermic needle, I.V., or the like. The dose may vary depending upon the size, age, and condition of the patient being treated and the particular percentages of components in the complex utilized, but normally between about 500-2000 mg of active complex is administered per day, with part of the total dose preferably taken at two or more different times during the day.
A typical manner of processing herbs to produce a complex according to the invention may be as follows, although a wide variety of different known processing techniques may be utilized depending upon the exact form of the material desired, and the availability of material or equipment:
The powder end product of the complex is typically a 1:1 extract. Testing of raw materials used is conducted using standard organoleptic, High performance Liquid Chromatography, and microbiologic methods. The solvent mixture used for extractions for herbs used in the complex is about 95% SDA-3C and about 5% potable water. SDA-3C is specifically denatured alcohol composed of 95% ethanol and 5% isopropyl. The extraction method is thermokinetic maceration, specifically about 180° F. for about three hours, plus warm up and cool down.
Following extraction, a sample is tested for the percentage of dissolved solids recovered. This is compared with the specified standards and, when necessary, the processing is continued until the standards are reached. The base material of the extract is marc; no rinse of the extracted powder is required. The miscella is distilled. The distilled total miscella is dehydrated onto the base material. This receives a final milling (1/32" screen) in a sanitary stainless mill, using a vacuum system to transport the product directly into the final containers. Samples are taken for quality control tests which are visual, taste, microbiologic and High Performance Liquid chromatography. Samples are also taken for permanent record. That material is readily made into tablets, or placed in ingestible capsules, e.g. about 300 mg per capsule. The nacre powder may be added at any time (but preferably near or at the end) and mixed thoroughly with the other ingredients.
Another possible technique is as follows:
The powder and end product of this formula is typically a 1:1 extract. Testing of raw materials used is conducted using standard organoleptic, High Performance Liquid Chromatography and microbiologic methods. The solvent solution is preferably about 95% SDA-3C and 5% water.
The herb components and the solvent are added together in the extract processor for processing. The supernatant liquid of solvent and solids is drained into the holding/settling tank where the volume is measured and the solids content is determined by analysis. Samples are drawn of both and liquid supernatant and sediment for microbiologic testing. The supernatant liquid is pumped through a 100 mesh liquid filter into the Sanitizing vessel. The liquid is processed for a minimum of four hours at the boiling temperature of about 178° F. The volume of the liquid is measured and a solids analysis is done. A sample is drawn for microbiologic testing. The liquid is pumped through a 100 mesh filter and sprayed into the vacuum dryer, using volume and solids data to adjust the product to the desired concentration for the finished product. The resulting material is dried. The processor is emptied into sanitary bulk bins or barrels and transported to milling. A pre-grind sample is drawn for biologic testing. The material is milled in a sanitary stainless steel milling system using a 1/16" screen. The material is unloaded from the mill system directly via Vac-u-Max collector into double lined 44 gallon fiber drums. A sample is drawn from each container for biologic testing. Typical microbiologic requirements are:
______________________________________ Limits______________________________________Aerobes max. 10,000/gColiform negativeSalmonella negativeE. Coli negativeYeast max. 100/gMold max. 100/g______________________________________
The nacre powder may be added at any time (preferably near or at the end) and mixed thoroughly with the other ingredients.
According to the present invention it is thus possible to provide a number of highly advantageous nacre-based formulations which can effectively treat a number of different ailments and conditions, to substantially eliminate or ameliorate the ailments and conditions, or at least their symptoms. While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment thereof it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent products and methods.
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Various complex formulations including the nacre form of calcium as a primary constituent are provided for dealing with a number of human ailments including insomnia, skin inflammation and itching, and anxiety disorders, and for increasing bone density. For bone density increase nacre is the main constituent, but the complex also includes sources of plant and/or animal collagen. The other compositions include nacre along with herbs to facilitate use of the nacre for treatment of various ailments or conditions.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] Under 35 U.S.C. §119, this application claims priority to U.S. Provisional Patent Application Ser. No. 61/157,604, filed Mar. 5, 2009, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure relates to photovoltaic cells having multiple electron donors and/or multiple acceptors, as well as related components, modules, systems, and methods.
BACKGROUND
[0003] Photovoltaic cells are commonly used to transfer energy in the form of light into energy in the form of electricity. A typical photovoltaic cell includes a photoactive material disposed between two electrodes. Generally, light passes through one or both of the electrodes to interact with the photoactive material to generate electron charge carriers (e.g., electrons or holes).
SUMMARY
[0004] This disclosure is based on the unexpected discovery that incorporating two or more electron donors (e.g., a low bandgap electron donor and a relatively high bandgap electron donor) in a single photoactive layer of a photovoltaic cell can significantly improve the power conversion efficiency (e.g., to at least about 4%) of the photovoltaic cell and can form a photoactive layer with a relatively large thickness (e.g., at least about 150 nm), which is easier and less expensive to manufacture, without sacrificing the charge transfer capability of the photoactive layer.
[0005] In one aspect, this disclosure features articles that include a first electrode, a second electrode, and a photoactive layer between the first and second electrodes. The photoactive layer includes an electron donor material and an electron acceptor material. The electron donor material contains a first polymer and a second polymer different from the first polymer. The first polymer includes a first comonomer repeat unit containing a silacyclopentadithiophene moiety or a cyclopentadithiophene moiety and a second comonomer repeat unit containing a benzothiadiazole moiety. The second polymer includes a monomer repeat unit containing a thiophene moiety. The first polymer has a first bandgap. The second polymer has a second bandgap higher than the first bandgap. The article is configured as a photovoltaic cell.
[0006] In another aspect, this disclosure features articles that include a first electrode, a second electrode, and a photoactive material between the first and second electrodes. The photoactive material includes an electron donor material and an electron acceptor material. The electron donor material contains a first polymer and a second polymer different from the first polymer. The first polymer includes a first comonomer repeat unit containing a silacyclopentadithiophene moiety or a cyclopentadithiophene moiety and a second comonomer repeat unit containing a benzothiadiazole moiety. The first polymer has a first bandgap. The second polymer has a second bandgap higher than the first bandgap. The article is configured as a photovoltaic cell.
[0007] In still another aspect, this disclosure features articles that include a first electrode, a second electrode, and a photoactive material between the first and second electrodes. The photoactive layer has a thickness of at least about 150 nm. The article is configured as a photovoltaic cell. The article has a power conversion efficiency of at least about 4% under AM 1.5 conditions.
[0008] Embodiments can include one or more of the following features.
[0009] In some embodiments, the first comonomer repeat unit in the first polymer includes a silacyclopentadithiophene moiety of formula (1) or a cyclopentadithiophene moiety of formula (2):
[0000]
[0000] in which each of R 1 , R 2 , R 3 , and R 4 , independently, is H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl. In certain embodiments, each of R 1 and R 2 , independently, is H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl. For example, each of R 1 and R 2 , independently, can be C 1 -C 20 alkyl (e.g., 2-ethylhexyl or hexyl).
[0010] In some embodiments, the second comonomer repeat unit in the first polymer includes a benzothiadiazole moiety of formula (3):
[0000]
[0000] in which each of R 1 and R 2 , independently, is H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl. For example, each of R 1 and R 2 , independently, can be H.
[0011] In some embodiments, the first polymer further includes a third comonomer repeat unit different from the first and second comonomer repeat units. For example, the third comonomer repeat unit can include a silacyclopentadithiophene moiety (e.g., a silacyclopentadithiophene moiety of formula (1) described above) or a cyclopentadithiophene moiety (e.g., a cyclopentadithiophene moiety of formula (2) described above).
[0012] In some embodiments, the first polymer includes
[0000]
[0000] in which n is an integer from 1 to 1,000 and m is an integer from 1 to 1,000.
[0013] In some embodiments, the second polymer includes a monomer repeat unit containing a thiophene moiety, such as a thiophene moiety of formula (4):
[0000]
[0000] in which each of R 5 , R 6 , R 7 , and R 8 , independently, is H, C 1 -C 20 alkyl (e.g., hexyl), C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl. For example, one of R 5 and R 6 can be hexyl. In certain embodiments, the second polymer includes poly(3-hexylthiophene) (P3HT).
[0014] In some embodiments, the electron acceptor material includes a material selected from the group consisting of fullerenes, inorganic nanoparticles, oxadiazoles, discotic liquid crystals, carbon nanorods, inorganic nanorods, polymers containing CN groups, polymers containing CF 3 groups, and combinations thereof. For example, the electron acceptor material can include a substituted fullerene, such as [6,6]-phenyl C61-butyric acid methyl ester (C60-PCBM), [6,6]-phenyl C71-butyric acid methyl ester (C70-PCBM), bis(1-[3-(methoxycarbonyl)propyl]-1-phenyl)[6.6]C62 (Bis-C60-PCBM), or 3 ′Phenyl-3′H-cyclopropa[8,25][5,6]fullerene-C70-bis-D5h(6)-3′ butanoic acid methyl ester (Bis-C70-PCBM). As an example, the chemical structure of Bis-C60-PCBM is shown as
[0000]
[0015] In some embodiments, the weight ratio of the first and second polymers ranges from about 20:1 to about 1:20 (e.g., about 1:4 or about 1:5).
[0016] In some embodiments, the first polymer, the second polymer, and the electron acceptor material has a first highest occupied molecular orbital (HOMO) level, a second HOMO level, and a third HOMO level, respectively, and the first HOMO level is between the second and third HOMO levels.
[0017] In some embodiments, the first polymer, the second polymer, and the electron acceptor material has a first lowest unoccupied molecular orbital (LUMO) level, a second LUMO level, and a third LUMO level, respectively, and the first LUMO level is between the second and third LUMO levels.
[0018] In some embodiments, the weight ratio of the electron donor material and the electron acceptor material ranges from about 1:1 to about 1:3 (e.g., about 1:1).
[0019] In some embodiments, the photoactive layer has a thickness of at least about 150 nm.
[0020] In some embodiments, the article has a power conversion efficiency of at least about 4% under AM 1.5 conditions.
[0021] Embodiments can provide one or more of the following advantages.
[0022] Without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer of a photovoltaic cell can significantly improve the power conversion efficiency of the photovoltaic cell (e.g., to at least about 4%).
[0023] Without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer of a photovoltaic cell provides an advantage over including these semiconducting polymers in two separate photoactive layers of a cell (e.g., a tandem cell) as the former cell is easier and less expensive to make, thereby significantly reducing the manufacturing costs of the cell.
[0024] Without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer and result in a layer with a relatively large thickness (e.g., at least about 200 nm) without sacrificing the charge transfer capability of the layer. Such a photoactive layer is easier and less expensive to make and therefore can significantly reduce the manufacturing costs of the photovoltaic cell.
[0025] Without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in the photoactive layer could significantly improve the lifetime of a photovoltaic cell.
[0026] Other features and advantages of the invention will be apparent from the description, drawings, and claims.
DESCRIPTION OF DRAWINGS
[0027] FIG. 1 is a cross-sectional view of an embodiment of a photovoltaic cell.
[0028] FIG. 2 is a cross-sectional view of an embodiment of a tandem photovoltaic cell.
[0029] FIG. 3 is a schematic of a system containing multiple photovoltaic cells electrically connected in series.
[0030] FIG. 4 is a schematic of a system containing multiple photovoltaic cells electrically connected in parallel.
[0031] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0032] FIG. 1 shows a cross-sectional view of a photovoltaic cell 100 that includes a substrate 110 , an electrode 120 , an optional hole blocking layer 130 , a photoactive layer 140 (containing an electron acceptor material and an electron donor material), a hole carrier layer 150 , an electrode 160 , and a substrate 170 .
[0033] In general, one or both substrates 110 and 170 can be formed of a transparent material to transmit solar light. During use, when substrate 110 is formed of a transparent material, light impinges on the surface of substrate 110 , and passes through substrate 110 , electrode 120 , and optional hole blocking layer 130 . The light then interacts with photoactive layer 140 , causing electrons to be transferred from the electron donor material (e.g., one or more conjugated polymers) to the electron acceptor material (e.g., a fullerene). The electron acceptor material then transmits the electrons through optional hole blocking layer 130 to electrode 120 , and the electron donor material transfers holes through hole carrier layer 150 to electrode 160 . Electrodes 120 and 160 are in electrical connection via an external load so that electrons pass from electrode 120 , through the load, and to electrode 160 .
[0034] In general, photoactive layer 140 can include an electron donor material (e.g., an organic electron donor material) and an electron acceptor material (e.g., an organic electron acceptor material). In some embodiments, the electron donor or acceptor material can include one or more polymers (e.g., homopolymers or copolymers). A polymer mentioned herein includes at least two identical or different monomer repeat units (e.g., at least 5 monomer repeat units, at least 10 monomer repeat units, at least 50 monomer repeat units, at least 100 monomer repeat units, or at least 500 monomer repeat units). A homopolymer mentioned herein refers to a polymer that includes only one type of monomer repeat units. A copolymer mentioned herein refers to a polymer that includes at least two (e.g., two, three, four or five) co-monomer repeat units with different chemical structures. The polymers can be conjugated semiconducting polymers and can be photovoltaically active.
[0035] In some embodiments, the electron donor material can include a first polymer and a second polymer different from the first polymer. In certain embodiments, the electron donor material can include more than two (e.g., three, four, or five) different polymers. Each polymer in the electron donor material can be either a homopolymer or a copolymer.
[0036] The first polymer in the electron donor material can be a copolymer and can include two or more (e.g., three, four, or five) different comonomer repeat units. For example, the first polymer can include a first comonomer repeat unit and a second comonomer repeat unit different from the first comonomer repeat unit.
[0037] The first comonomer repeat unit in the first polymer can include a silacyclopentadithiophene moiety of formula (1) or a cyclopentadithiophene moiety of formula (2):
[0000]
[0000] in which each of R 1 , R 2 , R 3 , and R 4 , independently, is H, C 1 -C 20 alkyl (e.g., hexyl or 2-ethylhexyl), C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl.
[0038] An alkyl can be saturated or unsaturated and branched or straight chained. A C 1 -C 20 alkyl contains 1 to 20 carbon atoms (e.g., one, two, three, four, five, six, seven, eight, nine, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 carbon atoms). Examples of alkyl moieties include —CH 3 , —CH 2 —CH═CH 2 , and branched —C 3 H 7 . An alkoxy can be branched or straight chained and saturated or unsaturated. An C 1 -C 20 alkoxy contains an oxygen radical and 1 to 20 carbon atoms (e.g., one, two, three, four, five, six, seven, eight, nine, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 carbon atoms). Examples of alkoxy moieties include —OCH 3 and —OCH═CH—CH 3 . A cycloalkyl can be either saturated or unsaturated. A C 3 -C 20 cycloalkyl contains 3 to 20 carbon atoms (e.g., three, four, five, six, seven, eight, nine, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 carbon atoms). Examples of cycloalkyl moieties include cyclohexyl and cyclohexen-3-yl. A heterocycloalkyl can also be either saturated or unsaturated. A C 1 -C 20 heterocycloalkyl contains at least one ring heteroatom (e.g., O, N, and S) and 1 to 20 carbon atoms (e.g., one, two, three, four, five, six, seven, eight, nine, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 carbon atoms). Examples of heterocycloalkyl moieties include 4-tetrahydropyranyl and 4-pyranyl. An aryl can contain one or more aromatic rings. Examples of aryl moieties include phenyl, phenylene, naphthyl, naphthylene, pyrenyl, anthryl, and phenanthryl. A heteroaryl can contain one or more aromatic rings, at least one of which contains at least one ring heteroatom (e.g., O, N, and S). Examples of heteroaryl moieties include furyl, furylene, fluorenyl, pyrrolyl, thienyl, oxazolyl, imidazolyl, thiazolyl, pyridyl, pyrimidinyl, quinazolinyl, quinolyl, isoquinolyl, and indolyl.
[0039] Alkyl, alkoxy, cycloalkyl, heterocycloalkyl, aryl, and heteroaryl mentioned herein include both substituted and unsubstituted moieties, unless specified otherwise. Examples of substituents on cycloalkyl, heterocycloalkyl, aryl, and heteroaryl include C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, aryl, aryloxy, heteroaryl, heteroaryloxy, amino, C 1 -C 10 alkylamino, C 1 -C 20 dialkylamino, arylamino, diarylamino, hydroxyl, halogen, thio, C 1 -C 10 alkylthio, arylthio, C 1 -C 10 alkylsulfonyl, arylsulfonyl, cyano, nitro, acyl, acyloxy, carboxyl, and carboxylic ester. Examples of substituents on alkyl include all of the above-recited substituents except C 1 -C 20 alkyl. Cycloalkyl, heterocycloalkyl, aryl, and heteroaryl also include fused groups.
[0040] The second comonomer repeat unit in the first polymer can include a benzothiadiazole moiety of formula (3):
[0000]
[0000] in which each of R 1 and R 2 , independently, is H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl. For example, each of R 1 and R 2 , independently, can be H.
[0041] The first polymer can further include a third comonomer repeat unit different from the first and second comonomer repeat units. For example, the third comonomer repeat unit can include a silacyclopentadithiophene moiety (e.g., a silacyclopentadithiophene moiety of formula (1) described above) or a cyclopentadithiophene moiety (e.g., a cyclopentadithiophene moiety of formula (2) described above).
[0042] Examples of the first polymer include
[0000]
[0000] in which n is an integer from 1 to 1,000 and m is an integer from 1 to 1,000.
[0043] In some embodiments, the first polymer has a relatively low bandgap. The term “bandgap” mentioned herein refers to the energy difference between the top of the valence band (e.g., the HOMO level) and the bottom of the conduction band (e.g., the LUMO level) of a material. For example, the first polymer can have a bandgap of at most about 1.8 eV (at most about 1.7 eV, at most about 1.6 eV, at most about 1.5 eV, at most about 1.4 eV, or at most about 1.3 eV) or at least about 1.1 eV (e.g., at least about 1.2 eV, at least about 1.3 eV, at least about 1.4 eV, or at least about 1.5 eV). Preferably, the first polymer has a bandgap of from about 1.3 eV to about 1.6 eV (e.g., from about 1.4 eV to about 1.6 eV). For example, polymers 1-3 have a bandgap in the range of about 1.3 eV to about 1.4 eV.
[0044] In some embodiments, the second polymer in the electron donor material can be a homopolymer. The monomer repeat unit in the second polymer can contain a thiophene moiety, such as a thiophene moiety of formula (4):
[0000]
[0000] in which each of R 5 , R 6 , R 7 , and R 8 , independently, is H, C 1 -C 20 alkyl (e.g., hexyl), C 1 -C 20 alkoxy, C 3 -C 20 cycloalkyl, C 1 -C 20 heterocycloalkyl, aryl, heteroaryl, halo, CN, OR, C(O)R, C(O)OR, or SO 2 R; R being H, C 1 -C 20 alkyl, C 1 -C 20 alkoxy, aryl, heteroaryl, C 3 -C 20 cycloalkyl, or C 1 -C 20 heterocycloalkyl. An example of the second polymer is poly(3-hexylthiophene).
[0045] In some embodiments, the second polymer has a relatively high bandgap. For example, the second polymer can have a bandgap of at least about 1.5 eV (at least about 1.6 eV, at least about 1.7 eV, at least about 1.8 eV, at least about 1.9 eV, or at least about 2.0 eV) or at most about 2.5 eV (e.g., at most about 2.4 eV, at most about 2.3 eV, at most about 2.2 eV, at most about 2.1 eV, or at most about 2.0 eV). For example, P3HT has a bandgap of about 1.9 eV. Preferably, the second polymer has a bandgap higher than that of the first polymer.
[0046] Other polymers that can be used as an electron donor material in photoactive layer 140 are described in, for example, commonly-owned co-pending U.S. Application Publication Nos. 2007-0014939, 2007-0158620, 2007-0017571, 2007-0020526, 2008-0087324, 2008-0121281, and 2010-0032018.
[0047] The first and second polymers can either be prepared by methods known in the art or purchased from commercial sources. For example, methods of preparing polymer containing a silacyclopentadithiophene moiety of formula (1) have been disclosed in commonly-owned co-pending U.S. Application Publication Nos. 2008-0087324 and 2010-0032018. As another example, methods of preparing polymers containing a cyclopentadithiophene moiety of formula (2) have been disclosed in commonly-owned co-pending U.S. Application Publication No. 2007-0014939. As another example, methods of preparing polymers containing benzothiadiazole moiety of formula (3) have been disclosed in commonly-owned co-pending U.S. Application Publication No. 2007-0158620. Polymers containing a thiophene moiety of formula (4) are generally commercially available or can be made by methods known in the art.
[0048] In general, the weight ratio of the first and second polymers can vary as desired. For example, the weight ratio of the first and second polymers can range from about 20:1 to about 1:20 (e.g., from about 10:1 to about 1:10, from about 5:1 to about 1:5, or from about 3:1 to about 1:3). Preferably, the weight ratio of the first and second polymers can be at least about 1:4, (e.g., at least about 1:3, at least about 1:2, or at least about 1:1).
[0049] Without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer of a photovoltaic cell can significantly improve the power conversion efficiency of the photovoltaic cell (e.g., to at least about 4%). In some embodiments, when photoactive layer 140 includes two or more semiconducting polymers (such as the first and second polymers described above), photovoltaic cell 100 can have a power conversion efficiency of at least about 2.5% (e.g., at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, or at least about 5%).
[0050] Further, without wishing to be bound by theory, it is believed that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer of a photovoltaic cell provides an advantage over including these semiconducting polymers in two separate photoactive layers of a cell (e.g., a tandem cell) as the former cell is easier and less expensive to make, thereby significantly reducing the manufacturing costs of the cell.
[0051] In some embodiments, photoactive layer 140 can include two or more semiconducting polymers (e.g., one low bandgap polymer and one relatively high bandgap polymer) having complementary absorption spectra. For example, P3HT (i.e., an exemplary second polymer described above) has an absorption peak at the wavelength of about 500-550 nm. Polymer 1 (i.e., an exemplary first polymer described above) has an absorption peak at the wavelength of about 700-900 nm and has a minimum absorption at the wavelength of about 500-550 nm. Thus, including P3HT and polymer 1 in photoactive layer 140 can enhance light absorption within a broad solar light spectrum and improve the external quantum efficiency of photovoltaic cell 100 , and consequently improve the power conversion efficiency of the photovoltaic cell.
[0052] In some embodiments, the first polymer, the second polymer, and the electron acceptor material can have first HOMO and LUMO levels, second HOMO and LUMO levels, and third HOMO and LUMO levels, respectively. Preferably, the first HOMO level falls between the HOMO levels of the second polymer and the electron acceptor material. In such embodiments, photo-induced positive charges (e.g., holes) generated from the first polymer can be transferred to the second polymer. As such, both the first and second polymers contribute to charge generation and transfer, thereby improving the external quantum efficiency and the power conversion efficiency of photovoltaic cell 100 . In addition, as the second polymer is generally a superior charger carrier, it can facilitate transfer of positive charges generated from the first polymer to a corresponding electrode in the event that the first polymer has a relatively poor charge transfer capability.
[0053] On the other hand, there is no significant transfer of negative charges (e.g., electrons) between the first and second polymers. Thus, it is not critical for the first LUMO level to fall between the second and third LUMO levels. However, in some embodiments, it is preferable for the first LUMO level to fall between the second and third LUMO levels.
[0054] In some embodiments, photoactive layer 140 can include a semiconducting polymer (e.g., a low bandgap polymer such as the first polymer) having a HOMO level and a LUMO level that respectively fall between the HOMO levels and LUMO levels of another semiconductor polymer (e.g., a relatively high bandgap polymer such as the second polymer) and the electron acceptor material (e.g., a fullerene such as C60-PCBM). For example, polymer 1 has a HOMO level of about −5.3 eV that falls between the HOMO levels of P3HT (i.e., about −5.1 eV) and C60-PCBM (i.e., about −6 eV) and a LUMO level of about −3.6 eV that falls between the LUMO levels of P3HT (i.e., about 2.9 eV) and C60-PCBM (i.e., about −4.3 eV). Thus, photo-induced electrons from polymer 1 can be transferred to C60-PCBM (and subsequently to a neighboring electrode) and photo-induced holes from polymer 1 can be transferred to P3HT (and subsequently to a neighboring electrode). In other words, in addition to electron donor P3HT, electron donor polymer 1 can also contribute to charge generation and transfer, thereby improving the external quantum efficiency and the power conversion efficiency of photovoltaic cell 100 .
[0055] It is known in the art that increasing the thickness of the photoactive layer in a photovoltaic cell would generally make it more difficult for photo-induced charge carriers generated in this layer to be transferred to a neighboring layer and eventually to the corresponding electrode, thereby reducing the charge transfer capability of the photoactive layer. However, it is found unexpectedly that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer can result in a layer with a relatively large thickness (e.g., at least about 150 nm) without sacrificing the charge transfer capability of the layer. Such a photoactive layer is easier and less expensive to make and therefore can significantly reduce the manufacturing costs of the photovoltaic cell. In some embodiments, such a photoactive layer can have a thickness of at least about 100 nm (e.g., at least about 150 nm, at least about 200 nm, at least about 300 nm, or at least about 500 nm).
[0056] Further, without wishing to be bound by theory, it is found unexpectedly that including (e.g., blending) both one or more low bandgap semiconducting polymers (e.g., the first polymer described above) and one or more relatively high bandgap semiconducting polymers (e.g., the second polymer described above) in a single photoactive layer can significantly improve the lifetime of a photovoltaic cell.
[0057] In some embodiments, the electron acceptor material in photoactive layer 140 can include a material selected from the group consisting of fullerenes, inorganic nanoparticles, oxadiazoles, discotic liquid crystals, carbon nanorods, inorganic nanorods, polymers containing CN groups, polymers containing CF 3 groups, and combinations thereof. For example, the electron acceptor material can include fullerenes (e.g., substituted fullerenes).
[0058] In some embodiments, photoactive layer 140 can include one or more unsubstituted fullerenes and/or one or more substituted fullerenes as the electron acceptor material. Examples of unsubstituted fullerenes include C 60 , C 70 , C 76 , C 78 , C 82 , C 84 , and C 92 . Examples of substituted fullerenes include PCBMs (e.g., C60-PCBM, C70-PCBM, Bis-C60-PCBM, or Bis-C70-PCBM) or fullerenes substituted with C 1 -C 20 alkoxy optionally further substituted with C 1 -C 20 alkoxy and/or halo (e.g., (OCH 2 CH 2 ) 2 OCH 3 or OCH 2 CF 2 OCF 2 CF 2 OCF 3 ). Without wishing to be bound by theory, it is believed that fullerenes substituted with long-chain alkoxy groups (e.g., oligomeric ethylene oxides) or fluorinated alkoxy groups have improved solubility in organic solvents and can form a photoactive layer with improved morphology. Other materials that can be used as an electron acceptor material in photoactive layer 140 are described in, for example, commonly-owned co-pending U.S. Application Publication Nos. 2007-0014939, 2007-0158620, 2007-0017571, 2007-0020526, 2008-0087324, 2008-0121281, and 2010-0032018. In certain embodiments, a combination of electron acceptors (e.g., two different fullerenes) can be used in photoactive layer 140 . Such embodiments have been described in, for example, commonly-owned co-pending U.S. Application Publication No. 2007-0062577.
[0059] In general, the weight ratio between the electron donor material and the electron acceptor material can vary as desired. In some embodiments, the weight ratio of the electron donor material and the electron acceptor material ranges from about 1:1 to about 1:3 (preferably about 1:1).
[0060] It is known in the art that blending two or more semiconducting polymers (e.g., blending an electron donor polymer with an electron acceptor polymer) could lead to large phase separation with domain size in several micrometers, which could significantly reduce the charge transfer capability of the photoactive layer thus formed and consequently lower the power conversion efficiency of the photovoltaic cell. Unexpectedly, blending the first and second polymers described above does not show significant phase separation (e.g., having a domain size larger than 500 nm) between these two polymers and therefore minimizes the efficiency loss caused by phase separation between these two polymers.
[0061] Photoactive layer 140 is generally formed by mixing the electron donor material (e.g., the first and second polymers described above) and the electron acceptor material (e.g., a substituted fullerene) with a suitable solvent (e.g., an organic solvent) to form a solution or a dispersion, coating the solution or dispersion on layer 130 , and drying the coated solution or dispersion.
[0062] In general, after photoactive layer 140 is formed (e.g., after the entire photovoltaic cell 100 is formed), it is desirable to anneal this layer (e.g., by heating) at a suitable temperature for a suitable period of time. The annealing temperature can be at least about 70° C. (e.g., at least about 80° C., at least about 100° C., at least about 120° C., or at least about 140° C.) or at most about 200° C. (e.g., at most about 180° C., at most about 160° C., at most about 140° C., or at most about 120° C.). The annealing time can be at least about 30 seconds (e.g., at least about 1 minute, at least about 3 minute, at least about 5 minute, or at least about 7 minute) or at most about 15 minutes (e.g., at most about 13 minutes, at most about 11 minutes, at most about 9 minutes, or at most about 7 minutes). Without wishing to be bound by theory, it is believed that non-annealed photoactive layer would have a lowered short circuit current density, a lowered fill factor, and an elevated serial resistance. However, annealing photoactive layer 140 could significantly improve the short circuit current density and therefore increase the power conversion efficiency of photovoltaic cell 100 .
[0063] Turning to other components of photovoltaic cell 100 , substrate 110 is generally formed of a transparent material. As referred to herein, a transparent material is a material which, at the thickness used in a photovoltaic cell 100 , transmits at least about 60% (e.g., at least about 70%, at least about 75%, at least about 80%, at least about 85%) of incident light at a wavelength or a range of wavelengths (e.g., from about 350 nm to about 1,000 nm) used during operation of the photovoltaic cell. Exemplary materials from which substrate 110 can be formed include polyethylene terephthalates, polyimides, polyethylene naphthalates, polymeric hydrocarbons, cellulosic polymers, polycarbonates, polyamides, polyethers, and polyether ketones. In certain embodiments, the polymer can be a fluorinated polymer. In some embodiments, combinations of polymeric materials are used. In certain embodiments, different regions of substrate 110 can be formed of different materials.
[0064] In general, substrate 110 can be flexible, semi-rigid or rigid (e.g., glass). In some embodiments, substrate 110 has a flexural modulus of less than about 5,000 megaPascals (e.g., less than about 1,000 megaPascals or less than about 5,00 megaPascals). In certain embodiments, different regions of substrate 110 can be flexible, semi-rigid, or inflexible (e.g., one or more regions flexible and one or more different regions semi-rigid, one or more regions flexible and one or more different regions inflexible).
[0065] Typically, substrate 110 is at least about one micron (e.g., at least about five microns, at least about 10 microns) thick and/or at most about 1,000 microns (e.g., at most about 500 microns thick, at most about 300 microns thick, at most about 200 microns thick, at most about 100 microns, at most about 50 microns) thick.
[0066] Generally, substrate 110 can be colored or non-colored. In some embodiments, one or more portions of substrate 110 is/are colored while one or more different portions of substrate 110 is/are non-colored.
[0067] Substrate 110 can have one planar surface (e.g., the surface on which light impinges), two planar surfaces (e.g., the surface on which light impinges and the opposite surface), or no planar surfaces. A non-planar surface of substrate 110 can, for example, be curved or stepped. In some embodiments, a non-planar surface of substrate 110 is patterned (e.g., having patterned steps to form a Fresnel lens, a lenticular lens or a lenticular prism).
[0068] Electrode 120 is generally formed of an electrically conductive material. Exemplary electrically conductive materials include electrically conductive metals, electrically conductive alloys, electrically conductive polymers, and electrically conductive metal oxides. Exemplary electrically conductive metals include gold, silver, copper, aluminum, nickel, palladium, platinum, and titanium. Exemplary electrically conductive alloys include stainless steel (e.g., 332 stainless steel, 316 stainless steel), alloys of gold, alloys of silver, alloys of copper, alloys of aluminum, alloys of nickel, alloys of palladium, alloys of platinum and alloys of titanium. Exemplary electrically conducting polymers include polythiophenes (e.g., doped poly(3,4-ethylenedioxythiophene) (doped PEDOT)), polyanilines (e.g., doped polyanilines), polypyrroles (e.g., doped polypyrroles). Exemplary electrically conducting metal oxides include indium tin oxide, fluorinated tin oxide, tin oxide and zinc oxide. In some embodiments, combinations of electrically conductive materials are used.
[0069] In some embodiments, electrode 120 can include a mesh electrode. Examples of mesh electrodes are described in, for example, commonly-owned co-pending U.S. Patent Application Publication Nos. 2004-0187911 and 2006-0090791.
[0070] Optionally, photovoltaic cell 100 can include a hole blocking layer 130 . The hole blocking layer is generally formed of a material that, at the thickness used in photovoltaic cell 100 , transports electrons to electrode 120 and substantially blocks the transport of holes to electrode 120 . Examples of materials from which the hole blocking layer can be formed include LiF, metal oxides (e.g., zinc oxide, titanium oxide), and amines (e.g., primary, secondary, or tertiary amines, or polymer containing amino groups). Examples of amines suitable for use in a hole blocking layer have been described in, for example, commonly-owned co-pending U.S. Patent Application Publication No. 2008-0264488.
[0071] Without wishing to be bound by theory, it is believed that when photovoltaic cell 100 includes a hole blocking layer made of amines, the hole blocking layer can facilitate the formation of ohmic contact between photoactive layer 140 and electrode 120 without being exposed to UV light, thereby reducing damage to photovoltaic cell 100 resulted from UV exposure.
[0072] In general, the thickness of hole blocking layer 130 (i.e., the distance between the surface of hole blocking layer 130 in contact with photoactive layer 140 and the surface of electrode 120 in contact with hole blocking layer 130 ) can be varied as desired. Typically, hole blocking layer 130 is at least 0.02 micron (e.g., at least about 0.03 micron, at least about 0.04 micron, at least about 0.05 micron) thick and/or at most about 0.5 micron (e.g., at most about 0.4 micron, at most about 0.3 micron, at most about 0.2 micron, at most about 0.1 micron) thick.
[0073] Hole carrier layer 150 is generally formed of a material that, at the thickness used in photovoltaic cell 100 , transports holes to electrode 160 and substantially blocks the transport of electrons to electrode 160 . Examples of materials from which layer 130 can be formed include polythiophenes (e.g., PEDOT), polyanilines, polycarbazoles, polyvinylcarbazoles, polyphenylenes, polyphenylvinylenes, polysilanes, polythienylenevinylenes, polyisothianaphthanenes, and copolymers thereof. In some embodiments, hole carrier layer 150 can include a dopant used in combination with a semiconductive polymer. Examples of dopants include poly(styrene-sulfonate)s, polymeric sulfonic acids, and fluorinated polymers (e.g., fluorinated ion exchange polymers).
[0074] In some embodiments, the materials that can be used to form hole carrier layer 150 include metal oxides, such as titanium oxides, zinc oxides, tungsten oxides, molybdenum oxides, copper oxides, strontium copper oxides, or strontium titanium oxides. The metal oxides can be either undoped or doped with a dopant. Examples of dopants for metal oxides includes salts or acids of fluoride, chloride, bromide, and iodide.
[0075] In some embodiments, the materials that can be used to form hole carrier layer 150 include carbon allotropes (e.g., carbon nanotubes). The carbon allotropes can be embedded in a polymer binder.
[0076] In some embodiments, the hole carrier materials can be in the form of nanoparticles. The nanoparticles can have any suitable shape, such as a spherical, cylindrical, or rod-like shape.
[0077] In some embodiments, hole carrier layer 150 can include combinations of hole carrier materials described above.
[0078] In general, the thickness of hole carrier layer 150 (i.e., the distance between the surface of hole carrier layer 150 in contact with photoactive layer 140 and the surface of electrode 160 in contact with hole carrier layer 150 ) can be varied as desired. Typically, the thickness of hole carrier layer 150 is at least 0.01 micron (e.g., at least about 0.05 micron, at least about 0.1 micron, at least about 0.2 micron, at least about 0.3 micron, or at least about 0.5 micron) and/or at most about five microns (e.g., at most about three microns, at most about two microns, or at most about one micron). In some embodiments, the thickness of hole carrier layer 150 is from about 0.01 micron to about 0.5 micron.
[0079] Electrode 160 is generally formed of an electrically conductive material, such as one or more of the electrically conductive materials described above with respect to electrode 120 . In some embodiments, electrode 160 is formed of a combination of electrically conductive materials. In certain embodiments, electrode 160 can be formed of a mesh electrode.
[0080] Substrate 170 can be identical to or different from substrate 110 . In some embodiments, substrate 170 can be formed of one or more suitable polymers, such as the polymers used in substrate 110 described above.
[0081] In some embodiments, the semiconducting polymers described above (such as the first and second polymers) can be used as an electron donor material in a system in which two photovoltaic cells share a common electrode. Such a system is also known as tandem photovoltaic cell. FIG. 2 shows a tandem photovoltaic cell 200 having two semi-cells 202 and 204 . Semi-cell 202 includes an electrode 220 , an optional hole blocking layer 230 , a first photoactive layer 240 , and a recombination layer 242 (also serving as a common electrode). Semi-cell 204 includes recombination layer 242 , a second photoactive layer 244 , a hole carrier layer 250 , and an electrode 260 . An external load is connected to photovoltaic cell 200 via electrodes 220 and 260 .
[0082] Depending on the production process and the desired device architecture, the current flow in a semi-cell can be reversed by changing the electron/hole conductivity of a certain layer (e.g., changing hole blocking layer 230 to a hole carrier layer). By doing so, a tandem cell can be designed such that the semi-cells in the tandem cells can be electrically interconnected either in series or in parallel.
[0083] A recombination layer refers to a layer in a tandem cell where the electrons generated from a first semi-cell recombine with the holes generated from a second semi-cell. Recombination layer 242 typically includes a p-type semiconductor material and an n-type semiconductor material. In general, n-type semiconductor materials selectively transport electrons and p-type semiconductor materials selectively transport holes. As a result, electrons generated from the first semi-cell recombine with holes generated from the second semi-cell at the interface of the n-type and p-type semiconductor materials.
[0084] In some embodiments, the p-type semiconductor material includes a polymer and/or a metal oxide. Examples of p-type semiconductor polymers include polythiophenes (e.g., poly(3,4-ethylene dioxythiophene)), polyanilines, polyvinylcarbazoles, polyphenylenes, polyphenylvinylenes, polysilanes, polythienylenevinylenes, polyisothianaphthanenes, polycyclopentadithiophenes, polysilacyclopentadithiophenes, polycyclopentadithiazoles, polythiazolothiazoles, polythiazoles, polybenzothiadiazoles, poly(thiophene oxide)s, poly(cyclopentadithiophene oxide)s, polythiadiazoloquinoxaline, polybenzoisothiazole, polybenzothiazole, polythienothiophene, poly(thienothiophene oxide), polydithienothiophene, poly(dithienothiophene oxide)s, polytetrahydroisoindoles, and copolymers thereof. The metal oxide can be an intrinsic p-type semiconductor (e.g., copper oxides, strontium copper oxides, or strontium titanium oxides) or a metal oxide that forms a p-type semiconductor after doping with a dopant (e.g., p-doped zinc oxides or p-doped titanium oxides). Examples of dopants includes salts or acids of fluoride, chloride, bromide, and iodide. In some embodiments, the metal oxide can be used in the form of nanoparticles.
[0085] In some embodiments, the n-type semiconductor material (either an intrinsic or doped n-type semiconductor material) includes a metal oxide, such as titanium oxides, zinc oxides, tungsten oxides, molybdenum oxides, and combinations thereof. The metal oxide can be used in the form of nanoparticles. In other embodiments, the n-type semiconductor material includes a material selected from the group consisting of fullerenes, inorganic nanoparticles, oxadiazoles, discotic liquid crystals, carbon nanorods, inorganic nanorods, polymers containing CN groups, polymers containing CF 3 groups, and combinations thereof.
[0086] In some embodiments, the p-type and n-type semiconductor materials are blended into one layer. In certain embodiments, recombination layer 242 includes two layers, one layer including the p-type semiconductor material and the other layer including the n-type semiconductor material. In such embodiments, recombination layer 242 can also include three layers, in which the first layer includes the p-type semiconductor material, the second layer includes the n-type semiconductor material, and the third layer containing mixed n-type and p-type semiconductor materials is between the first and second layers.
[0087] In some embodiments, recombination layer 242 includes at least about 30 wt % (e.g., at least about 40 wt % or at least about 50 wt %) and/or at most about 70 wt % (e.g., at most about 60 wt % or at most about 50 wt %) of the p-type semiconductor material. In some embodiments, recombination layer 242 includes at least about 30 wt % (e.g., at least about 40 wt % or at least about 50 wt %) and/or at most about 70 wt % (e.g., at most about 60 wt % or at most about 50 wt %) of the n-type semiconductor material.
[0088] Recombination layer 242 generally has a sufficient thickness so that the layers underneath are protected from any solvent applied onto recombination layer 242 . In some embodiments, recombination layer 242 can have a thickness at least about 10 nm (e.g., at least about 20 nm, at least about 50 nm, or at least about 100 nm) and/or at most about 500 nm (e.g., at most about 200 nm, at most about 150 nm, or at most about 100 nm).
[0089] In general, recombination layer 242 is substantially transparent. For example, at the thickness used in a tandem photovoltaic cell 200 , recombination layer 242 can transmit at least about 70% (e.g., at least about 75%, at least about 80%, at least about 85%, or at least about 90%) of incident light at a wavelength or a range of wavelengths (e.g., from about 350 nm to about 1,000 nm) used during operation of the photovoltaic cell.
[0090] Recombination layer 242 generally has a sufficiently low surface resistance. In some embodiments, recombination layer 242 has a surface resistance of at most about 1×10 6 ohm/square (e.g., at most about 5×10 5 ohm/square, at most about 2×10 5 ohm/square, or at most about 1×10 5 ohm/square).
[0091] Without wishing to be bound by theory, it is believed that recombination layer 242 can be considered as a common electrode between two semi-cells (e.g., one including electrode 220 , hole blocking layer 230 , photoactive layer 240 , and recombination layer 242 , and the other including recombination layer 242 , photoactive layer 244 , hole carrier layer 250 , and electrode 260 ) in photovoltaic cells 200 . In some embodiments, recombination layer 242 can include an electrically conductive grid (e.g., mesh) material, such as those described above. An electrically conductive grid material can provide a selective contact of the same polarity (either p-type or n-type) to the semi-cells and provide a highly conductive but transparent layer to transport electrons to a load.
[0092] In some embodiments, recombination layer 242 can be prepared by applying a blend of an n-type semiconductor material and a p-type semiconductor material on a photoactive layer. For example, an n-type semiconductor and a p-type semiconductor can be first dispersed or dissolved in a solvent together to form a dispersion or solution, which can then be coated on a photoactive layer to form a recombination layer.
[0093] In some embodiments, a two-layer recombination layer can be prepared by applying a layer of an n-type semiconductor material and a layer of a p-type semiconductor material separately. For example, when titanium oxide nanoparticles are used as an n-type semiconductor material, a layer of titanium oxide nanoparticles can be formed by (1) dispersing a precursor (e.g., a titanium salt) in a solvent (e.g., an organic solvent such as an anhydrous alcohol) to form a dispersion, (2) coating the dispersion on a photoactive layer, (3) hydrolyzing the dispersion to form a titanium oxide layer, and (4) drying the titanium oxide layer. As another example, when a polymer (e.g., PEDOT) is used a p-type semiconductor, a polymer layer can be formed by first dissolving the polymer in a solvent (e.g., an organic solvent such as an anhydrous alcohol) to form a solution and then coating the solution on a photoactive layer.
[0094] Other components in tandem cell 200 can be formed of the same materials, or have the same characteristics, as those in photovoltaic cell 100 described above.
[0095] Examples of tandem photovoltaic cells have been described in, for example, commonly-owned co-pending U.S. Application Publication Nos. 2007-0181179 and 2007-0246094.
[0096] In some embodiments, the semi-cells in a tandem cell are electrically interconnected in series. When connected in series, in general, the layers can be in the order shown in FIG. 2 . In certain embodiments, the semi-cells in a tandem cell are electrically interconnected in parallel. When interconnected in parallel, a tandem cell having two semi-cells can include the following layers: a first electrode, a first hole blocking layer, a first photoactive layer, a first hole carrier layer (which can serve as an electrode), a second hole carrier layer (which can serve as an electrode), a second photoactive layer, a second hole blocking layer, and a second electrode. In such embodiments, the first and second hole carrier layers together can be a recombination layer, which can include either two separate layers or can be one single layer. In case the conductivity of the first and second hole carrier layers is not sufficient, an additional layer (e.g., an electrically conductive mesh layer) providing the required conductivity may be inserted.
[0097] In some embodiments, a tandem cell can include more than two semi-cells (e.g., three, four, five, six, seven, eight, nine, ten, or more semi-cells). In certain embodiments, some semi-cells can be electrically interconnected in series and some semi-cells can be electrically interconnected in parallel.
[0098] In general, the methods of preparing each layer in photovoltaic cells described in FIGS. 1 and 2 can vary as desired. In some embodiments, a layer can be prepared by a liquid-based coating process. In certain embodiments, a layer can be prepared via a gas phase-based coating process, such as chemical or physical vapor deposition processes.
[0099] The term “liquid-based coating process” mentioned herein refers to a process that uses a liquid-based coating composition. Examples of the liquid-based coating composition include solutions, dispersions, or suspensions. The liquid-based coating process can be carried out by using at least one of the following processes: solution coating, ink jet printing, spin coating, dip coating, knife coating, bar coating, spray coating, roller coating, slot coating, gravure coating, flexographic printing, or screen printing. Examples of liquid-based coating processes have been described in, for example, commonly-owned co-pending U.S. Application Publication No. 2008-0006324.
[0100] In some embodiments, when a layer includes inorganic semiconductor nanoparticles, the liquid-based coating process can be carried out by (1) mixing the nanoparticles with a solvent (e.g., an aqueous solvent or an organic solvent such as an anhydrous alcohol) to form a dispersion, (2) coating the dispersion onto a substrate, and (3) drying the coated dispersion. In certain embodiments, a liquid-based coating process for preparing a layer containing inorganic metal oxide nanoparticles can be carried out by (1) dispersing a precursor (e.g., a titanium salt) in a suitable solvent (e.g., an anhydrous alcohol) to form a dispersion, (2) coating the dispersion on a substrate, (3) hydrolyzing the dispersion to form an inorganic semiconductor nanoparticles layer (e.g., a titanium oxide nanoparticles layer), and (4) drying the inorganic semiconductor material layer. In certain embodiments, the liquid-based coating process can be carried out by a sol-gel process (e.g., by forming metal oxide nanoparticles as a sol-gel in a dispersion before coating the dispersion on a substrate).
[0101] In general, the liquid-based coating process used to prepare a layer containing an organic semiconductor material can be the same as or different from that used to prepare a layer containing an inorganic semiconductor material. In some embodiments, when a layer includes an organic semiconductor material, the liquid-based coating process can be carried out by mixing the organic semiconductor material with a solvent (e.g., an organic solvent) to form a solution or a dispersion, coating the solution or dispersion on a substrate, and drying the coated solution or dispersion.
[0102] In some embodiments, the photovoltaic cells described in FIGS. 1 and 2 can be prepared in a continuous manufacturing process, such as a roll-to-roll process, thereby significantly reducing the manufacturing cost. Examples of roll-to-roll processes have been described in, for example, commonly-owned co-pending U.S. Application Publication No. 2005-0263179.
[0103] While certain embodiments have been disclosed, other embodiments are also possible.
[0104] In some embodiments, photovoltaic cell 100 includes a cathode as a bottom electrode and an anode as a top electrode. In some embodiments, photovoltaic cell 100 can also include an anode as a bottom electrode and a cathode as a top electrode.
[0105] In some embodiments, photovoltaic cell 100 can include the layers shown in FIG. 1 in a reverse order. In other words, photovoltaic cell 100 can include these layers from the bottom to the top in the following sequence: a substrate 170 , an electrode 160 , a hole carrier layer 150 , a photoactive layer 140 , an optional hole blocking layer 130 , an electrode 120 , and a substrate 110 .
[0106] In some embodiments, multiple photovoltaic cells can be electrically connected to form a photovoltaic system. As an example, FIG. 3 is a schematic of a photovoltaic system 300 having a module 310 containing photovoltaic cells 320 . Cells 320 are electrically connected in series, and system 300 is electrically connected to a load 330 . As another example, FIG. 4 is a schematic of a photovoltaic system 400 having a module 410 that contains photovoltaic cells 420 . Cells 420 are electrically connected in parallel, and system 400 is electrically connected to a load 430 . In some embodiments, some (e.g., all) of the photovoltaic cells in a photovoltaic system can have one or more common substrates. In certain embodiments, some photovoltaic cells in a photovoltaic system are electrically connected in series, and some of the photovoltaic cells in the photovoltaic system are electrically connected in parallel.
[0107] While organic photovoltaic cells have been described, other photovoltaic cells can also be integrated with one or more of the semiconducting polymers described herein. Examples of such photovoltaic cells include dye sensitized photovoltaic cells and inorganic photoactive cells with an photoactive material formed of amorphous silicon, cadmium selenide, cadmium telluride, copper indium selenide, and copper indium gallium selenide. In some embodiments, a hybrid photovoltaic cell can be integrated with one or more of the semiconducting polymers described herein.
[0108] While photovoltaic cells have been described above, in some embodiments, the polymers described herein can be used in other devices and systems. For example, the polymers can be used in suitable organic semiconductive devices, such as field effect transistors, photodetectors (e.g., IR detectors), photovoltaic detectors, imaging devices (e.g., RGB imaging devices for cameras or medical imaging systems), light emitting diodes (LEDs) (e.g., organic LEDs (OLEDs) or IR or near IR LEDs), lasing devices, conversion layers (e.g., layers that convert visible emission into IR emission), amplifiers and emitters for telecommunication (e.g., dopants for fibers), storage elements (e.g., holographic storage elements), and electrochromic devices (e.g., electrochromic displays).
[0109] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference herein in their entirety.
[0110] The following examples are illustrative and not intended to be limiting.
EXAMPLE 1
Fabrication of Photovoltaic Cells Containing Two Semiconducting Polymers
[0111] Poly(3,4-ethylenedioxy thiophene)/poly(styrene sulfonicacid) (PEDOT:PSS) (Baytron PH) was purchased from H.C. Starck. P3HT (4002E) was purchased from Rieke. Polymer 1 was prepared by Konarka Technologies, Inc. following the procedures described in U.S. Application Publication No. 2007-0014939. C60-PCBM was purchased from SolenneBV.
[0112] Photovoltaic devices were fabricated as follows: A 100 nm hole carrier layer containing PEDOT:PSS was first coated on indium tin oxide (ITO) covered glass substrates (Merck) by doctor blading. P3HT, polymer 1 (having a number-average molecular weight of 35,000 g/mol and a weight-average molecular weight of 47,000 g/mol), and C60-PCBM were dissolved in o-dicholorbenzene in different weight ratios. The solution thus formed was deposited via doctor-blading on top of the PEDOT:PSS layer to form a photoactive layer. A LiF/Al (0.6 nm/80 nm) metal electrode was then thermally deposited onto the photoactive layer to form a photovoltaic cell.
[0113] Following the procedures above, three photovoltaic cells containing P3HT, polymer 1 and C60-PCBM in the following weight ratios were prepared: (1) 95:5:100, (2) 9:1:10, and (3) 8:2:10, respectively. A fourth photovoltaic cell (i.e., cell (4)) without polymer 1 was also prepared and used as a control.
[0114] The current-voltage characteristics of photovoltaic cells (1)-(4) were measured using a Keithley 2400 SMU while the solar cells were illuminated under AM1.5G irradiation on an Oriel Xenon solar simulator (100 mW cm −2 ). The results showed that cells (1)-(4) exhibited power conversion efficiencies of 2.48%, 2.38%, 2.86%, and 2.6%, respectively. The results indicated that a photovoltaic cell containing 20% polymer 1 in the electron donor material in the photoactive layer (i.e., cell (3)) exhibited a higher power conversion efficiency than that of a photovoltaic cell containing P3HT alone as the electron donor material (i.e., cell (4)).
EXAMPLE 2
Fabrication of Photovoltaic Cells Having Different Photoactive Layer Thickness
[0115] P3HT and PEDOT:PSS were purchased from the same commercial sources as those described in Example 1. Polymers 2 and 3 were prepared by Konarka Technologies, Inc. following the procedures described in U.S. Application Publications No. 2008-0087324 and 2010-0032018, respectively. C70-PCBM and Bis-C60-PCBM were purchased from SolenneBV.
[0116] For device preparation, all photoactive materials were mixed in the desired weight ratios and dissolved in o-dichlorobenzene. Devices were prepared in the following way:
[0117] Photovoltaic cells were prepared as follows: An ITO coated glass substrate was cleaned by sonicating in isopropanol. A thin electron injection layer containing polyethyleneimine and glycerol propoxylate triglycidyl ether was then formed by blade coating a solution on top of the ITO. An o-dichlorobenzene solution containing one or two semiconductor polymers as an electron donor material and a substituted fullerene as an electron acceptor material was blade coated onto the hole blocking layer and then dried to form a photoactive layer. A solution containing PEDOT:PSS was blade coated on top of the photoactive layer to form a hole carrier layer. A silver electrode was then thermally deposited onto the hole carrier layer to form a photovoltaic cell.
[0118] Four photovoltaic cells were prepared following the procedures above. Photovoltaic cell (1) included a photoactive layer containing polymer 2 and C70-PCBM in a weight ratio of 1:2 and having a thickness of less than 100 nm. Photovoltaic cell (2) included a photoactive layer containing polymer 2 and C70-PCBM in a weight ratio of 1:2 and having a thickness of between 100 nm and 200 nm. Photovoltaic cell (3) included a photoactive layer containing P3HT, polymer 2, and C70-PCBM in a weight ratio of 5.6:1:6.7 and having a thickness of between 150 nm and 200 nm. Photovoltaic cell (4) included a photoactive layer containing P3HT, polymer 3, and Bis-C60-PCBM in a weight ratio of 5.6:1:6.7 and having a thickness of about 200 nm.
[0119] The current-voltage characteristics of photovoltaic cells were measured using a Keithley 2400 SMU while the solar cells were exposed to simulated sun-light delivered by an Steuernagel Solar Simulator (70-80 mW cm −2 ). The results show that photovoltaic cells (1)-(4) exhibited power conversion efficiencies of about 4.5%, 3.6%, 4.2%, and 4.6%, respectively. Without wishing to be bound by theory, it is believed that cell (2) exhibited a lower power conversion efficiency than that of cell (1) due to its larger thickness of the photoactive layer, which would decrease its capability to transfer charge carriers (i.e., electrons or holes) to the neighbouring hole block or carrier layer. Further, without wishing to be bound by theory, it is believed that cell (3) exhibited a higher power conversion efficiency than that of cell (2) due to the presence of a combination of a low bandgap semiconducting polymer (i.e., polymer 2) and a relatively high bandgap semiconducting polymer (i.e., P3HT), which could improve the charge carrier capability of the photoactive layer and even though cell (3) had a photoactive layer with a thickness similar to that of cell (2). In addition, the results showed that replacing polymer 2 and C70-PCBM used in cell (3) with polymer 3 and Bis-C60-PCBM used in cell (4), respectively, could result in a photovoltaic cell with a higher efficiency.
EXAMPLE 3
Lifetime of Photovoltaic Cells Containing Different Photoactive Layers
[0120] Two photovoltaic cells were prepared following the procedures described in Example 2 above. Photovoltaic cell (1) included a photoactive layer containing P3HT, polymer 3, and Bis-C60-PCBM in a weight ratio of 5.6:1:6.7. Photovoltaic cell (2) included a photoactive layer containing P3HT and Bis-C60-PCBM in a weight ratio of 1:1.
[0121] The power conversion efficiencies of cells (1) and (2) were measured following the procedures described in Example 2 after these two cells were heated at 65° C. under 85% humidity after a certain period of time (i.e., an accelerated experiment for measuring the lifetime of a photovoltaic cell). The results showed that cell (2) lost 20% of its efficiency after about 190 hours of heat treatment, while cell (1) lost 20% of its efficiency after about 450 hours of heat treatment. The results suggested that using both a low bandgap polymer (e.g., polymer 3) and a relatively high bandgap polymer (e.g., P3HT) in the photoactive layer could significantly improve the lifetime of a photovoltaic cell.
[0122] Other embodiments are within the claims.
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Photovoltaic cells having multiple electron donors and/or multiple acceptors, as well as related components, modules, systems, and methods, are disclosed.
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FIELD OF THE INVENTION
This invention relates to air ventilation in buildings, and more particularly, to the evacuation of stale air in burial monuments such as mausoleums.
BACKGROUND OF THE INVENTION
Burial monuments are buildings provided with a vault, which is a chamber having a plurality of compartments or crypts each for receiving the body of a dead person in a coffin. These buildings also have adjacent rooms, for access by the public wishing to pay respect to the deceased persons in the crypts.
With time, the body of the dead person decomposes within the coffin, and fluids escape outwardly therefrom into the crypt. Such organic degradation produces stale air which must be evacuated from the crypt. Known systems include a series of vertical pipes communicating with the crypts at their bottom end and endwisely opening at their top end to outside ambient air about an outdoor riser or air gate. The stale air escapes freely, without any attempt to control pollution to nearby populations. These odors in ambient air is one reason why burial or interment monuments are buildings which are relatively isolated.
With ecology including air pollution being a major concern worldwide, such cannot remain the case forever.
OBJECT OF THE INVENTION
The gist of the invention is to apply known air filtering systems to existing air circulation systems to burial monument vaults, in a very cost-effective fashion.
SUMMARY OF THE INVENTION
In accordance with the object of the invention, there is provided an air circulation and filtration system for the vault of a burial monument, comprising in combination: (a) a vault, including a plurality of closed crypts disposed laterally and in superimposed fashion relative to each other; (b) coffins, mounted in at least some of said crypts, said coffins having decomposing organic matter therein, each coffin having a volume smaller than the inner volume of the corresponding said crypt, wherein air is free to circulate around said coffin within said crypt; (c) first pipe members, opening at an air intake end to outside ambient air and at its other end into said crypts, and partly extending between said crypts, and destined to feed ambient air to said crypts; (d) second pipe members, opening at one end into said crypt and defining an air outlet end at its downstream end section opening to outside ambient air, and partly extending between said crypts, and destined to evacuate stale air from within said crypt to outside ambient air; (e) air filtration means, mounted to said downstream end section of said second pipe members, for absorbing stale odors evacuated from said crypt before escape to ambient air; and (f) air circulation means, for inducing a continuous air flow between said air intake end and said air outlet end, wherein the whole of said stale air engaging said second pipe members will be processed by said air filtration means before escape in ambient outside air.
Preferably, said air filtration means is of a type based on the activated charcoal principle.
Advantageously, each said crypt defines a floor, side walls and a top wall; said crypt defining air intake ports in operative, fluid communication with said first pipe members other end, and air outlet ports in operative, fluid communication with said second pipe members one end; there being at least one of each of these air intake and air outlet ports for each crypt and each air port being placed on the side walls of said crypt at a substantial distance from the floor of said crypt.
Profitably, liquid discharge means is mounted to said first pipe members, for evacuating organic-rich liquids seeping from the decomposing organic matter inside the coffins to an ecologically suitable collecting basin. These liquid discharge means could consist in pipe extensions, downwardly depending from said first pipe members in fluid communication therewith and extending into a gravel bed retained by a water-tight concrete base, and liquid outlet ports, made in the side walls of said crypts adjacent the crypt floor and in operative, fluid communication with said pipe extensions.
There is envisioned to add fluid-tight plugs, releasably and selectively sealing said liquid outlet ports and said air intake and outlet ports in the crypts not occupied by a coffin, wherein air circulation is prevented through these empty crypts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a burial monument;
FIG. 2 is a horizontal sectional view about line 2--2 of FIG. 1;
FIG. 3 is a vertical sectional view along broken line 3--3 of FIG. 2;
FIG. 4 is an enlarged, vertical sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is an enlarged, partly broken view of the area circumscribed within area 5 of FIG. 4;
FIG. 6 is a sectional view along line 6--6 of FIG. 4;
FIG. 7 is a sectional view along line 7--7 of FIG. 6; and
FIG. 8 is a slightly enlarged, partly broken view of the area circumscribed by circle 8 in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
The burial monument 10 shown in FIGS. 1-3 conventionally consists of a large building 12 having a vault section 12, for housing coffins C, and an open room section 14, for the public wishing to enter the burial monument to pay respect to the deceased persons in the vault.
The vault section 12 is detailed in FIG. 4. The vault section 12 conventionally consists of a plurality of chambers or crypts, 20, recessed in the inner side walls 22 of the burial monument 10, for receiving the coffins containing the bodies of the dead. The crypts 20 are staggered laterally and in superimposed fashion, and are thus arranged in horizontal rows, spaced by concrete, horizontal walls 24, and in vertical columns, spaced by concrete, vertical walls 26. The bottom row of crypts 20 are supported by a thick, concrete base 28, overlying a gravel bed 30. The building 10 has a bottom, ground-engaging, waterproof foundation 32, supporting and retaining the gravel bed 30. A network of fluid pipes 34 extend thicknesswisely through the vertical walls 26, from the gravel bed 30 (FIG. 7) upwardly beyond the uppermost horizontal row of crypts 20, and through the vault concrete ceiling tiles 36 to open into an outlet member 38.
Outlet member 38 includes a sheath 40 (FIG. 7) partly embedded into the ceiling tile 38 and projecting upwardly outwardly therefrom, a mosquito net 42 covering fully the mouth 40a of duct 40, and a domed cover 44 supported spacedly above mouth 40a by conical body 46 which abuts onto the water-tight, wear-resistant covering 36a of the ceiling tiles 36. Sheath 40 is preferably made from lead, and cover 44, from copper.
Each pipe 34 has transverse pipe sections or extensions 48, at least a few of them engaging one or more side walls of each crypt 20, including at least one 48a about the flooring level of the crypt 20 (see FIGS. 6-7). Outlet ports 48a are conventional liquid outlets, for escape of the decomposing body organic-rich liquid substances seeping out from the coffin located within the crypt, through these ports 48a, and downwardly through the lower leg of the corresponding pipes 34 to be discharged into gravel bed 30, as suggested by the full arrow at the bottom of FIG. 7, through bottom open mouth 34a of each pipe 34. Accordingly, the remaining air escape ports 48 should be spaced from the flooring of crypt 20, so as to be engaged by air exclusively of liquids from the coffin, which liquids will by gravity remain on the crypt flooring.
A removable air-tight plug 50 seals each pipe sections 48 until a given crypt 20 houses a coffin C, wherein the few corresponding plugs 50 are pulled out to allow stale air to escape from the crypt, through air outlet 48 and pipes 34 and 40, and across the mosquito net 42 to be freely evacuated to the outside.
In accordance with the teachings of the invention, there is provided to the vault section an air filtering system, best shown in FIGS. 6 and 8. More specifically, to the exterior ceiling tiles 36 of the burial monument 10 is mounted a raised casing 52 anchored in position. Casing 52 supports a power operated, centrifugal ventilator 54, being connected at its intake 52a to some of the vertical pipes 34, at 34', via a few horizontal tubes 56, which extend horizontally through and are embedded thicknesswisely in wall 36 and which transversely merge with the last-mentioned pipes 34', at selected intervals, and a large outlet duct 58, extending vertically through wall 36 and interconnecting the tubes 56 and the ventilator air intake 52a. These latter vertical pipes 34' differ from the pipes 34 in that they do not open directly to the outside as in FIG. 7: sheath 40 and elements 42, 44 are thus removed, and the uppermost channel section of the pipe within wall 36, closed and sealed. Pipes 34' thus transversely merge with diametrally larger tubes 56.
Each crypt 20 must have at least one outlet pipe section 48' opening therein and fluidingly communicating with the ventilator 54 through the corresponding pipe 34', and at least one inlet pipe section 48 opening therein (two being shown in FIG. 6) and fluidingly communicating with a corresponding outlet member 38 through its pipe 34.
It can now be understood from FIG. 6 that in the present invention, element 38 becomes an air inlet member instead of a stale air outlet. Indeed, by removing all the plugs 50 from a given crypt 20, the corresponding pipes 34 and 34' communicating with this crypt will thus be in indirect fluid communication. By activating ventilator 54, a negative air pressure gradient will be applied about mouth 40a of air gate riser or air inlet means 38, wherein, as suggested by the multiple arrows in FIG. 6, continuous multiple air flows will be generated from ambient outside air, through mosquito net 42, downwardly into sheath 40 and pipe 34, through the crypt air intake port(s) 48, through crypt itself 20 and around the side and top walls of coffin C, to escape through the crypt air outlet port(s) 48', upwardly along pipes 34', 56 and 58 to the ventilator 54 for air ejection through an enlarged, extended nozzle 60.
Accordingly with the heart of the invention, nozzle 60 is provided with a filter means 62, about a diametrally large section thereof. Filter means 62 is preferably a filter panel of the activated charcoal bed type. The whole of the stale air from the decomposing human body within the crypt 20, must be directed by the nozzle 60 to pass through filter 62, to thus be processed, and the odors, adsorbed by the activated charcoal, so that the air finally being evacuated at the nozzle outlet 60a will be odorless.
Preferably, a metallic grate 64 is provided about nozzle mouth 60a, to prevent ambient air contaminant from clogging filter 62 while not hampering free air flow therethrough. Elongated nozzle 60 may be supported by bracket 66 over brick support casing 52.
Coffin C is smaller than the inner volume of each crypt 20, so that air may freely circulate therearound. As suggested in FIGS. 6 and 7, the same pipe 34 feeding air into a crypt 20 through air intake ports 48 (upper pipe section) will also be used for receiving organic-rich liquid substances from the crypt passing through floor level liquid outlet port 48a, and to discharge same in the gravel bed 30 (lower pipe section). Clearly, fresh air inflow into the crypt 20 through air intake ports 48 can be effected concurrently with outflow of organic-rich liquid substance through liquid outlet ports 48. On the other hand, the bottom end 35 of the modified vertical pipes 34' should extend downwardly short of the concrete base 28, and will be sealingly closed by a sealing cap 37, as illustrated in FIGS. 4 and 5.
It is to be understood that although the inventor has found particularly cost-efficient to use the existing vertical pipes of the standard air circulation system of burial monument vaults, including some of the existing conventional vault vertical pipes 34 as the air feeders for the main tubes 56, these pipes 34 being slightly structurally modified as disclosed above for the stated purpose, it is to be considered well within the scope of the present invention that the modified pipes 34' be replaced by additional vertical pipes, not shown, including their transverse pipe sections, so as to be similar to elements 34', 48', again in view of evacuation of stale air through filter means 62.
All the piping, ducts, tubes, and so on coming in contact with the organic-rich fluids from the crypt should be made from a fluid-resistant, rigid material, preferably a plastic material such as polyvinyl chloride (PVC).
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A system for promoting air circulation through the crypts of a burial monument vault in which coffins are exposed, and for treating the air evacuated therefrom by an activated charcoal-based filter panel wherein the odors from the decomposing body in the coffins will be absorbed before escape to ambient air. The system makes extensive use of the conventional existing air outlet pipes and water drainage pipes.
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[0001] This invention relates to a method of gas production from a field containing natural gas processing particularly for transport of stranded gas to conserve resources and reduce emissions.
BACKGROUND OF THE INVENTION
[0002] The traditional way to deliver natural gas to market has always been to ship it by pipeline. However the main factors that determine the viability of such a scheme are volumes of gas to be delivered and the length and cost of the pipeline to bring the gas to market. If the volume of gas is small, the revenues generated by the sale of the gas cannot justify the cost of constructing a lengthy pipeline to deliver the product to buyers. Natural gas which cannot be produced at a profit because it is remote from markets is referred to as stranded gas.
[0003] There are numerous examples of non-economic stranded gas but one is very common source is solution gas from oil production. An oil battery's principal activity is to produce oil and the solution gas which is dissolved in the oil is often considered to be a by-product which cannot economically be brought to market. This off gas is therefore often flared. Solution gas is usually rich in liquefiable components such as propane, butane and pentane which, if incinerated along with the lighter gas, represent a significant economic loss as well as waste of a valuable resource.
[0004] Another source of stranded gas is the numerous small gas wells which are located in remote areas far from existing pipelines or markets. These small wells often produce from tight formations which have low pressure at the sandface and even lower pressure at the wellhead. Reserves in such reservoirs maybe plentiful but even with fracking, productive life may be short. Such wells are usually capped and the field is not developed because of the unfavorable economics using traditional technology.
[0005] Whether the source of the natural gas is solution gas from an oil battery or a small stranded gas well, it is likely that the gas should be compressed if it is to be delivered to a customer. In addition to the pipeline itself, the additional cost of compression equipment adds to the burden of bringing stranded gas into production.
[0006] Conventional technology has an envelope within which economic factors such as production rates, revenues, capital expenses and operating costs should create a clear profit. If the balance falls below the lower limit where profit is possible, the plans to exploit the gas are abandoned. The valuable resource is both incinerated and wasted or the wells are capped and the field abandoned. The new technology proposed in this invention can make previously unprofitable projects profitable by bringing natural gas from stranded oil and gas fields to market economically, thus exploiting and conserving a valuable resource and avoiding the wasteful practice of flaring.
SUMMARY OF THE INVENTION
[0007] It is one object of the present invention to provide a method of gas production from a field containing natural gas which provide processing and transport of stranded gas to conserve resources and reduce emissions.
[0008] According to the invention there is provided a method of gas production from a field containing natural gas comprising:
extracting gas supply from a plurality of individual gas wells in the field; initially at the individual gas wells providing a recovery unit having a production capacity arranged to approximate that of the well for carrying out liquid recovery from the gas supply and compression of the natural gas; transporting the compressed natural gas to a point of delivery; when a production rate of the well declines to a level which no longer approximates to that of the recovery unit:
removing the recovery unit for redeployment; substituting the recovery unit by a dehydration system and gas compressors having a lower production capacity; and transporting the compressed natural gas to said point of delivery.
[0016] The compressed natural gas can transported at least in part using portable pressure vessels or using short pipelines to a central processing plant.
[0017] In one preferred arrangement, the initial recovery unit is redeployed to a different well with higher production rate. In this arrangement gas from each low production gas well is transported directly from the well by the portable pressure vessels to the point of delivery and there is provided a liquid recovery unit and compressor at each well.
[0018] This allows the liquid recovery unit to process the raw gas into potentially commercial products right at the well using simple, small scale processing equipment.
[0019] Preferably the liquid recovery unit and compressor is arranged to be packaged into compact skid mounted units that are easily transportable by truck.
[0020] In another arrangement, gas from a plurality of the low production wells is transported to a central plant and gas from each the central plant is transported by the portable pressure vessels to the point of delivery. In this case the gas is transported from the plurality of wells to the central plant by pipe and the gas from the central plant is transported by the portable pressure vessels.
[0021] In this case the initial recovery unit can be redeployed to the central plant for separating liquids therefrom where the initial recovery unit can operate at the central plant in parallel with recovery units at other wells.
[0022] The maximum number of gas wells feeding said central plant is typically about 10.
[0023] Flaring can be reduced or eliminated at each location by liquid recovery at the recovery unit.
[0024] Preferably the point of delivery comprises a main gas pipeline. However other arrangements can be used including direct supply to customers or storage facilities depending on the circumstances.
[0025] Preferably the distance between each of the plurality of wells and the main gas pipeline is below 100 miles.
[0026] Preferably the portable pressure vessels are formed of fiber reinforced polymer. However other materials can be used including steel tanks. The polymer can be thermosetting or thermoplastic resins and the fibers can be metal fibers, ceramic fibers, glass fibers, carbon fibers, aramid fibers, polyolefin fibers, polyacrylate fibers, polyamide fibers, polyesters fibers, and combinations thereof.
[0027] Preferably the liquefied petroleum gas and stabilized condensates separated by the recovery unit are recombined with liquids from an oil battery or an upstream oil production separator.
[0028] Preferably the flow rate of the gas to be supplied to the portable pressure vessels is arranged to be continuous and at a relatively steady rate.
[0029] Preferably the gas to be supplied to the portable pressure vessels is arranged to be dehydrated to a few PPM of water such as by using a desiccant process using silica-gel.
[0030] Preferably the transportation of gas by the portable pressure vessels is continuous and related to the supply rate so as to avoid requirement on site for stationary high pressure gas storage.
[0031] Preferably the transportation of gas by the portable pressure vessels is arranged to transport the raw unprocessed gas at minimum cost to another site for processing.
[0032] Preferably the gas is processed prior to transportation in said portable pressure vessels to remove small quantities of H 2 S.
[0033] Preferably the gas is processed prior to transportation in said portable pressure vessels to cool the gas
[0034] Preferably the gas is fed into said portable pressure vessels and distributed by an internal sparger running the full length of the vessel where the sparger preferably lays along the bottom of the vessel.
[0035] In general the new technology provided by the arrangement described in more detail hereinafter relates to the production of remotely located small flows of natural gas is to compress the gas and transport it to market by wheeled vehicles such as trucks. Each truck is hitched to either single, double or triple trailers, each of which for example, if equipped with three 42″ diameter tanks forty feet long, is capable of transporting approximately 250 Mscf of compressed natural gas (CNG) in a single load. A single trailer can ship 250 Mscf, a double trailer 500 Mscf and a triple trailer 750 Mscf approximately.
[0036] If composite construction of the tanks is used, the weight of the empty tanks is much lighter than all-steel tanks. This permits using larger tanks to carry more gas while staying within the weight limits imposed by highway regulations. This advanced design for the tanks makes transport of gas by truck more efficient and practical by allowing more gas to be carried in each load.
[0037] Whether the gas source is solution gas from an oil battery or from multiple small gas wells, the flow rate of the gas should be continuous and at a relatively steady rate. This means that as one truck/trailer unit is filled up the next truck and empty trailer is standing by, already connected up and ready to begin loading its cargo of CNG. The rate of production ultimately depends on how much gas the buyer wants to accept, but the flow rate at the source should preferably be continuous and be reasonably steady without stopping and starting.
[0038] The loading time of the truck/trailer combination can be the net gas capacity of the trailer when loaded divided by the rate at which gas is produced. Loading time depends on whether single, double, or triple trailer units are used. Loading time is also influenced by the final pressure in the tanks when full. Reducing the final pressure can shorten the loading time and it may be done to keep loading time and travel time in better balance.
[0039] Another important factor to be considered when planning the loading and unloading sequence is the travel time on the road for the truck/trailer combinations plus the time to connect and disconnect from the loading and unloading stations. This can determine how many trucks are required to complete the circuit. It is reasonable to assume that the travel time between the loading and unloading terminals is the same, whether the truck is travelling empty or full. It is also assumed that the sum of connect and disconnect times is the same for both terminals. It is preferred that the loading time be fixed by production rate and trailer capacity because of the need for continuous flow during loading. However, at the unloading terminal it may not necessarily be mandatory to have continuous flow during unloading. If unloading is not continuous, then there is a waiting time at the unloading station. If unloading is continuous, wait time is zero. Consider the following two examples:
[0000]
Unloading
Time
=
Loading
Time
:
Connect
time
+
loading
time
+
disconnect
time
=
Distance
one
way
(
miles
)
(
number
of
trucks
)
(
speed
MPH
)
Rearrange
:
Speed
MPH
=
Distance
one
way
miles
(
number
of
trucks
)
(
Connect
time
+
loading
time
+
disconnect
time
)
[0040] Estimate number of trucks enroute one way and calculate speed. If speed is reasonable the assumed number of trucks is correct enroute one way. The number of trucks should be an integer and the minimum number is one. If calculated speed is too slow, there will be waiting time at the terminals if the trucks drive faster.
[0041] If unloading time is greater than loading time then trucks should drive faster to make up for lost time:
[0000]
Unloading
Time
≥
Loading
Time
:
Correction
factor
for
above
speed
Correction
factor
=
Connect
time
+
unloading
time
+
disconnect
time
Connect
time
+
loading
time
+
disconnect
time
[0042] If the corrected speed is reasonable, then the assumed number of trucks is correct enroute one way.
[0043] If the speed is not reasonable assume a new value for the number of trucks enroute one way and repeat the calculation.
[0044] The total number of truck/trailer combinations is double the number of trucks estimated above plus one more at each of the two terminals. If desired, spare trailers can be standing by at the loading station and unloading station in case of breakdowns.
[0045] To keep the trucks on the road and to reduce driver waiting time, when a truck/trailer arrives at either the loading or unloading rack the first thing the driver should do is park his trailer at the rack and connecting it to the rack facilities. Then disconnect the truck from the trailer and move it to the adjacent trailer which is nearing the end of its cycle. Connect the truck to the trailer and wait until flow is switched to the recently arrived trailer. Then disconnect the trailer from the rack in preparation for departure. After completing the transfer documents, the driver should drive his truck/trailer to the opposite station.
[0046] For economy and to minimize maintenance the trucks can be powered by natural gas drawn from the tanks on the trailer.
[0047] For the complete transport system two terminals are required; a site for loading the trailers and a site for unloading. For a basic system at the loading site, an inlet separator is required to remove free liquids from the gas. This may only be free water but it may also include hydrocarbon liquids. The gas then proceeds from the separator to a compressor with discharge cooler and separator on every stage to remove possible condensed liquids.
[0048] Before the CNG can be loaded into the trailers it should first be dehydrated to a few PPM of water. A low water dew point is required because cryogenic temperatures are encountered during processing and when the gas is chilled during unloading due to auto-refrigeration effect.
[0049] The dehydrator is probably located on an inter-stage of the compressor, depending on the pressure of the inlet gas. The most likely dehydration process to use is the desiccant process using silicagel or molecular sieve because of the low dew point required.
[0050] As a minimum the equipment required for a basic system at the loading site is gravitational separators, a dehydrator and a gas compressor. Provision should also be made for free liquids, if any, to be removed from the site, either by trucking or in the case of free water possibly by local disposal. There is normally no requirement on site for stationary high pressure gas storage because the plan normally is to load gas directly into the trailers coupled to the loading rack as soon as the gas leaves the compressor. The CNG entering the tanks in a basic system is dehydrated unprocessed raw gas which is to be processed after it is off loaded at the unloading site. In a more complex system, liquids are recovered from the gas before it is loaded into the trailers.
[0051] It could be possible to incorporate stationary tanks at the loading and unloading sites but in most cases this unnecessarily complicates the process and adds to the cost.
[0052] The basic system described above provides minimal processing at the loading terminal with the goal being to transport the raw unprocessed gas at minimum cost to another site for processing. However an alternate method could also be considered.
[0053] Transport of CNG by truck or even by train necessarily means that production rates are low and that processing equipment is be miniature by industrial standards. However, in spite of the small size of the equipment, depending on local marketing conditions, it may be economical as an alternative to the basic system described above to process the raw gas into potentially commercial products right at the loading site using simple, small scale processing equipment. For example a moderately rich gas stream could hypothetically be processed into 3 MMscfd of pipeline quality gas to be delivered by truck to users, plus 100 BPD of propane/butane mix produced to commercial specifications and 30 BPD of a non volatile stabilized hydrocarbon condensate consisting mainly of pentane and heavier components. A proprietary cryogenic process based on the Clausius Clapeyron expansion principle can typically recover 80% or more of propane from the feed gas and 95% or more of pentane and heavier. A variation of the same process can also recover ethane. Desiccant dehydration is necessary if a deep cut process is used.
[0054] The process to recover commercial products typically requires three pipe sized fractionation columns, a miniature propane refrigeration unit and a small reciprocating process compressor unit. Storage tanks or trailers on site are also required on site for the liquid products which, it is anticipated, is trucked to market. This equipment is all required in addition to the separators, dehydrator and compressor required for the basic system.
[0055] Whether the basic system or the more complex process to recover liquid products is chosen, there are no emissions from the process except possibly engine exhaust or heater stack emissions and no waste product streams except water which is disposed of in an environmentally acceptable manner.
[0056] The decision whether to choose a basic system or the more complex liquid recovery process at the loading site is a decision based on markets and on local economic conditions.
[0057] The most fortunate situation is when the gas entering the process does not contain objectionable components such as H 2 S, organic sulphur or excessive amounts of CO 2 . If commercial products are being produced, the presence of these contaminants could exceed commercial specifications. Also, in some jurisdictions the level of sulphur compounds in CNG that can be transported by truck is severely limited. If commercial liquids are produced on site using a cryogenic process it may be necessary to reduce CO 2 concentration to prevent freezing of CO 2 in low temperature equipment. Also, cryogenic temperatures can be encountered during de-pressuring of tanks at the unloading station which may determine the need to reduce CO 2 . Because the volume of gas to be processed is relatively small, the simplest and most practical way to remove small quantities of H 2 S is to use a non regenerable chemical such as iron oxide which removes H 2 S down to 4 PPMV or less and partially removes mercaptans. If quantities of sulphur exceed the practical limit for non regenerable chemicals then processes such as SulFerox or amine which use circulating regenerable liquids could be considered. The non regenerable process and the SulFerox process both produce a solid waste that should be trucked away. The amine process removes both H 2 S and CO 2 from the feed gas and releases them in gaseous form from the regenerator. If quantities of these contaminants are small they may be incinerated. If quantities of H 2 S are significant, further processing is required. A major goal in the development of this invention is to package the processing equipment into compact skid mounted units that are easily transportable by truck. The equipment is relatively small so this concept is quite practical. The skids are designed to rest on gravel pads to eliminate the need for foundations. This also makes it easier to return the site to its natural state when gas production is abandoned. When production ceases, the skid mounted packaged equipment is loaded up and transported to the next location.
[0058] In any CNG transport system an important thing to consider is the thermodynamic heating effects that occur to the gas which is already in the tanks as it is pressured up during loading. Cooling of the gas in the tanks which occurs during unloading due to thermodynamic effects in the gas when the pressure is reduced should also be considered.
[0059] During loading the gas as it enters the tank is relatively cool, but after it enters the tank the pressure of the gas already in the tank increases and the resulting heat of compression causes the temperature to rise. When the tank is empty its pressure may be, for example, 150 psig, and when it is full the pressure could be approximately 3400 psig. Final pressure depends mainly on the structural design pressure of the tanks. The first gas that enters the tank at low pressure goes through the full range of pressure increase and is therefore the hottest gas. If there is no internal flow distributor for the inlet gas, the hottest gas in the tank is forced to the far end of the tank and since longitudinal thermal mixing is limited, the far end of the tank could become very warm. Therefore the inlet gas should be distributed by an internal sparger running the full length of the tank. This assures that incoming gas is distributed uniformly and that the heat of compression inside the tank is averaged over the entire length of the tank. The sparger should lay along the bottom of the tank so that condensed liquids, if any, are drawn out of the vessel when the tank is unloaded. It is not unusual for liquids to condense during de-pressuring due to the low temperatures that may be encountered, but if a sparger is laid at the bottom of the tank the liquid does not pool since it is drawn out of the tank as soon as it forms.
[0060] The compression of the gas inside the tanks is not entirely adiabatic because some heat is transferred by free convection to the cool walls of the tank. An all steel tank is capable of absorbing a lot of heat because of its great mass of metal, but a composite tank with its non-metallic components picks up much less heat because of its reduced mass and does therefore not have as great a cooling effect on the gas. Excessively hot gas in the tank is objectionable because it reduces the weight of gas that can be carried in the tanks as cargo. For example, at 3400 psig, a 30° F. reduction in gas temperature increases the CNG payload by approximately 8%. Also, for composite tanks, excessively high temperatures may have a detrimental effect on the non metallic components of the tank.
[0061] There are several options for dealing with heat of compression inside the tanks. The cool walls of the tank will absorb a significant amount of heat from the gas and should be included in the heat balance. However there is always a degree of uncertainty in calculating the final temperatures of the gas in the tank because the initial temperature of the empty vessel itself is usually not known. During unloading, the vessel is cooled by de-pressuring of gas inside the tanks and the tanks may remain cool when the empty vessels are transported back to the loading station. If the initial temperature of the tank is cold, the vessel is capable of absorbing more heat from the gas before the system approaches temperature equilibrium when the tanks are full. This results in a lower final gas temperature when the filling cycle ends.
[0062] Gas temperature in the tanks during filling is something to be concerned about and there are several approaches to the problem. The first option is to do nothing. This is the usual approach when all-metal tanks are used. The massive weight of the tanks themselves acts to absorb a lot of heat and reduce the gas temperature to what is considered to be an acceptable level. Gas exiting from the final stage of compression is cooled, usually by ambient air, then flows in this case directly to the tanks. If the coolant is ambient air the ambient temperature can be extremely variable, but for design purposes a CNG discharge temperature into the tanks not exceeding 120° F. is a reasonable typical temperature. For a composite tank the final average temperature in this case is in the neighborhood of 160° F., assuming that the initial temperature of the tank was near ambient. The final gas temperature for an all metal tank is a few degrees cooler.
[0063] Doing nothing about the uncontrolled rise in temperature inside the tanks is obviously the simplest and least expensive way to produce CNG, but there are direct benefits to be considered in cooling the gas. For example, if the gas could be inexpensively cooled by 30° F., the quantity of gas in the tanks would increase by approximately 8%. This means that for every twelve loads carried it is as if an extra load is delivered at minimal extra cost, so it is a goal worth pursuing.
[0064] One way to reduce the final temperature of the gas is to provide supplemental cooling for the CNG after it leaves the discharge cooler on the final stage of compression but before it enters the tanks. There are several ways to cool the gas before it enters the tanks.
[0065] Joule Thomson cooling can be used to directly cool the gas by taking advantage of the potential pressure drop available between the final stage of compressor discharge and the initial low pressure in the tanks. By holding a back pressure on the gas exiting the final compressor discharge cooler, as the gas expands through the back pressure valve, significant Joule Thomson cooling will occur, especially when the tanks are empty at low pressure. For example, with the goal of attaining a final average gas temperature reduction of 30° F., it could be possible to attain this final temperature by holding a back pressure of 1200 psig on the compressor discharge cooler. When tank pressure was below 1200 psig the choking effect of the back pressure valve would produce cooling, but if the tank is above 1200 psig the valve is wide open and there is no cooling effect. The cooling at the beginning of the fill cycle is sufficient to reduce the final average gas temperature to the desired level. The set point pressure of the back pressure valve could be adjusted to provide the desired degree of cooling. The only capital expense for this option is the cost of the back pressure valve downstream of the final cooler stage and the control loop. There is no change to the compressor itself but its operating profile is altered to provide additional horsepower hours during the time when the back pressure valve was choking the gas flow.
[0066] Another way to use the Joule Thomson effect to cool the gas entering the tanks is to use a back pressure valve on the interstage pressure of the compressor. If, for example, the initial pressure in the tank is 150 psig and the final pressure is 3400 psig, multiple stages of compression are required to reach the final pressure. If four stages were used the pressure ratio per stage is approximately the fourth root of the overall pressure ratio. The third stage discharge would then be a maximum of about 1600 psig. A back pressure valve could hold a back pressure of anything up to 1600 psig on the discharge cooler from the third stage. If tank pressure was below the set point of the back pressure controller, Joule Thomson cooling is created in the interstage gas. However, since cooling is required for the final stage gas going to the tanks, a heat exchanger is necessary to transfer the cool energy from the interstage to the gas flowing to the tanks. Joule Thomson cooling is available only when tank pressure was below the back pressure set point. Above this tank pressure the valve is wide open and there is no cooling. It is estimated that a 1500 psig back pressure would produce a 30° F. reduction of final gas temperature in the tanks. For this option a gas back pressure valve is required. Also a heat exchanger can be provided to exchange cool interstage gas temperature to the final compressor discharge gas going to the tanks. This scheme does not change the compressor itself but does increase the horsepower hours for the time when the back pressure valve is activated.
[0067] Another way to cool the CNG flowing to the tanks is to use an external means to extract heat energy from the gas. The advantage of external cooling over Joule Thomson cooling is that it is continuous throughout the entire cycle, not just at the beginning when tank pressure is low. Also, cooling by external means is much more energy efficient than cooling by Joule Thomson effect. The preferred source of external cooling is cooling water, if available. Ambient air cooling can reduce gas temperature to a maximum of 120° F. Cooling water as a coolant could probably reduce this temperature by as much as 40° F. An alternate external cooling system could be a small refrigeration unit using a refrigerant such as propane as coolant. Refrigeration could be used to cool the CNG exiting the final stage of compression before the gas flows into the tanks. If a refrigeration system was added to the basic simple system to transport raw gas by truck, it would add considerably to the cost and complexity of the system. However if the loading station included a deep cut system to recover liquids it would already include a refrigeration system and it is easy to tap into the system to cool the gas feeding into the tanks.
[0068] Another way to use external cooling to dissipate the heat of compression inside the tanks as they are pressured up is to recycle hot gas from the tanks through an external cooler then flow it back into the tank. This requires a second nozzle in the tank so that recycle gas can be withdrawn. Assuming there is an inlet distribution duct, there should also be a pickup duct running the full length of the vessel for the exit of the recycle gas to avoid pockets of hot gas accumulating in the tanks. Probably the recycle gas is cooled by rejecting the heat to ambient air, but other means such as cooling water could be used. After being cooled the recycle gas would combine with the process gas from the final stage discharge cooler, and then flow into the tanks. There is a small frictional pressure drop in the recycle loop that should be overcome by some means such as a compressor or blower. A high pressure eductor using high pressure process gas as motive force could also be used to induce the recycle gas to combine with the process gas. The cooling load increases with every incremental increase in gas pressure. This is because for every increase in pressure there is also more gas in the tanks that heats up due to compression which should then be cooled. For example for a trailer that is empty it may contain only 600 lbs of gas at the beginning of the fill cycle, so the cooling load is small. But as the process nears the end of the filling cycle there is about 14000 lbs of gas on board and this amount of gas requires a lot of cooling. The flow of recycle gas should therefore ramp up as the fill cycle advances. Initially when the tank is empty the recycle flow can be low, but as the tanks are close to being filled, the recycle gas could equal or exceed the flow of process gas coming from the compressor. Although the discharge head is very low it could be difficult to find a centrifugal compressor or blower for the recycle gas that could accommodate a twenty fold increase in flow rate and pressure that occurs over a single fill cycle. As an alternate, instead of a centrifugal machine, another method to recycle the cooling gas by compressor is to fit an additional cylinder to the reciprocating process compressor. Then as the pressure in the tanks increased, the capacity of the extra cylinder would increase in exact proportion to the demand. Since the discharge head is so low, the horsepower required for this option is almost negligible. Since the extra cylinder is driven off the same crank as the rest of the process compressor, it would automatically compensate for changes in demand due to changes in process flow rate. As an alternative to a recycle compressor, since the head requirement is so low it is possible to use a high pressure eductor to circulate the recycle gas. The eductor is located on the feed line to the tanks, using the pressure of the feed gas to induce recycle gas to flow into the side port of the eductor. It is necessary that the recycle gas be under flow control to control the flow of recycle gas to match the demand of the process. If recycle flow is not controlled excessive recycle flow adds significantly to process compressor horse power. It is expected that the recycle gas can be cooled by ambient air, but other means such as cooling water could be used. The cooler should be designed to take the full pressure of the tanks on the trailers. If direct air cooling is used the header boxes on the cooler should be designed for this high pressure. High pressure header boxes are usually machined from a solid billet of steel and for this reason are extremely expensive. Also, the intricate drilled passage ways inside the billet can restrict flow and create pressure drop, especially at low pressure. As an alternate to high pressure direct air cooling, low pressure indirect air cooling could be used. A high pressure pipe coil is used to contain the high pressure, not the finned air cooler. The high pressure pipe coil is immersed in a bath of volatile liquid such as propane with a containment vessel for both the pipe coil and the bath liquid. As the volatile liquid picks up heat from the pipe coil it evolves vapors which rise above the pool of liquid and flow into a finned air cooler mounted above the vessel that contains the pipe coils. The vapors enter the finned tubes of the air cooler where they reject latent heat to the atmosphere and condense as liquid which drains by gravity back to the liquid pool in the vessel below. An equilibrium is established between the temperature of the recycle stream, the volatile liquid and the ambient air. It is similar to the principle of the heat pipe.
[0069] At the unloading station, the process facilities required ultimately depend on what type of service is required by the user of the CNG. In most cases the minimum equipment required is a let-down valve to reduce the high tank pressure to the pressure required by the receiver's system. For example if the initial tank pressure is 3400 psig when full and 150 psig when empty, the gas free flows from the initial pressure of 3400 psig down to the receiver's pressure which is probably above 150 psig. When the period of free flow ends, a compressor starts to evacuate the tanks down to the final pressure of 150 psig while pumping the low pressure gas into the receiver's system. At 150 psig the tanks are considered empty. Liquid condensing, if it occurs, probably occurs during the free flow period of unloading and liquid is swept out of the tanks as soon as it formed. However, liquid should not be allowed to enter the compressor cylinders and a suction drum should be used as a safeguard. As the tanks are de-pressured the gas in the tanks expands and cools. Depending on initial and final pressures and on the extent of condensing in the tanks, the temperature in the tanks could drop approximately 70° F. between being full and being empty. The gas exiting the tank flows through a let down valve during the free flow period of emptying the tank, which creates additional Joule Thomson cooling that initially, can make the gas extremely cold. This is why it is necessary to attain extremely low water content for the gas back at the loading station. For the gas compressor the period of low Joule Thomson temperature has passed before the compressor starts up, so it has no effect on the compressor. The lowest temperature exiting the valve occurs initially when the tanks are full and the pressure drop is at a maximum. But as the tank pressure decreases the exit temperatures from the valve is due to the combined effect of temperature lowering in the tank plus Joule Thomson cooling of the let down valve. The gas temperature rises gradually until tank pressure equilibrates with the pressure of the receiver's system which triggers the startup of the process compressor. After the compressor starts, the let-down valve is wide open and a constant temperature discharges from the compressor. Whether or not the low temperature of the gas is objectionable depends on the destination of the gas. If, for example, the gas is injected into a pipe line where it mixes with large volumes of gas at normal temperatures, the temperature of a relatively small volume of intermittently cold gas would probably be of no concern. However if the gas Is flowing into a local consumer network it may be necessary to warm the gas by some means such as a gas fired water bath heater. Or if the gas was flowing into a deep cut system it may be practical to recover the cold energy of the gas by transferring it into the deep cut processing system. Or another possibility is that the gas could be transferred directly into stationary tanks at the unloading site to serve as a filling station for CNG powered vehicles.
[0070] Equipment for the individual wells including the compressor, desiccant unit, and liquid recovery system are very compact and portable for ease of relocation and hookup. For producers who have a marginal gas supply it offers an inexpensive way to get into production. Initially, in its simplest form, the process is a method to reduce flaring while generating revenue by the sale of liquids. Flaring the residue gas is wasteful but the stripping of liquids from the flare gas could reduce the amount flared by about 20%. Reduction of flaring is a benefit to be considered in addition to the recovery of liquids. Whether the source of flare gas is individual stranded gas wells or an oil battery, the most desirable solution is to install the complete system and recover both CNG and commercial liquids and deliver them to market, thus eliminating flaring completely.
[0071] Liquids including LPG and stabilized condensate can be recovered and delivered to market by truck, or in the case of stabilized condensate it can possibly be recombined with liquids from the oil battery or production separator upstream. Integration of the liquid recovery process into facilities upstream should be considered on a case by case basis. The same basic deep cut technology could also be used to recover ethane in addition to LPG and stabilized condensate but, because of its high vapor pressure, unless it is chilled it would most likely be marketed as a gas. This makes it more difficult to transport to market.
[0072] In the case of stranded gas wells the entire gas field can be developed one well site at a time as described above until a number of sites, possibly about half a dozen to a dozen have been put into production. Characteristically with marginal gas wells, especially shale gas wells, the production rate declines rapidly and after about two years of production the gas flow declines to about 20% of the initial flow. This means that the liquid recovery equipment and compressors originally installed on the wells are too big to efficiently handle the reduced production rate and should be moved intact to a new well whose initial flow matches the capacity of the process equipment. A smaller compressor/dehydrator combination can be substituted on the original wells which matches the long term reduced deliverability of the wells. Marginal gas wells, although they decline rapidly, often continue to flow at a reduced rate almost indefinitely. It is not practical to process extremely small volumes of gas for liquid recovery on site so it is necessary to group the production from several small wells together and send it by a gathering system consisting of small short pipelines to a central location for processing. The moderately sized central deep cut plant is strategically placed in the midst of the small wells to minimize the cost of the pipelines connecting the well sites to the central plant. Gas delivered from the wells to the central plant is dehydrated and compressed to a level that delivers the gas to the plant at about 500 psia, but on entry into the plant the gas is not yet stripped of hydrocarbon liquids.
[0073] The process used in the central plant is essentially the same deepcut process used originally at the well sites except on a larger scale. The products are the same, CNG, LPG, and stabilized condensate, all of which are shipped to market by truck or possibly by train. In some cases ethane can also be a commercial product. Non-commercial products such as Y-grade liquid can be produced if there is a market for it. The choice of products depends mostly on what the market demands.
[0074] One thing that should be planned in advance is how many wells the central plant can serve. This is part of the planned development of the field, to know what gas flow the central plant ultimately can handle. The location of the central plant and the most economical design of the gathering system between the wells and the plant is an essential consideration in the design and layout of the system. Pipelines from the wells to the central plant should be kept as short as possible to minimize the cost.
[0075] As development of the field progresses the initial high capacity process packages are moved one by one to new well sites when initial gas flow declines to its long term stable flow rate. The original units are replaced by low capacity compressor dehydrator units to suit the reduced deliverability of the wells. The new low capacity units dehydrate and compress the gas and deliver it via a short pipeline to a central deep cut plant to recover CNG and hydrocarbon liquids. Conversion of the individual wells to the low capacity system occurs gradually, probably one well at a time, requiring that the central plant be capable of accommodating a very wide range of flow rates, starting possibly at about 10% of design rates and building gradually to 100%. The Clausius Clapeyron expansion process, which is the heart of the deep cut system, is capable of turn down to extremely low rates. This is unlike conventional deep cut processes that are based on turbo expanders which are extremely inflexible in turn down ability.
[0076] It is important that so long as the field is developing and new wells are continuously being opened up, the existing high capacity process packages should be relocated to new wells, to be replaced by new low capacity compressor/dehydrator units on the old wells and that ideally all equipment is in use and there is no surplus equipment left over. But eventually, the field is fully developed and all of the wells are tied into the low capacity compressor/dehydrator combinations. At that point there are several high capacity process packages left over. The number of left over units depends on the pace of new wells being brought on stream. The time interval between installing high capacity units on new wells is critical. If, for example, two new wells are brought on stream each year and if it requires two years for each well stabilize at its diminished flow, then there are four high capacity units required which eventually become surplus when the field is fully developed. Likewise if four new wells are tied in each year eight high capacity packages is required and eventually eight units become surplus.
[0077] However, since the process employed in the high capacity units is similar to the process used in the central plant, it is possible to recycle these surplus units into the final central plants being situated in the gas field. Assuming that the diminished flow of each well declines to 20% of initial flow, one high capacity process package could serve up to five wells. For example if the plan is for a typical central plant to serve ten low flow wells in a 30 well field, then two high capacity units can be configured to run in parallel at a central plant facility for processing and compression for 10 wells. Assume that a typical well requires two years to decline to its stable 20% flow rate. Suppose the plan has been to tie in two new wells per year, then eventually there are four surplus high capacity units left over when the entire 30 well field was developed. For the first 10 wells a new central plant #1 is required. But for the second block of ten wells, in order to avoid having surplus units left over, one of the four high capacity units left over can be located centrally as the beginning of central plant #2. This leaves three high capacity units available to develop new wells, and central plant #2 meanwhile serves the first five wells of the second block of ten wells. Eventually another of the potentially surplus high capacity units are refurbished and moved to central plant #2 to run in parallel with the first unit. In order to use up the final two surplus units by the time the field is fully developed only one new well is tied in per year, resulting in a surplus of two high capacity units which can be reconfigured one at a time to run in parallel at the proposed central plant #3, serving the final ten wells. By staging the development logically in this way, the maximum use can be made of the invested capital. The disadvantage is that development would proceed slowly.
[0078] Alternatively, instead of reconfiguring the high capacity units to serve as central plants, they can be kept intact and moved to an entirely new field where the development process can begin again. In that case the surplus units are really surplus because they are put to immediate use in the new field. Development of the first field has then proceeded rapidly without the delay caused by recycling high capacity units to serve as central plants and all central plants are new, purpose designed plants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] FIG. 1 is a schematic layout of a first arrangement according to the present invention for reduction of flare gas by recovering propane plus.
[0080] FIG. 1 b is a schematic layout of the arrangement of FIG. 1 at a high-level.
[0081] FIG. 2 is a schematic layout of a second arrangement according to the present invention for total recovery of CNG and liquid from flare gas.
[0082] FIG. 2 b is a schematic layout of the arrangement of FIG. 2 at a high-level.
[0083] FIG. 3 is a schematic layout of a third arrangement according to the present invention for reduction of flare gas by recovering ethane and heavier components.
[0084] FIG. 4 is a schematic layout of a fourth arrangement according to the present invention for total recovery of CNG and liquid from flare gas.
[0085] FIG. 5 is a schematic layout of a fifth arrangement according to the present invention for total recovery of CNG and liquid from flare gas with rich feed gas.
[0086] FIG. 6 is a schematic layout of a sixth arrangement according to the present invention for multiple low flow wells feeding into a central plant.
[0087] FIGS. 7 , 8 , 9 and 10 show plan views of four typical developments of gas fields.
[0088] FIGS. 11A , 11 B, 11 C and 11 D show four arrangements for cooling CNG before it enters the tanks, where FIG. 11A shows Joule Thomson cooling from interstage, FIG. 11B shows Joule Thomson cooling from discharge, FIG. 11C shows cooling CNG by external coolant and FIG. 11D shows cooling of the recycle stream.
[0089] FIG. 12 is a graph showing the gas temperature profile related to the percentage filling of a tank capacity.
DETAILED DESCRIPTION
[0090] FIG. 1 shows reduction of flare gas by recovering propane plus and illustrates a typical facility where the quantity of flare gas is decreased by stripping the gas of liquefied components such as LPG and stabilized condensate. Recovery of liquids typically reduces flaring by as much as 20% depending on the composition of the flare gas. FIG. 1 is a process scheme based on the Clausius Clapeyron Expansion Principle to recover propane and heavier hydrocarbon components. The advantage of this process over conventional turbo expander processes is its extreme flexibility, especially its wide operating range in handling varying flow rates. The LPG produced meets commercial standards for marketing and the stabilized condensate meets commercial standards for Reid vapor pressure. Details of the process may vary somewhat depending on operating conditions, the composition of the gas and the required specifications for the products.
[0091] In FIG. 1 , items 100 and 101 , which are both upstream of the proposed patented process scheme, represent typical production equipment in the field such as a valve 100 , to control pressure and flow of the wellstream, and separation equipment 101 , which divides the incoming stream into its three respective phases of gas, hydrocarbon liquid, and water. For gas wells, this equipment would primarily be gravitational separators and for oil wells, the equipment is a combination of gravitational separators and oilfield treaters. For gas wells, if liquids from the separation equipment were sufficient to justify production in spite of a lack of market for the gas, then the byproduct gas would conventionally be sent to flare stack 102 , likewise for oil batteries. The non-marketable gas is sent to flare.
[0092] By the use of this invention, instead of sending what is considered to be waste gas to flare, it is diverted to a compressor 103 and a gas discharge cooler 101 , which raises the pressure to approximately 500 PSIA at 120° F. The gas then flows to a desiccant dehydrator 106 A/B/C, which may be either two tower or three tower units, depending on conditions, and it may also sometimes remove a small quantity of hydrocarbon liquid in addition to water. For regeneration, either dry product gas or wet inlet gas can be used to regenerate the beds of desiccant. Regeneration gas is typically heated in a salt bath heater 107 and cooled in an air cooled heat exchanger 108 which condenses water and possibly some hydrocarbon liquid which is removed from the regeneration stream in separator 109 . The gas from the separator 109 then recombines with inlet gas entering the desiccant towers.
[0093] Downstream of the dehydrator the dry gas is divided into two streams, one of which is cooled in a gas/gas exchanger 110 , then proceeds to a propane refrigerated chiller 118 , then to an expansion valve 119 , then enters the gas fractionator 120 below the bottom stage. The other dry gas stream flows to a compressor 111 and a discharge cooler 112 which raises the pressure to approximately 1500 PSIA at 120° F. The gas is then cooled in Gas/Gas exchangers 113 and 115 and in propane refrigerated chiller 114 . Propane is the refrigerant normally used in gas processes but other commercial refrigerants could also be used. The chilled gas then enters the expansion valve 116 which lowers the pressure to approximately 450 psia, resulting in an extremely cold feed stream entering the gas fractionator 120 at the top stage of the column. In the FIG. 1 version of the process there is no market for the gas, so the residue gas from the gas fractionator is sent to flare 102 after the liquids have been stripped out.
[0094] The bottom liquid product from the gas fractionator 120 contains the propane and heavier components which are to be recovered, but the liquids are heavily loaded with light gases, mainly methane and ethane which should be separated from the liquid product. Most of these light gases can be flashed off in the deethanizer's feed flash drum 121 without losing a significant amount of recoverable liquid. The overhead vapor from the flash drum is sent to flare stack 102 .
[0095] Bottom liquid from the flash drum 121 is reduced in pressure by a let-down valve which produces a very cold feed stream which enters on the top stage of the deethanizer 126 . The deethanizer is typically a top feed fractionator without a reflux condenser but with a bottom reboiler 127 which produces the necessary temperature profile in the column. Normally the specification imposed on the bottom product from the deethanizer is that the molar C 2 /C 3 ratio should not exceed 2%. The light gases, mainly methane and ethane that are stripped from the liquid in the deethanizer are sent to the flare 102 . Losses overhead of valuable liquids in the deethanizer overhead vapor are not significant.
[0096] The bottom liquid that flows from the deethanizer contains the liquid product that can be recovered from the flare gas. The purpose of the debutanizer 128 is to separate the incoming mixture into the final products, normally Liquefied Petroleum Gas (LPG), a mixture of volatile hydrocarbons consisting of mainly propane and butane, and stabilized condensate, consisting mainly of pentanes and heavier. The debutanizer feed enters at about mid stage of the column, and the feed stream is often boosted in pressure with a pump so that the reflux condenser can use ambient air as coolant. The debutanizer has an air cooled reflux condenser 129 and a bottom reboiler 130 .
[0097] The LPG is a pressurized product so should be stored under pressure. It may be stored on site in a stationary tank to be offloaded into a propane truck, or it could be loaded directly into a trailer stationed at the site to be picked up and delivered to market as required. The commercial specification that normally applies to the LPG is that the C 2 /C 3 ratio should not exceed 2%. This ratio is determined in the deethanizer.
[0098] The bottom product is stabilized condensate which normally is produced with a Reid Vapor Pressure specification not exceeding 12 psia. From a single source such as a small well the quantity of stabilized condensate can be relatively small. The most convenient way to handle it is to recycle it back to the inlet separation facility 101 and combine it with the liquid hydrocarbon leaving the inlet separator. Alternatively, the stabilized condensate could be cooled by tube and shell or by air cooled heat exchanger, and then stored on site in a small atmospheric tank. The condensate has been de-gassed so has very low vapor pressure to enable storage by atmospheric pressure. It could be trucked to market when the on-site tank was full.
[0099] The process equipment in FIG. 1 is self contained and provides a complete processing facility when installed on an individual gas well or oil battery.
[0100] FIG. 1 b is a simplified block diagram of FIG. 1 showing a typical facility where the quantity of flare gas is decreased by stripping the gas of liquefied components such as LPG and stabilized condensate.
[0101] In FIG. 2 is shown an arrangement for the total recovery of CNG and liquid from flare gas. The details of the upstream production facilities, compressors, dehydrators, and liquid recovery packages described in FIG. 1 apply also to FIG. 2 . The only difference is that instead of sending residue gas to flare it is compressed, cooled and loaded directly into special CNG tanker trucks to be transported as commercial product to market.
[0102] The combined overhead vapors from the gas fractionator, the feed flash drum, and deethanizers, after transferring cold energy back into the deep cut process, are compressed in two stages to a final pressure of approximately 3415 psia. This choice of the final pressure depends on the design of the tanks on the trucks. The inter-stage discharge has a back pressure valve 135 to hold a constant back pressure on the first stage compressor 131 downstream of the air cooled exchanger 132 during the initial stages of filling when tank pressure is below inter-stage pressure. This is to provide Joule Thomson cooling of the gas through valve 135 as it flows into the tank 137 from the time when the tank is empty until the tank pressure equals inter-stage pressure. Cooling the gas during the early stages of filling can prevent the final temperature in the tank from rising too high. When tank pressure reaches inter-stage pressure the gas flow is diverted from the back pressure valve 135 to the Stage 2 compressor 133 and its discharge cooler 134 which then starts up and continues to fill the tank until fully charged. The CNG is metered 136 at the loading station.
[0103] As the tanks near their loaded capacity a second truck arrives which is empty. It is connected up in readiness to receive its cargo of CNG when the first truck is fully loaded. Flow of gas during loading is continuous without interruption. The loaded truck departs and carries its cargo to the destination where it is unloaded under controlled conditions into the users system.
[0104] FIG. 2 b is a simplified block diagram of FIG. 2 showing a typical facility where the flare gas is eliminated by stripping the gas of liquefied components such as LPG and stabilized condensate and the residual gas is compressed, cooled and loaded directly into special CNG tanker trucks to be transported as commercial product to market.
[0105] FIG. 3 shows a reduction of flare gas by recovering ethane and heavier components and is generally similar in principle to the process described in FIG. 1 . Like FIG. 1 , the FIG. 3 process scheme is intended to be installed at individual well sites or oil batteries and it includes compression, dehydration, and recovery of commercial products, but the difference is that the FIG. 3 process also recovers ethane in addition to LPG and stabilized condensate. Ethane is a volatile component and at normal ambient temperatures it is probably a gas having a vapor pressure approaching 1000 psia. Therefore the usual way to ship ethane is as a gas in a pipeline, or it could be compressed and shipped by truck, the same as CNG. Or, if it could be chilled to 0° F. or less it could be shipped as a liquid at about 250 psia, provided that it could be continuously cooled. FIG. 3 recovers ethane as a gas but does not show how it is shipped to market.
[0106] The production facilities 100 and 101 upstream of the process in FIG. 3 are identical to the corresponding items 100 and 101 in FIG. 1 . The compressors and the dehydrator in FIG. 3 are also identical to those in FIG. 1 . The differences are all in the deep cut liquid recovery process.
[0107] The first difference occurs when the dry gas is split into two streams. The first stream is cooled by a gas/gas exchanger 110 then flows to a flash drum 117 , the overhead vapors from which flow to chiller 118 and valve 119 and enter the gas fractionator 120 as a bottom feed. FIG. 1 had no flash drum. The second dry gas stream flows to compressor 111 , cooler 112 , exchangers 113 and 115 , chiller 114 , then through expansion valve 116 to produce an extremely cold stream that enters the gas fractionator 120 as the top feed, the same as in FIG. 1 .
[0108] Although there are physical similarities to FIG. 1 , the process to recover ethane in general requires lower temperatures in the gas fractionator than are required to recover propane and heavier as in FIG. 1 . As before, the residue gas from the gas fractionator is sent to flare. The bottom liquid from the gas fractionator is sent to the second fractionator in the line, the demethanizer ( 122 ).
[0109] For the recovery of ethane the process requires an additional fractionating column, the demethanizer, 122 to remove light gases, principally methane from the liquid mixture. The bottom product from the gas fractionator 120 is reduced in pressure by a level control valve and then enters the demethanizer 122 at a very low temperature as top feed. Liquids from the flash tank 117 also enter the demethanizer at about the midpoint of the column as a second feed. Because the demethanizer 122 has a very cold top feed a reflux condenser is not required. A bottom reboiler 123 provides heat for the necessary temperature profile in the column. The overhead vapor from the demethanizer has no market so is sent to flare. The specification imposed on the bottom product from the demethanizer is typically a molar ratio of C 1 /C 2 not exceeding 2%. This is to enable a relatively pure ethane stream to be produced in the following fractionator. The bottom liquid leaving the demethanizer contains all the commercial products to be recovered by the process. Subsequent fractionation just divides the liquid into the desired products.
[0110] The bottom liquid exiting the demethanizer 122 flows downstream and enters the deethanizer 124 as feed at approximately the mid-point of the column. The purpose of this deethanizer is to separate the product, ethane gas, as overhead from the propane and heavier components in the feed. Since methane and light gases have already been removed, and since a relatively high reflux ratio is used in the deethanizer 124 , a relatively pure ethane product can be produced. The deethanizer has a refrigerated reflux condenser 125 and a bottom reboiler 126 . The bottom product from the deethanizer is a liquid mixture of propane and heavier, which, as in FIG. 1 , flows to the debutanizer.
[0111] The bottom product that flows from the deethanizer 124 contains LPG and stabilized condensate as a liquid mixture and it is the function of the debutanizer 128 to separate the mixture into the desired commercial products. The operation and function of the debutanizer is exactly as described previously for FIG. 1 .
[0112] FIG. 4 shows the total recovery of CNG and liquid from flare gas and the details of the upstream production facilities, compressors, dehydrators and liquid recovery packages described in FIG. 3 apply also to FIG. 4 . The only difference is that instead of sending residue gas to flare it is compressed, cooled, and loaded directly into special CNG tanker trucks to be transported as commercial product to market.
[0113] The deep cut process detailed in FIG. 4 recovers ethane in addition to LPG and stabilized condensate. Ethane leaves the process in the form of a gas at a pressure probably below 200 psia. There are various ways to deliver the ethane to market.
[0114] a) It could be compressed and delivered by truck using methods similar to the CNG technology
[0115] b) It could be transported as a liquid at about 250 psia in a truck refrigerated to below 0° F.
[0116] c) If an ethane pipeline was in the area, ethane could be shipped by pipeline. Details of the delivery method for ethane have not been detailed in FIG. 4 .
[0117] The combined overhead vapors from the gas fractionator and the demethanizer after transferring cold energy back into the deep cut process, are compressed in two stages to a final pressure of approximately 3415 psia. The choice of final pressure depends on the design of the tanks on the trucks. The inter-stage discharge has a back pressure valve 135 to hold a constant back pressure on the first stage compressor 131 down-stream of the air cooled exchanger ( 132 ) during the initial stages of filling when tank pressure is below inter-stage pressure. This is to provide Joule Thomson cooling of the gas through valve 135 as it flows into tank 137 from the time when the tank is empty until the tank pressure equals inter-stage pressure. Cooling the gas during the early stages of filling can prevent the final temperature in the tank from rising too high. When tank pressure reaches inter-stage pressure the gas flow is diverted from the back pressure valve 135 to the stage 2 compressor 133 and its discharge cooler 134 which then starts up and continues to fill the tank until fully charged. The CNG is metered at the loading station in meter 136 .
[0118] As the tanks near their loaded capacity a second truck arrives at the loading station which is empty. It is connected up in readiness to receive its cargo of CNG when the first truck is fully loaded. Flow of gas during loading is continuous without interruption. As flow is transferred from one truck to the other, the loaded truck departs and carries its cargo to the destination where it is unloaded under controlled conditions into the users system.
[0119] FIG. 5 shows total recovery of CNG and liquid from flare gas with rich feed gas where the same references are used as in FIGS. 1 , 2 , 3 and 4 . 101 is the three-phase inlet separator as before, but in this case is integral part with the liquid recovery system. Item 138 is the liquid stabilizer which fractionates the hydrocarbon liquid from the inlet separator.
[0120] Feed gas that typically enters the deep cut plant is single phase gas which contains no appreciable amount of hydrocarbon liquid because either the gas is lean and is inherently free of liquid as it exits the well or possibly because the free liquid has already been removed by separation equipment upstream of the deep cut facility.
[0121] However in some cases the gas, as it leaves the well, contains significant quantities of free liquid, and if there are no separation facilities upstream, it is necessary to provide additional equipment to handle the free liquids entering the system from the inlet stream. The complicating factor in processing these inlet hydrocarbon liquids is that they can be water saturated and in addition to dissolved water, can typically contain 1,000 to 5,000 ppm of entrained water droplets in a very fine dispersion.
[0122] It is difficult to remove water from liquid hydrocarbons to the level necessary to permit processing the liquids at cryogenic temperature. The processing of these liquids should therefore be done at temperatures safely above hydrate of freezing temperatures. It is first necessary to use gravitational separation to separate the inlet stream into its respective three phases of gas, hydrocarbon liquid and free water. The gas proceeds from the inlet separator to compression and dehydration as prescribed previously and the free water is sent to disposal. The water wet hydrocarbon liquid from the inlet separator are then fractioned to produce an overhead product consisting of light gases which are recycled back to the inlet separator. The bottom liquid product should meet the necessary specifications determine the design of the fractionator. The liquid specification is sometime 12 psia Reid vapor pressure, or if the liquid is to be processed for ethane recovery the liquid specification is typically a methane/ethane ration of 1%. If the liquid is being processed to recover propane and heavier, the bottom product is typically an ethane/propane ration not exceeding 2%. The fractionation process normally drives almost all of the water overhead, either as water vapor or as liquid from a water draw off tray. But the bottom liquid can still contain traces of water so should not enter this cryogenic plant unless it is first dehydrated.
[0123] If the plant is designed to recover propane and heavier, the stabilizer strips the liquid of ethane and other light gases, so the slightly wet liquid can be sent as feed to the debutanizer without causing excessive ethane content in the LPG. The minor amount of water in the feed is not a problem in this debutanizer because it runs hot. Also, the amount of water is so small it does not exceed allowable limits in the products.
[0124] FIG. 6 shows an arrangement for Multiple Low Flow Wells Feeding Into a Central Plant where the most likely application for this patented technology is for relatively small gas wells which suffer a severe reduction in gas production within a fairly short time after startup. Initially that gas flow rate may typically be about 2.5 MMscfd, declining gradually by about 80% to a stable, long term flow rate of about 0.5 MMscfd.
[0125] FIGS. 1 , 2 , 3 , and 4 show various process configuration to handle the brief period of maximum flow following initial startup for each individual well. The processes described in those figures are of self contained equipment packages which intake raw, unprocessed, water saturated gas and produce marketable commercial products. These equipment packages are basically intended to be temporarily installed at a well site to process the gas from a single well for the duration of the high flow phase of the operation.
[0126] When gas production falls to its minimum stable flow rate, the initial high capacity process package is too big to efficiently process the very low gas flow, so the initial process package, being portable, is disconnected from the well and moved to a new well site which has a higher flow rate. The initial big unit can be replaced at this low flow well by a much smaller package consisting of a miniature compressor/dehydrator combination. Deep cut liquid recovery equipment encounters many difficulties when operating at extremely low flow rates, so the liquid recovery system is relocated to a central processing plant which handles the gas from a cluster of several miniature compressor/dehydrator packages located at the low flow well sites.
[0127] FIG. 6 shows a typical development where the self contained high capacity units have been replaced by seven of the miniature compressor/dehydrator combinations, each of which sends gas by pipeline to the central gas plant, from the seven well sites. The particular example shown in FIG. 6 recovers CNG, LPG and stabilized condensate in a deep cut facility at the central station. Each of these products is shipped to market by truck. For CNG, the gas is loaded directly into tanker trailers on a continuous basis. CNG trailers are available on site continuously as required so that flow is not interrupted. For LPG, FIG. 6 shows a stationary pressurized LPG tank on site which is pumped periodically into a propane tanker truck when the stationary tank on site is full. Alternatively, a propane trailer can be stationed on site at the central plant which takes the place of the stationary tank, provided that a trailer is on site continuously. When one propane tanker is full a second one is on site, already connected and ready to take on its cargo of LPG. For stabilized condensate, the anticipated production is probably very small, so a small atmospheric storage tank on site at the central plant is sufficient, to be pumped out on a weekly or bi weekly basis and trucked to market. All products leaving the central plant are metered before loading.
[0128] Equipment numbers applicable to FIG. 6 are the same as corresponding items of equipment in FIG. 2 .
[0129] As an alternative to desiccant dehydration at the well-site, it may be practical to use glycol dehydration and use desiccant dehydration at the central plant.
[0130] FIGS. 7 , 8 , 9 , 10 show an arrangement for typical development of gas field where the four figures illustrate a typical case of the various stages in the development of a small gas field having a total of thirty marginal gas wells. FIG. 7 shows ten wells tied in, FIG. 8 shows twenty wells tied in, FIG. 9 shows all thirty wells tied in and in production but with the final four wells still in their initial high production phase. FIG. 10 shows the field fully developed with all thirty wells configured for long term low volume production. The three stage development in this particular example had ten wells per stage and three central plants serving ten wells each when the plan was complete.
[0131] The characteristics of this reservoir in the example are typical of many tight gas reservoirs, especially shale gas reservoirs, which have an initial flow which can be five times as much as their long term steady flow rate. Usually the deliverability tends to fall quite rapidly following the high production rate following startup. High flow for this type of well might be approximately 2.5 MMscfd which would decline over time to a stable flow of about 0.5 MMscfd which would then continue almost indefinitely. The figures in this example suggest a development plan for this type of field.
[0132] The development scheme for this field is to take advantage of the brief period of maximum production by installing portable self contained processing facilities which can handle the high flow period which on an individual well basis is complete and can produce CNG, LNG stabilized condensate, and possibly in some cases, ethane. This scheme enables the field to get into production quickly based on very few wells tied in and using miniature processing equipment to begin generating revenue right away from the sale of gas and liquids. The high flow facility at each well site is complete and self contained requiring only utilities from the power grid if available.
[0133] The scheme for this particular example calls for using four high capacity portable processing packages which are installed either one at a time or all four simultaneously in a tight cluster that can enable a planned expansion of a gathering system when the high capacity units are moved onto new wells to be replaced by low capacity compressor/dehydrator packages. The four high capacity units, each processing 2.5 MMscfd for a total of 10 MMscfd are moved step by step until all ten wells of the first ten well clusters are in production, four at high capacity and six at low capacity producing 0.5 MMSCFD each for an overall production of 13 MMscfd. As each set of four high volume units run down to 0.5 MMscfd, the portable high capacity units are moved on to new high volume wells to be replaced by miniature compressor/dehydrator combinations designed for 0.5 MMscfd each. Meanwhile, this central plant which uses a deep cut cryogenic process to produce CNG, LNG and Stabilized Condensate should be ready to accept the dry field gas from the low volume compressor/dehydrator units as soon as they are installed. Dry gas arrives at the central plant at about 500 psia.
[0134] Development proceeds in this way until the first cluster of ten wells is in production. FIG. 7 illustrates this, showing four high capacity wells and six low capacity wells which at this point are sending 3 MMscfd to the central plant which is designed for an ultimate capacity of 5 MMscfd when all ten wells are tied in to the plant. The four high capacity self contained units in FIG. 7 are processing 10 MMscfd in total and sending commercial products directly to market by truck. The central plant likewise sends commercial products to market by truck.
[0135] Among the things to consider in preparing a development plan is the location of the central plant among the cluster of wells. It should be placed so that the cost of the gathering system is minimized. The design and location of well stream metering equipment should also be considered if it is within the scope of the project. Reservoir engineers can recommend the sequence of developing new wells. For diagrammatic simplicity FIGS. 7 to 10 show development proceeding in an orderly way from south to north. Reservoir science, taking account of the delicate and sometimes temperamental nature of tight reservoirs may dictate otherwise.
[0136] FIG. 8 shows the first cluster of ten wells fully developed and tied in to the central plant. All ten wells of the second cluster are in production with four wells in high production mode and six wells in low production and tied in to control plant #2. As in FIG. 7 , CNG, LNG, and stabilized condensate are delivered to market by truck. The example shows the CNG being unloaded into a pipeline; this probably requires a compressor to empty the truck. Delivery of CNG for industrial or domestic users may not require a compressor.
[0137] FIG. 9 , like FIG. 8 shows the next stage of development with all thirty wells in production with the final four wells still in their high volume mode. Six wells are tied into the gathering system and are producing into central plant #3.
[0138] FIG. 10 shows the field fully developed with all 30 wells producing at 0.5 MMscfd each and tied in to their respective central plants.
[0139] This example illustrates the development of only one hypothetical field. The general principles are applicable to many fields but each case is different and the development plan should be specific to each situation.
[0140] FIGS. 11A to 11D show a number of arrangements for cooling CNG before it enters the tanks, assuming the truck tanks are considered empty at 165 psia and full at 3415 psia. Compression of gas into the tanks begins at 165 psia and ends at 3415 psia. As the tanks are filled, the gas already in the tanks increases in pressure and becomes warmer due to heat of compression. If the discharge cooler of the compressor cools the gas to 120° F. and if no further cooling occurs except convective cooling from the cool walls of the tank, the final average temperature in the tanks can be approximately 160° F. It is desirable to cool the gas further to increase the payload carried in the tanks. For example, if the temperature could be lowered by 30° F. the weight of gas carried in the tanks would increase by approximately 8%. Another issue to consider if composite materials are used in the tanks, excessive temperature can degrade the non metallic components in the tank, increasing possible risk of failure. As compression proceeds the gas initially in the tank is pushed to the far end of the tank and because this initial gas experiences the greatest change in pressure it also experiences the greatest increase in temperature. The far end of the tank becomes very hot while the inlet end remains cool. To prevent this misdistribution of temperature the inlet nozzle is connected to an inlet sparger that runs the full length of the tank to evenly distribute the gas as it enters the tank. This can produce an even, average, temperature rise for the full length of the tank, rather than one hot end and one cool end. The sparger runs along the bottom of the shell of the tank to act as a pickup duct for any liquid that may condense in the tank.
[0141] FIG. 11A shows an arrangement for Joule Thomson cooling from interstage where maintaining a back pressure on the interstage gas and choking it directly into the trucks' tanks produces a maximum temperature drop of about 50 to 60° F. for the gas initially flowing into the empty tank. This cooling effect can continue until the tank pressure equals interstage pressure. At that time the back pressure valve 135 is by passed and compressor 133 and cooler 134 start up and gas flowing into the tank can be constant at approximately 120° F. This system adds to horsepower hours to produce cooling.
[0142] FIG. 11B shows an arrangement for Joule Thomson cooling from discharge which uses Joule Thomson for cooling by maintaining a back pressure on the discharge gas entering the tank. The advantage of this system is that the back pressure setting is variable between interstage pressure and final pressure. As before, when tank pressure equals the back pressure, the choke is bypassed. Joule Thomson cooling adds to horse power hours to produce cooling.
[0143] FIG. 11C shows an arrangement for cooling CNG by external coolant where the discharge air cooler lowers the gas temperature to approximately 120° F., depending on ambient temperature. If an alternate coolant such as cooling water is available for exchanger ( 138 ) it possibly lowers the temperature by a further 40° F. Or, if refrigeration is used it lowers the inlet temperature sufficiently that that the final average temperature in the tanks can be about 120° F. The advantage of an external cooling is that it is constant throughout the filling cycle. Excessive cooling should be avoided however to avoid extreme cryogenic temperatures when the tanks are unloaded.
[0144] FIG. 11D shows an arrangement for cooling of recycle stream where instead of precooling the gas before it enters the tank so that when it undergoes compression inside the tank it is not too hot, an alternate approach is to recycle the gas in the tanks after it has become heated due to compression through a cooler 139 to remove the heat of compression directly. An external coolant such as ambient air or cooling water can be used. This cooled recycle gas is combined with inlet gas entering the tanks. A means to circulate the recycle gas should be used. Because pressure losses in the recycle circuit are very low, an educator ( 140 ) can be used to provide the motive power as shown in FIG. 11D . Recycle gas flow through the eductor should be positively controlled to avoid adding excessive loads to the compressor ( 133 ). Alternately a blower or compressor could be used in the circuit to recycle the cooled gas.
[0145] FIG. 12 shows the temperature profile during the filling phase of a tank: the choking effect of the back pressure valve on the final-stage compressor produces cooling. The cooling at the beginning of the fill cycle is sufficient to reduce the final average gas temperature to a desired level.
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A method of gas production from a field containing natural gas processing particularly for transport of stranded gas to conserve resources and reduce emissions includes extracting gas a gas supply from a plurality of individual gas wells in the field and initially at the individual gas wells providing a recovery unit having a production capacity matching that of the well for carrying out liquid recovery from the gas supply and compression of the natural gas. When a production rate of the well declines to a low level, typically to about 20% of the original,
the recovery unit is removed for redeployment either at a central plant or at other wells which are still at the high production and is substituted by a dehydration system and gas compressor arranged to fill portable pressure vessels typically on trucks for transporting the compressed natural gas to a main pipe line.
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BACKGROUND OF THE INVENTION
This invention relates to ice chopping apparatus for a kitchen appliance or as an attachment to a food processor or similar appliance for processing ice chunks, cubes or similar ice pieces into ice fragments of controlled size. A plethora of kitchen appliances have become available which perform a variety of functions in the processing and preparation of food items as well as juicers, blenders etc. The more versatile these appliances become, namely in the performance of multiple functions, eliminates the requirement to have a multiplicity of such appliances cluttering or taking up useful counter space in the kitchen. Food processors are an example of these versatile multi-function devices which may be utilized for performing a variety of cutting, rasping, chopping, kneading, mixing, grinding, etc. functions. However, most of the attachments or tools used in the food processors do not perform a good job of fragmentating ice chunks with a predetermined size or configuration of suitable size as well as having an appetizing appearance.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a new and improved apparatus for processing ice chunks to produce ice fragments of controlled size in a kitchen type appliance.
A further object of this invention is to provide a new and improved ice chopping apparatus which can utilize and be mounted on the base of a food processor and which employs the motor and motor drive of the food processor.
A further object of this invention is to provide a new and improved ice chopping apparatus which is compact, efficient, attractive and produces ice fragments of controllable size.
Another object of this invention is to provide an ice chopping apparatus which may be attached to a food processor and which enjoys all the safety interlock features which are presently utilized in food processors to prevent damage or injury to the machine or user.
Among the further advantages of this invention is an ice chopping apparatus which may be easily and safely attached to and disengaged from the motor driven tool drive means of a food processor, and is convenient and easy to mount in operating position and to use.
In carrying out this invention in one illustrative embodiment thereof, apparatus for producing ice fragments of controlled size in an electrical kitchen appliance of the type having a motor drive and a working bowl with the motor drive extending into the working bowl involves the steps of mounting a rotary ice chopping tool on the motor drive in the working bowl, establishing an annular channel in the bowl leading to and around the rotary ice chopping tool and forming an escape gap of predetermined size around the perimeter of the annular channel. Ice chunks are fed into the channel of the bowl for reducing the ice chunks to ice fragments which when reduced to the proper size are discharged through the escape gap and deposited in the bowl. The size of the escape gap may be adjusted for controlling the size of the ice fragments which are discharged from the channel into the bowl thereby controllably varying the size of the ice fragments which are processed by the kitchen appliance.
The ice chopping apparatus includes a rotary ice chopper tool having a disc-like head with a geometrically shaped socket on the underside thereof and at least one projecting blade from the flat disc-like surface of the upper side and preferably two radially spaced chopper blades, the outer of which may be angled with respect to the periphery for deflecting the ice fragments into the escape gap. The socket is adapted to be connected by a removable shank to the rotary drive means of the appliance. The shank includes the same geometrical shaped head as the socket with a key on one surface thereof which is adapted to fit into key shaped channels of varying length in the socket for controlling the distance that the shank is moved into the socket. Accordingly the height of the ice chopper with respect to the annular channel, which is formed by an annular channel member resting between a cover and the bcwl and having a cylindrical skirt extending downward therefrom, the bottom perimeter of which forms a gap between the rotary ice chopper, is controlled by the amount that the shank penetrates the socket. Since the annular channel member elevates the cover at a higher position than it would normally be on a regular food processor without the channel mounted therein, additional longer locking cams have been added to an existing cover. Accordingly, the safety interlock system included in certain types of food processors is preserved by the ice chopping apparatus of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with further objects, features, advantages and aspects thereof will be more fully understood from a consideration of the following description taken in conjunction with the accompanying drawings in which like elements are designated with the same reference numerals throughout the various views.
FIG. 1 is a top view of a food processor utilizing the ice chopping apparatus in accordance with the present invention.
FIG. 2 is a side elevational view, partly in section, of the apparatus illustrated in FIG. 1.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1 illustrating a "1" escape gap setting for determining the size of ice fragments which are discharged into the bowl of the food processor.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a partial cross-sectional view of the ice chopping apparatus shown in FIG. 3 illustrating a "6" setting of the escape gap.
FIG. 6 is similar to FIG. 5 showing a "5" setting of the escape gap of the apparatus.
FIG. 7 is an exploded perspective view of the shank of the ice chopper tool and the motor drive means to which it is attached.
FIG. 8 is a perspective view, partly broken away, illustrating the annular channel member having a downwardly extending cylindrical skirt or wall which directs ice chunks inserted therein to the ice chopping tool.
FIG. 9 is a perspective view of the ice chopper tool showing the socket in phantom.
FIG. 10 is another perspective view of a modification of the ice chopping tool of FIG. 9 illustrating the outer blade being angled with respect to the periphery of the tool.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrative embodiment of the present invention is described in connection with its use in food processors of the type having a working bowl with motor driven tool drive means extending into the bowl with which various selected rotary food processing tools can be engaged to be driven for performing various food processing operations in accordance with the desires of the user. A removable cover is secured over the top of the bowl during use. The cover includes a feed tube having a passageway which opens downwardly through the cover into the bowl, and food items to be processed are placed in the feed tube and then pushed down into the bowl if required by means of a removable food pusher which is adapted to slide down in the manner of a plunger in the feed tube. The food items are sliced, grated or otherwise processed by the rotary tool in the bowl. The bowl carries on its periphery a push rod which forms a part of a safety interlock system for actuating the motor drive for driving the tool drive means only when the bowl and the cover are properly positioned on the food processor. The present invention which is described hereinafter is an ice chopping apparatus adapted to be used as an accessory or an attachment to the type of food processor just described. However, it will be understood that the ice processing apparatus of this invention is applicable as a separate kitchen appliance solely for processing ice or in combinations with other mixing, blending or food processing operations or may be applicable for use with other types of kitchen appliances which have a motor and a motor driven tool drive means to which the applicant's invention may be applied.
As used in this application, the ice chopping method apparatus enables the processing of ice or frozen food items which are desired to be processed and reduced in size while in their frozen state. Accordingly, the term ice chunks may at times be used to define a larger piece of ice which is to be reduced into smaller pieces or fragments of predetermined size. The ice chunks may consist of ice in the form of cubes, pieces, cones, cylinders, any of which may be solid or hollow or in any shape in which such ice is formed by ice trays, ice forming apparatus or ice machines. Thus, the purpose of the apparatus of the present invention is to reduce ice of one size into a smaller size regardless of its shape or configuration or the terminology used.
Referring now to FIG. 2, the ice chopping apparatus in this invention is illustrated in use in connection with a food processor which is indicated generally with the reference numeral 10. The food processor 10 includes a base housing 12 having a relatively powerful electric motor 14 mounted therein which is energized by power cord 16 via a switch 17 having a vertically movable actuating button 18. A vertical drive shaft 15 extends upward from the base housing 10 and a working bowl 20 is mountable on the housing 12 surrounding the drive shaft 15. An ice chopper tool 25 which will be described more in detail hereinafter is mounted on the drive shaft 15 for rotation therein within the bowl 20. It will be understood that in conventional food processors a variety of different types of food processing tools may be selectively mounted on the drive shaft 15 to be driven by the motor 14 within the bowl 20.
A vertical semi-cylindrical boss 21 formed an the side of the bowl 20 defines a guideway in which is carried a vertical movable operating rod 22 which is normally urged upwardly by means of a spring 24. When the bowl 20 is properly positioned on housing 12, the operating rod 22 is aligned with the actuating button 18 of the switch 17 being separated therefrom by means of a flexible liquid-tight membrane 26. A handle 27 is attached to the bowl 20 opposite to the boss 21. The top of the bowl 20 is closed by a cover 28 which is arranged to be engaged in lock relationship in a normal operating position on the bowl 20 whenever the food processor 10 is in operation. The cover 28 may be held in lock engagement with the bowl by placing the cover on the rim of the bowl and turning the cover to obtain a twist lock effect. A conventional way of obtaining this locking engagement is illustrated with the cover having a plurality of circumferentially located depending lugs 30 which upon rotation of the cover 20 engage underneath a plurality of cooperating radial edges 32 on the bowl 20 near its rim. At the same time a cam 34 extending downwardly on the cover 20 depresses the actuator rod 22 which closes the switch 17 to enable the operation of the motor 14 for driving the tool shaft 15. The cover also includes a feed tube 35 which in the present application feeds ice chunks or frozen food pieces which are to be chopped and reduced in size through the cover to be applied to the ice chopper tool 25.
In order to control the application of the ice which is to be chopped by the food processor 10 as well as to aid in the regulation of the size of the ice fragments which are produced, a removable annular channel member 40 as is best seen in perspective view of FIG. 8 and in sectional view in FIG. 3 is provided with an annular shelf 36 having an upstanding rim 38 extending therefrom as well as a down turned annular skirt 39. The annular channel member 40 is adapted to be positioned on the working bowl with the shelf 36 lying on the upper periphery of the bowl with the upturned rim 38 providing a continuation of the cylindrical side wall of the bowl 20 and the down turned annular skirt 39 resting in the upper interior annular side wall of the bowl 20. The annular channel member 40 includes an upstanding annular wall 42 which forms on its top an annular seat 44 for the cover 28. A slope guide 46 extends downward from the annular seat 44 and terminates in a downward extending cylindrical skirt or wall portion 48 which extends to an area above the periphery of the ice chopper tool 25 forming an escape gap 50 therebetween which in effect determines the size of ice particles which are permitted to escape or be discharged into the bowl 20 as will be described in greater detail hereinafter.
It will be noted that the insertable annular channel member 40 which is mounted on top of the working bow 20 between the bowl and the cover 28 thus elevates the cover roughly by the distance or length of the upstanding annular wall 42. In view of this fact the cover 28 must be equipped with a cam 34 which extends to a lower level on the bowl 20 so that it may engage the push rod 22 when the annular channel member 40 is inserted on the bowl 20. Accordingly, as will be seen in FIGS. 1 and 2 the cover 28 is equipped with conventional cams 33 which are adapted to actuate the push rod 22 when the ice chopping apparatus of the present invention is not in use, and it is desired to actuate the food processor by locking the cover on top of the bowl for other food processing operations. In addition the cover 28 is equipped with the lower extending cams 34 so that the ice chopping apparatus of the present invention can be used on the bowl 20 and the mounting of the diametrically opposed camming arrangement is so that the cover with its feed tube 350 may be positioned on different sides of the bowl 20. It will be appreciated that only one of the conventional cams 33 may be formed on the cover along with one of the longer cams 34 if so desired.
As will best be seen in FIGS. 3 and 9, the ice chopper tool 25 has a disc 52 with a flat, smooth disc-like upper surface 53 having an annular skirt 54 thereon. The disc 52 carries a hub 56 illustrated as having a three piece construction including a disc-like plate 58, a socket member 62 having a socket 60 therein and a sleeve 64. The hub 56 may be formed of a single member instead of the three piece construction which is illustrated. The upper surface 53 of the disc 52 has blades 66 and 68 protruding therefrom. The leading edges 69 of these blades with the disc 52 rotating in the direction shown by the arrow 70 chops ice which comes into contact therewith. Two blades 66 and 68 are illustrated since this is the preferred form. However, one or more blades can be used with two appearing to be the most efficient. The blades are also spaced radially outward on either side of the hub 56 with the outer blade 68 being the furthest from the hub and closest to the perimeter skirt 54 on the periphery of the disc 52. As will best be seen in FIG. 3, the hub 56 and the cylindrical skirt 48 form a channel 72 above the blades 66 and 68 which funnels the ice fed through the feed tube 35 onto the blades hitting the ice with a powerful impact thereby performing the chopping function.
The hub 56 contains a socket 60 having semi-curcular grooves or keyways 74 therein which extend different distances upwardly into the walls of the socket and are spaced around the walls of the socket. As will be seen in FIG. 4, the socket 60 has a hexagonal configuration with the grooves 74 being spaced and centered on the six hexagonal surfaces of the socket member 62. As will be explained, the socket 60 is adapted to receive a male head 76 of a shank 78.
As will best be seen in FIG. 7, the shank head 76 has the same external configuration as the socket 60 being illustrated in hexagonal form with one face thereof carrying a key 80 thereon. The other end 82 of the shank 78 is adapted to be positioned on the vertical drive shaft 15 of the motor 14. In other words, the shank 78 may be removably mounted on the shaft 15 on end 82 and the other end, namely the head 76 is adapted to be removably mounted in the socket 60 of the hub 56.
The geometric configurations of the socket 60 and the male shank head 76 must be geometrically complementary so that the male head 76 will fit into the socket 60. Spaced around the interior of the socket 60 are the semi-circular keyways or grooves which receive the key 80 of the male head 76. The depth of the semi-circular grooves or keyways are varied so that when the shank head 76 is inserted into the socket 60, it will penetrate to different depths thereby mounting the disc 52 carrying the hub 56 at varying heights on the shank head 76. This in effect provides a way of elevating or lowering the disc 52 on the shank 78. The ability to vary the positioning of the disc 52 with respect to the cylindrical skirt 48 of the annular channel 40, thereby varies the escape gap 50 and provides the means of adjusting the size of the fragments which are chopped by the apparatus.
Returning again to FIG. 3, it will be noted that the escape gap 50 is established between the lower end of the skirt 48 and the periphery of the disc 52 above its skirt 54. The escape gap 50 provides a means for ice chopped in the channel 72 to be discharged or ejected from the channel 72 into the bowl 20. In other words, the escape gap 50 determines the size to which the ice fed from the feed tube 35 into the channel 72 must be fragmented before it can leave the channel 72. As is illustrated in FIG. 4 in the present illustrations six settings are provided which determine how high the disc 52 is mounted on the shank 78. By rotating the shank head 76 so that the key 80 is aligned with one of the settings 1 through 6 and inserting it into the socket 60 provides the separation between the disc 52 and the lower end of the skirt 48 designated as the escape gap 50. As will be seen in FIG. 3, a "1" setting of the gap is illustrated which is extremely fine for producing ice fragments of almost snow flake particle size. On the other hand, by placing the key 80 in the keyway groove 74 under setting 6 as shown in FIG. 4, a "6" setting as illustrated in FIG. 5 is produced. Similarly, by removing the shank head 76 and rotating the key 80 to a number 5 setting as shown in FIG. 4 produces the "5" setting as illustrated in FIG. 6. The varying of the escape gap 50 produces different separations between the upper surface 53 of the disc 52 and the lower edge of the cylindrical skirt 48 which permits ice fragments to leave the channel 72 in accordance with that setting. The greater the separation, the larger the escape gap 50 which produces larger ice fragments by the apparatus.
Reviewing the operation, if a food processor is utilized, the cover 28 is first removed and any rotary tools which are positioned on the shaft 15 are removed. The shank 78 is then inserted into the hub 56 with the key 80 being inserted in the socket 60 in the setting that is desired. Suppose, for example, it is desired to make ice for a shrimp cocktail, then a setting of 3 or 4 would be suitable and the keyway 80 would be placed in the socket with the key aligning with setting number 3 as shown in FIG. 4. The ice chopping tool is then mounted on the motor shaft 15 and the annular channel member 40 is mounted on top of the bowl 20. The cover 28 is positioned such that the lower extending cam 34 actuates the push rod 22 to turn on the switch 17 to operate the motor 14. Ice chunks, pieces or cubes which are desired to be reduced in size are fed through the feed tube 35 which are directed by the slope guide 46 into the channel 72 between the hub 56 and the cylindrical skirt 48 where the ice comes in contact with the leading edge 69 of the chopping blades 66 and 68. The impact with the leading edge of the chopping blade fragments the ice chunks, and the process is continued until the ice fragments are reduced to a size capable of passing through the escape gap 50, thus being ejected and discharged through the escape gap into the bowl 20. Larger or smaller fragments may be provided simply by changing the positioning of the shank head 76 in the socket 60.
As is illustrated in FIG. 10, the outer chopping blade 68 may be turned at an angle with respect to the annular skirt 54 of the disc 52 which tends to deflect the ice fragments outward toward the escape gap 50.
In accordance with the present invention an annular channel 72 is established between the hub 56 and the cylindrical skirt 48 with an escape gap on the periphery thereof of predetermined size which permits ice which is reduced to that size to be discharged from the channel. This is a simple effective apparatus for reducing the size of ice chunks to any predetermined size desired. The structure for carrying out the production of ice particles of controlled size is simple and relatively easily adaptable to conventional food processors or to a less multiple function appliance such as a blender where controlled size of the ice fragments is a desirable feature. However, the biggest advantage of the present invention is its use with conventional food processors which in effect expands their utility. The addition of the chopper tool, the annular channel member and a multiple purpose cover which provides cam action for conventional as well as the ice chopping function are useful additions in the food processor field.
Since other changes and modifications varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the examples chosen for purposes of illustration, and includes all changes and modifications which do not constitute a departure from the true spirit and scope of this invention as claimed in the following claims and equivalents thereto.
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An ice chopping apparatus is provided for a food processor having a base containing a motor and a motor-driven rotary tool drive which extends into a working bowl. The apparatus involves mounting a rotary ice chopping tool on the tool drive in the working bowl and establishing an annular channel around the chopping tool, forming an escape gap of predetermined size around the perimeter of the annular channel and feeding ice chunks into the channel. These chunks when reduced to the proper size are discharged through the escape gap and become deposited in the bowl. The gap may be adjusted for varying the size of the discharged ice fragments. The apparatus includes a removable disc-like head having a socket on the underside and preferably two radially spaced blades protruding upwardly from the disc-like member, with their front edges chopping the ice. The socket receives a removable shank of the same geometrical shape coupled on the other end to the rotary drive. The shank has a key which fits into spaced key-shaped channels in the socket, extending to different depths therein for varying the size of the escape gap between the annular channel and the rotary tool, thereby varying the size of the ice fragments produced. The annular channel has a cylindrical skirt extending downwardly from an upstanding peripheral rim which fits onto the bowl for receiving a cover which includes auxiliary actuator cams to actuate the motor drive.
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TECHNICAL FIELD
[0001] The present invention relates generally to gas-fired appliances, and, more particularly, to a damper control mechanism for a water heater or other gas-fired appliance.
BACKGROUND OF THE INVENTION
[0002] Many gas-fired appliances, such as boilers or water heaters, include burners that fire to raise the temperature of materials, such as water, contained within a tank. In many such appliances, the burners periodically cycle on and off. When the contents of the tank fall below a desired minimum temperature, a call for heat is triggered, which initiates the firing of a main gas burner assembly. The resulting heat generated by the burner acts to raise the tank temperature. When the tank temperature reaches a desired maximum threshold, the main burner is deactivated, until such time as the tank cools and again falls below the minimum desired temperature. A small pilot burner can be provided to maintain a small flame under normal operation, which flame is used to ignite the main burner when desired.
[0003] To increase the energy efficiency of such gas-fired appliances, many systems include one or more dampers. For example, a flue damper can be provided within an exhaust flue near the top of a gas fired appliance. The flue damper is opened during operation of the main burner, to permit the venting of heat and exhaust gases generated during operation of the main burner. However, once the main burner is shut off, the flue damper closes the flue, thereby reducing heat loss out the flue and retaining heat within the appliance to improve the overall energy efficiency of the appliance.
[0004] Conventionally, dampers can be operated using an electric motor supplied by 24 volt or 120 volt power sources. However, such designs typically require the routing of a power source to the location of the gas-fired appliance, potentially increasing installation costs. More recently, gas fired appliances have been designed using thermoelectric devices such as one or more 750 millivolt thermopiles, operating using heat from the pilot flame, to power a low-power motor. The low-power motor in turn operates the flue damper.
[0005] However, many gas-fired appliances, particularly residential water heaters, do not include power sources having sufficient voltage to reliably operate a damper motor. As a result, many residential water heaters are primarily mechanically operated. While some such water heaters may utilize a thermocouple to operate a magnetic pilot safety switch, such thermocouples typically generate only 10 to 30 millivolts, and do not supply sufficient power to drive a damper motor. Because of such control limitations, flue dampers are often not provided on residential water heaters, thereby sacrificing potential improvements in energy efficiency.
SUMMARY OF THE INVENTION
[0006] In accordance with one exemplary form of the invention, a gas-fired appliance is provided, having a burner which is configured to receive and burn pressurized gas, such as natural gas, during operation. A diaphragm device includes an inlet which is exposed to the gas pressure during operation of the burner. The diaphragm device also includes a moveable member, such as a flexible diaphragm exposed to ambient pressure on one side and the pressure of the pressurized gas on the other, such that it moves in response to the application of pressurized gas at the diaphragm device inlet. A linkage, which may be directly or indirectly connected to the diaphragm device, moves in response to movement of the moveable member. In some embodiments, the linkage may be comprised of a metal cable sliding within a stationary sheath, or a shaft. The linkage is connected to a damper assembly, which includes a damper that is movable between open and closed positions in response to movement of the linkage. The damper assembly may also include a rotatable damper shaft on which the damper is mounted, and a lever arm secured to the rotatable damper shaft at a first location and secured to the linkage at a second location.
[0007] In accordance with some embodiments, the gas-fired appliance further includes a pilot burner, and a thermoelectric device, such as a thermocouple or thermopile, positioned near the pilot burner, such that the thermoelectric device generates an electrical voltage differential when exposed to heat from the pilot burner. A magnetic pilot valve controls gas flow to the pilot burner, and features an electrical input. The magnetic pilot valve is maintained in an open position in response to the maintenance of the voltage generated by the pilot flame. A switch circuit is interposed in an electrical conduction path between the thermoelectric device and the magnetic pilot valve electrical input, whereby it can operate to control the transmission of the electrical voltage differential generated by the thermoelectric device to the magnetic pilot valve electrical input. The switch circuit is movable between an open state and a closed state in response to movement of the linkage. Accordingly, if the linkage becomes resident in an intermediate state, corresponding to a partially-opened or partially-closed damper position, the switch circuit can be configured to assume an open state, thereby cutting off the application of electrical voltage to the magnetic pilot valve and thus stopping the supply of gas to the pilot burner.
[0008] The linkage may include a damper control activation arm, which pivots between a first position and a second position in response to movement of the linkage. In some embodiments, the damper control activation arm moves throughout a predetermined range of motion, in which the first position comprises a range from zero to about 20 percent of the predetermined range of motion, and the second position comprises a range from about 80 percent to 100 percent of the predetermined range of motion.
[0009] The damper control activation arm can interact with the switch circuit to control the state thereof. For example, the switch circuit can include a first switch and a second switch, electrically connected in parallel. The first switch is closed by the damper control activation arm when the damper control activation arm is in the first position, while the second switch is closed when the damper control activation arm is in the second position. Accordingly, the switch circuit can operate to provide a closed electrical path when the damper control activation arm is in either the first position or the second position.
[0010] In such an embodiment, additional components can be provided to maintain an electrical voltage differential at the magnetic pilot valve input for a period of time when the damper control activation arm transitions between the first and second positions. Such components may include a resistor and a capacitor, whereby the capacitor is connected between a signal path leading to the pilot valve electrical input and a ground reference voltage. Accordingly, the capacitor can become charged by the electrical voltage differential provided by the thermoelectric device when the switch circuit is in a closed state, and the capacitor can discharge to provide an electrical voltage differential to the magnetic pilot valve switch when the switch circuit is in an open state.
[0011] The damper control activation arm can include a first arm portion and a second arm portion. The first arm portion depresses a contact on the first switch when the damper control activation arm is in the first position. The second arm portion depresses a contact on the second switch when the damper control activation arm is in the second position.
[0012] A damper control mechanism for an appliance that operates through combustion of gas having a pressure greater than ambient pressure is also provided. The control mechanism includes a diaphragm device having an inlet that is exposed to the gas pressure during operation of the appliance. The diaphragm device further includes a moveable diaphragm having a first side and a second side. The moveable diaphragm is exposed to pressure conditions of the inlet on the first side, and ambient pressure conditions on the second side. Accordingly, the moveable diaphragm moves in response to change of pressure at the inlet. The moveable diaphragm occupies a first position when the inlet is under ambient pressure conditions, and a second position when the inlet is exposed to the gas pressure. The damper control mechanism also includes a linkage which is operably connected to the diaphragm device and the damper, whereby the linkage imparts movement on the damper in response to movement of the moveable diaphragm.
[0013] The damper control mechanism may also include a thermoelectric device having an output capable of generating an electrical voltage differential. A circuit which includes one or more electrical switches electrically connects the thermoelectric device and a magnetic pilot valve. The linkage contacts the one or more electrical switches to disconnect the thermoelectric device from the magnetic pilot valve when the movable diaphragm is not within either the first or the second position. A capacitor can be provided, having a first term terminal electrically connected with the thermoelectric device and the magnetic pilot valve, and a second terminal connected to a ground reference voltage. Accordingly, if, for example, the one or more switches are placed into an open position to disconnect the capacitor from the thermoelectric device, the capacitor can temporarily apply an electrical voltage differential to the magnetic pilot valve.
[0014] The linkage may include an arm attached to a pivot, such that the arm pivots between a first position and a second position during movement of the linkage. The arm can be mounted proximate the one or more electrical switches, such that it contacts the switches to change their state during movement of the arm.
[0015] A method for controlling a damper in a gas-fired appliance is also provided. The method includes the steps of applying pressurized gas to a first portion of the gas-fired appliance which includes a main burner. The method further includes the step of opening a damper by moving a linkage connected to the damper via an application of mechanical force generated by the introduction of pressurized gas into the first portion of the gas-fired appliance. The step of applying pressurized gas to a first portion of the gas-fired appliance may include the step of applying pressurized gas to a diaphragm device to cause movement of said diaphragm device. The step of opening a damper by moving a linkage may include the step of moving the linkage in response to said movement of the diaphragm device.
[0016] In other embodiments, the step of opening a damper via movement of the linkage can include the steps of: providing a magnetic pilot valve which maintains an open position in response to the maintenance of an electrical signal at an input terminal; applying the electrical signal to the magnetic pilot valve input terminal when the damper is in an open or closed position; and removing the electrical signal from the magnetic pilot valve input terminal when the damper occupies a partially-opened position for at least a predetermined period of time. The predetermined period of time can be zero or greater. In some embodiments, the predetermined period of time is at least about 2 seconds. In other embodiments, the predetermined period of time is between about two seconds and about three seconds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a diagrammatic view of a portion of a gas-fired appliance, having a manually-operated damper and pilot power control switch, in accordance with one embodiment of the invention.
[0018] FIG. 2 is a schematic block diagram of a flue damper control circuit.
[0019] FIG. 3 is a perspective view of a pilot power control switch.
[0020] FIG. 4 is an elevation view of a portion of a pilot power control switch, in a position corresponding to an open damper condition.
[0021] FIG. 5 is an elevation view of a portion of a pilot power control switch, in a position corresponding to a closed damper condition.
[0022] FIG. 6 is a perspective view of a damper.
DETAILED DESCRIPTION
[0023] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings and will herein be described in detail, certain specific embodiments with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments so illustrated or described.
[0024] Referring initially to FIG. 1 , a portion of a gas-fired appliance, such as a water heater, is illustrated. Gas fired appliance 100 receives combustible gas, such as natural gas, via supply line 110 . The gas is supplied at a pressure greater than the ambient air pressure in which the main appliance burners 112 (shown schematically) operate. Gas is fed into control body 120 and through pilot valve 130 , which supplies gas to a pilot burner 132 (shown schematically). Once pilot burner 132 is ignited, pilot valve 130 is maintained in an open position by pilot valve magnet 140 , which is energized by voltage received at thermoelectric device connection 150 . Thermoelectric device connection 150 is energized by thermoelectric device 160 (illustrated in FIG. 2 ). In exemplary embodiments, thermoelectric device 160 may include a thermocouple or a thermopile. Thermoelectric device 160 is positioned adjacent pilot burner 132 to generate voltage when exposed to the heat of the pilot flame. If the pilot flame is extinguished, thermoelectric device 160 ceases generation of sufficient voltage for pilot valve magnet 140 to maintain pilot valve 130 in an open position, thereby stopping the flow of gas to pilot burner 132 via supply tube 170 and preventing unintentional flooding of unburned gas.
[0025] Control body 120 further includes gas pressure regulator 180 , which operates to regulate the gas pressure within control body 120 . Temperature controlled burner valve 190 operates to limit the conditions under which gas is supplied to primary appliance burners 112 via burner supply tube 200 . For example, in an embodiment in which gas fired appliance 100 is a water heater, a temperature sensor can be provided within the water tank, such that a call for heat is issued when the water temperature falls below a desired level. In response to a call for heat, burner valve 190 is opened, thereby supplying gas to main burner 112 through burner supply tube 200 . When burner 112 acts to raise the monitored temperature above a desired maximum level, burner valve 190 is closed, thereby shutting off the flow of gas to burner 112 .
[0026] In addition to providing gas feeds to pilot burner supply tube 170 and main burner supply tube 200 , control body 120 further includes a gas pressure tap port 210 . Gas pressure tap port 210 is connected to a diaphragm device 220 via tube 230 to communicate pressure within control body 120 therethrough. Thus, when pilot valve 130 and main burner valve 190 are both open, the resulting flow of gas pressurizes a chamber to which gas pressure tap port 210 is connected. When main burner valve 190 is closed, gas pressure tap port 210 and thus diaphragm device 220 are exposed to ambient pressure conditions.
[0027] Diaphragm device 220 is a mechanism having an inlet 231 , which is alternatively exposed to pressure of the gas or ambient pressure conditions, depending upon the state of main burner valve 190 . Diaphragm device 220 also includes a movable member 232 , which is a structural component displaced in response to the application of gas pressure to an inlet portion of the device. Moveable member 232 includes a first surface 233 which is exposed to the pressure conditions of the inlet, and a second surface 234 that is exposed to ambient pressure conditions. Accordingly, moveable member 232 is displaced in response to changes in inlet pressure. For example, in some embodiments, moveable member 232 may include a diaphragm, such as a thin, flexible membrane, spanning inlet and ambient conditions.
[0028] Moveable member 232 within diaphragm device 220 is operably interconnected with intermediate shaft 235 and damper control activation arm 240 , forming a portion of an operable linkage with device 220 . When gas pressure is applied to the inlet side of diaphragm device 220 , intermediate shaft 235 moves upwards, causing damper control activation arm 240 to pivot about pivot point 250 in the direction of the illustrated arrow 251 . When gas pressure is released from diaphragm device 220 , intermediate shaft 235 returns to a lowered position and activation arm 240 pivots oppositely to the direction indicated by arrow 251 .
[0029] Damper control activation arm 240 is illustrated in perspective view in FIG. 3 . In the illustrated embodiment, damper control activation arm 240 is made with first arm portion 240 a and second arm portion 240 b , which are mechanically connected. One end 252 of damper control activation arm 240 interacts with a switch circuit 260 that includes pilot power control switches 260 a and 260 b , which are mounted adjacent to one another.
[0030] Pilot power control switches 260 a and 260 b are further illustrated in FIGS. 4 and 5 . Pilot power control switches 260 a and 260 b include switch arms 265 a and 265 b , respectively. Switch arm 265 a extends downwards from the point at which it is attached to switch 260 a . Switch arm 265 b extends upwards from the point at which it is attached to switch 260 b . Damper control activation arm 240 a is aligned to interact with pilot power control switch 260 a , such that switch arm 265 a is depressed when activation arm 240 is moved to a first position, as shown in FIG. 4 , and released when activation arm 240 is moved to a second position, as shown in FIG. 5 . Damper control activation arm 240 b is aligned to interact with pilot power control switch 260 b , such that switch 265 b is depressed when activation arm 240 is in the second position, shown in FIG. 5 , and released when activation arm 240 is in the first position of FIG. 4 . In the exemplary embodiment of FIGS. 4 and 5 , the first activation arm position ( FIG. 4 ) is maintained over a range from about 80% to about 100% of the normal range of travel of activation arm 240 , in which gas is being supplied to the main burner and the flue damper is substantially open. The second activation arm position ( FIG. 5 ) is maintained over a range from about zero to about 20% of the normal range of travel of activation arm 240 , in which the supply of gas to the main burner has been shut off and the flue damper is substantially closed.
[0031] Damper control activation arm 240 is further connected to link 270 , which extends to control the opening and closing of flue damper 280 , illustrated in FIG. 6 . In an exemplary embodiment, link 270 may incorporate a cable structure, such as a metal cable that slides freely within a polymer sheath. Alternatively, it is understood that other varieties of mechanical links that are known in the art could be implemented, such as a rod or shaft. The end of link 270 opposite damper control activation arm 240 is attached to lever arm 290 , which is secured to damper control shaft 300 . Damper 280 is mounted on control shaft 300 . Accordingly, movement of link 270 results in pivoting of control shaft 300 and damper 280 between open and closed positions.
[0032] In operation, when appliance 100 initiates a call for heat, temperature controlled burner valve 190 opens, which permits the flow of pressurized gas to main burner 112 , gas pressure tap port 210 , tube 230 and diaphragm device 220 . The resulting displacement of diaphragm device 220 causes movement of intermediate shaft 235 , pivoting of damper control activation arm 240 and movement of link 270 , which in turn pivots damper 280 into an open position, so that exhaust is vented while main burner 112 is ignited. When continued activation of main burner 112 is no longer required, temperature controlled burner valve 190 closed, thereby depressurizing gas pressure tap port 210 and diaphragm device 220 . Shaft 235 is displaced downwards, which pivots damper control activation arm 240 and moves link 270 , which in turn pivots damper 280 into a closed position, so that heat loss from appliance 100 is reduced.
[0033] Damper switches 260 a and 260 b operate to provide added safety measures in the event that damper 280 becomes stuck in a partially-opened position. In such a position, the flue may be opened sufficiently to permit operation of main burner 112 without tripping a flame safety switch in the burner chamber, but it may not provide enough venting of the flue to eliminate the creation of high levels of carbon monoxide. Accordingly, a further safety feature is provided to address partial opening of the damper.
[0034] In the embodiment illustrated in the schematic diagram of FIG. 2 , pilot power control switches 260 a and 260 b are wired in parallel, between thermoelectric device 160 and pilot magnet 140 , such that voltage generated by thermoelectric device 160 is applied to pilot magnet 140 when activation arm 240 is in a raised or lowered position. However, if damper 280 becomes stuck in a partially-opened or partially-closed position, activation arm 240 is likewise placed into an intermediate position, such that neither of switches 260 a and 260 b is closed. As a result, power to pilot magnet 140 is interrupted, such that pilot valve 130 is closed and the flow of gas to main burner supply tube 200 and pilot burner supply tube 170 is interrupted, thereby shutting off the main burner 112 and pilot burner 132 and avoiding misoperation that might otherwise be caused by partial closure of damper 280 during firing of main burner 112 . Further safety measures can be implemented through the operation of spill switch 302 , interposed between damper switches 260 a , 260 b and thermoelectric device 140 , and flame safety switch 304 , interposed in the connection of thermoelectric device 140 to ground. These components interrupt burner operation, thereby to avoid excessive heat generation in the combustion chamber, as may be caused by potentially a number of different conditions.
[0035] While the above-described termination of power to pilot valve magnet 140 can avoid undesired operating conditions if damper 280 sticks in a partially-open or partially-closed position, even during the intended operation, damper control activation arms 240 will inherently move momentarily through an intermediate position, in which neither of switches 260 a and 260 b is closed, when transitioning normally between elevated and lowered states. In some embodiments, gas pressure tap port 210 will fully pressurize in about 2 to 3 seconds after opening of burner valve 190 , during which period damper control activation arm 240 and flue damper 280 are moved between open and closed positions. In order to avoid unintentional closure of pilot valve 130 during this transition period, a lowpass filter or timer circuit is provided between damper switches 260 a and 260 b , and pilot magnet 140 . In the embodiment of FIG. 2 , a series RC circuit with resistor 310 and capacitor 320 is provided. Resistor 310 and capacitor 320 operate to temporarily maintain the voltage level present at pilot magnet 140 when both of switches 260 a and 260 b are opened.
[0036] Capacitor 320 can be sized to accommodate the target switching time, voltage levels and circuit resistance. For example, in an embodiment utilizing a thermocouple having a nominal minimum operating voltage of 10 millivolts and a circuit resistance of 0.017 Ohms, and requiring at least 5 millivolts applied to pilot magnet 140 to maintain pilot valve 130 in an open position, it can be determined that a 220 Farad capacitor would maintain the required voltage level for around 2.6 seconds. In embodiments utilizing a thermopile in place of a thermocouple, the higher operating voltages would allow for a smaller capacitor to maintain the required pilot magnet voltage for a given period of time.
[0037] The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto, inasmuch as those skilled in the art, having the present disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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A damper mechanism for a gas-fired appliance is disclosed. The damper mechanism is mechanically operated in response to changes in pressure within a portion of the appliance. Changes in gas pressure operate to displace a diaphragm, thereby moving a linkage attached to a flue damper, such that the damper can be moved between open and closed positions. An interim damper control activation arm can pivot in response to movement of the linkage to actuate electrical switches, which act to close a magnetic pilot valve when the damper is in a partially-opened or partially-closed position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of microprocessors, and in particular to microprocessors having an extended address space.
2. Description of Related Art
An 8-bit data structure and 16-bit address structure has been, and continues to be, a common architecture for low cost microprocessors, or microcontrollers, such as the 80C51 family of processors, and others, that have a legacy that extends back for decades. During these decades, a number of software/firmware applications and routines have been developed.
To remain competitive, application developers continually add features and functions to devices that use microprocessors. Unfortunately, the 16-bit address structure of common processors limits the size of programs, or the amount of data, that can be embodied within these devices. Larger capacity devices, such as 32-bit processors, can address a larger program or data space, but are typically more expensive than conventional 8-bit processors. Moving an existing application from one processor family to another in order to provide a larger addressable space for adding additional features, however, typically requires a substantial investment. The development personnel must be trained to use the new processor; libraries of “utility programs”, such as mathematical routines and interrupt routines, must be rewritten for the new processor; time-dependent routines must be tested and verified on the new processor; idiosyncratic behavior of the new processor must be discovered and overcome; and so on.
Expanding the addressing space of an existing processor alleviates a number of the difficulties associated with a transition to a new processor, but also introduces a number of compatibility issues with applications and routines that were developed for the existing shorter-address processor. Consider, for example, the effect of a larger addressing space on the operation of a conventional stack. When a subroutine is called, the location of the address to which the subroutine should return is “pushed” onto the stack. When a return is executed from the subroutine, the appropriate number of bytes must be “popped” off the stack. The number of bytes popped off the stack corresponding to an address must equal the number of bytes pushed onto the stack. A straightforward solution would be to always push the largest number of address bytes onto the stack, and to always pop this largest number of bytes off the stack. As is known in the art, however, stack resources are often limited, and, because stack utilization is dynamic and often condition-dependent, a maximum required stack size is difficult, and sometimes impossible, to determine. This is particularly problematic with regard to interrupt-driven processes. Each time an interrupt is received, the ‘next-address’ is pushed onto the stack and an address associated with the processing of the particular interrupt becomes the ‘next-address’. If the interrupt calls another process, another address is pushed onto the stack. These addresses remain on the stack until the process associated with the interrupt is completed. If an additional interrupt occurs before the original interrupt is completed, one or more additional addresses will be pushed onto the stack. If an address is pushed onto the stack beyond the limits of the stack (a “stack-overflow” error), unpredictable results will occur. As is also known in the art, stack overflow errors are extremely difficult to diagnose. Increasing each pushed and popped address from two bytes (16-bits) to three bytes could amount to a 50% increase in stack utilization. Such a large increase in stack utilization may preclude the use of this technique for a number of legacy applications, due to the increased likelihood of stack overflow errors.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide a processing system and method that allows for extended memory addressing while maintaining compatibility with legacy devices. It is a further object of this invention to provide a processing system and method that allows for a dynamic control of stack allocation and utilization. It is a further object of this invention to provide a processing system and method that allows for a dynamic control of stack allocation and utilization for interrupt processing.
These objects and others are achieved by providing a processing system with extended addressing capabilities, and with a control bit that controls the number of address bytes that are stored onto a program stack. If the control bit is set to a first state, the address is pushed onto the program stack in the same manner as that used for shorter-address legacy devices. If the control bit is set to a second state, the address is pushed onto the program stack using the number of bytes required to contain a longer extended address. This same control bit controls the number of bytes that are popped off the stack upon return from an interrupt subroutine. The state of the control bit is controlled by one or more program instructions, thereby allowing it to assume each state dynamically. This dynamic control of the number of bytes pushed and popped to and from the stack allows for an optimization of stack utilization, and thereby further compatibility with legacy devices and applications.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in further detail, and by way of example, with reference to the accompanying drawings wherein:
FIG. 1 illustrates an example block diagram of a processing system architecture that is suitable for use in accordance with this invention.
FIGS. 2A-2C illustrate an example program and stack operation in accordance with this invention.
Throughout the drawings, the same reference numerals indicate similar or corresponding features or functions.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an example block diagram of a processing system 100 in accordance with this invention. The processing system 100 includes an instruction processor 110 that executes a sequence of program instructions 120 . The program instructions 120 are located in a memory that may be integrated on the same integrated circuit as the instruction processor 110 , or external to the integrated circuit, or a combination of both, wherein some of the instructions are in an internal memory and some are in an external memory. The program counter 125 controls the sequence of instructions 120 that are executed by containing the address of the ‘next-instruction’ as each instruction is executed. Most often, the program counter 125 is merely incremented by each instruction's size, so that the execution progresses from one instruction to the next in a sequential manner. Some instructions, however, modify the contents of the program counter 125 to effect an execution of instructions at another segment of the instruction code. For example, in a continuous-operation application, when the instruction processor 110 executes the last instruction in the program instructions 120 , the content of the program counter is modified to contain the address of an instruction back at the beginning of the program instructions 120 .
The processing system 100 also contains a stack 130 and a stack pointer 135 . Often, the flow of a program involves a “call” to a subroutine at another segment of the instruction code to perform a particular task. Subroutines are often utility programs that may be called from any location in the program instructions 120 . When the task is completed, the program is expected to continue from the point at which the subroutine was called. To effect the return to the proper address, the address of the ‘next-instruction’ is pushed onto the stack 130 from the program counter 125 when the subroutine is called, and then is popped from the stack 130 into the program counter 125 when the subroutine completes. Because a number of addresses, and other items, may be pushed onto the stack, a block of memory is typically allocated for containing the stack 130 , and a stack pointer 135 is provided to address the current location in memory for storing the next set of bytes that are pushed onto the stack 130 . This stack pointer is incremented by the number of bytes pushed onto the stack, and decremented by the number of bytes popped from the stack, so that after each push and pop operation, it continues to contain the address of the current top of the stack 130 . The stack 130 may be located in an internal or external memory, or a combination of both.
The processing system 100 also includes an interrupt processor 140 that is configured to respond to interrupt events, which may be internal or external events. For example, an external event may be the receipt of a bit of information on a serial port, or a transition caused by the opening or closing of a switch, and so on. An internal event may be a timing signal that triggers the transmission of a bit of information on the serial port at a given bit rate, or an expiration of a watch-dog timer function, and so on. These interrupt events appear as signals on the interrupt inputs INT 1 141 , INT 2 142 , etc. of the interrupt processor 140 . As is common in the art, when an interrupt occurs the interrupt processor 140 effects a call to a subroutine that corresponds to the particular interrupt, as illustrated in FIG. 2 A. Typically, a particular memory location 201 , 202 , etc. is associated with each interrupt input INT 1 141 , INT 2 142 , etc. The set of memory locations corresponding to the set of interrupt inputs is termed the “interrupt vector”. Instructions located at each corresponding memory location are executed when the interrupt occurs. To conserve memory space, the interrupt vector in some processors only contains only the address of a subroutine that is to be executed when the interrupt occurs, and the effect of the occurrence of an address in the interrupt vector is equivalent to a program instruction to call the subroutine. For ease of reference and understanding, the memory locations 201 , 202 are illustrated with the corresponding interrupt call (ICALL) instruction in parentheses.
Also for ease of reference, a distinction is not made herein between implicit and explicit instructions, and the scope of this invention is not limited to either. For the purposes of this invention, an instruction corresponds to a cause of an action by the processing system 100 . As is known in the art, the cause of a processor's action may be the decoding of a sequence of bits in a program register, a predefined response to an internal event, a programmed response to an external event, and combinations of these sequencing methods and others, depending upon the particular processor's design. In response to an interrupt INT 1 141 , for example, in one embodiment, the processing system 100 may effect an implicit call to a subroutine at the address IAddr 1 that is located at the corresponding memory location 201 . In an alternative embodiment, the processing system 100 may effect the call to the subroutine in response to an explicit “ICALL IAddr 1 ” instruction that is located at the corresponding memory location 201 . Whether implicit or explicit, a call to a subroutine at a specified address is executed in response to an interrupt. As discussed above with regard to FIG. 1, a call to a subroutine causes the content of the program counter 125 to be pushed onto the stack 130 .
In accordance with this invention, the program counter is configured to contain an “extended address”. For the purposes of this disclosure, an extended address is an address field that may contain a larger numerical value than a non-extended address field. In the context of this invention, the non-extended address field corresponds to the conventional two-byte (16-bit) address field of a typical 8-bit processing system, such as the 80C51 family of processors, and the extended address field is a three-byte (24-bit) address field of a processing system of this invention that is designed to be compatible with programs that were developed for the conventional 8-bit processing system with 16-bit addressing. A 16-bit address is stored in the three-byte address field of the processing system of this invention by setting the upper order byte to zero and storing the 16-bit address into the lower two bytes of the three-byte address field. For ease of reference, a two-byte non-extended address field and a three-byte extended address field are used hereinafter, although one of ordinary skill in the art will appreciate that this invention is not limited to two-byte and three-byte fields.
Although the program counter 125 of the processing system 100 of FIG. 1 is three bytes wide, the processing system 100 of this invention allows for either two bytes or three bytes of the contents of the program counter 125 to be pushed onto the stack in response to an interrupt call (ICALL) instruction. An extended-interrupt flag 145 controls whether the interrupt processor 140 effects a two-byte or three-byte push of the contents of the program counter 125 onto the stack 130 . In a preferred embodiment, the extended-interrupt flag 145 is a programmable bit in a set of registers 150 used to control the operation of the various components of the processing system 100 . The extended-interrupt flag 145 also controls whether the return from the interrupt subroutine (RETI) effects a two-byte or three-byte pop from the stack 130 into the program counter 125 . If it is known, for example, that the execution of the program instructions 120 during a particular segment or time period will only include program instructions with addresses of 16 bits or fewer, the extended-interrupt flag 145 can be set to effect a two-byte push and pop during this segment or time period. In this manner, whenever an interrupt occurs during this segment or time period, only two bytes of stack memory will be used for storing the return address. When it is known that program instructions at addresses above 16-bits (64K) may be executed, and potentially interrupted, the extended-interrupt flag 145 is set to effect a three-byte push and pop for each ICALL instruction. Obviously, if the addresses of the potential program instructions are unknown, the extended-interrupt flag 145 is set to effect the three-byte push and pop.
FIG. 2B illustrates the operation of an example stack when the extended-interrupt flag is set to the non-extended state (two-byte mode), and FIG. 2C illustrates the operation of the example stack when the extended-interrupt flag is set to the extended state (three-byte mode). In FIG. 2B, an initial stack pointer SP value 250 is illustrated as pointing to an address A that corresponds to a current top of the stack. In the two-byte mode, the low order byte PCLow 261 is stored atop the stack, at address A+1, and the next higher order byte PCHigh 262 is stored atop that, at address A+2. The stack pointer SP value 250 ′ is updated to point to the new top of stack, A+2. In a preferred embodiment, the extended-interrupt flag defaults to the non-extended state, to provide compatibility with legacy applications.
In FIG. 2C, corresponding to the three-byte state of the extended-interrupt flag, after storing the PCLow and PCHigh bytes atop the stack, the next higher order (extended) byte PCExt 263 is stored atop them, at address A+3. The stack pointer SP value 250 ″ is updated to point to the new top of stack, A+3.
The called interrupt subroutine at IAddr 1 is illustrated in FIG. 2A as containing a sequence of instructions, at IAddr 1 , IAddr 1 +1, etc. that are executed when the processing system 100 executes the ICALL IAddr 1 instruction in response to an interrupt on input INT 1 141 . At the end of the subroutine, a return instruction RETI 219 is executed. The state of the extended-interrupt flag determines whether two bytes or three bytes are removed from the stack in response to this RETI instruction. If the extended interrupt flag is in the two-byte mode, corresponding to FIG. 2B, the PCHigh 262 byte is popped off the stack ( 130 of FIG. 1) and placed into the second order byte of the program counter ( 125 of FIG. 1 ), and the PCLow 261 is popped off the stack and placed into the low order byte of the program counter. The execution of the program continues at the address formed by the combination of the PCHigh and PCLow bytes. If the extended interrupt flag is in the three-byte mode, corresponding to FIG. 2C, the PCExt 263 byte is popped off the stack and placed into the third order byte of the program counter, and the PCHigh and PCLow bytes are popped off the stack and placed into the two lower order bytes of the program counter, as discussed above. The execution of the program continues at the address formed by the combination of the PCExt, PCHigh, and PCLow bytes. In both cases, the stack pointer SP value 250 is decremented to correspond to the top of the stack, A, before the interrupt routine was called, provided that the same number of bytes were pushed and popped from the stack at the execution of the ICALL and RETI instructions, respectively.
As would be evident to one of ordinary skill in the art, the dynamic control of the number of bytes pushed and popped to and from the stack allows for a high degree of stack utilization optimization, but also requires care to assure that a synchronization is maintained between the state of the extended-interrupt flag when the ICALL instruction is executed and when the RETI instruction is executed. The number of bytes pushed onto the stack by the ICALL instruction must match the number of bytes removed from the stack by the RETI instruction, otherwise, the stack pointer SP 250 will be pointing to a different location before and after the call to the interrupt subroutine. In a preferred embodiment, automated tools, such as compilers and linkers maintain control of the extended-interrupt flag, and insert the appropriate commands 230 that set the extended-interrupt flag to the desired state at select points in the program instructions.
The foregoing merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are thus within the spirit and scope of the following claims.
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A processing system with extended addressing capabilities includes a control bit that controls the number of address bytes that are stored onto a program stack. If the control bit is set to a first state, the address is pushed onto the program stack in the same manner as that used for shorter-address legacy devices. If the control bit is set to a second state, the address is pushed onto the program stack using the number of bytes required to contain a longer extended address. This same control bit controls the number of bytes that are popped off the stack upon return from an interrupt subroutine. The state of the control bit is controlled by one or more program instructions, thereby allowing it to assume each state dynamically. This dynamic control of the number of bytes pushed and popped to and from the stack allows for an optimization of stack utilization, and thereby further compatibility with legacy devices and applications.
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[0001] This application is a Divisional of co-pending application Ser. No. 11/205,164, filed on Aug. 17, 2005, which claims the benefit of Korean Patent Application No. P2004-65087 filed in Korea on Aug. 18, 2004, No. P2004-70600 and No. P2004-70601, filed in Korea on Sep. 4, 2004, and No. P2004-118586 filed in Korea on Dec. 31, 2004, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electro-luminescence display device, and more particularly, to a method and apparatus for driving an electro-luminescence display panel capable of doing an aging operation upon driving.
[0004] 2. Description of the Related Art
[0005] In recently, there has been developed various flat panel displays with a reduced weight and bulk that are free from the disadvantage of a cathode ray tube CRT. Such flat panel displays include a liquid crystal display LCD, a field emission display FED, a plasma display panel PDP, and an electro-luminescence (hereinafter, referred to as an EL) display devices.
[0006] Among these, the EL display panel is a self-luminous device capable of light-emitting a phosphorous material by a re-combination of electrons with holes. The EL display panel is generally classified into an inorganic EL panel using the phosphorous material as an inorganic compound and an organic EL panel using it as an organic compound. Such an EL display panel has many advantages of a low voltage driving, a self-luminescence, a thin-thickness, a wide viewing angle, a fast response speed and a high contrast, etc, such that it can be highlighted into a post-generation display device.
[0007] The EL display device includes: an anode formed of a transparent conductive material on a substrate; and a hole injection layer, a hole carrier layer, a light-emitting layer, an electron carrier layer, and an electron injection layer made of an organic material, and a cathode made of a metal having a low work function, which are disposed thereon. If a forward voltage is applied between the anode and the cathode, then electrons generated from the cathode move via the electron injection layer and the electron carrier layer to the light-emitting layer and holes generated from the anode moves via the hole injection layer and the hole carrier layer to the light-emitting layer. Accordingly, the electrons and the holes fed from the electron carrier and the hole carrier layer are re-combined each other in the light-emitting layer, to thereby emit light. In this case, the brightness of the organic EL device is in portion to a current between the anode and the cathode.
[0008] FIG. 1 is a circuit diagram showing equivalently a passive matrix type organic EL display device in which an organic EL element is arranged in a matrix type, and FIG. 2 is a driving waveform diagram of an EL panel 20 shown in FIG. 1 .
[0009] The EL display device shown in FIG. 1 includes: an EL panel 20 having an EL cell 26 formed at a cross of both scan lines SL 1 to SLn and data lines DL 1 to DLm; a scan driver 22 for driving the scan lines SL 1 to SLn; and a data driver 24 for driving the data lines DL 1 to DLm.
[0010] Each of the EL cells 26 formed in the EL panel 20 is represented as a diode, which is connected in a forward direction between the data line DL and the scan line SL. Herein, the data line DL is equivalently an anode and the scan line SL is equivalently a cathode. If a negative scan pulse, that is, a low scan voltage Vlow, is supplied to the scan line SL and a positive data signal (current) is supplied to the data line DL to as shown in FIG. 2 apply a forward voltage to each EL cell 26 , then each EL cell 26 emits light to generate light corresponding to the data signal. On the other hand, if a high scan voltage Vhigh is supplied to the scan line SL to thereby apply a reverse voltage to each EL cell 26 , then each EL cell 26 does not emit light.
[0011] The scan driver 22 , as shown in FIG. 2 , sequentially supplies a scan pulse to a n number of scan lines SL 1 to SLn. In other words, the scan driver 22 sequentially supplies the low scan voltage Vlow to the scan lines SL 1 to SLn during a scan period to thereby sequentially make the scan lines SL 1 to SLn to be enable, and supplies the high scan voltage Vhigh during the rest period to make the scan lines SL 1 to SLn to be disable. Further, the scan driver 22 repeats the sequential driving of the scan lines SL 1 to SLn for each frame F.
[0012] The data driver 24 supplies the data signal to the m number of data lines DL 1 to DLm for each period when the scan lines SL 1 to SLn are enabled.
[0013] In order for a stable driving in the related art organic EL display device, an aging process to make the EL cells 26 to be a reverse bias state is performed in manufacturing process. However, even the aging process is performed in the organic EL display device during the manufacturing process, the organic EL display device has a problem that its life-span becomes shorten because the EL cells 26 becomes deteriorated with the passage of driving time or a line defect such as short defect becomes generated due to a stress. In order to solve this problem, an aging operation is needed in the driving of the organic EL display device.
SUMMARY OF THE INVENTION
[0014] Accordingly, it is an object of the present invention to provide a method and apparatus for driving an electro-luminescence display panel capable of doing an aging operation upon driving.
[0015] In order to achieve these and other objects of the invention, a method of driving an electro-luminescence display panel according to the present invention includes: a scan period when electro-luminescence cells formed at a cross of both a plurality of scan lines and a plurality of data lines are line-sequentially emitted; and an aging period when an aging is performed in the electro-luminescence cells at the same time by applying a reverse bias, wherein the scan period and the aging period are repeated for each frame.
[0016] A high scan voltage is supplied the plurality of scan lines, and a low voltage is supplied to the plurality of data lines, in the aging period.
[0017] A low scan voltage is supplied to a scan line for an enable, and a first high scan voltage is supplied to a scan line for a disable, in the scan period, and wherein a second high scan voltage larger than the first high scan voltage is supplied to the plurality of scan lines in the aging period.
[0018] A method of driving an electro-luminescence display panel according to the present invention includes: a scan period when electro-luminescence cells formed at a cross of both a plurality of scan lines and a plurality of data lines are emitted; and an aging period when a voltage difference is generated between adjacent scan lines as floating the plurality of data lines to make a self-aging is performed in the electro-luminescence cells.
[0019] Aging voltages opposite to each other are applied to the adjacent scan lines in the aging period.
[0020] Any one aging voltage of high and low aging voltages is applied to an odd-numbered scan line, and an aging voltage opposite to that of the odd-numbered scan line is applied to an even-numbered scan line, in the aging period.
[0021] The aging voltage applied to the plurality of scan lines is reversed at least one time in the aging period.
[0022] The aging period is divided into a plurality of periods, and the aging voltage applied to each of the scan lines is reversed for each boundary spot of the divided periods.
[0023] The aging voltage applied to each of the scan lines is reversed at least one more time in the divided periods.
[0024] A low scan voltage is supplied to a scan line for an enable and a first high scan voltage is supplied to a scan line for a disable, in the scan period, and wherein a second high scan voltage larger than the first high scan voltage or equal to the first high scan voltage is supplied as the high aging voltage, and the low scan voltage is supplied as the low aging voltage, in the aging period.
[0025] The scan period and the aging period are repeated for each frame.
[0026] A method of driving an electro-luminescence display panel according to the present invention includes: a scan period when electro-luminescence cells formed at a cross of both a plurality of scan lines and a plurality of data lines are emitted; and an aging period when a voltage difference of a multilevel is generated between adjacent scan lines as floating the plurality of data lines to make a self-aging is performed in the electro-luminescence cells.
[0027] Aging voltages, which are changed in an opposite sequence to each other, are applied to the adjacent scan lines in the aging period.
[0028] The aging period further includes a neutralization step when the same aging voltage is applied to the adjacent scan lines.
[0029] A multilevel aging voltage, in which a voltage difference between an odd-numbered scan line and an even-numbered scan line is sequentially increased or decreased, is applied to the scan line in the aging period.
[0030] A multilevel aging voltage, in which a voltage difference between an odd-numbered scan line and an even-numbered scan line is sequentially increased and then decreased or is sequentially decreased and then increased, is applied to the scan line in the aging period.
[0031] An aging voltage, which is changed to a multilevel, is applied to an odd-numbered scan line, and an aging voltage, which is changed in a sequence opposite to that of the odd-numbered scan line, is applied to an even-numbered scan line, in the aging period.
[0032] A multilevel aging voltage, which is sequentially increased, is applied to any one of an odd-numbered scan line and an even-numbered scan line, and a multilevel aging voltage, which is sequentially decreased, is applied to the rest scan line, in the aging period.
[0033] A multilevel aging voltage, which is sequentially increased and then decreased, is applied to any one of an odd-numbered scan line and an even-numbered scan line, and a multilevel aging voltage, which is sequentially decreased and then increased, is applied to the rest scan line, in the aging period.
[0034] A multilevel aging voltage, which is sequentially increased or decreased, is applied to any one of an odd-numbered scan line and an even-numbered scan line, and a definite voltage is applied to the rest scan line, in the aging period.
[0035] A multilevel aging voltage, which is sequentially increased and then decreased or sequentially decreased and then increased, is applied to any one of an odd-numbered scan line and an even-numbered scan line, and a definite voltage is applied to the rest scan line, in the aging period.
[0036] The definite voltage applied in the aging period is a voltage identical to a lowest aging voltage of the multilevel aging voltage.
[0037] The definite voltage applied in the aging period is identical to a low scan voltage supplied as an enable voltage to the scan line in the scan period.
[0038] The aging period further includes a neutralization step, in which the same aging voltage is applied to the odd-numbered and the even-numbered scan lines.
[0039] The odd-numbered and the even-numbered scan lines are the same as a middle voltage of the multilevel aging voltage in the neutralization step.
[0040] The multilevel aging voltage is a voltage in which a voltage between a highest aging voltage, larger than a high scan voltage supplied as a disable voltage to the scan line or equal to the high scan voltage, and a lowest aging voltage, equal to a low scan voltage supplied as an enable voltage, is divided into a multilevel.
[0041] The multilevel aging voltage is repeated in the aging period.
[0042] The scan period and the aging period are repeated for each frame.
[0043] A method of driving an electro-luminescence display panel, according to the present invention includes: emitting electro-luminescence cells formed at a cross of both a plurality of scan lines and a plurality of data lines in a scan period; and making a self-aging of the organic electro-luminescence cells as floating the plurality of scan lines to have a voltage difference between adjacent data lines, in an aging period directly after the scan period.
[0044] Any one of first to third voltages is supplied to a ith sub-pixel connected to the data line, and a voltage different from the voltage supplied to the ith sub-pixel is supplied to sub-pixels adjacent to the ith sub-pixel, in the aging period.
[0045] The voltage supplied to each of the sub-pixels is repeatedly applied for each pixel including each of the sub-pixels.
[0046] The first to the third voltages, which are different from each other, are applied to each of the sub-pixels connected to the data line in the aging period.
[0047] The first to the third voltages are repeatedly applied for each pixel including each of the sub-pixels.
[0048] The second voltage has a voltage level different from that of the first voltage, and is formed by floating the third voltage.
[0049] An apparatus of driving an electro-luminescence display panel according to the present invention includes: an electro-luminescence display panel having an electro-luminescence cell for each cross of both a scan line and a data line; a scan driver to sequentially supply a scan pulse to the scan line in a scan period and to sequentially supply a high aging voltage to the entire scan lines in an aging period, in order to include the scan period and the aging period in each frame; and a data driver to supply a data signal to the data line in the scan period and to supply a low aging voltage to the data line in the aging period to make the entire electro-luminescence cell to be an reverse bias state.
[0050] The scan driver supplies a low scan voltage as the scan pulse in the scan period, a first high scan voltage to a disabled scan line in the scan period, and a second high scan voltage larger than the first high scan voltage as the high aging voltage.
[0051] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage, and a plurality of dummy stages to shift an output signal of the last stage in the stages to secure the aging period; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply it to each of the scan lines.
[0052] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply it to each of the scan lines.
[0053] The start pulse of the next stage is delayed to be supplied to include the aging period next the scan period.
[0054] Each of the stages supplies an output signal of a first voltage corresponding to the shifted start pulse, and further supplies an output signal of a second voltage.
[0055] When each of the level shifters is supplied with the output signal of the first voltage, each of the level shifters selects the low scan voltage, and when each of the level shifters is supplied with the output signal of the second voltage, each of the level shifters selects the first high scan voltage, in the scan period and select the second high scan voltage in the aging period to supply the selected voltage to a corresponding scan line.
[0056] Each of the low scan voltage, the first and second high scan voltages is supplied to each of the level shifters.
[0057] Each of the low scan voltage and the second high scan voltage is applied to each of the level shifters, and each of the level shifters uses the supplied second high scan voltage in the aging period and voltage-drops the second high scan voltage to the first high scan voltage in the scan period to use it.
[0058] An apparatus of driving an electro-luminescence display panel according to the present invention includes: a data driver to apply a data signal to a data line in a scan period and to float the data line in an aging period; a scan driver to apply a scan pulse to a scan line in the scan period and to make adjacent scan lines have a voltage difference in the aging period; and an electro-luminescence display panel having an electro-luminescence cell formed for each a cross of both the scan line and the data line, wherein the electro-luminescence cell is emitted in accordance with the data signal in the scan period and a self-aging is performed in the electro-luminescence cell in the aging period.
[0059] The scan driver applies an aging voltage opposite to that of the adjacent scan line in the aging period.
[0060] The scan driver applies any one aging voltage of high and low aging voltages to an odd-numbered scan line, and applies an aging voltage opposite to that of the odd-numbered scan line to an even-numbered scan line, in the aging period.
[0061] The scan driver reverses at least one time the aging voltage applied to the plurality of scan lines in the aging period.
[0062] The scan driver divides the aging period into a plurality of periods, and reverses the aging voltage applied to each of the scan lines for each boundary spot of the divided periods.
[0063] The scan driver reverses at least one more time the aging voltage applied to each of the scan lines in the divided periods.
[0064] The scan driver supplies a low scan low voltage to a scan line for an enable and supplies a first high scan voltage to a scan line for a disable, in the scan period, and wherein the scan driver supplies a second high scan voltage larger than the first high scan voltage or equal to the first high scan voltage as the high aging voltage, and supplies the low scan voltage as the low aging voltage, in the aging period.
[0065] The scan driver repeats the scan period and the aging period for each frame.
[0066] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage, and a plurality of dummy stages to shift an output signal of the last stage in the stages to secure the aging period; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply the scan pulse to the scan line in the scan period and to supply an aging voltage opposite to that of the adjacent scan lines in the aging period.
[0067] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply the scan pulse to the scan line in the scan period and to supply an aging voltage opposite to that of the adjacent scan lines in the aging period.
[0068] The start pulse of the next stage is delayed to be supplied to include the aging period next the scan period.
[0069] Each of the stages supplies an enable signal corresponding to the shifted start pulse, and wherein the level shifter part divides the aging period into a plurality of period when the enable signal is outputted in the each dummy stage, and reverses the aging voltage applied to each of the scan lines for each boundary spot of the divided periods.
[0070] The level shifter part reverses at least one more time the aging voltage applied to each of the scan lines in the divided periods.
[0071] An apparatus of driving an electro-luminescence display panel according to the present invention includes: a data driver to apply a data signal to a data line in a scan period and to float the data line in an aging period; a scan driver to apply a scan pulse to a scan line in the scan period and to make adjacent scan lines have a multilevel voltage difference in the aging period; and an electro-luminescence display panel having an electro-luminescence cell formed for each a cross of both the scan line and the data line, wherein the electro-luminescence cell is emitted in accordance with the data signal in the scan period and a self-aging is performed in the electro-luminescence cell in the aging period.
[0072] The scan driver applies multilevel aging voltages, which are changed in an opposite sequence to each other, are applied to the adjacent scan lines in the aging period.
[0073] The scan driver further includes a neutralization step when the same aging voltage is applied to the adjacent scan lines.
[0074] The scan driver applies a multilevel aging voltage, in which a voltage difference between an odd-numbered scan line and an even-numbered scan line is sequentially increased or decreased, is applied to the scan line in the aging period.
[0075] The scan driver applies a multilevel aging voltage, in which a voltage difference between an odd-numbered scan line and an even-numbered scan line is sequentially increased and then decreased or is sequentially decreased and then increased, is applied to the scan line in the aging period.
[0076] The scan driver applies an aging voltage, which is changed to a multilevel, to an odd-numbered scan line, and applies an aging voltage, which is changed in a sequence opposite to that of the odd-numbered scan line, to an even-numbered scan line, in the aging period.
[0077] The scan driver applies a multilevel aging voltage, which is sequentially increased, to any one of an odd-numbered scan line and an even-numbered scan line, and applies a multilevel aging voltage, which is sequentially decreased, to the rest scan line, in the aging period.
[0078] The scan driver applies a multilevel aging voltage, which is sequentially increased and then decreased, to any one of an odd-numbered scan line and an even-numbered scan line, and applies a multilevel aging voltage, which is sequentially decreased and then increased, to the rest scan line, in the aging period.
[0079] The scan driver applies a multilevel aging voltage, which is sequentially increased or decreased, to any one of an odd-numbered scan line and an even-numbered scan line, and applies a definite voltage to the rest scan line, in the aging period.
[0080] The scan driver applies a multilevel aging voltage, which is sequentially increased and then decreased or sequentially decreased and then increased, to any one of an odd-numbered scan line and an even-numbered scan line, and applies a definite voltage to the rest scan line, in the aging period.
[0081] The definite voltage applied in the aging period is a voltage identical to a lowest aging voltage of the multilevel aging voltage.
[0082] The definite voltage applied in the aging period is identical to a low scan voltage supplied as an enable voltage to the scan line in the scan period.
[0083] The scan driver further includes a neutralization step, in which the same aging voltage is applied to the odd-numbered and the even-numbered scan lines.
[0084] The scan driver applies the same middle voltage of the multilevel aging voltage to the odd-numbered and the even-numbered scan lines in the neutralization step.
[0085] The scan driver supplies the multilevel aging voltage in which a voltage between a highest aging voltage, larger than a high scan voltage supplied as a disable voltage to the scan line or equal to the high scan voltage, and a lowest aging voltage, equal to a low scan voltage supplied as an enable voltage, is divided into a multilevel, in the scan period.
[0086] The scan driver repeats the multilevel aging voltage in the aging period to supply it.
[0087] The scan driver repeats the scan period and the aging period for each frame.
[0088] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage, and a plurality of dummy stages to shift an output signal of the last stage in the stages to secure the aging period; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply the scan pulse to the scan line in the scan period and to supply a multilevel aging voltage to the adjacent scan lines to have the multilevel voltage difference in the aging period.
[0089] The scan driver includes: a shift register having a plurality of stages to shift a start pulse to supply it as each of output signals and a start pulse of next stage; and a level shifter part having a plurality of level shifters to level-shift each of the output signals of the shift register to supply the scan pulse to the scan line in the scan period and to supply a multilevel aging voltage to the adjacent scan lines to have the multilevel voltage difference in the aging period.
[0090] The start pulse of the next stage is delayed to be supplied to include the aging period next the scan period.
[0091] Each of the stages supplies an enable signal corresponding to the shifted start pulse, and wherein the level shifter part synchronizes the aging period with a period, when the enable signal is outputted in the each dummy stage, to change the multilevel aging voltage.
[0092] An apparatus of driving an electro-luminescence display panel, according to the present invention includes: an organic electro-luminescence display panel having electro-luminescence cells formed at a cross of both a scan line and a data line; a scan driver to supply a scan pulse to the scan line during a scan period and to float the scan line during an aging period directly after the scan period; a data driver to apply a data signal to the data line during the scan period; and an aging voltage supplier to apply voltages different from each other to adjacent data lines during the aging period to make a self-aging is performed in the organic electro-luminescence display panel.
[0093] The apparatus further includes a switch connected to the data line and connected between the data driver and the aging voltage supplier to switch the data signal and the aging voltage, which are supplied to the data line.
[0094] The aging voltage is any one of: a first voltage, which is supplied to a ith sub-pixel; a second voltage, which is supplied to sub-pixels adjacent to the ith sub-pixel and is different from the first voltage; and a third voltage, which is formed by floating the data line.
[0095] The aging voltage is repeatedly applied for each pixel including each of sub-pixels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0096] These and other objects of the invention will be apparent from the following detailed description of the embodiments of the present invention with reference to the accompanying drawings, in which:
[0097] FIG. 1 is a circuit diagram showing equivalently a related art passive matrix type organic EL display device;
[0098] FIG. 2 is a driving waveform diagram of an EL panel shown in FIG. 1 ;
[0099] FIG. 3 is a driving waveform diagram for describing a method of driving an organic EL display panel according to the present invention;
[0100] FIG. 4 is a block diagram showing an apparatus of driving an organic EL display panel according to a first embodiment of the present invention;
[0101] FIG. 5 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 4 ;
[0102] FIG. 6 is a block diagram showing an apparatus of driving an organic EL display panel according to a second embodiment of the present invention;
[0103] FIG. 7 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 6 ;
[0104] FIG. 8 is a driving waveform diagram for describing a method of driving the organic EL display panel according to the present invention;
[0105] FIG. 9 is a block diagram showing an apparatus of driving an organic EL display panel according to a third embodiment of the present invention;
[0106] FIG. 10 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 9 ;
[0107] FIG. 11 is a driving waveform of a scan driver shown in FIG. 9 in an aging period;
[0108] FIG. 12 is another driving waveform of the scan driver shown in FIG. 9 in the aging period;
[0109] FIG. 13 is a block diagram showing an apparatus of driving an organic EL display panel according to a fourth embodiment of the present invention;
[0110] FIG. 14 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 13 ;
[0111] FIG. 15 is a driving waveform diagram for describing a method of driving the organic EL display panel according to the present invention;
[0112] FIG. 16 is another scan driving waveform diagram in the aging period of the present invention;
[0113] FIGS. 17A and 17B are another scan driving waveform diagrams in the aging period of the present invention;
[0114] FIGS. 18A and 18B are still another scan driving waveform diagrams in the aging period of the present invention;
[0115] FIG. 19 is a block diagram showing an apparatus of driving an organic EL display panel according to a fifth embodiment of the present invention;
[0116] FIG. 20 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 19 ;
[0117] FIG. 21 is a block diagram showing an apparatus of driving an organic EL display panel according to a sixth embodiment of the present invention;
[0118] FIG. 22 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 21 ;
[0119] FIG. 23 is a driving waveform diagram for describing a method of driving the organic EL display panel according to a seventh embodiment of the present invention;
[0120] FIG. 24 is a view showing a state of a voltage supplied to each data line in an aging period of the seventh embodiment of the present invention; and
[0121] FIG. 25 is a block diagram showing an apparatus of driving an organic EL display panel according to the seventh embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0122] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0123] Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to FIGS. 3 to 25 .
[0124] FIG. 3 is a driving waveform diagram of a scan line and a data line in accordance with a method of driving an organic EL display panel according to the present invention.
[0125] In an aging period APD of the method of driving the organic EL display panel according to the embodiment of the present invention, a high voltage, i.e., a second high scan voltage Vhigh 2 , is supplied to a n number of scan lines SL 1 to SLn, and a low voltage, i.e., a ground voltage GND, is supplied to a m number of data lines DL 1 to DLm. In this case, in order to raise an aging efficiency, the high scan voltage Vhigh 2 is a voltage larger than the first high scan high voltage Vhigh 1 supplied in a light-emitting period LPD. For instance, the second high scan voltage Vhigh 2 is set as a larger voltage as much as about 10% to 20% than the first scan high voltage Vhigh 1 .
[0126] As set forth above, in the method of driving the organic EL display device according to the embodiment of the present invention, the aging period APD to make an entire EL cells to be a reverse bias state is secured to thereby do an aging of the EL panel upon driving. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0127] FIG. 4 is a block diagram showing an apparatus of driving an organic EL display panel according to a first embodiment of the present invention, and FIG. 5 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 4 .
[0128] The apparatus of driving the EL display panel shown in FIG. 4 includes: an EL panel 30 having an EL cell 36 formed at a cross of both scan lines SL 1 to SLn and data lines DL 1 to DLm; a scan driver 32 for driving the scan lines SL 1 to SLn; and a data driver 34 for driving the data lines DL 1 to DLm.
[0129] The scan driver 32 , as shown in FIG. 5 , sequentially supplies a low scan voltage Vlow to a n number of scan lines SL 1 to SLn in a scan period SPD of a frame Fi, and supplies a high scan voltage Vhigh in the rest period. Further, the scan driver 32 supplies a second high scan voltage Vhigh 2 , larger than the first high scan voltage Vhigh 1 , to all of the n number of scan lines SL 1 to SLn, in an aging period of one frame Fi.
[0130] For this, the scan driver 32 includes: a shift register 40 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit, and makes to secure an aging period APD; and a level shifter part 42 to level-shift each of output signals S 1 to Sn of the shift register 40 to supply it to each of scan lines SL 1 to SLn.
[0131] The shift register 40 includes: a n number of stages ST 1 to STn for outputting the n number of output signals S 1 to Sn as shifting the start pulse; and a k number of dummy stages DST 1 to DSTk to make to secure the aging period APD as shifting the output signal Sn of the nth stage STn.
[0132] The n number of stages ST 1 to STn and the k number of dummy stages DST 1 to DSTk are connected, in series, to an input line of the start pulse Vst, and are commonly connected to an input line of a clock signal CLK. The first to the nth stage ST 1 to STn sequentially shift the start pulse Vst in accordance with the clock signal CLK to output the first to the nth output signal S 1 to Sn to the level shifter part 42 as shown in FIG. 5 . In this case, each of the output signals S 1 to Sn of the n number of stages ST 1 to STn is supplies to an input line of a start pulse of a next stage. The k number of dummy stages DST 1 to DSTk sequentially shift the output signal Sn of the nth stage STn in accordance with the clock signal CLK. Each of the output signals DS 1 to DSk of the k number of dummy stages DST 1 to DSTk is not outputted to the level shifter part 42 and is supplies to an input line of a start pulse of a next dummy stage. Accordingly, each frame Fi, as shown in FIG. 5 , becomes secure a dummy period, when the dummy stages DST 1 to DSTk sequentially output the output signals DS 1 to DSk of a low voltage, as an aging period, separately from the scan period SPD, when the first to the nth stage ST 1 to STn output the output signals S 1 to Sn of a low voltage. During the aging period, the entire first to the nth stage ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0133] The level shifter part 42 includes a n number of level shifters LS 1 to LSn, which are respectively connected between the n number of stages ST 1 to STn and the n number of scan lines SL 1 to SLn. If the level shifters LS 1 to LSn, as shown in FIG. 5 , are supplied with the low voltage of the output signals S 1 to Sn from the shift register 40 in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage of the output signals S 1 to Sn from the shift register 40 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LSn, as shown in FIG. 5 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 40 in the aging period APD, then the entire level shifters LS 1 to LSn select a second high scan voltage Vhigh 2 to supply the selected second high scan voltage Vhigh 2 to each of the scan lines SL 1 to SLn.
[0134] To this end, as shown in FIG. 4 , the first and the second high scan voltages Vhigh 1 and Vhigh 2 together with the low scan voltage Vlow are respectively generated in power source and then are inputted to the level shifter part 42 via power lines different from each other. In this case, each of the level shifters LS 1 to LSn selects any one of the low scan voltage Vlow and the high scan voltages Vhigh 1 and Vhigh 2 in accordance with the output signals S 1 to Sn of the shift register 40 to output the selected voltage, and selects any one of the low scan voltage Vlow and the high scan voltages Vhigh 1 and Vhigh 2 in accordance with the scan period SPD and aging period APD to output the selected voltage.
[0135] Differently from this, the second high scan voltage Vhigh 2 and the low scan voltage Vlow are respectively generated in the power source and then are inputted to the level shifter part 42 . In this case, each of the level shifters LS 1 to LSn selects the high scan voltage Vhigh 2 in a case of the aging period APD to output it. Whereas, in a case of the scan period SPD, each of the level shifters LS 1 to LSn voltage-drops the second high scan voltage Vhigh 2 to the first high scan voltage Vhigh 1 with an aid of a resistance, and then selects any on of the first high scan voltage Vhigh 1 and the low scan voltage Vlow to output it.
[0136] The data driver 34 supplies a data signal to a m number of data lines DL 1 to DLm for each period when the scan lines are enabled in the scan period SPD, and supplies a low voltage, e.x, a ground voltage GND, in the aging period APD.
[0137] Each of the EL cells 36 formed in the EL panel 30 is represented as a diode, which is connected in a forward direction between the data line DL and the scan line SL. Herein, the data line DL is equivalently an anode and the scan line SL is equivalently a cathode. If a low scan voltage Vlow, is supplied to the scan line SL and a positive data signal (current) is supplied to the data line DL to apply a forward voltage to each EL cell 36 , then each EL cell 36 emits light to generate light corresponding to the data signal. On the other hand, if high scan voltages Vhighs 1 and Vhigh 2 are supplied to the scan line SL to thereby apply a reverse voltage to each EL cell 36 , then each EL cell 36 does not emit light. Especially, if the second high scan voltage is supplied to the entire scan lines SL 1 to SLn and the low voltage is supplied to the entire data lines DL 1 to DLm in the aging period, then each of the EL cells 36 becomes a reverse bias state for the aging. Accordingly, it is possible to extend a life-span of the EL panel 30 and to prevent badness such as line defect.
[0138] FIG. 6 is a block diagram showing an apparatus of driving an organic EL display panel according to a second embodiment of the present invention, and FIG. 7 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 6 .
[0139] The apparatus of driving the organic EL display panel shown in FIG. 6 has composition elements identical to those of the apparatus of driving the organic EL display panel shown in FIG. 4 except that a shift register 60 of a scan driver 52 has only n number of stages ST 1 to STn without a dummy stage DST. Therefore, a description on the identical composition elements will be omitted.
[0140] The scan driver 52 includes: a shift register 60 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit; and a level shifter part 62 to level-shift each of output signals S 1 to Sn of the shift register 60 to supply it to each of scan lines SL 1 to SLn.
[0141] The n number of stages ST 1 to STn included in the shift register 60 sequentially shift the start pulse Vst in accordance with a clock signal CLK to output the first to the nth output signals S 1 to Sn to the level shifter 62 as shown in FIG. 7 . The output signals S 1 to Sn are respectively supplied to an input line of a start pulse of a next stage. Accordingly, as shown in FIG. 7 , the first to the nth stages ST 1 to STn sequentially output the output signals S 1 to Sn of a low voltage. To secure an aging period APD next a scan period SPD, a point of supply time of the start pulse Vst in a next frame Fi+1 is delayed. During the aging period APD, the entire first to nth stages ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0142] If a n number of level shifters LS 1 to LS included in the level shifter part 62 , as shown in FIG. 7 , are supplied with the low voltage of the output signals S 1 to Sn from the shift register 60 in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage of the output signals S 1 to Sn from the shift register 60 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LSn, as shown in FIG. 7 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 60 in the aging period APD, then the entire level shifters LS 1 to LSn select a second high scan voltage Vhigh 2 to supply the selected second high scan voltage Vhigh 2 to each of the scan lines SL 1 to SLn.
[0143] Accordingly, if the second high scan voltage Vhigh 2 is supplied to the entire scan lines SL 1 to SLn and the low voltage is supplied to the entire data lines DL 1 to DLm in the aging period APD, then each of the EL cells 36 becomes a reverse bias state. Accordingly, an aging is performed in the EL cells 36 . Thus, it is possible to extend a life-span of the EL panel 30 and to prevent badness such as line defect.
[0144] FIG. 8 shows a driving waveform of both a scan line and a data line in accordance with the method of driving the organic EL display panel according to the embodiment of the present invention.
[0145] The method of driving the organic EL display panel according to the embodiment of the present invention includes an aging period APD when an aging is performed in the EL panel upon driving. For instance, as shown in FIG. 8 , a frame Fi includes a scan period SPD for line-sequentially emitting EL cells and an aging period APD to make a self-aging is performed in the EL cells by a voltage difference of adjacent two scan lines. To this end, a period of the frame Fi becomes increased to secure the aging period APD separately from the scan period SPD.
[0146] In one frame Fi, a negative scan pulse, i.e., a low scan voltage Vlow, is sequentially supplied to the n number of scan lines SL 1 to SLn during the scan period SPD, and a first high scan voltage Vhigh 1 is supplied during the rest period. Further, a positive data signal, e.x., a current, is supplied to a m number of data lined DL 1 to DLm for each period when the low scan voltage Vlow is supplied. Accordingly, the EL cells, to which a forward voltage is applied by the low scan voltage Vlow and the positive data signal, emit to generate light corresponding to the data signal. On the other hand, EL cells 36 , to which a reverse voltage is applied by the first high scan voltage Vhigh 1 , do not emit light.
[0147] In the aging period APD next the scan period SPD, each of the scan lines SL 1 to SLn has a voltage difference with an adjacent scan line to make a self-aging of the EL cells. In other words, aging voltages opposite to each other are applied to an odd-numbered scan line and an even-numbered scan line during the aging period APD, so that an odd-numbered scan line and an even-numbered scan lines have a voltage difference to each other and the data lines DL 1 to DLm become a floating state. Accordingly, an optional voltage is applied to each of the EL cells in accordance with state of the EL cell, so that a self-aging is performed in each of the EL cells.
[0148] For instance, as shown in FIG. 8 , as the data lines DL 1 to DLm are floated, a second high scan voltage Vhigh, i.e., a high aging voltage, is applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1, whereas, a low scan voltage Vlow, i.e., a low aging voltage, is applied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn. Or, the low scan voltage Vlow is applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1, and the second high scan voltage Vhigh 2 is applied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn. Accordingly, a self-aging is performed in the EL cells by a voltage difference between adjacent scan lines. Herein, the second high scan voltage Vhigh 2 , i.e., the high aging voltage, is set to be larger than the first high scan voltage Vhigh 1 applied during the scan period SPD or to be equal to the first high scan voltage Vhigh 1 . For instance, the second high scan voltage Vhigh 2 is set as a larger voltage as much as about 10% to 20% than the first scan high voltage Vhigh 1 .
[0149] Furthermore, in order to raise an aging efficiency, an aging voltage, supplied to each of the scan lines SL 1 to SLn in the same aging period APD, is set to be reversed at least one time.
[0150] For instance, as shown in FIG. 8 , the aging period APD is divided into first and second periods A 1 and A 2 . When the second high scan voltage Vhigh 2 is applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the low scan voltage Vlow is applied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, during the first period A 1 , the voltage is reversed during the second period A 2 to apply the low scan voltage to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and to apply the second high scan voltage Vhigh 2 to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn.
[0151] As described above, the method of driving the organic EL display device according to the embodiment of the present invention secure the aging period APD when the self-aging is performed in the entire EL cells in one frame Fi to enable to do self-aging of the EL panel upon driving. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0152] FIG. 9 is a block diagram showing an apparatus of driving an organic EL display panel according to a third embodiment of the present invention, FIG. 10 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 9 , and FIGS. 11 and 12 are driving waveforms of a scan driver shown in FIG. 9 in an aging period APD.
[0153] The apparatus of driving the EL display panel shown in FIG. 9 includes: an EL panel 130 having an EL cell 136 formed at a cross of both scan lines SL 1 to SLn and data lines DL 1 to DLm; a scan driver 132 for driving the scan lines SL 1 to SLn; and a data driver 134 for driving the data lines DL 1 to DLm.
[0154] Each of the EL cells 136 formed in the EL panel 130 is represented as a diode, which is connected in a forward direction between the data line DL and the scan line SL. Herein, the data line DL is equivalently an anode and the scan line SL is equivalently a cathode. If a low scan voltage Vlow is supplied to the scan line SL and a positive data signal (current) is supplied to the data line DL to apply a forward voltage to each EL cell 136 in a scan period SPD, then each EL cell 136 emits light to generate light corresponding to the data signal. On the other hand, if a first high scan voltage Vhigh 1 is supplied to the scan line SL to thereby apply a reverse voltage to each EL cell 136 , then each EL cell 136 does not emit light. Further, If the data lines DL 1 to DLn are floated, and voltages opposite to each other are applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, in the aging period APD, then the each of the EL cells 136 does not emit light and a self-aging is performed in the each of the EL cells 136 .
[0155] The data driver 134 supplies a data signal to the m number of data lines DL 1 to DLm for each period when the scan lines SL 1 to SLn are enabled during the scan period SPD, and the data driver 124 floats the data lines DL 1 to DLm during the aging period APD.
[0156] The scan driver 132 , as shown in FIG. 10 , sequentially supplies a low scan voltage Vlow to the n number of scan lines SL 1 to SLn in a scan period SPD of one frame Fi, and supplies a high scan voltage Vhigh in the rest period. Further, the scan driver 132 supplies aging voltages opposite to each other to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn in the aging period APD of one frame Fi.
[0157] For this, the scan driver 132 includes: a shift register 140 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit, and makes to secure an aging period APD; and a level shifter part 142 to level-shift each of output signals S 1 to Sn of the shift register 140 to supply it to each of scan lines SL 1 to SLn.
[0158] The shift register 140 includes: a n number of stages ST 1 to STn for outputting the n number of output signals S 1 to Sn as shifting the start pulse; and a k number of dummy stages DST 1 to DSTk to make to secure an aging period APD as shifting the output signal Sn of the nth stage STn.
[0159] The n number of stages ST 1 to STn and the k number of dummy stages DST 1 to DSTk are connected, in series, to an input line of the start pulse Vst, and are commonly connected to an input line of a clock signal CLK. The first to the nth stage ST 1 to STn sequentially shift the start pulse Vst in accordance with the clock signal CLK to output the first to the nth output signal S 1 to Sn to the level shifter part 142 as shown in FIG. 10 . In this case, each of the output signals S 1 to Sn of the n number of stages ST 1 to STn is supplies to an input line of a start pulse of a next stage. The k number of dummy stages DST 1 to DSTk sequentially shift the output signal Sn of the nth stage STn in accordance with the clock signal CLK. Each of the output signals DS 1 to DSk of the k number of dummy stages DST 1 to DSTk is not outputted to the level shifter part 142 and is supplies to an input line of a start pulse of a next dummy stage. Accordingly, each frame Fi, as shown in FIG. 10 , becomes secure a dummy period, when the dummy stages DST 1 to DSTk sequentially output the output signals DS 1 to DSk of a low voltage, as an aging period, separately from the scan period SPD, when the first to the nth stages ST 1 to STn output the output signals S 1 to Sn of a low voltage. During the aging period APD, the entire first to the nth stage ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0160] The level shifter part 142 includes a n number of level shifters LS 1 to LSn, which are respectively connected between the n number of stages ST 1 to STn and the n number of scan lines SL 1 to SLn. If the level shifters LS 1 to LSn, as shown in FIG. 10 , are supplied with the low voltage, i.e., an enable voltage of the output signals S 1 to Sn from the shift register 140 , in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage of the output signals S 1 to Sn from the shift register 140 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LSn, as shown in FIG. 10 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 140 in the aging period APD, then the entire level shifters LS 1 to LSn supply voltages opposite to each other to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan line SL 2 , SL 4 , . . . , SLn by using the second high scan voltage Vhigh 2 and the low scan voltage Vlow. Or, in order to raise an aging efficiency, a voltage is set to be reversed at least one time in the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 . . . , SLn within the aging period APD.
[0161] For instance, when the second high scan voltage Vhigh 2 is applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the low scan voltage Vlow is applied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, during the first period A 1 of the aging period APD, the voltage is reversed during the second period A 2 to apply the low scan voltage to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and to apply the second high scan voltage Vhigh 2 to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn.
[0162] Differently from this, as shown in FIG. 11 , the aging period APD is divided into first to kth periods A 1 to Ak, when the dummy stages DST 1 to DSTk of the shift register 140 sequentially output a low voltage, i.e., an enable voltage. The opposite voltages Vhigh 2 and Vlow applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1; SLodd and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn; SLeven are set to be reversed for each boundary spot of the first to the kth periods A 1 to Ak.
[0163] Or, as shown in FIG. 12 , the opposite voltages Vhigh 2 and Vlow applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1; SLodd and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn; SLeven are set to be reversed one more time in the first to the kth periods A 1 to Ak. In other words, the reverse period of the aging voltage applied to the odd-numbered scan line SLodd and the even-numbered scan line SLeven is set to be equal to each division period Ai of the aging period APD.
[0164] To this end, as shown in FIG. 9 , the first and the second high scan voltages Vhigh 1 and Vhigh 2 together with the low scan voltage Vlow are respectively generated in power source and then may be inputted to the level shifter part 142 via power lines different from each other. Differently from this, the second high scan voltage Vhigh 2 and the low scan voltage Vlow are respectively generated in the power source and then may be inputted to the level shifter part 142 . In a case of the aging period, the level shifter part 142 uses the second high scan voltage Vhigh 2 as it is, whereas, in a case of the scan period SPD, the level shifter 142 voltage-drops the second high scan voltage Vhigh 2 to the first high scan voltage Vhigh 1 with an aid of a resistance, and then uses it.
[0165] FIG. 13 is a block diagram showing an apparatus of driving an organic EL display panel according to a fourth embodiment of the present invention, and FIG. 14 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 13 .
[0166] The apparatus of driving the organic EL display panel shown in FIG. 13 has composition elements identical to those of the apparatus of driving the organic EL display panel shown in FIG. 9 except that a shift register 160 of a scan driver 152 has only n number of stages ST 1 to STn without a dummy stage DST. Therefore, a description on the identical composition elements will be omitted.
[0167] The scan driver 152 includes: a shift register 160 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit; and a level shifter part 162 to level-shift each of output signals S 1 to Sn of the shift register 160 to supply it to each of scan lines SL 1 to SLn.
[0168] The n number of stages ST 1 to STn included in the shift register 160 sequentially shift the start pulse Vst in accordance with a clock signal CLK to output the first to the nth output signals S 1 to Sn to the level shift part 162 as shown in FIG. 14 . The output signals S 1 to Sn are respectively supplied to an input line of a start pulse of a next stage. Accordingly, as shown in FIG. 14 , the first to the nth stages ST 1 to STn sequentially output the output signals S 1 to Sn of a low voltage. To secure an aging period APD next a scan period SPD, a point of supply time of the start pulse Vst in a next frame Fi+1 is delayed. During the aging period APD, the entire first to nth stages ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0169] If a n number of level shifters LS 1 to LSn included in the level shifter part 162 , as shown in FIG. 14 , are supplied with the low voltage of the output signals S 1 to Sn from the shift register 160 in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage of the output signals S 1 to Sn from the shift register 160 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LS, as shown in FIG. 14 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 160 in the aging period APD, then the entire level shifters LS 1 to LSn supply voltages opposite to each other to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan line SL 2 , SL 4 , . . . , SLn by using the second high scan voltage Vhigh 2 and the low scan voltage Vlow. Or, in order to raise an aging efficiency, the voltage is set to be reversed at least one time in the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 . . . , SLn within the aging period APD.
[0170] For instance, when the second high scan voltage Vhigh 2 is applied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the low scan voltage Vlow is applied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, during the first period A 1 of the aging period APD, as shown in FIG. 14 , the voltage is reversed during the second period A 2 to apply the low scan voltage Vlow to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and to apply the second high scan voltage Vhigh 2 to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn.
[0171] Accordingly, in the aging period APD, as the data lines are floated, a voltage difference is generated by opposite voltages between adjacent scan lines. As a result, a self-aging is performed in the entire EL cells 136 . Thus, it is possible to extend a life-span of the EL panel and to prevent badness such as line.
[0172] FIG. 15 shows a driving waveform of a scan line and a data line for describing a method of driving the organic EL display panel according to the present invention.
[0173] The method of driving the organic EL display panel according to the embodiment of the present invention includes an aging period APD when an aging is performed in the EL panel upon driving. For instance, as shown in FIG. 15 , a frame Fi includes a scan period SPD for line-sequentially emitting EL cells and an aging period APD for self-aging of the EL cells by a voltage difference of adjacent two scan lines. To this end, a period of the frame Fi becomes increased to secure the aging period APD separately from the scan period SPD.
[0174] In the frame Fi, a negative scan pulse, i.e., a low scan voltage Vlow, is sequentially supplied to the n number of scan lines SL 1 to SLn during the scan period SPD, and a first high scan voltage Vhigh 1 is supplied during the rest period. Further, a positive data signal, e.x., a current, is supplied to a m number of data lined DL 1 to DLm for each period when the low scan voltage Vlow is supplied. Accordingly, the EL cells, to which a forward voltage is applied by the low scan voltage Vlow and the positive data signal, emit to generate light corresponding to the data signal. On the other hand, EL cells, to which a reverse voltage is applied by the first high scan voltage Vhigh 1 , do not emit light.
[0175] In the aging period APD next the scan period SPD, as the entire data lines DL 1 to DLm are floated, each of the scan lines SL 1 to SLn has a voltage difference with an adjacent scan line. Accordingly, an optional voltage is applied to the EL cells in accordance with a state of the EL cells to make a self-aging of the EL cells. Especially, an aging voltage, which changes into a multilevel to have a voltage difference between the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, is supplied to raise a self-aging efficiency. As a result, the EL cells become stabilized more and more.
[0176] For instance, as shown in FIG. 15 , from a first step to a fifth step A 1 to A 5 in the aging period APD, an aging voltage, which is changed in a sequence of a low scan voltage Vlow, a middle voltage Vmiddle, a second high scan voltage Vhigh 2 , a middle voltage Vmiddle, and a low scan voltage Vlow, is supplied to the odd-numbed scan lines SL 1 , SL 3 , . . . , SLn−1. At this moment, an aging voltage, which is changed in a sequence of the second high scan voltage Vhigh 2 , the middle voltage Vmiddle, the low scan voltage Vlow, the middle voltage Vmiddle, and the second high scan voltage Vhigh 2 , is supplied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn oppositely to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1. Herein, the second high scan voltage Vhigh 2 , i.e., the high aging voltage, is set to be larger than the first high scan voltage Vhigh 1 applied in the scan period SPD, or to be equal to the first high scan voltage Vhigh 1 . For instance, the second high scan voltage Vhigh 2 is set as a larger voltage as much as about 10% to 20% than the first scan high voltage Vhigh 1 . The data lines DL 1 to DLm are floated in the aging period APD.
[0177] Accordingly, a voltage difference between adjacent scan lines, i.e. the odd-numbed scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbed scan lines SL 2 , SL 4 , . . . , SLn, makes that a self-aging is performed in the EL cells having the floated data lines DL 1 to DLm. Further, the aging period APD includes a neutralization step when voltages of the odd-numbed scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbed scan lines SL 2 , SL 4 , . . . , SLn become the same as the middle voltage Vmiddle. By the neutralization step, a parasitic capacitor formed in the EL panel can be reduced.
[0178] Moreover, a driving waveform capable of supplying to the scan lines SL 1 to SLn in the aging period APD is various as shown in FIGS. 16 to 18B .
[0179] Referring to FIG. 16 , in the aging period APD, an aging voltage AV 1 to AVi, which changes into first to (2i)th steps, is supplied to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1; SLodd, and an aging voltage AVi to AV 1 , which changed into the first to the (2i)th steps A 1 to A 2 i , is supplied to the even-numbered scan lines SL 2 , SL 4 , . . . , SLn; SLeven in a direction opposite to the odd-numbered scan line SLodd.
[0180] More specifically, an aging voltage, which is decreased in a sequence of AV 1 , AV 2 , . . . , AVi−1, and AVi from the first to the (2i)th steps A 1 to A 2 i of the aging period APD and then is again increased in a sequence of AVi−1, . . . , AV 2 , and AV 1 , is supplied to the odd-numbered scan line SLodd. On the other hand, an aging voltage, which is increased in a sequence of AVi, AVi−1, . . . , AV 2 , and AV 1 and then is decreased in a sequence of AV 2 , . . . , AVi−1, and AVi, is supplied to the even-numbered scan line SLeven. Accordingly, a voltage difference between the odd-numbed and the even-numbed scan lines SLodd and SLeven is differentiated for each of the first to the (2i)th steps A 1 to A 2 i . In other words, as shown in FIG. 16 , the voltage difference between the odd-numbered and the even-numbered scan lines SLodd and SLeven is sequentially decreased in the first to the ith steps A 1 to Ai, and is sequentially increased in the (i+1)th to the (2i)th steps Ai+1 to A 2 i , so that a self-aging is effectively performed in the EL cells. Further, oppositely to FIG. 16 , when a multilevel aging voltage A 1 to Ai is supplied to the odd-numbered and the even-numbered scan lines SLodd and SLeven, the voltage difference between the odd-numbered and the even-numbered scan lines SLodd and SLeven is sequentially increased and than is decreased in opposition to the above case. Thus, a self-aging is effectively performed in the EL cells.
[0181] And, in the aging period APD, the odd-numbered and the even-numbered scan lines SLodd and SLeven become the same with a middle voltage in the multilevel aging voltage AV 1 to AVi. Accordingly, the APD period includes at least one time neutralization step to reduce a parasitic capacitor in the EL panel.
[0182] Also, the multilevel aging voltage AV 1 to AVi is supplied to any one of the odd-numbered and the even-numbered scan lines SLodd and SLeven as shown in FIGS. 17A to 18B , and the reset scan lines is possible to be fixed with a lowest aging voltage AV 1 , i.e., a low scan voltage Vlow.
[0183] More specifically, the even-numbered scan line SLeven is fixed with the low scan voltage Vlow, and the odd-numbered scan line SLodd is supplied with an aging voltage, which changes in a sequence of AV 1 , AV 2 , . . . , AVi−1, AVi, AVi−1, . . . AV 2 , and AV 1 as shown in FIG. 17A , from the first to the (2i)th steps A 1 to A 2 i . Or, the odd-numbered scan line SLodd is supplied with an aging voltage, which changes in a sequence of AVi, AVi−1, . . . , AV 2 , AV 1 , AV 2 , . . . , AVi−1, and AVi, as shown in FIG. 17B , from the first to the (2i)th steps A 1 to A 2 i.
[0184] On the other hand, the odd-numbered scan line SLodd is fixed with the low scan voltage Vlow, and the even-numbered scan line SLeven is supplied with an aging voltage, which changes in a sequence of AV 1 , AV 2 , . . . , AVi−1, AVi, AVi−1, . . . AV 2 , and AV 1 as shown in FIG. 18A , from the first to the (2i)th steps A 1 to A 2 i . Or, the even-numbered scan line SLeven is supplied with an aging voltage, which changes in a sequence of AVi, AVi−1, . . . , AV 2 , AV 1 , AV 2 , . . . , AVi−1, and AVi, as shown in FIG. 18B , from the first to the (2i)th steps A 1 to A 2 i.
[0185] Accordingly, a voltage difference between the odd-numbed and the even-numbed scan lines SLodd and SLeven is differentiated for each of the first to the (2i)th steps A 1 to A 2 i . In other words, as shown in FIGS. 17A and 18B , a voltage difference between the odd-numbered and the even-numbered scan lines SLodd and SLeven is sequentially decreased and then increased in the first to the (2i)th steps A 1 to A 2 i , so that a self-aging is effectively performed in the EL cells. On the other hand, as shown in FIGS. 17B and 18A , the voltage difference between the odd-numbered and the even-numbered scan lines SLodd and SLeven is sequentially increased and than is decreased in opposition to the above case. Thus, a self-aging is effectively performed in the EL cells.
[0186] And, in the aging period APD, the odd-numbered and the even-numbered scan lines SLodd and SLeven become the same with the lowest aging voltage AVi of the multilevel aging voltage AV 1 to AVi, i.e., the low scan voltage Vlow. Accordingly, the APD period includes at least one time neutralization step to reduce a parasitic capacitor in the EL panel.
[0187] In addition, in the aging period APD of the present invention, it is possible to repeat the above-described first to (2i)th steps.
[0188] As described above, the method of driving the organic EL display device according to the embodiment of the present invention secure the aging period APD when a self-aging is performed in a multilevel in the entire EL cells during one frame Fi to enable to do self-aging of the EL panel upon driving. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0189] FIG. 19 is a block diagram showing an apparatus of driving an organic EL display panel according to a fifth embodiment of the present invention, and FIG. 20 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 19 .
[0190] The apparatus of driving the EL display panel shown in FIG. 19 includes: an EL panel 230 having an EL cell 236 formed at a cross of both scan lines SL 1 to SLn and data lines DL 1 to DLm; a scan driver 232 for driving the scan lines SL 1 to SLn; and a data driver 234 for driving the data lines DL 1 to DLm.
[0191] Each of the EL cells 236 formed in the EL panel 230 is represented as a diode, which is connected in a forward direction between the data line DL and the scan line SL. Herein, the data line DL is equivalently an anode and the scan line SL is equivalently a cathode. If a low scan voltage Vlow is supplied to the scan line SL and a positive data signal (current) is supplied to the data line DL to apply a forward voltage to each EL cell 236 in a scan period SPD, then each EL cell 236 emits light to generate light corresponding to the data signal. On the other hand, if a first high scan voltage Vhigh 1 is supplied to the scan line SL to thereby apply a reverse voltage to each EL cell 236 , then each EL cell 236 does not emit light. Further, If the data lines DL 1 to DLn are floated, and a difference of voltage, changed to a multilevel is generated in the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn, in the aging period APD, then the each of the EL cells 236 does not emit light and a self-aging is performed in the EL cells 236 .
[0192] The data driver 234 supplies a data signal to the m number of data lines DL 1 to DLm for each period when the scan lines SL 1 to SLn are enabled during the scan period SPD, and the data driver 234 floats the data lines DL 1 to DLm during the aging period APD.
[0193] The scan driver 232 , as shown in FIG. 20 , sequentially supplies a low scan voltage Vlow to the n number of scan lines SL 1 to SLn in a scan period SPD of a frame Fi, and supplies a first high scan voltage Vhigh 1 in the rest period. Further, the scan driver 232 supplies aging voltages, which is changed to a multilevel to make the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn have a voltage difference of a multilevel in the aging period APD of one frame Fi.
[0194] For this, the scan driver 232 includes: a shift register 240 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit, and makes to secure an aging period APD; and a level shifter part 242 to level-shift each of output signals S 1 to Sn of the shift register 240 to supply it to each of scan lines SL 1 to SLn.
[0195] The shift register 240 includes: a n number of stages ST 1 to STn for outputting the n number of output signals S 1 to Sn as shifting the start pulse; and a k number of dummy stages DST 1 to DSTk to make to secure an aging period APD as shifting the output signal Sn of the nth stage STn.
[0196] The n number of stages ST 1 to STn and the k number of dummy stages DST 1 to DSTk are connected, in series, to an input line of the start pulse Vst, and are commonly connected to an input line of a clock signal CLK. The first to the nth stage ST 1 to STn sequentially shift the start pulse Vst in accordance with the clock signal CLK to output the first to the nth output signal S 1 to Sn to the level shifter part 242 as shown in FIG. 20 . In this case, each of the output signals S 1 to Sn of the n number of stages ST 1 to STn is supplies to an input line of a start pulse of a next stage. The k number of dummy stages DST 1 to DSTk sequentially shift the output signal Sn of the nth stage STn in accordance with the clock signal CLK. Each of the output signals DS 1 to DSk of the k number of dummy stages DST 1 to DSTk is not outputted to the level shifter part 242 and is supplies to an input line of a start pulse of a next dummy stage. Accordingly, each frame Fi, as shown in FIG. 20 , becomes secure a dummy period, when the dummy stages DST 1 to DSTk sequentially output the output signals DS 1 to DSk of a low voltage, as an aging period, separately from the scan period SPD, when the first to the nth stage ST 1 to STn output the output signals S 1 to Sn of a low voltage, i.e., an enable voltage. During the aging period, the entire first to the nth stage ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0197] The level shifter part 242 includes a n number of level shifters LS 1 to LSn, which are respectively connected between the n number of stages ST 1 to STn and the n number of scan lines SL 1 to SLn. If the level shifters LS 1 to LSn, as shown in FIG. 20 , are supplied with the low voltage, i.e., an enable voltage of the output signals S 1 to Sn from the shift register 240 , in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage, i.e., a disable voltage, of the output signals S 1 to Sn from the shift register 240 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LSn, as shown in FIG. 20 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 240 in the aging period APD, then the entire level shifters LS 1 to LSn stepwise supply an aging voltage, which is changed in an opposite direction to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn.
[0198] For instance, as shown in FIGS. 15 and 20 , an aging voltage is changed in a sequence of Vhigh 2 , Vmiddle, Vlow, Vmiddle, and Vhigh 2 in the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 from first to fifth steps A 1 to A 5 , and an aging voltage is changed in a sequence of Vlow, Vmiddle, Vhigh 2 , Vmiddle, and Vlow in the even-numbered scan lines SL 2 , SL 4 , . . . , SLn from first to fifth steps A 1 to A 5 . Or, as shown in FIGS. 16 to 18B , an aging voltage, which is changed from the first to the (2i)th steps, is supplied.
[0199] To this end, the level shifter part 242 entirely inputs the multilevel aging voltage AV 1 to AVi to use them, or inputs only the highest aging voltage AV 1 and the lowest aging voltage AVi and then divides the highest aging voltage AV 1 by a divided-voltage resistance to use it.
[0200] Further, in the multi-step A 1 to Ai dividing the aging period APD, the aging period APD, as shown in FIG. 20 , is classified as a period when each of the dummy stages DST 1 to DSTk of the shift register 240 outputs the low voltage, i.e., an enable voltage.
[0201] FIG. 21 is a block diagram showing an apparatus of driving an organic EL display panel according to a sixth embodiment of the present invention, and FIG. 22 is a driving waveform of the apparatus of driving the organic EL display panel shown in FIG. 21 .
[0202] The apparatus of driving the organic EL display panel shown in FIG. 21 has composition elements identical to those of the apparatus of driving the organic EL display panel shown in FIG. 19 except that a shift register 260 of a scan driver 252 has only n number of stages ST 1 to STn without a dummy stage DST. Therefore, a description on the identical composition elements will be omitted.
[0203] The scan driver 252 includes: a shift register 260 , which outputs a n number of output signals S 1 to Sn as sequentially shifting a start pulse Vst inputted by a frame Fi unit; and a level shifter part 262 to level-shift each of output signals S 1 to Sn of the shift register 260 to supply it to each of scan lines SL 1 to SLn.
[0204] The n number of stages ST 1 to STn included in the shift register 260 sequentially shift the start pulse Vst in accordance with a clock signal CLK to output the first to the nth output signals S 1 to Sn to the level shift part 262 as shown in FIG. 22 . The output signals S 1 to Sn are respectively supplied to an input line of a start pulse of a next stage. Accordingly, as shown in FIG. 22 , the first to the nth stages ST 1 to STn sequentially output the output signals S 1 to Sn of a low voltage. To secure an aging period APD next a scan period SPD, a point of supply time of the start pulse Vst in a next frame Fi+1 is delayed. During the aging period APD, the entire first to nth stages ST 1 to STn output the output signals S 1 to Sn of a high voltage.
[0205] If a n number of level shifters LS 1 to LSn included in the level shifter part 262 , as shown in FIG. 22 , are supplied with the low voltage of the output signals S 1 to Sn from the shift register 260 in the scan period SPD, then the level shifters LS 1 to LSn select a low scan voltage Vlow, whereas, if the level shifters LS 1 to LSn are supplied with the high voltage of the output signals S 1 to Sn from the shift register 260 in the scan period SPD, then the level shifters LS 1 to LSn select a first high scan voltage Vhigh 1 . Accordingly, the level shifters LS 1 to LSn supply the selected voltages to each of the scan lines SL 1 to SLn. Further, if the level shifters LS 1 to LSn, as shown in FIG. 22 , are supplied with the high voltage of the output signals S 1 to Sn from the shift register 260 in the aging period APD, then the entire level shifters LS 1 to LSn stepwise supply an aging voltage, which is changed in an opposite direction to the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 and the even-numbered scan lines SL 2 , SL 4 , . . . , SLn.
[0206] For instance, as shown in FIGS. 16 and 22 , an aging voltage is changed in a sequence of Vhigh 2 , Vmiddle, Vlow, Vmiddle, and Vhigh 2 in the odd-numbered scan lines SL 1 , SL 3 , . . . , SLn−1 from first to fifth steps A 1 to A 5 , and an aging voltage is changed in a sequence of Vlow, Vmiddle, Vhigh 2 , Vmiddle, and Vlow in the even-numbered scan lines SL 2 , SL 4 , . . . , SLn from first to fifth steps A 1 to A 5 . Or, as shown in FIGS. 16 to 18B , an aging voltage AV 1 to AVi, which is changed from the first to the (2i)th steps, is supplied.
[0207] Accordingly, in the aging period APD, as the data lines are floated, a voltage difference of the multilevel is generated between adjacent scan lines. As a result, a self-aging is performed in the entire EL cells 236 . Thus, it is possible to extend a life-span of the EL panel 230 and to prevent badness such as line defect.
[0208] FIG. 23 is a driving waveform diagram of a scan line and a data line for describing a method of driving the organic EL display panel according to a seventh embodiment of the present invention.
[0209] The method of driving the organic EL display panel according to the seventh embodiment of the present invention includes an aging period APD when an aging is performed in the EL panel upon driving. For instance, as shown in FIG. 23 , a frame Fi includes a scan period SPD for line-sequentially emitting EL cells and an aging period APD to make a self-aging is performed in the EL cells by a voltage difference of adjacent two data lines. To this end, a period of the frame Fi becomes increased to secure the aging period APD separately from the scan period SPD.
[0210] In one frame Fi, a negative scan pulse, i.e., a low scan voltage Vlow, is sequentially supplied to the n number of scan lines SL 1 to SLn during the scan period SPD, and a high scan voltage Vhigh is supplied during the rest period. Further, a positive data signal, e.x., a current, is supplied to a m number of data lined DL 1 to DLm for each period when the low scan voltage Vlow is supplied. Accordingly, the EL cells, to which a forward voltage is applied by the low scan voltage Vlow and the positive data signal, emit to generate light corresponding to the data signal. On the other hand, EL cells, to which a reverse voltage is applied by the high scan voltage Vhigh, do not emit light.
[0211] In the aging period APD next the scan period SPD, as the entire scan lines SL 1 SLn are floated, each of the data lines DL 1 to DLm has a voltage difference with an adjacent data line. Accordingly, an optional voltage is applied to the EL cells in accordance with a state of the EL cells to make a self-aging of the EL cells. As a result, the EL cells become more stabilized.
[0212] For instance, a signal as shown in FIG. 24 can be repeatedly applied to the data lines DL 1 to DLm, which are connected to each of sub-pixels R, G and B, in the aging period APD. To specifically describe this as an example, the high voltage Vhigh is applied to the data line DL 1 connected to the R sub-pixel as shown in the first state, the low voltage Vlow is applied to the data lines DL 2 and DL 3 connected to the G sub-pixel and the B sub-pixel, and the voltage applying of the first state is repeatedly applied to other data lines DL 4 to DLm. Accordingly, each of the data lines DL 1 to DLm has a voltage difference with an adjacent data line. Accordingly, an optional voltage is applied to the EL cells in accordance with a state of the EL cells to make a self-aging of the EL cells.
[0213] Further, as shown in the twelfth state, the low voltage Vlow is applied to the data line DL 1 connected to the R sub-pixel, the high voltage Vhigh is applied to the data line DL 2 connected to the G sub-pixel, and the data line DL 3 connected to the B sub-pixel is floated. Accordingly, each of the data lines DL 1 to DLm has a voltage difference with an adjacent data line. Accordingly, an optional voltage is applied to the EL cells in accordance with a state of the EL cells to make a self-aging of the EL cells.
[0214] Consequently, in the method of driving the EL display panel according to the embodiment of the present invention, the signal applied to each of the sub-pixels R, G, and B is applied by associating three states of the high voltage Vhigh, the low voltage Vlow, and the floating. Accordingly, each of the data lines DL 1 to DLm has a voltage difference with an adjacent data line to make a self-aging of the EL cells.
[0215] As described above, the method of driving the organic EL display device according to the embodiment of the present invention secure the aging period APD when the self-aging is performed in the entire EL cells in one frame Fi to enable to do self-aging of the EL panel upon driving. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0216] FIG. 25 is a block diagram showing an apparatus of driving an organic EL display panel according to the seventh embodiment of the present invention.
[0217] The apparatus of driving the EL display panel shown in FIG. 25 includes: an EL panel 330 having an EL cell 336 formed at a cross of both scan lines SL 1 to SLn and data lines DL 1 to DLm; a scan driver 332 for driving the scan lines SL 1 to SLn; a data driver 334 for driving the data lines DL 1 to DLm; an aging voltage supplier 350 for supplying a signal for an aging by using the data lines DL 1 to DLm; and a multiplexer MUX 340 for switching the data driver 334 and the aging voltage supplier 350 .
[0218] Each of the EL cells 336 formed in the EL panel 330 is represented as a diode, which is connected in a forward direction between the data line DL and the scan line SL. Herein, the data line DL is equivalently an anode and the scan line SL is equivalently a cathode. If a low scan voltage Vlow, is supplied to the scan line SL and a positive data signal (current) is supplied to the data line DL in the scan period SPD to apply a forward voltage to each EL cell 336 , then each EL cell 336 emits light to generate light corresponding to the data signal. On the other hand, if a high scan voltage is supplied to the scan line SL to thereby apply a reverse voltage to each EL cell 336 , then each EL cell 336 does not emit light. Further, as the scan lines SL 1 to SLm are floated, a voltage is applied to each of the data lines DL 1 to DLn so that each of the data lines DL 1 to DLn has a voltage difference with an adjacent data line. Accordingly, the each of the EL cells 336 does not emit light and a self-aging is performed in the EL cells 336 .
[0219] The scan driver 332 sequentially supplies a low scan voltage Vlow to a n number of scan lines SL 1 to SLn in a scan period SPD of a frame Fi, and supplies a high scan voltage Vhigh in the rest period.
[0220] The data driver 334 supplies a data signal to a m number of data lines DL 1 to DLm for each period when the scan lines are enabled in the scan period SPD.
[0221] The aging voltage supplier 350 generates an aging signal supplied to the data lines DL 1 to DLm during the aging period. Herein, the aging signal can be repeatedly applied to the data lines DL 1 to DLm connected to each of the sub-pixels R, G, and B by associating three states of the high voltage Vhigh, the low voltage Vlow, and the floating. Further, the aging signal can be applied without dividing the sub-pixels R, G, and B, by associating three states of the high voltage Vhigh, the low voltage Vlow, and the floating, so that each of the data lines DL 1 to DLm has a voltage difference with an adjacent data line.
[0222] The MUX 340 supplies the data signal, which is supplied from the data driver 334 , to each of the data lines DL 1 to DLm, to thereby implement a picture during the scan period SPD, and supplies the aging signal, which is supplied from the aging voltage supplier 350 , to each of the data lines DL 1 to DLm, to thereby make an self-aging is performed in each EL cell during the aging period APD.
[0223] Herein, the apparatus of driving the organic EL display panel according to the embodiment of the present invention may be integrated as one chip by integrating the aging voltage supplier 350 , the MUX 340 the data driver 334 .
[0224] In the organic EL display panel according to the embodiment of the present invention having the above-mentioned structure, as the data lines DL 1 to DLm are floated in the aging period APD, a voltage difference of the multilevel is generated between adjacent scan lines. As a result, a self-aging is performed in the entire EL cells 336 . Thus, it is possible to extend a life-span of the EL panel 330 and to prevent badness such as line defect.
[0225] As described above, in the method and the apparatus of driving the organic EL display device according to the embodiment of the present invention, the aging period to make an entire EL cells to be a reverse bias state is secured separately from the scan period to thereby do an aging of the EL panel upon driving. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0226] Further, in the method and the apparatus of driving the organic EL display device according to the embodiment of the present invention, the period, when the self-aging is performed in the entire EL cells by the voltage difference between the adjacent scan lines and the floating state of the data line, is secured. Accordingly, it is possible to do an aging of the EL panel upon driving.
[0227] Moreover, the high and the low aging voltages, oppositely applied to the adjacent scan lines in the aging period, is reversed one more time to thereby improve an aging efficiency. Accordingly, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0228] In addition, in the method and the apparatus of driving the organic EL display device according to the embodiment of the present invention, the period, when the self-aging is performed in the entire EL cells by the voltage difference between the adjacent scan lines and the floating state of the data line, is secured separately from the scan period in the frame. Accordingly, it is possible to do an aging of the EL panel upon driving. Thus, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0229] Otherwise, the neutralization step, in which the same voltage is applied to the adjacent scan lines, is included at least one time in the aging period. Accordingly, it is possible to reduce a parasitic capacitor in the EL panel.
[0230] In addition, the aging period, when the self-aging is performed in the entire EL cells by the voltage difference between the adjacent data lines and the floating state of the scan line, is secured separately from the scan period in the frame. Accordingly, it is possible to do an aging of the EL panel upon driving. Thus, it is possible to extend a life-span of the EL panel and to prevent badness such as line defect caused by a stress.
[0231] Although the present invention has been explained by the embodiments shown in the drawings described above, it should be understood to the ordinary skilled person in the art that the invention is not limited to the embodiments, but rather that various changes or modifications thereof are possible without departing from the spirit of the invention. Accordingly, the scope of the invention shall be determined only by the appended claims and their equivalents.
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The present invention relates to a method and apparatus for driving an electro-luminescence display panel capable of doing an aging operation upon driving.
A method of driving an electro-luminescence display panel according to the present invention includes: a scan period when electro-luminescence cells formed at a cross of both a plurality of scan lines and a plurality of data lines are line-sequentially emitted; and an aging period when an aging is performed in the electro-luminescence cells at the same time by applying a reverse bias, wherein the scan period and the aging period are repeated for each frame.
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BACKGROUND TO THE INVENTION
[0001] The invention relates to clips for retaining two or more panels together.
[0002] It is known to provide a variety of co-operating threaded members such as nuts or bushes, and co-operating screws or bolts in order to retain two or more panels together. However, such co-operating threaded elements require relatively complex assembly.
[0003] An object of the invention is to provide means for retaining two or more panels relative to one another which is relatively easy to use and or simple to manufacture. Another object of the invention is to provide retaining means which are capable of handling relatively high loads and or which are accurate and/or positively Locatable with respect to two or more panels.
SUMMARY OF THE INVENTION
[0004] According to a first aspect of the invention there is provided a clip assembly for retaining two or more panels together comprising a clip having a first abutment and a second abutment moveable between first and second positions to enable the clip to pass through an opening in the panels, and a pin locatable with respect to the clip to cause the second abutment to remain in the second position thereby to enable retention of the two or more panels between the first and second abutments.
[0005] Preferably the second abutment is resiliently biased to the first position; beneficially therefore enabling the clip to be inserted into the panel opening without requiring any positive action on the second abutment.
[0006] Preferably the second abutment is formed proximal a wall of the clip and operably protrudes beyond the wall in the second position. Preferably, the abutment protrudes slightly beyond the wall in the first position; beneficially thereby enabling positive location of the clip with respect to the two or more panels prior to insertion of the pin.
[0007] Preferably, the pin and second abutment comprise co-operating camming means. In one form the second abutment comprises a cam surface such as a heel and or the pin comprises a cam surface such as a tapered portion.
[0008] Preferably the clip comprises means for retaining the pin such as an aperture having peripheral barbs for engaging a portion-of the pin.
[0009] Preferably two or more pairs of first and second abutments are provided on a clip.
[0010] According to another aspect of the invention there is provided a clip assembly for retaining two or more panels together comprising a clip having a first abutment, a resiliently movable second abutment, a moveable element, such as a pin, having means for effecting movement of the second abutment to a retaining position whereby the first and second abutment are operable to maintain two or more panels together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] An embodiment of the invention will now be described, by way of an example only, with reference to the accompanying drawings, in which:
[0012] [0012]FIG. 1 is a schematic perspective view of a clip assembly according to the invention in a pre formed configuration;
[0013] [0013]FIG. 2 is a schematic perspective view of the assembly shown in FIG. 1 in a partially formed configuration;
[0014] [0014]FIG. 3 is a perspective view of the clip assembly shown in FIGS. 1 and 2 in a formed configuration;
[0015] [0015]FIG. 4 is a schematic side elevation view of the clip shown in FIGS. 1, 2, and 3 ;
[0016] [0016]FIG. 5 is a schematic edge view of part of the clip shown in FIGS. 1 to 4 operably gripping two panels; and
[0017] [0017]FIG. 6 is a schematic side view of an embodiment of a pin according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring to FIGS. 1 to 5 , there is shown a clip assembly 10 according to the invention, comprising a clip 12 and a pin 14 . Pin 14 comprises a tapered nose 16 , a first cylindrical portion 18 , a tapered portion 20 and a second cylindrical portion 22 . Pin 14 further comprises an end tab 24 for ease of insertion of the pin into clip assembly 10 . Pin 14 can be formed of glass filled nylon for example. The percentage glass content can be between 30 and 70%. It is noted that tab 24 is not necessarily larger than cylindrical portion 22 . Alternatively the tab can form a much larger panel such that pin 14 can be integrally formed within such a panel.
[0019] Referring to clip 12 , it comprises a U shaped body 30 having a first side 32 comprising a first abutment or lug 34 and two inwardly directed edge flanges 36 . A moveable member 38 is formed in an aperture 40 in first side 32 . Body 30 comprises an end 42 having an aperture 44 for receiving both portions 16 and first cylindrical portion 18 of pin 14 . One or more means for retaining pin 14 relative to the clip are preferably provided proximal aperture 44 . In this example a pair of barbs 46 are disposed on opposite sides of the aperture.
[0020] Body 30 comprises a second side 48 having a pair of inwardly directed edge flanges 50 and providing a further first abutment or lug 52 . Side 48 further comprises a moveable member 54 formed within an aperture 56 .
[0021] Moveable members 54 and 38 are substantially the same and reference is made here to moveable member 54 for further detail as shown in FIG. 4. Moveable member 54 is pivotally attached on a fold or pivot 58 . Moveable member 54 comprises a body portion 60 which extends to a lug or second abutment 62 .
[0022] Clip 12 can be formed from sheet material such as spring steel by first stamping the sheet material to form the correct shape, followed by bending edge flanges 36 and 4 50 , bending barbs 46 downwardly, bending first abutments 34 and 52 , and bending second abutment 62 for each of moveable members 38 and 54 . Preferably the moveable members 38 and 54 are also displaced relative to their respective side walls 32 or 48 for position whereby the end of the second abutment 62 protrudes only slightly beyond the face of the respective side wall. Finally, the U shape body 30 is formed thereby to create the clip shown in FIGS. 1 and 2 example for.
[0023] Accordingly, it should be appreciated that moveable members 38 and 54 each comprise a heel such as heel 64 adjacent second abutment 62 .
[0024] In use, clip 12 is inserted into an aperture or slot formed in one or more panels such as panel P 1 and panel P 2 shown in FIG. 5. Beneficially, the resilient nature of the movable member and the fact that first abutment 62 only marginally protrudes beyond side wall 48 enables the clip 12 to be easily inserted and moreover positively located due to the outward motion of the moveable member due to its own resilience. Once located, pin 14 is inserted as shown from FIGS. 1 to 3 . Accordingly, as nose portion 16 is directed towards aperture 44 , heel 64 of the moveable members 38 and 54 initially abut the first member portion 18 and in turn tapered (or frusto conical) portion 20 . The outwardly tapering nature of portion 20 causes the moveable members 38 and 54 to move outwardly thereby causing the second abutments 62 to protrude further beyond their associated side wall. Eventually, nose portion 16 passes beyond the ends of barbs 46 which operably engage the first cylindrical portion 18 and act to retain pin 14 in position as shown in FIG. 3. In the retained position, the moveable members 38 and 54 are displaced sufficiently outwardly to effect an abutment surface for abutting part of a panel such as panel P 2 shown in FIG. 5 whereby first abutment 52 and second abutment 62 operably provide effective means for retaining panels P 1 and P 2 together.
[0025] Referring to FIG. 6, there is shown a second embodiment of a pin according to the invention. Pin 14 A comprises means for enabling separation of first cylindrical portion 18 A from the rest of the pin thereby to assist in removal of the pin 14 A from the clip assembly 10 . The means can for example comprise a circumferential line of weakness around cylindrical portion 18 A for example formed by a series of depressions 66 in portion 18 A. Beneficially therefore, pin 14 A retains a large degree of structural integrity thereby meeting requirements to help retain panels in position but enabling rotational weakness such as a rotational sheer to effect breakage of the pin thereby to remove a large part of the pin from the clip assembly.
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A clip assembly for retaining two or more panels together comprising a clip having a first abutment, and second abutment moveable between first and second positions to enable the clip to pass through an opening in the panels and a pin locatable with respect to the clip to cause the second abutment to remain in the second position thereby to enable the tension of two or more panels between first and second abutments.
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RELATED APPLICATIONS
This application is a continuation-in-part application of Ser. No. 07/467,620, now abandoned, filed on 19 Jan., 1990 and of U.S. application Ser. No. 07/770,566 filed on 3 Oct., 1991, now U.S. Pat. No. 5,330,239 issued Jul. 19, 1994.
FIELD OF THE INVENTION
This invention relates to couplings or connections for use in interconnecting lengths of pipe casing or tubing made of steel or the like. In the following description, both terms "coupling" and "connection" are used, usually interchangeably without preference, it being understood that the invention applies equally to threaded and coupled connections and to pin and box members integral with the pipe and interconnecting lengths of pipe.
BACKGROUND TO THE INVENTION
The invention of application Ser. No. 07/770,567, filed on 3 Oct. 1991, is a pipe coupling/connection provided with a seal that simulates the seal one would obtain by shrink-fitting a cylindrical box seal onto a mating cylindrical pin seal, preferably modified by increasing the load pressure at the proximal end of the pin sealing surface by designing the coupling to provide, as the coupling is being assembled, sealing area interference at least about as soon as and preferably before there is any interference between the load threads of the pin and box in the vicinity of the sealing area. Preferably the load threads of the coupling have negatively inclined load flank faces.
OBJECTIVES OF THE INVENTION
It is desirable to provide a relatively high sealing load pressure at the proximal end of the pin sealing surface when the coupling is assembled. Such high sealing load pressure tends to maintain a reliable seal notwithstanding thermal cycling of the pipe (repeated cyclic axial loading in compression and tension). The high sealing load pressure facilitates crushing of the solid particles in the preferred high-temperature graphite particle--containing lubricant used to coat the sealing surfaces, which promotes the establishment of a relatively impermeable seal. And the high sealing load pressure tends to flatten out peaks on the roughened sealing areas and burnish the sealing areas, which also promotes the establishment of an effective seal. Such flattening and burnishing occurs primarily during assembly of the coupling/connection, but may continue to some extent during thermal cycling, since there will be relative axial movement between pin and box sealing areas as the pipe is alternately stressed in compression and tension.
It is further desirable, as taught in the aforementioned application Ser. No. 07/770,567, to avoid interference between pin and box load threads in the vicinity of the sealing area before interference occurs between the pin and box sealing surfaces, as the coupling is being assembled.
SUMMARY OF THE INVENTION
Parent Application
The invention of the parent application is a pipe connection of the type having a female component (box) and a mating male component (pin), each matingly threaded for connection therebetween, and each provided with a sealing area adjacent the threaded area. The sealing area of the coupling components is formed by mating frusto-conical surfaces one on the pin and box. At least one and preferably both of these mating surfaces have controlled surface roughness formed e.g. by microgrooves. The respective sealing areas of the components are in axially aligned sealing engagement when the pipe connection has been assembled. The present invention is distinguished in one aspect by three principal characteristics, as follows:
(a) The slopes of the frusto-conical sealing surfaces are each relatively shallow. The term "shallow" is more fully explained below.
(b) The slope of the frusto-conical sealing surface of the male component is slightly less than that of the frusto-conical sealing surface of the female component. (This characteristic without more would result in a sealing bearing load relative to axial distance of the contacting sealing surfaces of the components, when the components have been assembled, simulating that of a pair of mating shrunk-fit circular cylindrical sealing surfaces. The analysis of this physical characteristic is set forth in related application Ser. No. 07/770,567 incorporated herein by reference.)
(c) The slope of the load thread pitch line of the male component relative to the axis thereof is slightly steeper than the load thread pitch line of the female component relative to the axis thereof.
Preferably the load flank faces of the load threads of both the male and female components are negatively inclined to the radial, the angle of negative inclination of the load flank faces not exceeding about 10 degrees.
Preferably the mismatch between male and female thread pitch line angle is less than that which would afford 50% contact between the distal threads of the male component and the mating threads of the female component.
Desirably, the female component is provided with an interior torque shoulder forming an annular seat whose face is negatively inclined to the radial, the seat being engageable by and mating with the distal end of the male component.
In another aspect, the pipe connection of the invention of the parent application has frusto-conical sealing surfaces whose slopes are each relatively shallow, as stated above. Further, the slope of the load thread pitch line of the male component relative to the axis thereof is slightly steeper than the load thread pitch line of the female component relative to the axis thereof, also as stated above. In this second aspect, the pipe connection is further characterized as follows:
(1) When the connection is being assembled, interference between the sealing surfaces occurs before the occurrence of any radially-directed interference of the load threads of the male and female components in the vicinity of the sealing surfaces.
(2) Upon complete assembly of the connection, any interference between the load threads is insufficient to tend to pry the sealing surfaces apart to an extent that would reduce the sealing bearing load below the minimum design value for the connection.
Desirably the pipe connection has the characteristics of both the first and second aspects of the invention as stated above.
It can be seen that the invention of the parent application of the present application achieves the stated objectives by following the aforementioned criteria common to the parent of this application and related application Ser. No. 07/770,567 but differing from the latter in that there is provided in the invention of the parent of this application a slight mismatch between pin and box load thread tapers, the pin taper being slightly steeper than the box taper.
(Note that this mismatch is in the opposite sense to the mismatch between sealing surface tapers disclosed in the aforementioned application Ser. No. 07/770,567).
The slight mismatch between pin and box load thread tends to ensure that root-to-crest contact does not occur at the threads in the vicinity of the seal such that the seal bearing load is compromised, and gives a degree of independence between axial loading and seal bearing pressure such that when axial loads are applied, the desired seal pressure distribution does not tend to be adversely affected. The increased bearing load at the proximal end of the effective pin sealing surface tends to ensure a seal that is acceptably tight even if there is damage to the distal end of the pin that interferes with the efficacy of the seal in the vicinity of the damage. Such increased bearing load also facilitates maintenance of adequate sealing pressure during thermal cycling of the pipe (alternating tension and compression of the coupling, which causes relative axial movement of the pin and box sealing surfaces).
The degree of mismatch between box and pin load thread tapers should be selected to be consistent with other coupling design objectives, including:
1. maintaining an adequate thickness of material at the distal end of the pin;
2. avoiding undue tilt of the distal end of the pin during make-up of the coupling (tilt resulting in strain that causes the yield strength of the steel to be exceeded is usually undesirable);
3. maintaining an adequate axial length of effective sealing area;
4. avoidance of galling of the sealing surfaces during make-up of the coupling;
5. maintaining the preferred box/pin sealing surface relationship, viz. a mismatch that simulates a circular cylindrical shrink-fit bearing load-vs.-distance characteristic; (this of course implies that there be no undue thread interference in the vicinity of the sealing area that would tend to part the box sealing surface from the pin sealing surface);
6. maintenance of an adequate seal during thermal cycling of the pipe, which causes cyclic relative axial movement between pin and box sealing surfaces.
The particular thread taper angles chosen may also depend in part on the pipe diameter, the grade of steel, the overall length of the pin sealing surface, the thread height, and the number of threads per axial length.
For most oil well pipe coupling applications, it is to be expected that the permitted maximum thread angle mismatch would result in the pin thread and box thread making only about 50% flank area contact at the distal end of the pin.
An advantage of the thread pitch line mismatch of the parent of the present invention is that the preferred bearing load vs. seal surface axial distance characteristic tends not to be adversely affected over the expected range of axial loading on the coupling.
Present Invention
While the foregoing characteristics are sufficient to the obtention of an adequate seal, even under high-temperature high-pressure operating conditions, some other factors have been found to have a beneficial effect in the optimization of the sealing reliability, especially if the distal end of the sealing surface of the pin has been damaged. The present application deals with such additional factors. The factors to which the present application is specifically directed are the following:
a) The load thread interference is selected within a range that facilitates the obtention of a sealing force greater than a predetermined design minimum sealing force over at least one-third and preferably over one-half of the available sealing area of the pin and box sealing areas, while maintaining the sealing force throughout this region below levels at which galling of the sealing surfaces would occur.
b) Load thread and sealing surface manufacturing tolerances are selected so that the foregoing sealing surface characteristic is maintained even at maximum departures from designed dimensional values.
c) The slope of the interference curve envelope for the effective sealing area is positive relative to the pin and lies entirely below values at which galling of the sealing surfaces would occur and entirely above the designed minimum interference corresponding to designed minimum sealing force in the effective sealing area.
d) Preferably, the effective sealing area, as defined above, extends over at least one-half inch and preferably over at least about two-thirds of an inch in the axial direction, for pipe of typical oil well casing size ranges.
e) It has been found empirically that if the female component is provided with an interior torque shoulder forming an annular seat engageable by and mating with the distal end of the male component, the face of the annular seat being negatively inclined to the radial, as discussed in more detail in related patent application Ser. No. 07/770,567, then that torque shoulder/pin engagement itself may contribute materially to the efficacy of the seal. When a torque shoulder is used, it tends to relieve the stress peak at the distal end of the pin sealing surface somewhat while contributing to a higher total interference over the effective sealing area in the vicinity of the distal end of the pin--in other words, the stress-versus-distance curve is smoother than would be the case if the torque shoulder were absent.
Some of the foregoing characteristics will now be discussed further as follows:
a) The immediate parent application Ser. No. 07/770,566 of this present application taken in conjunction with the teachings of related application Ser. No. 07/770,567 referred to the requirement during makeup of the coupling that interference of the pin and box sealing areas occurs at least about as soon as and preferably before there is any interference between the load threads of the pin and box members in the vicinity of the sealing areas. Accordingly it is to be understood that the load thread interference, especially the interference in the vicinity of the sealing area, can have a direct effect on the obtention of optimal sealing force over the effective sealing area. It is a requisite of the invention that the sealing force over the entire axial length of the effective sealing area be greater than design minimum sealing force. The sealing force is created by the load thread interference. Further, as mentioned above and to be discussed further below, the effective length of the available sealing area should be sufficient to maintain an adequate seal under high-pressure high-temperature operating conditions. This latter requirement is most reliably satisfied if the effective sealing area over which the sealing force is greater than design minimum is designed to be at least one-third and preferably more than one-half of the available sealing area.
Also, the thread interference should be chosen so that the sealing force over the effective sealing area remains below levels at which galling of the sealing surfaces would occur.
It must be kept in mind that the wall thickness of the distal end of the pin member and steel grade used can influence the choice of designed interference. A thin distal pin wall will tilt more than a thicker wall; generally speaking, a heavier wall requires more metal-to-metal seal interference than a thinner wall. The variance may not be significant, and may be ignored from an engineering point of view, over the range of pipe diameters, wall thicknesses and and material grades used for most oil well casing (say).
b) A second factor to be considered is that if manufacturing tolerances for the sealing area or for the load threads (especially in the vicinity of the sealing area) are too liberal, the sealing force in the vicinity of the gauge point selected for the sealing area may be within the range specified above, but nevertheless may fall outside of this range if manufacturing tolerances are not constrained to keep the sealing force within the preferred range.
Because it is desirable that the sealing force within an effective sealing area of at least one-third and preferably more than one-half of the available sealing area lie within the preferred range, it follows that tolerances should be constrained so that the foregoing result is enabled.
c) The tolerance seal taper mismatch envelope refers to the plot of sealing surface interference relative to distance along the sealing surface. This can of course be plotted either for the box or for the pin. If we select the pin as the reference element for the plot of interference against distance, then as we proceed along the pin from the proximal to the distal end of the effective sealing surface, the overall slope of the envelope formed by the curve of maximum interference (for any given designed tolerance) as an upper limit, and the minimum interference corresponding to the minimum permitted range of tolerance as a lower limit, over the length of the effective sealing area, should be essentially positive. That is, the slope of the envelope should be such that the interference values are higher at the distal end of the effective sealing area of the pin than they are at the proximal end of the effective sealing area along the pin sealing surface. Equally, the entirety of this envelope should lie below values at which galling of the sealing surfaces occurs.
d) Although effective sealing areas that are quite short may be sufficient to withstand the stresses of most pressure and temperature situations, it is desirable in high-pressure high-temperature extreme operating conditions to maintain the effective sealing area as large as possible over as long as possible an axial distance. Preferably for the range of sizes of pipe that are typically used in oil casing applications, the effective sealing length in the axial sense is at least about one-half an inch and preferably at least about two-thirds of an inch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial partial section view of a pin member wall constructed in accordance with the invention, at the end of a length of pipe, as seen through the pipe wall, showing the coupling threaded portion and adjacent sealing portion for engaging a mating box member of the coupling.
FIG. 2 is an axial partial section view of a wall portion of the mating female or box member of a coupling according to the invention showing the coupling threaded portion and sealing threaded portion for receiving the pin member of FIG. 1.
FIG. 3 is a partial view in axial section of a modified alternative construction of the wall portion of the box member modified to permit chaser manufacture of the box threads, and otherwise conforming to the box structure of FIG. 2.
FIG. 4A is a graph showing a representative seal bearing load vs. distance characteristic for the seal of a coupling or connection designed according to the principles of the invention of the aforementioned patent application Ser. No. 07/770,567, where thread interference in the vicinity of the sealing area begins about simultaneously with seal surface interference, as the coupling is being made up, and where box thread taper is the same as pin thread taper.
FIG. 4B schematically represents the slightly mismatched gently sloped tapers of box and pin sealing surfaces according to the invention, of the aforementioned patent application Ser. No. 07/770,567, giving rise to the graphs of FIGS. 4A, 4C and 4D. The dimensions, slopes and mutual spacing of the pin and box sealing areas have been exaggerated for ease of comprehension.
FIG. 4C is a graph showing a representative seal bearing load vs. distance characteristic for the seal of FIG. 4B, but where thread interference in the vicinity of the sealing area lags the occurrence of sealing area interference as the coupling is being made up.
FIG. 4D is a graph showing a representative seal bearing load vs. distance characteristic for the seal of FIG. 4B as modified in the same way as for FIG. 4C, but with pin thread taper being slightly steeper than box thread taper, in accordance with the principles of the present invention.
FIG. 5 is a graph depicting the envelope of the set of interference/distance curves determined by maximum and minimum interference over the effective sealing area, displayed relative to the pin, satisfactory for compliance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The end of a steel pipe, tube or casing 11 is formed to provide a pin generally indicated as 12. Pin 12 has a threaded portion 19 beginning at a chamfered starting thread 15 located at a position short of the distal end 18 of the pipe 11 and extending axially therefrom to terminate in a vanish point 13. The relatively shallow thread pitch line of threaded portion 19 of the pin 12 is sloped inwardly from its proximal end at vanish point 13 toward its distal end. The pin 12 terminates in a frusto-conical sealing area 21 provided with a controlled surface finish to provide a limited degree of roughness, e.g. helical microgrooves formed by way of threading, as more particularly illustrated in FIG. 7. The angle of slope Y of the sealing surface 21 along the frusto-conical surface relative to the axis of the pin is equal to that of the thread pitch line of the threaded portion 19.
It will be noted that in FIG. 1, the depth of the roots, and the height of the crests of the threads of threaded portion 19 relative to the roots of the threads, of pin 12 increases from the vanish point 13 to a maximum about midway along the axial length of coupling portion 19, well before reaching the starting thread 15. As illustrated, seven of the threads are perfect threads. The thread relationships may be as described in the aforementioned patent application Ser. No. 07/770,567, subject to the mismatch to be described.
Referring to FIG. 2, the box 31 of which half of a complete wall length (in the axial direction) is illustrated in FIG. 2, is internally configured and threaded to mate with the pin 12 of FIG. 1. The other half of box 31 (not illustrated) is similarly internally configured and threaded to receive the pin of the next length of pipe. In an integral connection, the pin could be formed as illustrated in FIG. 1, the female end as illustrated in FIG. 2 (or FIG. 3, as an alternative to FIG. 2).
Specifically, the female coupling element 31 is provided beginning at its distal end 33 with a threaded portion generally indicated as 35 extending into the interior of box member 31 as far as a terminating thread 38. Further inwardly from thread 38 is a gap functioning as a single-point threading tool relief groove, generally indicated as 39, terminating in a shoulder 41 which defines the outermost limit of an interior frusto-conically shaped, microgroove sealing surface generally indicated as 43, which terminates in a limit or torque shoulder 45 forming a negatively inclined annular seat 46. The negative inclination of seat 46 tends to prevent the pin end 18 from climbing over the shoulder 45 when excess torque or high axial loading is applied to the coupling.
Although the threaded portion 35 of box 31 and the sealing surface 43 of box member 31 are both tapered so as to receive in coupling and sealing engagement the mating pin 12 of FIG. 1, nevertheless the degree of taper of the interior sealing surface 43 of box 31 is deliberately chosen to be slightly steeper than the degree of taper of the mating sealing surface 21 of pin 12. The reason for this is to provide a preferred bearing load-versus-length relationship, as discussed above and to be discussed in greater detail in the aforementioned patent application Ser. No. 07/770,567.
The individual threads 35 (load threads) of box 31, shown in enlarged profile in FIG. 5, are angled to mate exactly with the threads of pin 12. Further, the thread pitch line of threads 35 is approximately that of threads 19, subject to the slight mismatch to be described. In other words, the surfaces of revolution of the thread pitch lines for the coupling threads of the male and female coupling components are or nearly mating frusto-conical surfaces. The box thread is typically deeper than the pin thread so as to afford the necessary thread clearance.
It is proposed according to the present invention that the interference values selected for the load threads, especially in the vicinity of the sealing area, be selected to avoid premature load thread interference when the connection is made up. It is proposed according to this invention and its immediate parent application Ser. No. 07/770,566 by reference to related application Ser. No. 07/770,567 that as the connection is made up, interference of the pin and box sealing area should occur at least about as soon as, and preferably before, the occurrence of any interference between the load threads of the pin and box members in the vicinity of the pin and box sealing areas. It is further proposed according to the present invention that the load thread interference be selected so that the sealing force in the sealing area is greater than design minimum sealing force for at least about a third and preferably over about half of the available sealing area. It is also a requirement of the present invention that such load thread interference be selected to prevent the sealing force within the effective sealing area from reaching values that would cause galling of the sealing surfaces within the effective sealing area.
See also in this connection the discussion of FIG. 5 below.
FIG. 3 illustrates an alternative structure for the interior of the box member. In FIG. 2, the coupling threaded portion was shown to terminate in a final thread crest 38, followed by a thread relief groove 39, followed by a curved shoulder 41, and sealing surface 43. By contrast, the relief groove 39 is omitted in the FIG. 3 alternative embodiment, and instead, there is a thread run-off area 73 intermediate the end of the coupling threaded portion 35 and the sealing surface 44, merging with surface 44 via a curved shoulder transition portion 75. The sealing surface 44 of FIG. 3 is substantially identical to the sealing surface 43 of FIG. 2, with the qualification that the total axial distance occupied by the sealing surface 44 of FIG. 3 is somewhat shorter than the total axial distance occupied by the sealing surface 43 of FIG. 2.
While the FIG. 3 embodiment has less total sealing area than the FIG. 2 embodiment, nevertheless the FIG. 3 embodiment is easier to manufacture using a chaser technique, using the same tool bit (requiring no withdrawal of one tool bit and insertion of a separate tool bit). The sealing surface 44 can, using the chaser technique, be machined first as a helical microgroove surface, immediately followed by the machining of the threaded portion 35, without withdrawing the tool. The FIG. 2 embodiment does not admit of this possibility, but would require three separate tool bits to cut the threads, the thread relief groove, and the sealing area respectively, assuming that microgrooves are formed on the sealing area.
In this specification, reference will occasionally be made to the gauge point of the load threads and of the sealing surfaces of both pin and box. This is the point at which nominal design values are selected for whatever parameters pertain to such point. For example, the nominal interference value designed for the coupling is selected relative to the gauge points of the box and pin--the sealing surface gauge points for seal interference, the load thread gauge points for thread interference.
The selection of the gauge point is arbitrary to some extent, but ordinarily conveniently chosen as some intermediate point rather than a terminating point (of sealing surface, or threading, as the case may be). Suitably selected gauge points are shown schematically in FIGS. 1 and 2. Pin thread gauge point 20 is selected to be at or near the mid-point of the range of perfect threads on the pin. Box gauge point 36 is selected to be approximately aligned with pin gauge point 20 when the coupling is made up. Pin seal gauge point 16 is selected to be in the vicinity of the mid-point (axially) of the effective pin sealing surface. Box seal gauge point 42 is selected to be approximately aligned with pin seal gauge point 16 when the coupling is made up.
A difference between the coupling/connection of the present invention (and its parent) on the one hand, and that of the aforementioned patent application Ser. No. 07/770,567 on the other hand, is that the pin taper angle Y of the pin load threads relative to the axis of the pin is slightly steeper (greater) than the box taper angle Z of the box.
If, for example, the angle Y is of the order of 3.0 degrees, then the angle Z might be of the order of 2.7 degrees.
The mismatch should be chosen consistent with other design objectives of the sort mentioned earlier.
The mismatch should not be so great that a significant portion of the load threading is rendered inefficient. The greater the difference between the thread pitch line angles Y and Z, the greater the loss of contact between the distal pin threads and the mating box threads. The greater the loss of contact, the more threading that will be required to maintain the tensile yield strength of the coupling.
In most cases, it is not advisable to lose more than 50% of the distal pin thread contact (i.e., contact between the threading at the distal end 15 of such pin threading, and the mating box threading adjacent thread relief groove 39 or thread run-off area 73), as an upper limit of the permitted mismatch.
At the other extreme, where the angles Y and Z are almost identical, there is little or no improvement over the result obtained by practising the invention of the aforementioned patent application Ser. No. 07/770,567.
In use, the pin 12 of FIG. 1 is stabbed into the opening generally indicated as 47 of the box 31. Pin 12 is thrust in sufficiently far that contact is made between the starting thread 15 and a contacting thread surface of the threaded portion of box 31, following which engagement of the threaded portions 19, 35 of pin 12 and box 31 respectively begins. The box 31 is then rotated relative to pin member 12 or vice versa so as to screw the pin member 12 into the box member 31. Rotation of the box member 31 relative to pin member 12 continues until the limit of the threaded portions is reached and the coupling threaded portion 19 of pin member 12 fully engages the mating coupling threaded portion 35 of box member 31. Rotation is effectively terminated when distal end 18 of pin 12 comes into pressure contact with annular seat 46 of box 31. This contact, assuming that the distal end 18 of pin 12 matingly seats against torque shoulder 45 in annular seat 46, will tend to form an effective auxiliary seal when the coupling is under compression.
Before this point is reached, the sealing portion 21 of pin 12 will have commenced engagement with the mating (but slightly differently tapered, as mentioned above and discussed in further detail below) interior sealing surface 43 (or 44) of box 31. If the sealing areas are surface-roughened by microgroove machining, it is apparent that the pitch of the microgrooves on sealing surfaces 21, 43 of pin 12 and box 31 respectively must be very much smaller than the pitch of the threaded coupling portions 19, 35. It follows that the microgrooves on pin 12 will skip relative to the microgrooves of box 31, as the box 31 is screwed onto pin 12. This action generally will not damage the sealing surfaces 21, 43 appreciably, but will tend to smooth out any surface irregularities and will also, if a sealing compound has been applied to the sealing surfaces, tend to spread the sealing compound over the sealing surfaces and cause entrapment of the sealing compound by depressions in the mating sealing surfaces 21, 43 of the pin 12 and box 31 respectively so as to facilitate formation of a large effective sealing area as between the microgroove sealing surface 21 and microgroove sealing surface 43. The entrapment of sealing lubricant will serve to protect against wear and will reduce any propensity of the sealing areas to gall destructively.
According to the invention of the aforementioned patent application Ser. No. 07/770,567, the slopes of the tapered pin and box sealing surfaces are selected to be gently angled and slightly mismatched, as appears schematically in FIG. 4B. In that case, the bearing load varies with axial distance over the sealing area according to curve B1 in the graph of FIG. 4A. The bearing load is at a design minimum M at an intermediate point along the sealing threaded portions of the pin and box and rises to a significantly higher value at both ends of the sealing threaded portion of the pin and box.
It has been assumed in depicting the graph and physical arrangement of box and pin of FIGS. 4A, 4B that there is some thread interference in the vicinity of the sealing surfaces when the coupling is made up. If thread interference is deliberately designed to lag the occurrence of sealing surface interference by a considerable distance as the coupling is being made up, a superior result is obtained, viz. that of FIG. 4C. In that case, curve B2 is essentially similar to curve B1 over most of the axial distance along the sealing area, but curve B2 rises to a significantly higher bearing force value than does curve B1 in the vicinity of the proximal end of the sealing area relative to the pin. This extra measure of proximal-end sealing force tends to cause some burnishing of the sealing surfaces where that force is present and presumably facilitates mashing of sealing compound also.
It is not necessary, even when the coupling is completely made up, that there be any thread interference in the vicinity of the sealing area. In such case, proximal pin sealing surface bearing load considerably exceeds the bearing load that would result if adjacent thread interference were to lag sealing surface interference by only a slight delay during make-up ("delay" of course being used in a relative box/pin rotational movement sense, not in an absolute time sense).
If there is a slight mismatch between load thread and box thread taper, the pin thread taper being slightly steeper (more inclined to the axial) than the box thread taper, as taught in the present patent application, such that the thread taper mismatch facilitates the avoidance of thread interference in the vicinity of the sealing area, then the result is a further increase in the value of the bearing force (sealing force) at the proximal end of the sealing area relative to the pin. The result is graphically depicted in FIG. 4D.
Due regard must be paid to permitted tolerances in the chosen design of coupling according to the invention. Tolerances should be chosen for both sealing surfaces and load threads that tend to minimize risk of galling of the sealing surfaces during make-up of the coupling. On the other hand, tolerances should not be chosen that would make possible a reduction of bearing load throughout the effective sealing area below design minimum. The design minimum normally should be at least equal to the expected pressure differential at the yield strength of the selected steel.
More tolerance is permitted for higher grade steel than for lower grade steel. If the design minimum interference to hold pressure is, say, 0.010" and this could be achieved by a relatively low grade of steel such as J-55, then the maximum interference may be 0.020" as limited by galling. A higher grade of steel such as L-80 may be able to tolerate 0.030" because it will not tend to gall up to that amount of interference.
The effect of manufacturing tolerances on interference values is depicted in the graph of FIG. 5. The abscissa of the graph is the distance along the pin of the effective sealing area of the coupling. The effective sealing area thus extends between proximal limit X P and distal limit X D . The ordinate of the graph is the interference value.
For a given design sealing force throughout the effective sealing area, there is a corresponding interference which is represented by interference level I D represented by the positively sloped straight line WZ between proximal limit X P and distal limited X D of the effective sealing area. Note that if sealing area surface load stress were being plotted against distance instead of interference against distance, the minimum design sealing surface stress load curve counterpart to line WZ would be horizontal. But because there is tilting of the pin and consequent redistribution of the stress on the sealing surface, the designed minimum interference over the sealing area is represented by a positively sloped line. In other words, given that the pin tilts and given that the sealing surface is frusto-conical rather than cylindrical, the coupling designer should design for a minimum interference that is higher at the distal end of the pin sealing surface than at the proximal end of the pin sealing surface. This fact is graphically represented by the positively sloped curve WZ shown in the Figure.
At the gauge point X G selected to be intermediate the proximal and distal limits X P , X D of the effective sealing area, the nominal interference is the value G n . However, because the tolerance at the gauge point permits some limited departure from the nominal value G n , the actual interference at the gauge point could be as much as G max or as little as G min .
On either side of the gauge point X G , because of the tolerance attaching not only to the nominal gauge point interference, but also to the seal taper mismatch, interference values could range between P max and P min at proximal limit X P of the effective sealing area, and between D max and D min at the distal limit X D of the effective sealing area. The result is an interference value envelope defined by the points P max , G max , D max and P min , G min and D min . Note that the overall slope of this interference envelope is essentially positive relative to the distance along the pin, meaning that the interference at the distal end is appreciably higher than the interference at the proximal limit of the effective sealing area.
In some region of elevated interference values, galling of the sealing surfaces will occur. This galling region cannot be depicted with precision on the graph of FIG. 5 because the point at which galling occurs depends not only upon interference per se, but also upon other factors, including especially the rate of speed at which make-up of the coupling occurs, the grade of steel used, the kind of lubricant present, the ambient temperature, and possibly other factors. However, for graphical convenience, it may be supposed for purposes of simplification that the minimum interference level at which galling occurs would be along the line UV in FIG. 5. Once the galling region is established, it is important that the interference envelope defined by the six points mentioned above be comfortably below the galling region UV.
Equally, it is desirable, although ordinarily not critical, that the point P min be above the design minimum interference value I D . Otherwise, in the worst condition at maximum negative permitted tolerance of both the seal taper mismatch and the nominal gauge point interference, the actual interference at the proximal limit X P of the effective sealing area could lie below design minimum value.
The actual value of the interference throughout the effective sealing area will depend not only upon the designed interference between the sealing surfaces themselves, but also upon any load thread interference in the vicinity of the sealing area. Consequently, the load thread interference should be selected so that the resulting interference envelope depicted in FIG. 5 remains within the permitted boundaries, that is below the galling region lower limit UV (which as explained above will be a variable range of values and not a fixed range of values) and above the minimum design interference I D . Preferably also, the load thread interference should be selected so that the designed minimum sealing force corresponding to interference value I D is exceeded throughout an effective sealing area that is at least about one-third and preferably over one-half of the total available sealing area. This condition tends to maintain the integrity of the seal even under extreme high temperature high pressure conditions. In absolute dimensions, it is preferred that the length of the effective sealing area be at least about one-half inch and preferably at least about two-thirds of an inch for the range of pipe diameters conventionally used in oil well casing applications.
EXAMPLE
Pin and box members according to the foregoing description were prepared for use in couplings for 7-inch pipe having wall thickness ratings of 23 and 26 pounds per foot. Such a coupling is intended for use with well casings where steam injection within the casing is required. Depending upon the length of pipe and the expected pressures, a 55,000 psi minimum yield strength or 80,000 psi minimum yield strength steel may be selected. Temperatures up to 650 degrees Fahrenheit must be withstood, and axial tensile and compressive loads are expected to occur which approach or even exceed the actual yield strength of the material in the pipe body. The coupling was designed to withstand this axial loading without failure whilst maintaining adequate resistance to leakage from internal pressures ranging up to actual yield strength of the pipe wall.
The coupling was prepared with approximately twelve complete turns of threads tapered at 0.095 inches per revolution for the pin and box, and having a pitch of 0.200 inches per revolution. Of the twelve threads on the pin, seven were perfect threads, and the other five were partial threads diminishing to the vanish point 13 as illustrated in FIG. 1. The flank face orientation for the pin threading was the same as that for the box threading, namely -3 degrees for the load flank and +18 degrees for the stab flank.
For the sealing surfaces, the microgrooves were formed by a 3/64 inch radius turning tool fed at an axial feed rate selected within the range of about 0.002 inches to 0.015 inches per revolution. (The lower rate facilitates leakage avoidance; the higher rate reduces manufacturing time). If the coupling will be used in a gaseous environment, such as a heavy oil steam environment, a feed rate nearer the lower value (0.002 inches/revolution) is preferred. For leak resistance in a conventional oil environment, a feed rate nearer the higher value (0.015 inches/revolution) is preferred. The total sealing length of the pin member was selected to be 0.900 inches; the sealing portion in the box member would be slightly smaller, depending upon whether the FIG. 2 or FIG. 3 embodiment is chosen. The microgrooves at, say, 0.008 inches/revolution pitch are about 0.0002 inch in depth and at, say, 0.015 inches/revolution pitch are about 0.0006 inch deep. The crests tend to be flattened upon tightening the coupling, perhaps removing at least about 20% from the trough depth, and more in the vicinity of the area of highest bearing pressure.
The gauge points for the pin and box were selected as follows:
The pin and box thread gauge position was selected to be at a point axially where the threads in the made-up (assembled) position of pin and box members were directly coincident and spaced from the last full-depth thread (after which only partial flank depth occurs, diminishing towards the vanish point). This axial position was also selected so as to afford greater than zero interference at the ends of the threaded portions in the vicinity of the outer end of the box, less as one progresses inwardly (because of the load thread taper mismatch between box and pin).
The pin seal gauge point 16 was arbitrarily chosen to be 3/8 (0.375) inch from the distal end of the pin. The box seal gauge point 42 was also arbitrarily selected to be 0.375 inch from the box seat 46 (see FIG. 2). The calculated minimum interference M was then based upon the nominal interference (0.019 inch) at a location 0.375 inch from the distal end of the pin which coincides exactly with gauge point of the box seal. Selecting the gauge point is somewhat arbitrary on the basis that to stop leakage, the interference at any point along the active seal must be equal to or greater than the minimum seal interference (0.012" in this case). Since the coupling has unequal seal tapers for the pin and the box, in this case it is more convenient to locate the gauge points at the same axial location from the torque shoulder.
At the gauge point, the nominal interference is 0.019 inches. The difference between the nominal interference 0.019 inches and the minimum design interference 0.012 inches is thus seen to be 0.007 inches. The requirement for a 0.007 inch difference arises from the fact that the sum of the diameter tolerances of the pin seal diameter and the box seal diameter is 0.007 inches.
The pin sealing area taper was 0.104 inches per inch on diameter, the same as that of the thread pitch line of the threads, whilst the box sealing area taper was 0.110 inches per inch on diameter. This is a seal taper mismatch of 0.006 inches per inch on diameter, or less than the minimum gauge point sealing area interference of 0.012 inches on diameter. The tolerance of the pin thread and seal at the gauge point was ±0.004 inches on diameter, and that of the box was ±0.003 inches on diameter.
The box thread taper was selected to be 0.095 inches per inch, and the box seal gauge point 42 was selected to be 0.500 inch from the box seat 46.
There was no thread interference in the vicinity of the sealing area even when the coupling was made up. And as noted, there was slight mismatch between box and pin thread taper, the pin taper being slightly more inclined to the axis than the box taper, with the result that the sealing force vs. distance characteristic resembled that of FIG. 4D.
In this exemplary structure, the nose of the pin was sloped inwardly toward the axis of the pin at an angle of 5° to a radial line perpendicular to the pin axis. The mating portion of the box is the annular seat of the box that forms the torque shoulder and that is formed at the same angle. Immediately prior to the seating of the nose of the pin in the annular seat in the box, the contact stress at the distal end of the pin is relatively low. However, once seating occurs, there is an axial compressive load on the seat and the contract stress distribution at the distal end of the pin more closely simulates a cylindrical shrink-fit condition.
Terminology
The scope of the invention is as presented in the appended claims.
In the appended claims:
1. The term "connection" includes a coupling.
2. The phrase "relatively shallow" with reference to the slopes of the frusto-conical sealing surfaces of the box and pin implies that:
(i) the taper is not so great as to give a bearing-load-vs.-axial-distance characteristic similar to that of FIG. 11A in the said copending patent application Ser. No. 07/770,567.
(ii) the taper is not so great as to create a significant risk of loss of seal due to thermal cycling of the coupling (i.e., alternate stressing of the coupling in tension and compression);
(iii) the taper is not so great as to reduce distal-end pin wall thickness unacceptably; and
(iv) the taper is nevertheless sufficient to avoid galling of the sealing surfaces during assembly of the coupling.
3. The term "slightly less" with reference to the slope of the frusto-conical sealing surface of the pin relative to that of the box implies that:
(i) the mismatch is sufficient to avoid a bearing-load-vs.-axial-distance characteristic similar to that of FIG. 10A in the said copending patent application Ser. No. 07/770,567;
(ii) the mismatch is not so great as to generate an effective contacting sealing area between the box and the pin that is unduly short in the axial direction;
(iii) the mismatch is not so great as to give a bearing-load-vs.-axial-distance characteristic similar to that of FIG. 12A in the said copending patent application Ser. No. 07/770,567; and
(iv) the mismatch is not so great as to cause undue tilt of the pin during assembly.
4. The term "slightly steeper" with reference to the taper of the pin load threads relative to those of the box implies compliance with the design objectives set forth in this specification, and in particular implies choice of a mismatch that is less than that which would cause undue loss of thread contact between pin and box threads in the vicinity of the distal end of the pin.
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A pipe coupling or connection comprises a female coupling component and a mating male coupling component. Each component is matingly threaded for coupling engagement, and each is provided with an adjacent frusto-conical sealing surface. The sealing surface is provided with a controlled surface roughness, viz. very shallow fine surface variations, preferably formed as microgrooves at a pitch small relative to the pitch of the threads. The slope of the frusto-conical surface of the sealing surface of the male component is slightly mismatched with that of the sealing surface of the female component to simulate the bearing force vs. axial distance characteristic of shrunk-fit circular cylindrical sealing surfaces. The mismatch enables the sealing pressure to be above a design minimum throughout the entire sealing area yet higher at each end of the sealing area. As the coupling is assembled, thread interference in the vicinity of the sealing surface lags the occurrence of interference between the sealing surfaces. Load threads are provided with negatively inclined load flank faces. The slope of the load thread pitch line of the male element is slightly steeper than the slope of the load thread pitch line of the female element. Load thread interference values and tolerances are selected to enable the shrunk-fit cylindrical sealing surface simulation to be met over the range of tolerances provided. The envelope of the range of curves of interference vs. distance along the effective pin sealing surface area has a positive slope. The effective sealing area is at least about one-third and preferably at least about half of the available sealing area.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to apparatus for controlling the temperature of a rotating dryer drum along its axial dimension by internally insulating a portion of the dryer drum from direct engagement by the steam within the drum.
2. Description of the Related Art
Rotating dryer drums are commonly used to heat webs of material, such as paper or fabric, for the purpose of drying the web. For instance, in the manufacture of paper, the web is passed over the outer periphery of a number of rapidly rotating steel drums internally heated by the injection of steam therein. As the paper engages the periphery of the hot drum, moisture is removed from the web, and by using a plurality of rapidly rotating drums high production of properly dried paper is achieved.
It is very important in the drying of paper webs that the extent of drying be closely controlled so the paper will have the proper moisture profile throughout the web width and meet the maximum and minimum moisture content specifications. Of course, the moisture content of the paper passing over the rolls must be uniform throughout the width of the web. Difficulty is often encountered in maintaining a uniform moisture content in the paper web throughout its width in that difficulty is encountered in maintaining a uniform temperature of a drying drum shell throughout its axial length.
The temperature of a dryer drum will often considerably vary throughout its length for several reasons. For instance, the uneven buildup of water condensate within the drum adversely affects its heat transfer ability, and syphon systems are located in the drum to control and remove the condensate. Also, there is a common tendency for the temperature of the dryer drums to be hotter adjacent the drum ends due to the fact that the amount of paper engaging the drum adjacent its ends will be less than the paper mass engaging the central portion of the drum and the rate of heat transfer will be less, and the presence of the drum head or end adjacent the ends of the drum shell often tend to maintain the ends of the drum at a higher temperature due to the effect of the greater heated mass of drum material adjacent the drum shell ends. Accordingly, it is common practice when drying paper webs to only use the central portion of the dryer drum shell resulting in inefficient use of the drum, requiring drums much wider than the web and restricting the width of the paper web being dried.
Various attempts have been made to overcome the above problem by reducing the temperature of the dryer drum adjacent the ends of the drum shell. Such attempts include the application of an insulating material on the exterior of the drum adjacent the drum ends whereby the amount of heat transferred to the web being dried adjacent the ends is reduced and the moisture profile within the paper web is controlled. Such modification of drying drums may include the wrapping of fabric or foil adjacent the drum ends as shown in U.S. Pat. Nos. 4,192,080; 4,639,291 and 4,639,292. However, the insulating of the exterior of the drum in the manner shown in these patents has the disadvantage of locating the temperature controlling apparatus on the drum exterior in direct contact with the paper web, and the insulation material is subject to wear, thinning and maintenance problems, and may also contaminate the web being dried if pieces thereof cling to the web.
3. Objects of the Invention
It is an object of the invention to provide drum shell temperature controlling apparatus for use with a rotating dryer drum wherein the apparatus is completely internally mounted within the drum and is not subject to damage or wear by the material being dried.
Another object of the invention is to provide temperature controlling apparatus for modifying the temperature of a rotating dryer drum shell along its length wherein such drum temperature control is achieved by insulating selective portions of the drum shell interior with respect to the heated medium, i.e. steam, within the drum, wherein the portion of the dryer drum engaged by the temperature controlling apparatus will be at a reduced temperature as compared to the interior portion of the drum directly exposed to the steam.
A further object of the invention is to provide internally mounted temperature control apparatus for a rotating heated dryer drum which permits a circumferential portion of the dryer drum shell to be maintained at a lower temperature than other drum shell portions wherein the temperature regulation occurs throughout the drum circumference at the desired location.
Yet an additional object of the invention is to provide internally mounted dryer drum temperature control apparatus which consists of a plurality of segments which may be readily inserted through the drum access port and assembled within the drum, and the assembly includes a plurality of segments selectively interconnectable to permit the desired axial width of insulation required, and also, by the use of a plurality of insulating segments of various lengths the apparatus may be readily accommodated to a variety of dryer drum diameters.
SUMMARY OF THE INVENTION
Insulation of selected circumferential portions of a dryer drum shell, usually circumferential portions adjacent the dryer drum ends, is achieved by assembling a plurality of thermal insulating segments within the dryer drum. Each of the segments includes a cylindrical configuration plate surface having a thermal insulation material mounted thereon, and the segments are assembled in an end-to-end relationship to define a closed circumferential assembly within the drum.
The segments are each provided with fasteners adjacent their ends whereby adjacent segments are connected to each other end-to-end to form the desired closed assembly. The fasteners preferably include compression springs whereby the segments are biased away from each other, within limits, to slightly vary the diameter of the assembly, and in this manner the compression springs firmly hold the segments and the thermal material mounted thereon firmly against the inner diameter of the dryer drum shell. However, the segment fasteners may be formed only by bolts whereby the adjustment of threaded fasteners may be used to expand the diameter of the assembly. The firm interconnection between the insulator assembly and the dryer drum shell produces a frictional engagement and mechanical modification to the drum shell is not required.
If desired, an insulated angle plate may be mounted adjacent a lateral side of selected segments for engaging the drum end head to reduce the rate of heat transfer thereto.
It is preferred that a mounting flange be mounted upon one of the lateral sides of the segments substantially perpendicular to the configuration thereof having fastener receiving holes whereby insulated segments mounted in a side-by-side relationship may be bolted together to define a completed assembly having a greater axial width than that provided by a single series of thermal insulated segments bolted in end-to-end relationship. As the width of the segments is limited by the dimension of the drum access port, the ability to interconnect the segments in side-by-side relationships permits the assembly to have the axial width often required.
As the apparatus of the invention is completely mounted within the drum interior, no wear or deterioration occurs to the web being dried during use, and drum temperature control apparatus in accord with the invention will provide long dependable use, as is required with dryer drum installations, such as paper mills.
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 perspective view of a typical dryer drum using the concepts of the invention,
FIG. 2 is a diametrical section through a dryer drum utilizing the invention as taken along Section 2--2 of FIG. 1,
FIG. 3 is a plan view of a pair of thermal insulating segments in accord with the invention as mounted in a side-by-side relationship, and prior to being assembled to other segments in an end-to-end assembly,
FIG. 4 is a side elevational view of FIG. 3 as taken along Section 4--4 thereof,
FIG. 5 is a sectional view of FIG. 4 as taken along Section 5--5 thereof,
FIG. 6 is a top plan view of an insulated segment using a side angle plate,
FIG. 7 is an elevational sectional view taken along Section 7--7 of FIG. 6, and
FIG. 8 is an enlarged detail side elevational sectional view, partially sectioned, taken through the drum and the ends of assembled segments, illustrating the details of the fasteners.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A typical dryer drum with which the invention is used is shown in FIG. 1 wherein the dryer drum is generally indicated at 10. The drum is rotatably mounted upon an axle 12 which is supported within conventional bearings, not shown, and the drum includes a cylindrical shell 14 closed at its ends by circular end head plates 16, the axle 12 being mounted within the end plates. Access to the interior of the drum 10 is through a typical port 18 formed in one of the end plates 16, and usually, the port 18 will have a maximum dimension of about fifteen inches. A cover normally seals the port 18.
In FIG. 1, the portions of the shell 14 in which it is desired to reduce the temperature is indicated at 20 between the dotted lines, and as will be appreciated the insulated portions 20 are located adjacent the ends of the shell wherein the highest temperatures usually occur. With reference to FIG. 2, the shell outer surface 22 will be concentric to the axis of drum rotation, and the drum shell inner surface is illustrated at 24. The drum inner surface 24 is, likewise, concentric to the drum axis of rotation, and the thickness of the drum shell is exaggerated in FIG. 2 for purpose of illustration.
The invention consists of an assembly 26 which is located within the shell 14 engaging the shell inner surface 24. The assembly 26 is formed of a plurality of circumferential extending segments 28, and the adjacent segments 28 are interconnected in an end-to-end relationship by fasteners 29, as is described below.
In FIG. 3, a typical assembly of a pair of segments 28 mounted in a side-by-side relationship is illustrated. In most cases, the assembly 26 will consist of a pair of segments 28 mounted in a side-by-side relationship in order to achieve the desired width of insulation within the drum 10, and as the segments 28 shown in FIGS. 3-5 are identical, the description of one segment suffices for identical segments. It is to be understood, however, that if a narrow width assembly 26 is desired only single segments 28 connected in end-to-end relationship would be used.
Each of the segments 28 includes a thin plate 30 in the order of 0.060 inches which, when viewed as in FIG. 3, is of a generally rectangular configuration. The segment length is defined by ends 32 perpendicularly related to the length of the plate 30, while the width of the plate 30 is defined by the parallel lateral sides 34.
Each segment plate 30 includes a cylindrical portion convex outer surface 36, FIG. 5, which is cylindrical in its form between ends 32, and the radius of the outer surface 36 is substantially identical to the radius of the drum shell inner surface 24. The segments inner surface 38 is also of a cylindrical configuration and is of a concave form. As will be appreciated from FIG. 5, the configuration of the segment surface 36 in a transverse direction between the plate lateral sides 34 is flat so as to correspond to the axial shape of the drum shell inner surface 24.
A thermal insulating material 40 is affixed to the segment outer surface 36 throughout the plate configuration. While there are a variety of thermal insulating materials which may be suitable in the practice of the invention, it is preferred that the insulated material 40 consist of a synthetic fabric or foam that is very porous and is able to absorb at least four times its weight in steam condensate.
On each segment 28, a pair of identical parallel support bars 42 are mounted upon the plate inner surface 38 by nuts and bolts 44, FIG. 8. The bolts 44 extend through holes in the plate 30 and through insulation 40 and the support bars 42 and the bolt heads 45 are thin and engage the insulation material 40 and in this manner the support bars are firmly attached to the plate 30 reinforcing the plate and as the support bars are of the same cylindrical segment configuration as the plate 30, the support bars aid the plate in maintaining its desired configuration. Simultaneously, the bolt heads 45 will maintain insulation material 40 firmly in engagement with the plate 30.
Each of the support bars includes a deformed end 46 which is bent inwardly so as to extend away from the associated plate 30. A hole 48 is formed in each of the support bar ends 46 for receiving the fasteners 29 as described below.
As it is usually desirable to assemble two segments 28 in a side-by-side relationship to achieve the desired axial width of the assembly 26, a sheet metal flange 50 is welded to a lateral side 34 of the plate 30. This flange 50 is perpendicularly related to the general configuration of the associated segment and plate, as will be appreciated from FIG. 5, and holes are formed in the flanges 50 whereby contiguous flanges 50 of segments 28 may be bolted together by nut and bolt assemblies 52 as will be appreciated from FIGS. 3-5. Usually, four nuts and bolts are sufficient to interconnect each pair of segments 28.
The fasteners 29 are best shown in detail in FIG. 8. A hollow threaded bolt 54 is mounted between support bar ends 46, and an inner threaded bolt 56 extends through the hollow bolt 54 and support bar end holes 48 and is provided with nuts 58 at each end whereby the inner bolt 56 will prevent excessive separation between the opposed support bar ends 46. A nut 60 is threaded upon the hollow bolt 54, and a compression spring 62 is interposed between the nut 60 and the opposed support bar end 46. The inner bolt nuts 58 are located upon the inner bolt such that a clearance 64, FIG. 8, will exist between the nuts 58 and the support bar ends, and in this manner, the spring 62 will impose a biasing force on interconnected segments 28 tending to separate the segments, while the inner bolt 56 prevents excessive segment separation.
Installation of the assembly 26 within the drum 10 is as follows. The installer will remove the cover from the port 18, and the components of the assembly 26 may be inserted through the port 18 piece by piece to the installer located within the drum. The width of the segments 28 is usually only slightly less than the maximum dimension of the port 18, and usually, it is desired that the portions 20 of the drum 10 to be insulated be in the order of approximately thirty inches, and hence, a pair of segments 28 are bolted together in side-by-side relationship. However, it will be appreciated that if only fifteen inches or less of the drum shell is to be insulated, only a single row of segments 28 need be used, and such segments would not require the presence of the flange 50.
Assuming that a pair of segments 28 are to be mounted in side-by-side relationship, two of the segments 28 will be positioned as shown in FIG. 3 wherein the flanges 50 will engage, and upon alignment of the flange holes the nut and bolt assemblies 52 may be inserted through the flange holes to assemble two of the segments in the relationship shown in FIG. 3. After the necessary number of pairs of segments 28 are assembled, six in the disclosed embodiment shown in FIG. 2, the interconnected pairs of segments may be preliminarily aligned in an end-to-end relationship and the fasteners 29 inserted into the support bar holes 48 as described above. The fastener nuts 60 will be backed off to relieve any biasing force or compression imposed upon the support bars by the spring 62, but the inner bolts 56 will maintain the preliminary assembly of the segments 28 of the assembly 26. Once the assembly 26 is properly located within the drum 10, the fastener nuts 60 will be rotated to compress the springs 62, and the outward biasing force imposed on the assembly 26 by the springs 62 will cause the insulated material 40 to be firmly forced against the drum shell inner surface 24 producing a firm frictional mechanical connection between the assembly 26 and the drum 10.
Upon completion of the installation of the insulator assembly 26 within the drum 10, it will be appreciated that the direct engagement of the insulating material 40 with the shell inner surface 24 will prevent the direct transfer of heat from the steam within the drum 10 to that portion of the shell 14 in alignment with and engaged by the assembly 26, and that portion of the shell 14, as indicated by the insulated portions 20 of FIG. 1, will be at a reduced temperature as compared to the temperature in the shell between the insulated portions. In this manner, the temperature in the drum shell can be regulated along its length to produce the desired moisture profile within the web being dried as it engages the shell outer surface 22. The firm mounting of the assembly 26 within the drum 10 will assure a long, trouble-free life of the apparatus of the invention, and as the assembly 26 is completely located within the drum 10, wear and deterioration is minimized in that the insulating assembly 26 does not come into contact with the web being dried.
FIGS. 6 and 7 disclose a variation of an insulated segment 28 that may be used, if desired, and in this embodiment components identical to those previously described are indicated by primed reference numerals.
In the embodiment of FIGS. 6 and 7, a portion adjacent a lateral edge 34' is welded to the edge 34' to define an angle plate 66 which extends inwardly with respect to that portion of the plate 30' located between the support bars 42'. The insulation material on the plate 66 is held in place by bolts 67. This angular orientation of the angle plate 66 permits the plate 66 to be placed against a drum end plate 16 to insulate that portion of the end plate 16 adjacent the shell 14, and reduce the likelihood of heat being transferred to the shell 14 through the end plate 16. Use of a segment 28' such as shown in FIGS. 6 and 7 will depend upon the particular operating characteristics and temperatures of the drum in which temperature control is desired.
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. For instance, the fasteners 29 need not utilize a compression spring. If the nuts 58 are located on the opposite sides of the support bar ends 46 as shown in FIG. 8, the nuts 58 can be used to separate the adjacent ends 46 to increase the diameter of the assembly, and the insulation material will be forced against the shell inner wall 24 as the assembly diameter is expanded.
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The invention pertains to apparatus for thermally insulating selected portions of a cylindrical dryer drum, usually adjacent the drum ends, for the purpose of obtaining a substantially uniform drum shell temperature throughout its length to obtain a uniform moisture profile throughout the width of the web being dried. A plurality of cylindrical segments are bolted together within the drum interior to define a circumferential assembly biased against the drum inner surface. The segments each include a thermal insulation material engaging the drum shell preventing direct access of that engaged portion of the shell with the steam within the drum thereby reducing the exterior temperature of the drum shell at the location of the thermally insulated segment. The segments may be bolted together, widthwise, to increase the axial dimension of the temperature controlling segment assembly.
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BACKGROUND OF THE INVENTION
The object of this invention is a high energy composition, which is meant for propellants, pyrotechnical compositions, explosives or corresponding items, in which composition as fuel there is used fine particle sized aluminum or composition and/or alloy of aluminum and magnesium, in which aluminum is being oxidized at low temperatures into aluminum oxide Al 2 O 3 and magnesium oxide MgO by means of a basic oxidizer, such as different kinds of nitrates, perchlorates, oxides and explosives containing oxygen.
The object of this invention also is the method of production of the composition in question.
DETAILED DESCRIPTION OF THE INVENTION
In high energy compositions the creating of the highest possible chemical combustion energy is based either partly or wholly on metal powders, as for example, aluminum or magnesium, oxidizing into an oxide (Al 2 O 3 , MgO). As an oxidizer there are often used different nitrates and perchlorates, such as, for example, NaNO 3 , KNO 3 , LiNO 3 , NaClO 4 , KClO 4 , LiClO 4 or explosives containing oxygen, such as for example, organic nitroesters, RDX and PETN as well as different oxides, for example Fe 3 O 4 .
It is generally known that the combustion of aluminum in this kind of composition is more or less incomplete also in stoichiometric compositions, when aluminum content is high, for example, more than 25%-by-weight and especially, when combustion takes place in air (1 atm pressure). Instead magnesium is oxidized more completely in corresponding conditions. It is known that the chemical properties of an oxidizer will have clearly different kinds of effects on oxidizing of different metals. In addition each processing technique, for example, casting or pressing, will influence the choice of metal. In general aluminum is used in cast compositions, such as rocket propellants, in which the strength properties of a mass are produced by a cured polymer binder. Then the benefit of aluminum is its great density (2.7 g/m 3 ), spherical form (atomized) also in the extremely small grain size (below 10 m) and the high chemical combustion energy per mass unit. Regarding these compositions the maximum content of aluminum normally is less than 25%-by-weight, for example, when ammonium perchlorate is used as an oxidizer. Within this concentration range and at relatively high pressure (100-200 atm) the oxidizing of aluminum will be done well enough.
Concerning pressed masses, the use of magnesium is very common, for example, flare masses, the combustion of which occurs in air. Then the most important benefit of magnesium is its perfect combustion also in high concentrations (>25%-by-weight), especially when sodium nitrate is used as an oxidizer. A disadvantage is that MgO, a product of combustion, has a tendency to decompose at very high temperatures (>3000° C.).
For safety reasons and due to facility of production technology the trend nowadays is toward cast masses. The ignition sensitivity of masses in the pressing stage imposes definite limits for the size of a pressed piece.
On trying to increase aluminum content in above mentioned mass types, the problem in compositions of over 25%-by-weight is the incomplete combustion of aluminum.
The objective of this invention is to create a high energy composition, in which aluminum is to be combusted perfectly also in high concentrations, i.e. from over 25%-by-weight to 50%-by-weight.
The objective of this invention will be attained by a high energy composition, which is characterized mainly in that in the composition there is stoichiometrically too little oxygen for oxidizing aluminum Al and magnesium Mg into aluminum oxide Al 2 O 3 and magnesium oxide MgO, or for just oxidizing aluminum Al into aluminum oxide Al 2 O 3 , so that part of the aluminum will be oxidized into aluminum suboxide (Al 2 O) at a temperature of over 2200° C.
Mainly characteristic of the method of this invention is, that in regard to Al 2 O and/or MgO there is used an underoxidized composition, so that part of aluminum will be oxidized into aluminum suboxide Al 2 O at a temperature of over 2200° C.
The method of this invention is based on following experiences:
1. Magnesium will be oxidized into oxide at a lower temperature than aluminum. At the highest temperatures magnesium oxide acts as a secondary oxidizer for aluminum and for the carbon of a binder that is in the composition, and will oxidize aluminum into Al 2 O and carbon into CO, and
2. A perchlorate type high energy oxidizer decomposes spontaneously without any reaction with the metal fuels. Thus a greater part of the aluminum has time to heat up without being oxidized up to a higher temperature (>2200° C.), at which the oxidizing directly into Al 2 O takes place. The decomposition temperature of an oxidizer can be reduced by suitable catalysts, for example by adding a little manganese metal powder into the composition which improves spreading of the aluminum powder into a gaseous reaction zone.
3. In the composition it is also possible to use 0-10%-by-weight boron (B), which acts as a stabilizer for aluminum oxide at the highest temperatures reacting with the oxygen that is transformed in decomposition of aluminum oxide. In addition, formed boric oxide (B 2 O 3 ) advances the forming of Al 2 O by reacting in a temperature range of over 2000° C. according to following equation:
1/2Al.sub.2 O (gas)+1/2B.sub.2 O.sub.3 (gas)→AlBO.sub.2 (gas)
With the high energy composition of this invention numerous important advantages will be achieved. Since aluminum (Al) can be oxidized at low temperatures into Al 2 O 3 and at high temperatures into Al 2 O, the formation heat of which at high temperatures per oxygen is about the same as Al 2 O 3 has, such compositions can be made in which the fuel content (Al, Mg, B) can rise up to 60%-by-weight, when the chemical energy of the composition increases in the same proportion. Thus it essentially increases, for example, impulse concerning rocket propellants using a perchlorate oxidizer (especially LiClO 4 ) and aluminum and boron as fuel. Regarding flare masses, in which magnesium (Mg) is a mainly used fuel, adding aluminum and its consequent oxidizing at a high temperature into a very energetic Al 2 O-gas increases light output and illuminance.
Below the invention is explained more in detail.
The oxidizing power of metals at different temperatures can be scrutinized by comparing values of corresponding oxides' free energy (G) at the temperatures in question. In order to enable reaction, the value of G must be negative at the temperature in question. At temperatures below 1300° C. the free energy of MgO is more negative than the same of Al 2 O 3 per oxygen atom. Within this temperature range Mg has a greater ability to oxidize than Al has, being even about three times greater. Within the temperature range of over 1300° C. the situation is opposite. Within the temperature range of over 2200° C. aluminum has a greater tendency to be oxidized into gaseous Al 2 O than to liquid Al 2 O 3 . The point of this invention is, that the circumstances of practice can be made such that aluminum will be oxidized selectively into Al 2 O at high temperatures. Adding of boron (B) into the composition improves forming of Al 2 O, because boric oxide B 2 O 3 reacts with Al 2 O forming AlBO 2 -gas. In addition the reaction is a little exothermic (H 2200 =-15 kcal/mole). The use of boron is advantageous in a rocket propellant mass, where there is no magnesium as fuel. As the formed AlBO 2 is a gas, by adding boron the formation of visible smoke can be reduced.
The development work of aluminum fueled flare mass has led to this invention. In this work we were met by the fact, that on using magnesium and aluminum together and on the other hand on using only aluminum as fuel, together with perchlorate oxdizers the illumination properties disappeared compared with a magnesium/sodium nitrate flare mass. The reason is just the formation of Al 2 O and not of Al 2 O 3 , which was hypothetical. The changing of the oxidizing mechanism of aluminum at the highest temperatures will not appear in connection with normal calorimetric measurements, because the formation heats of Al 2 O and Al 2 O 3 per oxygen atom do not much differ from each other in practice measuring conditions.
EXAMPLE 1
(Percentages by weight)
______________________________________Flare mass 1 Flare mass 2 (comparison)______________________________________Mg (coarse particle size) 24.0 Mg (coarse particle size) 53.0Al/Mg (50:50) alloy 29.0NaNO.sub.3 37.0 NaNO.sub.3 37.0LiClO.sub.4 5.0 LiClO.sub.4 5.0Binder 5.0 Binder 5.0______________________________________
The illumination efficiency of flare mass 1 was 64.000 cd.s/g and burning rate 2.8 mm/s.
Flare mass 2 was similar, except that Al/Mg alloy had been replaced by magnesium and its illumination efficiency was 47,700 cd.s/g and burning rate 4.3 mm/s.
EXAMPLE 2
(Percentages by weight)
______________________________________LiClO.sub.4 48.0Al (atomized extra fine particle size) 37.0B 3.0Binder 12.0(for example, hydroxyterminated polybutadiene)______________________________________
A composition like this gives a very high specific impulse for a rocket propellant. Adding the amount of boron increases the amount of AlBO 2 -gas, and the amount of Al 2 O 3 decreases in the reaction products. Then also the amount of visible smoke will decrease.
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High energy composition which is meant for propellants, pyrotechnical and technical compositions, explosives or corresponding items, and production method.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is in the field of removing particulates from the air, particularly as applied to sampling contaminants.
[0004] 2. Background
[0005] Removing particulate contaminants from the atmosphere may be achieved with several known technologies. One known device is an electrostatic particulate collector. Known electrostatic particulate collectors have traditionally been designed for continuous, high volume use, as for example, as antipollution devices. Prior art devices are disadvantageous in contaminant sampling situations for multiple reasons.
[0006] Electrostatic particulate collectors are typically designed with a metallic chamber through which a gas, typically air, is directed for removal of particulate matter such as contaminants. Disposed within the chamber is a current carrying element supplied with sufficient electrical voltage that the potential between itself and the metallic walls of the chamber creates a coronal discharge. The coronal discharge electrostatically charges particulates in the gas within the chamber, and these ionized particles are thereby electrostatically driven to adhere to the walls of the chamber.
[0007] Once collected on the chamber walls, the contaminants may be removed. Manual removal of collected contaminants requires frequent shutdown for a replacement and/or cleaning of the chamber walls. To avoid this, it is known to rinse the chamber walls with a liquid in order to collect the removed contaminants and also retard contaminant buildup on the chamber walls. Purified water is often used as a rinse liquid.
[0008] Some prior art designs fail to wet all of the chamber wall, allowing disadvantageous contaminant buildup on dry portions of the chamber wall. Prior art devices do not wet the chamber walls quickly, and require significant volumes of liquid in order to achieve adequate wetting of the chamber walls. Prior art designs typically use large cumbersome components, use larger volumes of rinse liquid and demand a high power draw for both rinse liquid distributors and blowers used to propel the atmosphere being treated through the treating chambers.
SUMMARY OF THE INVENTION
[0009] The present invention is an electrostatic particulate collector having a novel structure. One aspect of the present invention is to achieve 100% wetting of the inner surface of the chamber wall with a minimum volume of liquid. It is another aspect of the invention to achieve 100% wetting of the inner surface of the chamber wall quickly. In so doing, the structure of the present invention promotes greater efficiency, greater throughput of air to be sampled, greater portability and/or greater automation. Smaller volumes of the required purified water need to be transported or installed with the test unit. Power requirements may be reduced. Speed, water volume and volume of air throughput may be improved because impedance of air flow by the wetting structures is reduced.
[0010] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0012] FIG. 1 is an exploded view of the electrostatic particulate collector of the present invention.
[0013] FIG. 2 is a perspective and cutaway view of a prior art weir type fluid distributor and collection tube.
[0014] FIG. 3 is a perspective view of a collection tube and fluid distributor.
[0015] FIG. 4 is an exploded view of a collection tube and fluid distributor.
[0016] FIG. 5 is a cutaway view of the fluid distributor and collection tube.
[0017] FIG. 6 is a bottom view of the fluid distributor and collection tube.
[0018] FIG. 7 is a side view of the fluid distributor and collection tube.
[0019] FIG. 8 is a perspective view of the fluid distributor insert.
[0020] FIG. 9 is a side view of an alternative collection tube and fluid distributor
[0021] FIG. 10 is an exploded view of an alternative collection tube and fluid distributor in an open position.
[0022] FIG. 11 is a perspective view of an alternative fluid distributor insert.
[0023] FIG. 12 is an exploded view of alternative fluid distributor insert.
[0024] FIG. 13 is an exploded view of alternative fluid distributor insert.
[0025] FIG. 14 is a cutaway view of the collection chamber and blower.
[0026] FIG. 15 is a graph of wetting times and rinse liquid volumes.
DETAILED DESCRIPTION
[0027] Referring now to the drawings in which like reference numbers indicate like elements, FIG. 1 is an exploded overall view of the electrostatic particulate collector of the present invention. Particulate collector 10 is a compact device to promote portability for mobile and rapid response testing of atmospheres such as may have been purposefully contaminated, as for example with a biological agent such as anthrax or other detrimental particulate matter suspended in the air. Accordingly, the compact unit 10 has a housing 12 . Alternatively, the unit may also be deployed for automatic testing in response to actuation by a sensor. This provides for installation of the unit for constant monitoring of certain facilities such as government buildings.
[0028] Within the housing 12 are the major components of the electrostatic particulate collector including a battery 16 , electronic control module 18 , high voltage power supply 20 , an air handling system having a blower 22 , fluid connector 24 , pump 26 and the test chamber 30 . A fluid reservoir 28 which may be separate, is provided to supply any rinse liquid for wetting the test chamber internally.
[0029] In the depicted embodiments the test chamber is a tube. FIG. 2 depicts a prior art cylindrical test chamber 30 A comprised of a metal cylinder 32 A and a fluid distributor 34 A. The prior art device was a weir type fluid distributor which injected water into the chamber space within the tube 32 A by simply over topping the edge of the chamber cylinder 32 A. By force of gravity then the provided liquid descended onto the walls of the inner surface of the chamber 32 A, thereby wetting it. This design disadvantageously failed to wet 100% of the inner surface of the chamber wall, and left substantial vertical dry portions on the wall between the streams of the fluid provided.
[0030] FIG. 3 depicts the test chamber 30 of the present invention. In the depicted embodiment, the test chamber is a cylindrical tube 32 . At a top end a fluid distributor 34 is mounted. In the depicted embodiment the fluid distributor 34 is comprised of an outer shell or receiver 36 and an inner insert 38 . The female outer receiver has frustoconical internal surface 40 which is dimensioned to mate with a corresponding frustoconical outer surface 42 of the male fluid distributor insert 38 . The components of the fluid distributor 34 may be plastic.
[0031] The chamber is a cylindrical tube 32 in the depicted embodiment which may be made of metal. The metal may be steel, titanium, aluminum or otherwise. In the depicted embodiment the tube 32 is comprised of a cylindrical wall 44 having an inner surface 46 . The inner surface may be comprised of titanium. Providing a titanium inner surface may be achieved by constructing the entire tube wall 44 of titanium. Alternatively, the tube wall 44 may be aluminum, stainless steel, or other material, with a coating of titanium on its inner surface 46 .
[0032] As is known in the prior art, disposed within the collection chamber is a voltage potential inducer 50 (see FIG. 4 ). In the depicted embodiment this may be a wire suspended along the axis of the cylinder 32 . A voltage is provided to the inducer 50 of sufficient potential, typically on the order of 5,000-30,000 volts, to induce a coronal discharge within the chamber. Hence a potential is established between the inducer 50 and the walls 44 of the chamber 32 . Contaminant particles entering into this field are electrostatically biased against the inner surface 46 of the chamber wall.
[0033] In operation, air flow is created through the chamber by a blower ( 22 in FIG. 1 , 196 in FIG. 14 ) blowing contaminated air in the direction A (see FIG. 3 ).
[0034] FIG. 4 and FIG. 5 depict the internal structure of the spiral or swirl injection rinse liquid distributor 34 . Insert 38 includes grooves 60 . Insert 38 and receiver 36 are dimensioned such that when they are assembled together the grooves 60 are covered by the inner surface 40 of the receiver 36 , and rinse channels are thereby defined between them. These rinse channels are in fluid communication with a liquid intake port 82 . The fluid injection path is sealed by a recess 64 that serves as a seat for an O ring seal.
[0035] The grooves 60 and the rinse channels they form are oriented in a spiral configuration. Each rinse channel is at an angle therefore to the longitudinal axis of the cylinder 32 . As will be appreciated by those of skill in the art, this spiral orientation advantageously avoids the streaking and consequent dry portions of the inner surface 46 of the chamber that was typical of prior art devices. That is, injection of the rinse liquid in a spiral fashion, at an angle to the axis of the tube, promotes 100% wetting. 100% wetting, in the shortest amount of time and/or with the smallest volume of rinse liquid, is further promoted by the titanium surface 46 of the cylindrical chamber 32 .
[0036] As best seen in FIG. 5 , the outer portion of the liquid distributor receiver 36 includes an annular seat 68 dimensioned to receive the cylindrical tube 32 comprising the collection chamber. The depth of the seat 68 is dimensioned to correspond to the thickness of the chamber wall 44 . The liquid distributor insert 38 has an inner diameter 66 dimensioned to substantially match the inside diameter of the cylindrical chamber 32 . Accordingly, upon assembly of the tube 32 with the outer liquid distributor receiver 36 and liquid distributor insert 38 , an overall collection chamber assembly 30 having a constant internal diameter is created. At the juncture of the liquid distributor insert 38 and the tube 32 the inner walls of each mate and multiple exit ports 70 for the liquid rinse channels 60 are defined. Rinse liquid exit ports 70 are flush with the constant internal diameter of the overall assembly. Accordingly, the rinse liquid injector assembly advantageously avoids any structure obstructing air flow from the liquid distributor air intake 72 and through the chamber. Therefore the flow of air over the rinse liquid exiting the multiple exit ports 70 further promotes the rapid and complete disbursal of rinse liquid over substantially 100% of the inner surface 46 of the chamber wall.
[0037] FIGS. 9 , 10 , 11 , 12 and 13 depict an alternative embodiment of the present invention. This alternate embodiment also avoids obstruction of air throughput by components of the liquid distributor, and also uses the air flow over the exit ports to spread, flatten and rapidly distribute the rinsing liquid over the interior wall of the chamber. The alternative embodiment is comprised of a chamber wall 132 , which is again a cylinder in the depicted embodiment. The wall 132 defines within itself a collection chamber having a first diameter. The liquid distributor 134 is assembled to be a single piece in this embodiment. It has an interior wall 166 that defines a second diameter that is smaller than the first diameter defined by the chamber wall 132 . The liquid distributor 134 has an annular extension 142 with an exterior wall 186 that has a diameter substantially corresponding to the interior diameter of the collection chamber wall 132 , so that the later receives the former in close cooperation upon assembly to establish a tight fit. The liquid distributor 134 is further comprised of a housing 180 having at least one liquid intake port(s) 182 that is in fluid communication with the spiral liquid distribution rinse channels 160 and ultimately with the liquid exit ports 170 . The rinse liquid channel is created in the housing 180 by assembling an upper housing portion 180 A with a lower housing portion 180 B, each of which has a trough, 190 A and 190 B respectively, that mate upon assembly and form the rinse channel 190 connecting intake port(s) 182 with spiral rinse channels 160 . Interior rinse channel 190 proceeds through multiple vertical channels 192 .
[0038] Upon assembly, the liquid exit ports 170 are disposed so that an outer side of the exit port 170 is substantially flush with the first diameter that is the inner wall of the collection chamber. The aperture of the exit ports 170 are on the step 184 that is the inner end of the liquid distribution extension 142 .
[0039] FIG. 14 is a cutaway view of the collector assembly showing the rinse liquid collection reservoir 194 and a blower 196 .
[0040] In one embodiment, the particulate collector may be a cylinder having an internal diameter of between about 0.25 inches and about 6.0 inches. The particulate collector may have a length of between about 1.0 inches and about 36 inches. In embodiments with Titanium coatings, the coatings may be from about 0.25 microns to about 6 microns thick. In the depicted embodiments, the cylinder has a diameter of about 2 inches. The rinse liquid ports in the depicted embodiment are spaced about ¾ of an inch apart and the ports have a complex cross section ranging from about 1/64 of an inch to about ¼ of an inch.
[0041] Test data confirm an unexpected, synergistic effect when combining both a swirl liquid distributor with a titanium collection chamber wall in the configuration disclosed herein, as compared to the effect of either component by itself. The time and liquid volume needed to attain substantially 100% wetting is only marginally increased by combining a swirl liquid distributor as depicted herein with a traditional steel or aluminum inner chamber surface, in a compact contaminant sampling device. At a flow rate of 528 mil/min, 100% wetting was obtained in a range of from 9 to 34 seconds, with an average of about 19 seconds. Little or no improvement is achieved by combining a titanium inner chamber surface with a prior art weir liquid distributor, as compared to a traditional aluminum inner chamber surface combined with a weir liquid distributor, in a compact contaminant sampling device. In fact, 100% wetting was not achieved in experimental apparatuses combining a Titanium coated cylinder with a weir distributor.
[0042] Surprisingly, combining the swirl liquid distributors depicted herein with a titanium inner chamber surface in a compact contaminant sampling device improves results more than the sum of the individual degrees of improvement attained by each component individually. In a compact sample collector having both a swirl injector and titanium inner surface, substantially 100% wetting was attained faster and with less liquid than the expected sum of the two features tested individually. Hence, test data confirms an unexpected synergy when combining both features.
[0043] The particulate collector of this invention may attain substantially 100% wetting of said inner surface of said chamber with a rinse liquid flow rate of no more than about 520 milliliters/minute. The particulate collector may attain substantially 100% wetting of said inner surface of said chamber within no more than about 26 seconds. The particulate collector having a collection chamber of titanium coated aluminum may attain substantially 100% wetting of said inner surface of said chamber within no more than about 11 seconds at a rinse liquid flow rate of about 290 milliliters/minute.
EXAMPLES
[0044] In each of the examples, De-ionized (DI) water was used as the rinse liquid. DI water was pumped from a reservoir into the Fluid Distributor. Depending on the flow rate required, one or two diaphragm pumps were used to deliver the DI water to the Fluid Distributor. The DI water was collected in a beaker placed under the test item.
[0045] Using the test set-up described above, the flow rate required to produce a fully wetted collection surface within approximately 30 seconds was determined for each device configuration. The actual flow rate was calculated by measuring the amount of fluid collected in the beaker per unit time.
[0046] Using these fluid pump settings, a repetitive series of tests was performed to determine the required time to fully wet the collection surface. The collection surface was air dried between every test using a small fan.
Example 1
Prior Art
Aluminum Chamber Surface with Weir Distributor
[0047]
[0000]
Configuration ID: 01
Collection Surface Treatment: Bead blasted Al 6061
Fluid Distributor: Weir
Serial Number: 01
Test
Flow Rate
Time to coat 100%
number
(ml/min)
(sec)
1
1750
9
2
1750
25
3
1750
13
4
1750
33
5
1750
34
6
1750
26
7
1750
59
8
1750
18
9
1750
20
10
1750
5
11
1750
6
12
1750
13
13
1750
7
14
1750
4
15
1750
30
16
1750
4
17
1750
4
18
1750
35
19
1750
11
20
1750
6
21
1750
4
22
1750
4
23
1750
5
24
1750
6
25
1750
5
26
1750
5
27
1750
4
28
1750
6
29
1750
6
30
1750
11
Example 2A and 2B
Swirl Injector with Titanium Coated Aluminum Chamber
[0048]
[0000]
Flow Rate
Time to coat 100%
Test number
(ml/min)
(sec)
Configuration ID: 02A
Collection Surface Treatment: Al with Ti coating
Fluid Distributor: Swirl injector
1
285
4
2
285
4
3
285
10
4
285
6
5
285
4
6
285
5
7
285
11
8
285
5
9
285
4
10
285
5
Configuration ID: 02B
Collection Surface Treatment: Al with Ti coating
Fluid Distributor: Swirl injector
1
290
3
2
290
3
3
290
3
4
290
3
5
290
3
6
290
3
7
290
3
8
290
3
9
290
3
10
290
3
Example 3
Swirl Distributor with Polished Titanium Chamber
[0049]
[0000]
Configuration ID: 03
Collection Surface Treatment: Polished Ti tube
Fluid Distributor: Swirl injector
Flow Rate
Time to coat 100%
Test number
(ml/min)
(sec)
1
520
21
2
520
26
3
520
19
4
520
19
5
520
17
6
520
23
7
520
19
8
520
19
9
520
16
10
520
19
Example 4
Swirl Distributor with Titanium Coated Steel
[0050]
[0000]
Configuration ID: 04
Collection Surface Treatment: SST with Ti coating
Fluid Distributor: Swirl injector
Flow Rate
Time to coat 100%
Test number
(ml/min)
(sec)
1
365
14
2
365
32
3
365
23
4
365
29
5
365
24
6
365
21
7
365
17
8
365
21
9
365
21
10
365
22
11
365
27
12
365
30
13
365
35
14
365
35
15
365
14
16
365
31
17
365
30
18
365
21
19
365
31
20
365
23
21
365
29
22
365
31
23
365
21
24
365
49
25
365
28
26
365
30
27
365
23
28
365
35
29
365
36
30
365
27
Example 5
Swirl Distributor with Aluminum Chamber
[0051]
[0000]
Configuration ID: 05
Collection Surface Treatment: Bead blasted Al 6061
Fluid Distributor: Swirl Injector
Serial Number: 01
Flow Rate
Time to coat 100%
Test number
(ml/min)
(sec)
1
528
11
2
528
22
3
528
23
4
528
17
5
528
11
6
528
28
7
528
32
8
528
22
9
528
26
10
528
22
11
528
20
12
528
27
13
528
34
14
528
15
15
528
13
16
528
16
17
528
23
18
528
21
19
528
25
20
528
17
21
528
28
22
528
11
23
528
16
24
528
16
25
528
11
26
528
15
27
528
16
28
528
9
29
528
11
30
528
12
[0052] In FIG. 15 , the y-axis left hand scale illustrates the time needed to achieve 100% wetting for each of the different versions from the examples, which are along the x-axis. The vertical bar extends from the fastest time to the slowest time for individual test runs, and a numerical average for each example version is given within the vertical bar at the oval. As can be seen, the lowest times achieved with any reliable consistency are with Example 2, a swirl distributor combined with titanium coated aluminum.
[0053] FIG. 15 also depicts the rinse liquid volume required to achieve 100% wetting with each of the different versions with the right hand scale of the y-axis. An oval with an X marks rinse liquid volumes. As can be seen, the prior art device having a Weir distributor and no titanium surface requires the most liquid by far, a disadvantage. All of the titanium coated examples have been proven to require a smaller volume of rinse liquid to achieve 100% wetting.
[0054] FIG. 15 combines the data for time results and rinse liquid volume results to illustrate the performance of all versions combining swirl injection with titanium chamber walls. As can be seen, Example 2, the combination of the swirl injector with titanium coated aluminum, surprisingly achieves advantageous results in both reduced time and reduced liquid volume required for 100% wetting, as compared to the other examples.
[0055] As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
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A compact electrostatic particulate collector for sampling contaminants has a collection chamber defined by a titanium inner surface of a wall. A potential inducer is disposed within the chamber to create a field potential between itself and the wall of the chamber. A blower is disposed to propel air to be sampled through the chamber. At least one rinse channel is disposed to wet the inner surface of the wall of the chamber substantially 100%. The rinse channel is angled to direct a rinse liquid in a spiral direction around the inner surface of the wall. Contaminants in the air being sampled are electro statically biased into the rinse liquid on the wall and rinsed out of the chamber for collection.
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This invention relates to a method of modifying and controlling the performance results of a Fischer-Tropsch Synthesis process. Particularly, this invention relates to a modified method of predicting, controlling and thus improving the product selectivity of the High Temperature Fischer-Tropsch synthesis process, and more specifically, the selectivity of the olefinic fraction of the product spectrum.
BACKGROUND OF THE INVENTION
Fischer-Tropsch processes are known to produce gaseous and liquid hydrocarbons as well as oxygenates containing, amongst others, paraffins, olefins, alcohols and aromatics, with a variety of carbon chain length ranges and isomers, which, in general, follow the well-known Anderson-Schulz-Flory distribution. Much emphasis has been placed on the modification endeavors, more particularly to improve, as well as maximize the selectivity of the unsaturated hydrocarbons, especially olefins in the C 2 -C 4 range. whilst maintaining high activity and stability under the normal Fischer-Tropsch synthesis conditions with an iron catalyst. Equation 1 is a general presentation of the Fischer-Tropsch reaction:
CO+(1 +x )H 2 τCH 2x +H 2 O (1)
The reaction can be carried out in fixed, fluidized or slurry bed reactors. The production of olefins and petrol range products is most favoured by synthesis carried out in a two-phase fluidized bed reactor operating at ˜350° C. and 20 bar or higher pressures and utilizing a fused promoted iron catalyst. The fused iron catalyst is typically promoted with alkali chemical and structural promoters. As a result of the high temperatures which are used in these reactors, they are known as High Temperature Fischer-Tropsch (HTFT) reactors, thus distinguishing them from fixed bed and slurry bed reactors (Low Temperature Fischer-Tropsch—LTFT), which operate at temperatures which are about 100-150° C. lower than the said HTFT process.
The HTFT process also utilizes a technique which facilitates online removal of spent catalyst and online addition of fresh catalyst to maintain catalyst activity and selectivity profiles at levels which are as favourable as possible. This technique is aimed at achieving an equilibrium performance and also inhibiting the occurrence of undesirable and negative sudden changes in synthesis performance; thus providing a means through which the product spectrum demands, as dictated by the market forces and downstream requirements, can be met.
The Fischer-Tropsch process is known to be directly influenced by process conditions, for example, feed composition, feedrate, conversion, reaction pressure and temperature. In addition, and particularly for the HTFT process, the chemical composition of the catalyst used in the synthesis process has been shown to have a direct influence on the said product spectrum. Thus the concentration level of the chemical components of the Synthol catalyst matrix, such as sodium, potassium, alumina, silica and the like, has been shown to have a direct correlation with yields and the selectivities of the olefins, paraffins, acids and the oils produced in the process. A number of reports have been published which claim that potassium increases the alkene content of the hydrocarbon products, increases the rate of the water-gas shift reaction and suppresses methane formation.
SUMMARY OF THE INVENTION
The applicant has surprisingly found a method of modifying and controlling, and thus improving, the selectivity profile in favour of the desired Fischer-Tropsch synthesis products. Particularly, the applicant has found a unique method of manipulating, and thus improving, the selectivity profile of the lower olefins produced by means of a High Temperature Fischer-Tropsch process.
The method is characterized in that predetermined amounts of promoter-carrying compound either dissolved in solution or in a powdered form are directly injected into the reactor medium, typically into the reactor feedstream. A typical chemical promoter for the HTFT process is potassium. The applicant has found that by adding or doping the reaction medium with the promoter-containing compound during the synthesis process, the promoter being potassium, the selectivity profile of the olefins and the paraffins in the product stream is significantly changed, with more olefins being formed whilst the level of paraffins is reduced.
Analysis of the iron catalyst sample has surprisingly shown that within the catalyst matrix, potassium is the most mobile component in the solid solution. The Scanning Electron Microscope (SEM), Energy Dispersing X-ray (EDX) and Secondary Iron Mass Spectrometry (SIMS) techniques have convincingly shown that, with time online, a fraction of the potassium promoter continuously migrates away from the iron metal nuclei, to an extent that it is eventually lost altogether from the matrix and is ultimately captured, for example, in the carbon mass deposit that is formed around the catalyst particle during the synthesis process. The applicant has found that the potassium promoter becomes diluted by migration into the mass of the continuously forming elemental carbon around the catalyst particle with time online.
Furthermore, the analysis has surprisingly revealed that the catalyst particles do not contain a homogeneous concentration of the potassium promoter i.e. the amount of potassium contained in the catalyst particles progressively follows a Gaussian trend. Surprisingly, this applies to catalyst particles of the same size. The effect hereof is that some particles have very low levels of K 2 O. This appears to be an inherent problem which originates from the procedure that is used in the preparation of the catalyst (fusion process).
The applicant has found that when physically adding potassium into a HTFT reactor during the synthesis process, the added potassium replenishes the ‘lost’ potassium in the catalyst matrix, and in the process the product spectrum becomes more olefinic. The potassium that is added online is in the form of a compound dissolved in solution or in a pulverized state, the compound selected from potassium carbonate and potassium silicate. This added potassium distributes itself homogeneously through all the catalyst particles inside the reactor, boosting those particles which initially contain very little K 2 O.
The applicant has further found that an expression which combines the concentrations of the previously mentioned catalyst components, known as the selectivity factor, can be successfully used in correlating the selectivities and the yields of the olefins, paraffins, and thus the olefin/paraffin ratios. Previously, such correlations could not be established, so that it was virtually impossible to predict the yield and the selectivity profiles of the Synthol product spectrum. The applicant has also shown that, to a reasonable degree of accuracy, the selectivity levels of the olefins, as compared to the paraffins in the product stream, may be sufficiently predicted based on the amount of potassium added in the solution prepared for injection.
Accordingly, according to a first embodiment of the invention there is provided a method for controlling a selectivity profile of products of a Fischer-Tropsch synthesis process, the method including the step of introducing into a Fisher-Tropsch reaction medium, during the synthesis process, a catalyst promoter or substance, composition or salt containing the catalyst promoter.
The Fischer-Tropsch process is preferably a High Temperature Fischer-Tropsch process, and the catalyst promoter may be introduced into a fluidized bed Fischer-Tropsch reactor feedstream or at any other suitable location.
The catalyst promoter may be a promoter for an iron catalyst. The catalyst promoter may be a Group I element, more particularly the Group I element may be potassium or a salt or compound thereof.
An alkali promoter-containing compound may be used to introduce the catalyst promoter into the feedstream, the promoter-containing compound including an oxide or salts thereof. Typically, the promoter-containing compound is a potassium oxide or a potassium halide. More particularly, the promoter-containing compound may be potassium carbonate, potassium silicate or potassium bromide, preferably potassium carbonate. The promoter-containing compound may be in the form of a solution or a powder.
The selectivity profile of olefins, preferably olefins in the C 2 -C 4 range, may be increased by the addition of the catalyst promoter to the reaction medium during the synthesis process The selectivity factor may relate to the catalyst composition, and conversely the catalyst composition may be determined according to the required selectivity factor. More particularly, the selectivity factor may relate to the potassium oxide, alumina and silica concentrations within the iron catalyst, and even more particularly does not relate to the sodium oxide composition of the catalyst.
The selectivity factor (SF) may be expressed according to the following equation: SF = ( K 2 O ) ( Al 2 O 3 + SiO 2 ) ( 3 )
It will, however, be apparent to a person skilled in the art that this is not the only equation which may be used to determine the selectivity factor.
The quantity of additional catalyst promoter required to achieve the desired selectivity factor may be calculated according to the following equation if K 2 CO 3 is used as the promoter-carrying compound:
p =[ReqComp r x (SiO 2 +Al 2 O 3 )−K 2 O]/0.68 (4)
where p is the amount of additional potassium promoter per 100 g Fe;
SiO 2, Al 2 O 3 and K 2 O refer to the composition of the spent catalyst to be modified; and
ReqComp r is used to indicate the SF which corresponds to a catalyst with the desired olefin selectivity.
If a compound other than K 2 CO 3 is used (e.g. K 2 SiO 3 ), then the equation should be modified in accordance with the molecular weight of the specific compound.
According to a second embodiment of the invention there is provided a Fischer-Tropsch catalyst system having a desired olefin selectivity factor, the catalyst system including a quantity of catalyst promoter related to the catalyst composition and the selectivity factor.
The catalyst and a catalyst promoter may be substantially as described above. The promoter may be selected from a group including potassium oxide, alumina, silica and sodium oxide.
The selectivity factor may be related to the iron catalyst promoter's potassium oxide, alumina and silica concentrations, and preferably not necessarily to the sodium oxide concentration. The selectivity factor may be determined substantially as described above, as may the quantity of catalyst promoter be determined.
According to yet a further embodiment of the invention there is provided a method of maintaining a selectivity profile of products of a Fischer-Tropsch synthesis process within a preselected range the method including the step of introducing into a Fisher-Tropsch reaction medium, during the synthesis process, a catalyst promoter or substance, composition or salt containing the catalyst promoter.
The method may be the same or substantially similar to the method of modifying and controlling the selectivity profile described above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is on the basis of the favourable promotional effects of potassium that an optimum amount thereof is maintained consistently within the catalyst inventory during the synthesis reaction. Under HTFT conditions the iron catalyst particles are known to continuously show the deposition of elemental carbon occurring around them. When carbon is deposited on the iron catalyst is the particles swell arid also disintegrate. In a fluidized catalyst bed in particular, the fines which are produced as a result of catalyst disintegration have a high carbon content and hence have a low particle density. The fine, low density particles are also preferentially lost via cyclones during the synthesis, thereby lowering the available alkali levels even further.
At this stage the potassium is diluted (in terms of K 2 O unit volume) inside the catalyst particles, and the amount of potassium that is in contact with iron is lowered. In practice, as the synthesis reaction progresses, the amount of potassium promoter within the catalyst particles gradually diminishes due to the high mobility rate of this particular promoter within the solid solution. As the level of the active potassium within the catalyst matrix progressively decreases, the catalyst itself, complementarily, becomes more selective towards a paraffinic hydrocarbon product. As a result, a desired Fischer-Tropsch product selectivity profile wherein the olefinic fraction is dominant cannot be maintained indefinitely if the diminishing potassium content continuously alters the catalyst effective composition.
The applicant has found a method of continuously maintaining the product yield and selectivity of the HTFT process using an iron-based catalyst, wherein the olefinic product content is dominant. The method of the present invention includes the physical injection of a potassium containing compound, for example potassium carbonate and potassium silicate, into a Fischer-Tropsch fluidized bed reactor feedstream or into the reaction medium at any other suitable location, whilst the process operation is in progress. The injection of the potassium-containing compound is capable of immediately, or substantially immediately, restoring the otherwise declining olefin selectivity levels to the original maximum levels.
The present invention also provides a method for determining, to within a reasonable degree of accuracy, the selectivity levels of the olefins and the paraffins within the hydrocarbon product stream. Previously, it was believed that it was feasible to correlate, with a variable degree of precision, the iron-based Synthol catalyst composition, also known as the catalyst type, with the olefin (and paraffin) product selectivity. The following expression, which is known as the selectivity factor (SF), combines the concentrations of the promoters and the support components of the iron catalyst: SF = ( K 2 O + Na 2 O ) ( Al 2 O 3 + SiO 2 ) ( 2 )
wherein each oxide is expressed per 100 g Fe. This factor has traditionally been used, with limited success, as a measurement entity to test whether the hydrocarbon product selectivity profile correlated directly with the catalyst composition. However, it has now been established that the influence of potassium on the selectivity profile is much more pronounced than that of sodium, such that the sodium component concentration, once present in similar amounts to that of potassium, can be excluded from the selectivity factor expression, thereby improving the accuracy of the selectivity factor under these conditions. The new selectivity factor is now expressed as follows: SF = K 2 O ( Al 2 O 3 + SiO 2 ) ( 3 )
Analysis of the synthesis results shows that there is indeed a direct correlation between the modified selectivity factor and the olefin selectivity as well as the olefin: paraffin selectivity ratios. Expressed differently, if the concentrations of the alumina and silica support components are constant, there exists a direct correlation between the potassium promoter concentration in the catalyst matrix and the olefin selectivity and the olefin: paraffin selectivity ratio. Therefore, a decrease in the amount of active potassium correlates to an increase in selectivity of the paraffinic hydrocarbons, and consequently a decrease in the olefin: paraffin ratio.
By physically injecting an alkali compound containing potassium, such as potassium carbonate or potassium silicate, into a Fischer-Tropsch process operating with a catalyst in a fluidized bed mode, the diminishing catalyst is potassium promoter content is suddenly replenished, and in line with phenomena discussed above, the selectivity profile of the synthesis process is such that the olefin selectivity, and thus also the olefin: paraffin selectivity ratios correspondingly increase. The alkali promoter injection method as herein described is carried out online, and the compound is added either in a solution or a powdered form at a selected injection point to allow mixing with the total feed gas prior to entrance into the reactor. The alkali promoter injection method also increases the synthesis gas conversion capacity. Characteristically, the acids in the reaction water as well as in the unstabilized light oil (ULO) fraction are also increased, whilst the alcohols and the carbonyls remain substantially unchanged.
Furthermore, the process of the present invention, through the results obtained, provides an additional or alternative means of countering negative or poisoning effects of the coal-derived synthesis gas side components, such as sulphur, specifically as regards to the question of catalyst selectivity. The iron catalyst is characteristically sensitive towards the increase in the levels of sulphur as sulphur is preferentially adsorbed onto alkali-rich sites on the catalyst surface thereby rendering them ineffective. Thus if high amounts of sulphur are present in the synthesis gas the catalyst activity and selectivity are severely affected. The present invention, wherein fresh alkali is injected into the catalyst bed, counteracts the negative effects of sulphur poisoning by re-instating the presence of fresh alkali-rich and active sites.
The invention will now be illustrated by means of the following non-limiting examples and with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a graphic representation showing the percentage ethylene in reactor tailgas of a Circulating Fluidized Bed reactor when controlling a product selectivity profile of a HTFT process according to the invention;
FIG. 2 shows a graphic representation of the C 2 total split of ethylene and ethane from a test similar to the test of FIG. 1 but conducted on a fixed fluidized bed reactor;
FIG. 3 shows a graphic representation of acids in an unstabilized light oil is fraction and in reaction water during the test of FIG. 2;
FIG. 4 shows a graphic representation of C 1 -C 4 paraffin selectivity during the test of FIG. 2;
FIG. 5 shows a graphic representation of methane selectivity during the test of FIG. 2;
FIG. 6 shows a graphic representation of an ethene:ethane selectivity ratio of the test of FIG. 2;
FIG. 7 shows a graphic representation of a propene:propane selectivity ratio of the test of FIG. 2;
FIG. 8 shows a graphic representation of a butene:butane selectivity ratio of the test of FIG. 2;
FIG. 9 shows a graphic representation of a C 1 -C 4 olefin:paraffin selectivity ratio of the test of FIG. 2; and
FIG. 10 shows a graphic representation of the selectivity factor on unstabilised light oil acids in the test of FIG. 2 .
EXAMPLE 1
This example illustrates that a direct online injection of a compound which is a potassium promoter carrier into a Fischer-Tropsch synthesis reactor operating with an iron-based catalyst in a fluidized mode, and under the conditions of the Sasol Synthol process, immediately increases the product olefins and acids selectivities of the process. Furthermore, the injection of the potassium carrier results in a complementary decrease in the paraffin selectivity. This technique was shown to be effective for both the circulating fluidized bed (CFB) reactor and the fixed fluidized bed reactor (Sasol Advanced Synthol (SAS) reactor).
As means of determining the viability of an online promoter addition to a Synthol Fischer-Tropsch reactor, two test runs were conducted on a CFB reactor. 175 kg of potassium carbonate were dissolved in water in order to achieve an estimated increase in the total potassium promoter amount in the reactor by 0.05 g/100 g iron. The overall aim was to monitor the effect which such an online increase of the promoter in the reactor has on the ethylene:ethane ratio in the tailgas of the test reactor.
The injection point includes the preheated total feed to the reactor, comprising fresh synthesis gas feed and internally recycled feed.
Referring to FIG. 1, after the first addition 10 of the potassium carbonate an increase of ˜3% in the ethylene content of the C 2 total product in the tailgas was immediately observed (from 57% to 60%), which corresponded to a decrease in the ethane content from 43% to 40%. The effect continued until Synthol online catalyst removal and addition (SOLCRA technique) 12 was conducted on the reactor. Thereafter, the ethylene content of the C 2 total product in the tailgas decreased to values as low as 55%.
A second addition 14 of 175 kg potassium carbonate was performed three days later, and the effects were again immediate. The gain on ethylene content of the C 2 total product in the tailgas was about 4%, which later stabilized at 3% continuously until the reactor was shut down.
FIG. 2 shows the C 2 total split of ethylene and ethane from a test conducted on the SAS reactor, wherein the complementary effect of potassium online addition on these two products is illustrated. 220 kg potassium carbonate were added to the reaction medium at injection point 16 , and the SOLCRA technique was conducted on the reactor at points 18 and 20 . Visually, the profile depicts the ethylene content of the C 2 total product as a mirror image of that of ethane, i.e. an increase in ethylene is complemented by a corresponding decrease in ethane. This increase in the ethylene yield due to the loose injection of a potassium promoter is stable, and the ethylene selectivity does not show the normal decay that is observed after the normal online catalysts addition and removal procedures. The acids in the reaction water, as well as in the ULO fraction, also increased as a result of the injection of the potassium carrier into the reactor, as depicted in FIG. 3 .
EXAMPLE 2
This example illustrates that the catalyst composition is the major variable that influences the Synthol process selectivities under standard operating conditions which include feed gas composition and feedrate, conversions, pressures and temperatures.
The selectivity factor (SF) is defined by an expression which combines the iron catalyst potassium oxide, alumina and silica compositions, with the exclusion of sodium oxide. SF = ( K 2 O ) ( Al 2 O 3 + SiO 2 ) ( 3 )
This factor was used to investigate whether there exists any correlation between the selectivity profile of the various components of the product spectrum and the catalyst composition. The data parameters that were correlated were the selectivities for methane, ethylene/ethane, propylene/propane, butene/butane, C 1 -C 4 paraffins and ULO acids.
The results, shown in FIGS. 4 to 10 , suggest that the correlation between the selectivity factor and the Synthol reactor observed selectivities is prevalent. Despite the data scattering there exists a clear trend between the selectivity factor and the said parameters.
FIGS. 4 and 5 show the C 1 -C 4 paraffins selectivities. The direction or the slope of the trends obtained indicate that as the potassium content of the catalyst composition decreases, the selectivity towards C 1 -C 4 paraffins increases. The olefins:paraffins selectivity ratios for the C 2 -C 4 hydrocarbons to are shown in FIGS. 6 to 8 . The rest of the data followed the by-now-expected trend. The total C 2 -C 4 olefin paraffin selectivity ratios (FIG. 9) compare favourably with those of the previous periods.
FIG. 10 shows the trend between the selectivities of the ULO acids and the selectivity factor.
EXAMPLE 3
This example illustrates that the selectivity factor may be accurately used to determine the amount of additional potassium promoter that is required in the Synthol Fischer-Tropsch reactor operating with an iron based catalyst in a fluidized mode, in order to predictably achieve a specific product olefin selectivity.
In an attempt to increase the C 2 olefin selectivity of a catalyst online, a certain amount of potassium promoter is added to alter the catalyst composition ratio (Comp r ) (determined using the above selectivity factor formula).
The general formula for the online addition of potassium (p) is therefore: Required composition ratio = p + K 2 O SiO 2 + Al 2 O 3
Expressed differently:
p =[ReqComp r x (SiO 2 +Al 2 O 3 )−K 2 O]/0.68 (4)
where SiO 2, Al 2 O 3 and K 2 O refer to the composition of the spent catalyst that has the desirable C 2 selectivity. The term ReqComp r is used to indicate the ratio 1/SF which corresponds to a catalyst with the desired C 2 olefin selectivity. This formula applies specifically to K 2 CO 3 as the promoter-carrying compound. If another promoter-carrying compound is used the formula will need to be modified to take into account the molecular weight of the specific compound.
To illustrate the effectiveness of this relation by way of an example, Table 1 shows the following date of spent Sasol Advanced Synthol catalyst compositions which are to be considered.
TABLE 1
Component per 100 g
Fe
Catalyst A
Catalyst B
SiO 2
1,03
1,015
Al 2 O 3
0,32
0,37
K 2 O
0,427
0,385
Calculated Comp r * (SF)
0,316
0,278
Ethylene/ethane
3,07
1,58
(calculated selectivities)
Ethylene/ethane
2,52
1,53
(In tailgas)
*According to K 2 O/(SiO 2 + Al 2 O 3 )
In order to improve the ethylene selectivity of catalyst B to that of catalyst A, using online promoter addition, application of formula (4) yields:
For K 2 O: p = 0.316 ( 1.015 + 0.37 ) - 0.385 = 0.053 g K 2 O per 100 g Fe
Therefore, an additional 0.053 g of K 2 O per 100 g Fe is required to lower the composition ratio (Comp r ) of catalyst B to that of the catalyst A giving the required ethylene olefin selectivity.
For K 2 SiO 3 :
1 g K 2 SiO 3 forms 0.61 g K 2 O and 0.39 g SiO 2 Req comp = 0.61 p + K 2 O ( 0.39 p + 1 ) SiO 2 + Al 2 O 3 p = K 2 O - Req comp ( SiO 2 + Al 2 O 3 ) 0.39 × Req comp - 0.61 For Req Comp = 0.316 p = 0.385 - 0.316 ( 1.015 + 0.37 ) 0.39 × 0.316 - 0.61 = 0.10818 g
i.e. addition of 0.10818 g K 2 SiO 3 per 100 g Fe
Therefore the required catalyst composition is:
SiO 2 =1.015+0.10818×0.39=1.05719 g
Al 2 O 3 =0.37 g
SiO 2 +Al 2 O 3 =1.427 9
K 2 O=0.385+0.10818×0.61=0.45099 g
thus
SF
=
0.45099
1.0572
+
0.37
=
0.316
For K 2 CO 3
1 g K 2 CO 3 forms 0.68 g K 2 O Req Comp = 0.68 p + K 2 O SiO 2 + Al 2 O 3 p = Req Comp ( SiO 2 + Al 2 O 3 ) - K 2 O 0.68 e . g . p = 0.316 ( 1.015 + 0.37 ) - 0.385 0.68 = 0.0774 g K 2 CO 3
i.e. addition of 0.0774 g K 2 CO 3 per 100 g Fe
Therefore the required catalyst composition is:
SiO 2 =1.015 g
Al 2 O 3 =0.37 g
K 2 O=0.385+0.0774×0.69=0.438 g
or
SF
=
0.438
1.015
+
0.37
=
0.316
The invention is not limited to the precise constructional details as hereinbefore described. For example, the catalyst promoter need not be restricted to potassium carbonate or potassium silicate, and could be any similar substance or chemical equivalent which achieves the same or similar results. It will also be apparent to a person skilled in the art that equations other than the ones listed above may also be used to determine the selectivity factor. It is therefore to be understood that the method for calculating the selectivity factor is not to be limited to the equations as set out herein.
The applicant believes that the invention as illustrated and described is advantageous in that it provides a novel method for modifying, and thus controlling the selectivity profile of a Fischer-Tropsch synthesis process operating with a catalyst in a fluidized mode.
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The invention provides a method for controlling a selectivity profile of products of a Fischer-Tropsch synthesis process, wherein a catalyst promoter, either dissolved in solution or in a powdered form, is directly injected into the reactor medium, typically into the reactor feedstream. The Fischer-Tropsch process is typically a High Temperature Fischer Tropsch (HTFT) process, and a typical chemical promoter for the HTFT process is potassium. By adding or doping the reaction medium with the catalyst promoter during the synthesis process, the selectivity profile of olefins and paraffins in the product stream is significantly changed, with more olefins being formed whilst the level of paraffins is reduced, and typically the level of olefins in the C 2 -C 4 range is increased. The catalyst promoter may form part of a promoter-carrying compound, for example, potassium carbonate.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This invention is an improved version of this inventor's previous application (U.S. Pat. No. 5,722,097 to Deveer, 1998 Mar. 3.)
BACKGROUND
1. Field of Invention
This invention is in the field of sanitary products, specifically of bidets, to to cleanse a person's buttocks after defecation.
2. Discussion of Prior Art
The Antiseptic Bidet in combination with a Hygiene Safety Guard which has a turnable vertical spray bidet (which moves inside the toilet bowl), can be turned away while a person is in the process of defecating and moved back directly under the dirty buttocks after defecating. Prior art bidets did not allow for moving the bidet structure out of the way when a person was in the process of defecating (this was the disadvantage in U.S. Pat. No. 3,310,813 to Jonsson, 1967 Mar. 28.) If the bidet structure is not moved away when a person is defecating, then the bidet is soiled. This would lead to unsanitary conditions when the person is using the bidet after defecating. The water sprayed from the bidet would not be clean.
This takes away the sanitary aims of the use of a vertical spray bidet; this situation, in turn, may lead to serious disease. If the Jonsson bidet is placed on the toilet seat after the process of defecating, (and removed after the use of the bidet,) it be unsanitary; to remove an item, the structure of which had been in the toilet bowl. This may lead to serious disease when handling the bidet structure in and out of toilet bowl.
Other prior art mentioned in this inventor's previous application (U.S. Pat. No. 5,722,097 to Deveer, 1998 Mar. 3.) did not include a combination of a vertical spray with an antiseptic spray & a Hygiene Safety Guard. These prior art include the following U.S. Patents and their Inventors:
U.S. Pat. No. 1,520,892 Jan., 1924 Koppin
U.S. Pat. No. 4,069,519 Jan., 1978 Alexander
U.S. Pat. No. 4,998,300 Mar., 1991 Sharifzadeh
U.S. Pat. No. 5,359,736 Nov., 1994 Olivier
U.S. Pat. No. 5,504,948 Apr., 1996 Chandler
U.S. Pat. No. 5,566,402 Oct., 1996 Agha El-Rifai et al.
The above mentioned patents also do not include a separate, movable unit with water and antiseptic controls that can be placed in front of the person seated on the toilet seat. These controls enable easier adjustment of water pressure and antiseptic spray controls.
OBJECTS AND ADVANTAGES
The Antiseptic Bidet in combination with a Hygiene Safety Guard has many objects and advantages. These include a complete toilet seat and bidet structure which comes in one unit that replaces the existing seat. This enables easy installation of the invention onto an existing toilet seat. My invention also comes with a separate, movable unit with water & antiseptic controls that can be placed in front of a person seated on the toilet seat. This enables easier adjustment of the water, pressure, and antiseptic controls for greater comfort. The built in Hygiene Safety Guard enables the male penis to be kept safely away from the dirty water in the toilet bowl. The bidet structure and the toilet seat is enclosed within a splash guard that keeps any spray within the toilet bowl. The nozzle of the vertical spray tubing structure is crimped to create a high water pressure water stream that enables effective cleansing of the dirty buttocks. The pressure of this water stream is adjustable through the pressure adjustment knob. The second tube of the twin tubing structure sprays antiseptic.
This invention may reduce infections that may afflict children, adults, and the elderly, who may find toilet paper difficult to use. Toilet paper is not as effective as this invention. Human excrement has many serious diseases such as meningitis, certain types of hepatitis, and many other less serious infections. Some people maybe chronically infecting themselves due to improper toilet paper use.
This invention can quickly provide a higher state of hygiene that is easy to use against bacteria and virus that may lead to serious and/or minor infections. My invention is also easy to install in most households. It comes with screws that easily attach on to the existing toilet. It's as simple as replacing an old toilet seat with a new toilet seat. This invention also does not need a permanent connection to the existing water supply. It comes with a multi-groove funnel that can be placed under any size faucet. The funnel is placed temporarily under the faucet until the water tank is filled. The antiseptic container uses common antiseptic found in most drug stores and department stores. This is sold as yellow mouthwash and is inexpensive and available everywhere.
DESCRIPTIONS OF DRAWINGS
FIG. 1 shows the Bidet structure ( 20 ) and overall unit structure from an overhead view. The Hygiene Safety Guard ( 23 ) can be seen on top of the overhead view. The supports ( 24 ) that separate the lower section ( 22 ) from the upper section ( 21 ) can also be seen. The upper section ( 21 ) is comprised of the toilet seat of the of the overall unit structure. We can also see the easy installation screws ( 25 ) in FIG. 1 .
FIG. 2 shows the bidet tubing structure ( 20 ) and how it moves in an arc pattern to position ( 29 ) when handle ( 27 ) is moved forward in the direction of the arrow near handle ( 27 .) FIG. 2 also shows the lower section ( 22 ) and and the upper section ( 21 ) which is the toilet seat.
The supports ( 24 ) that separate the lower section and the upper section can also be seen. FIG. 2 also shows the inner splash guard ( 31 ) and the outer splash guard ( 30 .) The bidet handle moves back and forth through the narrow opening ( 28 ) which is in the outer splash guard ( 30 .)
FIG. 3 shows another section of the overall unit structure. This shows the Hygiene Safety Guard ( 23 ) and the opening ( 26 ) where the male penis is inserted. This diagram also shows a small aperture ( 32 ) at the base of the Hygiene safety guard ( 23 ) that acts as a drain for urine to the toilet bowl below. FIG. 3 also shows the lower section ( 22 ) & upper section ( 21 ) and and the supports ( 24 ) of the overall bidet structure.
FIG. 4 shows a closer view of the bidet twin tubing structure. This diagram shows the tube that sprays water ( 38 ) and the other tube that sprays antiseptic ( 37 ). The crimped nozzles ( 39 ) & ( 40 ) can also be seen on both tubes. We can also see the drain aperture ( 41 ). FIG. 4 also shows the bindings ( 34 ). The twin tubes are also attached to the flexible tubes that carry antiseptic ( 36 ) and water ( 35 ). FIG. 4 also shows the round aperture ( 33 ) which acts as a pivot for the bidet structure. This round aperture ( 33 ) is present in the lower section ( 22 ) of the overall bidet structure.
FIG. 5 shows the containers that store water & antiseptic, and the motor-pump system. The faucet & sink is shown by ( 42 ). The funnel ( 64 ) is shown placed under the faucet. The funnel is connected to a flexible tube ( 43 ) that is shown connected to water tank ( 44 ). The smaller antiseptic container ( 45 ) is also shown in FIG. 4 . FIG. 4 also shows a flexible tube leading from the water & antiseptic tanks to the round pumps ( 49 ) & ( 50 ) that are, in turn, connected to drills ( 46 ) & ( 51 ). We can also see the pressure adjust valve ( 60 ) connected to flexible tube ( 35 ). The bindings ( 47 ) on the drill controls and the permanent-on button on the drills ( 48 ) can also be seen. The drills are connected by wire to on/off switches ( 52 ) & ( 53 ). The wire is then connected to a common electric plug ( 54 ). The pumps are then connected to flexible tubes ( 35 ) & ( 36 ) that are in turn connected to the rigid twin tubing structure of the bidet.
FIG. 6 shows the Flow Control Valve ( 60 ) The valve knob ( 61 ) can also be seen. The flexible water delivering tube ( 35 ) can be seen placed through the Flow Control Valve. This valve is sold by U.S. Plastic Corp., of Lima, Ohio.
FIG. 7 shows the Multi-groove Funnel ( 64 ). We can see the closed section on top of the funnel showing the circular grooves ( 62 ) within this section. We can also see the aperture in the center of the funnel ( 63 ). This funnel is sold by The Blitz Co., of Miami, Fla.
LIST OF REFERENCE NUMERALS
20 The rigid bidet tubing structure
21 The upper section and toilet seat of the overall unit structure
22 The lower section of the overall unit structure
23 The Hygiene Safety Guard
24 The supports that separate the lower section from the upper section of the overall unit structure
25 The attachment screws that connect the bidet structure to the toilet bowl
26 The round opening in the Hygiene Safety Guard, where the male penis is inserted
27 The handle of the bidet rigid tubing structure
28 The long narrow opening in the outer splash guard
29 The position where the bidet nozzle moves to when handle is moved forward
30 The outer splash guard
31 The inner splash guard
32 The small aperture in the base of the Hygiene Safety Guard
33 The round bidet tubing pivot aperture in the lower section of the overall bidet structure
34 The bindings that bind the twin tubes of the bidet rigid tubing structure into one unit
35 The flexible tube that delivers water to the rigid tubing structure
36 The flexible tube that delivers antiseptic to the rigid tubing structure
37 The tube that sprays antiseptic
38 The tube that sprays water
39 The crimped spray nozzle that streams water
40 The crimped spray nozzle that streams antiseptic
41 The drain aperture in the base of the water delivery rigid tube
42 The sink & faucet found in most bathrooms
43 The flexible tube that is connected to the funnel
44 The water container
45 The antiseptic container
46 The electric drill used as the motor to turn the pump for pumping water
47 The bindings around the on button for the drills
48 The permanent-on button found on electric drills
49 The round drill pump used for pumping water
50 The round drill pump used for pumping antiseptic
51 The electric drill used as the motor to turn the pump for pumping antiseptic
52 The on/off switch to control the electric motor inside the water pumping drill
53 The on/off switch to control the electric motor inside the antiseptic pumping drill
54 The electric plug to connect the drill-motors to the electric outlet
60 The Flow Control valve that lowers the water pressure
61 The knob of the Flow Control valve that controls the water pressure
62 The closed top section that contains the multi-grooves of funnel ( 64 )
63 The aperture in the center of funnel ( 64 ) that allows water to flow through
64 The multi-groove funnel
SUMMARY
In summary, my invention enables effective cleansing of the dirty buttocks after defecating. It includes a high pressure-adjustable water spraying nozzle and a second nozzle that sprays antiseptic. It also has a hygiene safety guard that enables the male penis to be inserted, keeping it away from the dirty water in the toilet bowl. This invention is also easy to install & operate, since no connection to the existing water supply is required. It can also be easily installed onto an existing toilet bowl by unscrewing the existing toilet seat and screwing on the Antiseptic bidet onto the toilet bowl. The water & antiseptic controls are conveniently placed in a separate movable unit that can be placed in front of the person seated on the toilet seat.
DESCRIPTION OF THE INVENTION
The overall bidet structure as shown in FIG. 1 is comprised of an upper section ( 21 ) and a lower section ( 22 ). The upper section is comprised of the toilet seat and a hygiene safety guard ( 23 ). This hygiene safety guard is shown more clearly in FIG. 3 . It's angled towards the person seated on toilet seat and has a round aperture ( 26 ) that serves as the opening of this hollow safety device. A small drain aperture ( 32 ) exists at the base of this hygiene safety device as shown in FIG. 3 .
FIGS. 2 & 3 also show the upper section affixed to, and supported & separated, from the lower section by the use of supports ( 24 ). The lower section ( 22 ) forms the base of the overall unit structure. The lower section contains the round aperture ( 33 ) as shown in FIG. 4 . The twin rigid tubing structure ( 20 ) is then bent through the round aperture ( 33 ) to form a pivot apparatus.
The lower section also has the toilet bowl connecting screws ( 25 ). The lower and the upper sections are basically 2 toilet seats held together by supports ( 24 ). The inside edges of the upper & lower sections are enclosed by the inside splash guard ( 31 ). The outside edges of the upper & lower sections are enclosed by the outside splash guard ( 30 ) enclosed completely on their inside edges, along the contours of the toilet seat forms of said upper and lower sections, by a length of flat, flexible, material whose height is equal to the vertical height between the upper and lower sections, enabling an effective means to contain any extraneous spray that may occur during bidet operation, and said upper and lower sections are also enclosed on their outer edges with another flat, flexible material, whose height is equal to the vertical height between the upper and lower sections and whose shape follows the contours of the outer toilet seat shape of the upper and lower sections, which enables a means for an outer splash guard, and there also exists a long narrow opening on same outer splash guard, that enables a means for the hollow handle of said rigid twin tubing structure, to move back and forth, and. The water source is connected to the hollow handle ( 27 ) via flexible tubing ( 35 ), which in turn, is connected to the water delivering tube ( 38 ). The hollow handle ( 27 ) is comprised of the twin tubes that deliver water ( 38 ) and the other tube that delivers antiseptic ( 37 ). This twin-tubing rigid bidet structure can be seen in FIG. 4 . FIG. 4 also shows the bindings ( 34 ) that form a single rigid unit structure out of two separate rigid tubes.
The flexible water carrying tube ( 35 ) also has a pressure adjust valve ( 60 ) shown in FIG. 5 & FIG. 6 . The water delivering tube ( 38 ) of the rigid twin tubing structure of the bidet is bent ninety degrees upward and its tip is crimped into a high pressure nozzle ( 39 ). The base of the nozzle contains a small drain aperture ( 41 ). The tubing of the bidet structure has a long horizontal section equal to the radius of the average toilet bowl and then it's again bent ninety degrees upward to create a “U” shaped form. The tubing is then placed through the pivot aperture ( 33 ), and then horizontally bent ninety degrees into a length greater than the width of the upper & lower sections and approximately two inches beyond the outer edge of the lower section. This horizontal section then passes through a narrow & long opening ( 28 ) which exists on the outer splash guard ( 30 ). The two inches of tubing extending beyond the outer edge of the lower section is represented by handle ( 27 ) as shown in FIG. 2 .
The invention also includes a water container ( 44 ) & antiseptic container ( 45 ) which are housed in a separate, movable unit. This unit shown in FIG. 5 , includes the electric motor drills ( 46 ) & ( 51 ) which are connected the round liquid pumps ( 49 ) & ( 50 ). The electric motor drills are plugged into the electric outlet via an electric cord and via electric plug ( 54 ). The electric cords are routed through on/off switches ( 52 ) & ( 53 ). The round liquid pumps are connected to water container ( 44 ) & antiseptic container ( 45 ) via another section of flexible tubes ( 36 ) & ( 35 ) as shown in FIG. 5 . The water tube ( 35 ) that connects the water round pump to the water tank ( 44 ) is placed through the pressure adjust valve ( 60 ) as shown in FIG. 5 & FIG. 6 . FIG. 6 shows the knob ( 61 ) that is part of the pressure adjust valve ( 60 ). The output of the round water pump ( 49 ) is connected to flexible water delivery tube ( 35 ), which in turn is connected to the rigid water streaming tube ( 38 ) of the rigid twin tubing structure of the bidet. The output of the antiseptic pump ( 50 ) is connected to the flexible antiseptic delivery tube ( 36 ), which in turn, is connected to the rigid antiseptic spraying tube ( 37 ) of the rigid twin tubing structure of the bidet.
FIG. 5 also shows a sink & faucet ( 42 ), and, we can also see the funnel ( 64 ) placed under the faucet. The funnel ( 64 ) is connected to flexible tube ( 43 ), which in turn, is connected to water tank ( 44 ). The funnel ( 64 ) has an enclosed top with several circular grooves ( 62 ) as shown in FIG. 7 . There is also an aperture in the center of the funnel ( 63 ).
OPERATION OF INVENTION
The installation of the Antiseptic Bidet onto the existing toilet is simple and easy. An ordinary person simply unscrews the existing toilet seat and connects the Antiseptic Bidet to the toilet bowl using the screws ( 25 ). It's the same process as replacing an old toilet seat with a new one.
There is no connection necessary to the water supply in the household as well. The water tank ( 44 ) is filled by placing the funnel ( 64 ) under the faucet/sink ( 42 ) as shown in FIG. 4 . The funnel ( 64 ) is connected to flexible tube ( 43 ) that is connected to water tank ( 44 ). The funnel has a closed top with many circular grooves ( 62 ) that enable the funnel to be placed under any faucet of any size. This is shown in the lower diagram in FIG. 5 . The funnel has an aperture ( 63 ) in the center of the circular grooves that lets water through into the flexible tube ( 43 ). The funnel is placed temporarily under the faucet until the water tank ( 44 ) is filled. The user of the bidet can adjust the temperature of the water by the controls of the faucet. The water tank holds many gallons of water that is enough for the average person to cleanse himself/herself. The user of the bidet also has to fill the antiseptic container with antiseptic. The best antiseptic is the yellow mouthwash antiseptic sold in most drug stores and department stores. It was originally developed in England by the Listerine Co. to disinfect surgical instruments. It's an effective and gentle antiseptic on the skin. (The meaning of antiseptic is an anti-germ agent that is effective against bacteria and virus'.) This antiseptic is inexpensive and available almost everywhere in the United States.
The person who is seated on the toilet seat ( 21 ) shown in FIG. 1 would then insert the male penis into the hygiene safety guard ( 23 ). This keeps the penis away from any splash and/or contact with the dirty toilet bowl and the dirty water that may splash during the process of defecation. When the person urinates, the urine will go to the base of the Hygiene Safety Guard and drain out of the urine drain ( 32 ) and into the toilet bowl below. Before the process of defecation starts, the person would move the handle ( 27 ) forward in the direction of the arrow shown in the top diagram in FIG. 2 . This moves the nozzles ( 39 ) & ( 40 ) shown in FIG. 3 of the twin tubes of the bidet tubing structure away from the center of toilet bowl (and away from the anus of person who is about to start the process of defecation.) By turning the handle ( 27 ) forward the entire twin-tubing bidet structure pivots through the aperture ( 33 ) located on the inside edge of the lower section as shown in FIG. 4 and places nozzles ( 39 ) & ( 40 ) into the position ( 29 ) as shown in FIG. 2 . The handle also moves back & forth through the narrow opening ( 28 ) that is present on the outer splash guard ( 30 ). The bindings ( 34 ) bind both tubes together into a single rigid structure that pivots as one unit through aperture ( 33 ) shown in FIG. 4 . The handle is formed out of only two inches of the twin rigid tubing structure. This enables the invention to be used in bathrooms which are very small, where the space around the toilet bowl is very limited.
After the person has completed the process of defecation, he/she moves the handle ( 27 ) backward, which in turn, pivots the twin-tubing structure & its twin nozzles ( 39 ) & ( 40 ) forward. The person stops moving handle forward until the handle is perpendicular to his/her seated position and to the toilet seat. This places the nozzles ( 39 ) & ( 40 ) directly under the anus of the person seated on the toilet seat. The person then turns switch ( 52 ) on. This sends electric current to the drill motor ( 46 ) shown in FIG. 5 . Since the bindings ( 47 ) around the drill on/off switch and the permanent on buttons ( 48 ) are depressed, the drills turn on and off when switches ( 52 ) & ( 53 ) are turned on and off.
The drill motor turns the round drill pump ( 49 ), which delivers a pressurized stream of water to flexible tube ( 35 ). Flexible tube ( 35 ) is connected to the rigid tube ( 38 ) which is the water delivering tube of the twin tubes of the bidet's rigid tubing structure. The water streams out of the water delivery nozzle ( 39 ) and onto to the dirty buttocks. The drain aperture ( 41 ) enables draining of any water remaining (after use of the bidet), from the “U” shaped bidet rigid tubing structure. This creates a block against contamination of the water tank from any dirty water remaining in the water delivery tube ( 38 ). The drill motor & drill pump combination delivers an optimal pressure (at 25 psi) for effective cleansing of the dirty buttocks. However, this pressure can be lowered by turning the knob of the pressure adjust valve ( 61 ) clockwise as shown by the arrow in FIG. 6 .
While the person is using the water stream to cleanse his/her dirty buttocks, the higher water pressure creates water spray & splash when the water stream comes into contact with the dirty buttocks. This extraneous spray & splash is contained effectively by the inside splash guard ( 31 ), which completely encircles and seals the inside edges of the upper section ( 21 ) and the lower section ( 22 ). This can be seen in FIG. 2 . There is also an outer splash guard ( 30 ). This seals the outer edges of lower section ( 22 ) and the upper section ( 21 ).
After 3 to 5 minutes of cleansing with water, the user of the antiseptic bidet turns off the water stream by turning switch ( 52 ) to the off position. Then, the person would turn on the antiseptic stream, by turning on switch ( 53 ). This sends electric current to drill motor ( 51 ) which turns on pump ( 50 ). This is used for a short time only, between 1 to 2 minutes. After the buttocks are sprayed with antiseptic, the person would turn off the antiseptic spray by turning switch ( 53 ) to the off position.
The person may use some toilet paper to blot any excess antiseptic that may be dripping.
CONCLUSION, RAMIFICATIONS, AND SCOPE OF INVENTION
This invention enables the average consumer access to an effective hygiene device with advanced innovations such as a high pressure water stream bidet that is that is controllable with a separate, movable water control unit (that can be placed in front of the person seated on the lavatory seat.) The high pressure water stream is adjustable. The water and antiseptic controls are easily adjustable with the controls in front of the seated person on the toilet seat. This invention may also reduce risk of infection to male genitals due to the built in Hygiene Safety Guard. This feature is unavailable in any similar products elsewhere. The antiseptic spray may reduce infections that may be afflicting children, adults, and the elderly. Toilet paper may be difficult to use for many people. This invention also comes with easy to install connectors that simply replace the existing toilet seat. There are no connections required to the water supply as well. This makes this invention to be installed and used easily & quickly by the average person.
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An effective hygiene device that enables easy installation to the toilet bowls of most households. It is comprised of a high pressure, adjustable water stream & an antiseptic spray. A built in Hygiene Safety Guard enables a safety margin against the male penis being in the toilet bowl. This invention easily installs onto toilet bowls found in most households. It also requires no connection to the water supply in the household. This invention may reduce infections that maybe afflicting children, adults, and the elderly, who may find toilet paper difficult to use. There are many serious diseases associated with human excrement, and the antiseptic spray feature of this invention may reduce the risk of many infections. This invention also leads to a higher quality of life and a greater feeling of cleanliness.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/491,788, filed Jul. 24, 2006, which is a continuation of U.S. application Ser. No. 10/886,016, filed Jul. 7, 2004, now U.S. Pat. No. 7,101,960, which is a continuation of U.S. application Ser. No. 10/264,350, filed Oct. 3, 2002, now U.S. Pat. No. 6,784,254, which is a continuation of U.S. application Ser. No. 10/060,556, filed Jan. 30, 2002, now abandoned, which is a continuation of U.S. application Ser. No. 09/803,647, filed Mar. 9, 2001, now U.S. Pat. No. 6,433,026, which is a continuation of U.S. application Ser. No. 09/532,984, filed Mar. 22, 2000, now U.S. Pat. No. 6,225,355, which is a continuation of U.S. application Ser. No. 09/388,876, filed Sep. 2, 1999, now U.S. Pat. No. 6,066,678, which is a continuation of U.S. application Ser. No. 09/288,357, filed Apr. 8, 1999, now U.S. Pat. No. 5,981,693, which is a continuation of U.S. application Ser. No. 09/129,286, filed Aug. 5, 1998, now U.S. Pat. No. 5,917,007, which is a continuation of U.S. application Ser. No. 08/910,692, filed Aug. 13, 1997, now abandoned, which is a divisional of U.S. application Ser. No. 08/460,980, filed on Jun. 5, 1995, now U.S. Pat. No. 5,679,717, which is a continuation-in-part of U.S. application Ser. No. 08/258,431, filed Jun. 10, 1994, now abandoned. The entire teachings of all the above applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to removing bile salts from a patient.
[0003] Salts of bile acids act as detergents to solubilize and consequently aid in digestion of dietary fats. Bile acids are precursors to bile salts, and are derived from cholesterol. Following digestion, bile acids can be passively absorbed in the jejunum, or, in the case of conjugated primary bile acids, reabsorbed by active transport in the ileum. Bile acids which are not reabsorbed by active transport are deconjugated and dehydroxylated by bacterial action in the distal ileum and large intestine.
[0004] Reabsorption of bile acids from the intestine conserves lipoprotein cholesterol in the bloodstream. Conversely, blood cholesterol level can be diminished by reducing reabsorption of bile acids.
[0005] One method of reducing the amount of bile acids that are reabsorbed is oral administration of compounds that sequester the bile acids and cannot themselves be absorbed. The sequestered bile acids consequently either decompose by bacterial action or are excreted.
[0006] Many bile acid sequestrants, however, bind relatively hydrophobic bile acids more avidly than conjugated primary bile acids, such as conjugated cholic and chenodeoxycholic acids. Further, active transport in the ileum causes substantial portions of sequestered conjugated primary bile acids to be desorbed and to enter the free bile acid pool for reabsorption. In addition, the volume of sequestrants that can be ingested safely is limited. As a result, the effectiveness of sequestrants to diminish blood cholesterol levels is also limited.
[0007] Sequestering and removing bile salts (e.g., cholate, glycocholate, glycochenocholate, taurocholate, and deoxycholate salts) in a patient can be used to reduce the patient's cholesterol level. Because the biological precursor to bile salt is cholesterol, the metabolism of cholesterol to make bile salts is accompanied by a simultaneous reduction in the cholesterol in the patient.
[0008] Cholestyramine, a polystyrene/divinylbenzene ammonium ion exchange resin, when ingested, removes bile salts via the digestive tract. This resin, however, is unpalatable, gritty and constipating. Resins which avoid (totally or partially) these disadvantages and/or possess improved bile salt sequestration properties are needed.
SUMMARY OF THE INVENTION
[0009] The invention relates to the discovery that a new class of ion exchange resins have improved bile salt sequestration properties and little to no grittiness, thereby improving the palatability of the composition.
[0010] The resins comprise cross-linked polyamines which are characterized by one or more hydrophobic substituents and, optionally, one or more quaternary ammonium containing substituents.
[0011] In general, the invention features resins and their use in removing bile salts from a patient that includes administering to the patient a therapeutically effective amount of the reaction product of:
(a) one or more crosslinked polymers, salts and copolymers thereof characterized by a repeat unit selected from the group consisting essentially of:
[0000] (NR—CH 2 CH 2 ) n (3)
[0000] (NR—CH 2 CH 2 —NR—CH 2 CH 2 —NR—CH 2 CHOH—CH 2 ) n (4)
[0000] where n is a positive integer and each R, independently, is H or a substituted or unsubstituted alkyl group (e.g., C 1 -C 8 alkyl); and
(b) at least one alkylating agent. The reaction product is characterized in that: (i) at least some of the nitrogen atoms in the repeat units are unreacted with the alkylating agent; (ii) less than 10 mol % of the nitrogen atoms in the repeat units that react with the alkylating agent form quaternary ammonium units; and (iii) the reaction product is preferably non-toxic and stable once ingested.
[0014] Suitable substituents include quaternary ammonium, amine, alkylamine, dialkylamine, hydroxy, alkoxy, halogen, carboxamide, sulfonamide and carboxylic acid ester, for example.
[0015] In preferred embodiments, the polyamine of compound (a) of the reaction product is crosslinked by means of a multifunctional crosslinking agent, the agent being present in an amount from about 0.5-25% (more preferably about 2.5-20% (most preferably 1-10%)) by weight, based upon total weight or monomer plus crosslinking agent. A preferred crosslinking agent is epichlorohydrin because of its high availability and low cost. Epichlorohydrin is also advantageous because of it's low molecular weight and hydrophilic nature, increasing the water-swellability and gel properties of the polyamine.
[0016] The invention also features compositions based upon the above-described reaction products.
[0017] The invention provides an effective treatment for removing bile salts from a patient (and thereby reducing the patient's cholesterol level). The compositions are non-toxic and stable when ingested in therapeutically effective amounts.
[0018] Other features and advantages will be apparent from the following description of the preferred embodiments thereof and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
Compositions
[0019] Preferred reaction products include the products of one or more crosslinked polymers having the formulae set forth in the Summary of the Invention, above, and one or more alkylating agents. The polymers are crosslinked. The level of crosslinking makes the polymers completely insoluble and thus limits the activity of the alkylated reaction product to the gastrointestinal tract only. Thus, the compositions are non-systemic in their activity and will lead to reduced side-effects in the patient.
[0020] By “non-toxic” it is meant that when ingested in therapeutically effective amounts neither the reaction products nor any ions released into the body upon ion exchange are harmful. Cross-linking the polymer renders the polymer substantially resistant to absorption. When the polymer is administered as a salt, the cationic counterions are preferably selected to minimize adverse effects on the patient, as is more particularly described below.
[0021] By “stable” it is meant that when ingested in therapeutically effective amounts the reaction products do not dissolve or otherwise decompose in vivo to form potentially harmful by-products, and remain substantially intact so that they can transport material out of the body.
[0022] By “salt” it is meant that the nitrogen group in the repeat unit is protonated to create a positively charged nitrogen atom associated with a negatively charged counterion.
[0023] By “alkylating agent” it is meant a reactant which, when reacted with the crosslinked polymer, causes an alkyl group or derivative thereof (e.g., a substituted alkyl, such as an aralkyl, hydroxyalkyl, alkylammonium salt, alkylamide, or combination thereof) to be covalently bound to one or more of the nitrogen atoms of the polymer.
[0024] One example of preferred polymer is characterized by a repeat unit having the formula
[0000]
[0000] or a salt or copolymer thereof; wherein x is zero or an integer between about 1 to 4.
[0025] A second example of a preferred polymer is characterized by a repeat unit having the formula
[0000] (NH—CH 2 CH 2 ) n (6)
[0000] or a salt or copolymer thereof.
[0026] A third example of a preferred polymer is characterized by a repeat unit having the formula
[0000] (NH—CH 2 CH 2 —NH—CH 2 CH 2 —NH—CH 2 CHOH—CH 2 ) n (7)
[0000] or a salt or copolymer thereof.
[0027] The polymers are preferably crosslinked prior to alkylation. Examples of suitable crosslinking agents include acryloyl chloride, epichlorohydrin, butanedioldiglycidyl ether, ethanedioldiglycidyl ether, and dimethyl succinate. The amount of crosslinking agent is typically between 0.5 and 25 weight %, based upon combined weight of crosslinking agent and monomer, with 2.5-20%, or 1-10%, being preferred.
[0028] Typically, the amount of crosslinking agent that is reacted with the amine polymer is sufficient to cause reaction of between about 0.5 and twenty percent of the amines. In a preferred embodiment, between about 0.5 and six percent of the amine groups react with the crosslinking agent.
[0029] Crosslinking of the polymer can be achieved by reacting the polymer with a suitable crosslinking agent in an aqueous caustic solution at about 25° C. for a period of time of about eighteen hours to thereby form a gel. The gel is then combined with water and blended to form a particulate solid. The particulate solid can then be washed with water and dried under suitable conditions, such as a temperature of about 50° C. for a period of time of about eighteen hours.
[0030] Alkylation involves reaction between the nitrogen atoms of the polymer and the alkylating agent (which may contain additional nitrogen atoms, e.g., in the form of amido or ammonium groups). In addition, the nitrogen atoms which do react with the alkylating agent(s) resist multiple alkylation to form quaternary ammonium ions such that less than 10 mol % of the nitrogen atoms form quaternary ammonium ions at the conclusion of alkylation.
[0031] Preferred alkylating agents have the formula RX where R is a C 1 -C 20 alkyl (preferably C 4 -C 20 ), C 1 -C 20 hydroxy-alkyl (preferably C 4 -C 20 hydroxyalkyl), C 7 -C 20 aralkyl, C 1 -C 20 alkylammonium (preferably C 4 -C 20 alkyl ammonium), or C 1 -C 20 alkylamido (preferably C 4 -C 20 alkyl amido) group and X includes one or more electrophilic leaving groups. By “electrophilic leaving group” it is meant a group which is displaced by a nitrogen atom in the crosslinked polymer during the alkylation reaction. Examples of preferred leaving groups include halide, epoxy, tosylate, and mesylate group. In the case of, e.g., epoxy groups, the alkylation reaction causes opening of the three-membered epoxy ring.
[0032] Examples of preferred alkylating agents include a C 1 -C 20 alkyl halide (e.g., an n-butyl halide, n-hexyl halide, n-octyl halide, n-decyl halide, n-dodecyl halide, n-tetradecyl halide, n-octadecyl halide, and combinations thereof); a C 1 -C 20 dihaloalkane (e.g., a 1,10-dihalodecane); a C 1 -C 20 hydroxyalkyl halide (e.g., an 11-halo-1-undecanol); a C 1 -C 20 aralkyl halide (e.g., a benzyl halide); a C 1 -C 20 alkyl halide ammonium salt (e.g., a (4-halobutyl)trimethylammonium salt, (6-halohexyl)trimethyl-ammonium salt, (8-halooctyl)trimethylammonium salt, (10-halodecyl)trimethylammonium salt, (12-halododecyl)-trimethylammonium salts and combinations thereof); a C 1 -C 20 alkyl epoxy ammonium salt (e.g., a (glycidylpropyl)-trimethylammonium salt); and a C 1 -C 20 epoxy alkylamide (e.g., an N-(2,3-eoxypropane)butyramide, N-(2,3-epoxypropane) hexanamide, and combinations thereof).
[0033] It is particularly preferred to react the polymer with at least two alkylating agents, added simultaneously or sequentially to the polymer. In one preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R′X where R′ is a C 1 -C 20 alkyl ammonium group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide ammonium salt).
[0034] In another preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R′X where R′ is a C 1 -C 20 hydroxyalkyl group and X includes one or more electrophilic leaving groups (e.g., a hydroxy alkyl halide).
[0035] In another preferred example, one of the alkylating agents is a C 1 -C 20 dihaloalkane and the other alkylating agent is a C 1 -C 20 alkylammonium salt.
[0036] The reaction products may have fixed positive charges, or may have the capability of becoming charged upon ingestion at physiological pH. In the latter case, the charged ions also pick up negatively charged counterions upon ingestion that can be exchanged with bile salts. In the case of reaction products having fixed positive charges, however, the reaction product may be provided with one or more exchangeable counterions. Examples of suitable counterions include Cl − , Br − , CH 3 OSO 3 − , HSO 4 − , SO 4 2− , HCO 3 − , CO 3 − , acetate, lactate, succinate, propionate, butyrate, ascorbate, citrate, maleate, folate, an amino acid derivative, a nucleotide, a lipid, or a phospholipid. The counterions may be the same as, or different from, each other. For example, the reaction product may contain two different types of counterions, both of which are exchanged for the bile salts being removed. More than one reaction product, each having different counterions associated with the fixed charges, may be administered as well.
[0037] The alkylating agent can be added to the cross-linked polymer at a molar ratio between about 0.05:1 to 4:1, for example, the alkylating agents can be preferably selected to provide hydrophobic regions and hydrophilic regions.
[0038] The amine polymer is typically alkylated by combining the polymer with the alkylating agents in an organic solvent. The amount of first alkylating agent combined with the amine polymer is generally sufficient to cause reaction of the first alkylating agent with between about 5 and 75 of the percent of amine groups on the amine polymer that are available for reaction. The amount of second alkylating agent combined with the amine polymer and solution is generally sufficient to cause reaction of the second alkylating agent with between about 5 and about 75 of the amine groups available for reaction on the amine polymer. Examples of suitable organic solvents include methanol, ethanal, isopropanol, acetonitrile, DMF and DMSO. A preferred organic solvent is methanol.
[0039] In one embodiment, the reaction mixture is heated over a period of about forty minutes to a temperature of about 65° C., with stirring. Typically, an aqueous sodium hydroxide solution is continuously added during the reaction period. Preferably, the reaction period at 65° C. is about eighteen hours, followed by gradual cooling to a room temperature of about 25° C. over a period of about four hours. The resulting reaction product is then filtered, resuspended in methanol, filtered again, and then washed with a suitable aqueous solution, such as two molar sodium chloride, and then with deionized water. The resultant solid product is then dried under suitable conditions, such as at a temperature of about 60° C. in an air-drying oven. The dried solid can then be subsequently processed. Preferably, the solid is ground and passed through an 80 mesh sieve.
[0040] In a particularly preferred embodiment of the invention, the amine polymer is a crosslinked poly(allylamine), wherein the first substituent includes a hydrophobic decyl moiety, and the second amine substituent includes a hexyltrimethylammonium. Further, the particularly preferred crosslinked poly(allylamine) is crosslinked by epichlorohydrin that is present in a range of between about two and six percent of the amines available for reaction with the epichlorohydrin.
[0041] The invention will now be described more specifically by the examples.
EXAMPLES
A. Polymer Preparation
1. Preparation of Poly(vinylamine)
[0042] The first step involved the preparation of ethylidenebisacetamide. Acetamide (118 g), acetaldehyde (44.06 g), copper acetate (0.2 g), and water (300 mL) were placed in a 1 L three neck flask fitted with condenser, thermometer, and mechanical stirred. Concentrated HCl (34 mL) was added and the mixture was heated to 45-50° C. with stirring for 24 hours. The water was then removed in vacuo to leave a thick sludge which formed crystals on cooling to 5° C. Acetone (200 mL) was added and stirred for a few minutes, after which the solid was filtered off and discarded. The acetone was cooled to 0° C. and solid was filtered off. This solid was rinsed in 500 mL acetone and air dried 18 hours to yield 31.5 g of ethylidenebis-acetamide.
[0043] The next step involved the preparation of vinylacetamide from ethylidenebisacetamide. Ethylidenebisacetamide (31.05 g), calcium carbonate (2 g) and celite 541 (2 g) were placed in a 500 mL three neck flask fitted with a thermometer, a mechanical stirred, and a distilling heat atop a Vigroux column. The mixture was vacuum distilled at 24 mm Hg by heating the pot to 180-225° C. Only a single fraction was collected (10.8 g) which contained a large portion of acetamide in addition to the product (determined by NMR). This solid product was dissolved in isopropanol (30 mL) to form the crude vinylacetamide solution used for polymerization.
[0044] Crude vinylacetamide solution (15 mL), divinylbenzene (1 g, technical grade, 55% pure, mixed isomers), and AIBN (0.3 g) were mixed and heated to reflux under a nitrogen atmosphere for 90 minutes, forming a solid precipitate. The solution was cooled, isopropanol (50 mL) was added, and the solid was collected by centrifugation. The solid was rinsed twice in isopropanol, once in water, and dried in a vacuum oven to yield 0.8 g of poly(vinylacetamide), which was used to prepare poly(vinylamine as follows).
[0045] Poly(vinylacetamide) (0.79 g) was placed in a 100 mL one neck flask containing water (25 mL) and conc. HCl (25 mL). The mixture was refluxed for 5 days, after which the solid was filtered off, rinsed once in water, twice in isopropanol, and dried in a vacuum oven to yield 0.77 g of product. Infrared spectroscopy indicated that a significant amount of the amide (1656 cm −1 ) remained and that not much amine (1606 cm −1 ) was formed. The product of this reaction (˜0.84 g) was suspended in NaOh (46 g) and water (46 g) and heated to boiling (˜140° C.). Due to foaming the temperature was reduced and maintained at ˜100° C. for 2 hours. Water (100 mL) was added and the solid collected by filtration. After rinsing once in water the solid was suspended in water (500 mL) and adjusted to pH 5 with acetic acid. The solid was again filtered off, rinsed with water, then isopropanol, and dried in a vacuum oven to yield 0.51 g of product. Infrared spectroscopy indicated that significant amine had been formed.
2. Preparation of Poly(ethyleneimine)
[0046] Polyethyleneimine (120 g of a 50% aqueous solution; Scientific Polymer Products) was dissolved in water (250 mL). Epichlorohydrin (22.1 mL) was added dropwise. The solution was heated to 60° C. for 4 hours, after which it had gelled. The gel was removed, blended with water (1.5 L) and the solid was filtered off, rinsed three times with water (3 L) and twice with isopropanol (3 L), and the resulting gel was dried in a vacuum oven to yield 81.2 g of the title polymer.
3. Preparation of Poly(allylamine)hydrochloride
[0047] To a 2 liter, water-jacketed reaction kettle equipped with (1) a condenser topped with a nitrogen gas inlet, (2) a thermometer, and (3) a mechanical stirrer was added concentrated hydrochloric acid (360 mL). The acid was cooled to 5° C. using circulating water in the jacket of the reaction kettle (water temperature=0° C.). Allylamine (328.5 mL, 250 g) was added dropwise with stirring while maintaining the reaction temperature at 5-10° C. After addition was complete, the mixture was removed, placed in a 3 liter one-neck flask, and 206 g of liquid was removed by rotary vacuum evaporation at 60° C. Water (20 mL) was then added and the liquid was returned to the reaction kettle. Azobis(amidinopropane) dihydrochloride (0.5 g) suspended in 11 mL of water was then added. The resulting reaction mixture was heated to 50° C. under a nitrogen atmosphere with stirring for 24 hours. Additional azobis(amidinopropane) dihydrochloride (5 mL) suspended in 11 mL of water was then added, after which heating and stirring were continued for an additional 44 hours.
[0048] At the end of this period, distilled water (100 mL) was added to the reaction mixture and the liquid mixture allowed to cool with stirring. The mixture was then removed and placed in a 2 liter separatory funnel, after which it was added dropwise to a stirring solution of methanol (4 L), causing a solid to form. The solid was removed by filtration, re-suspended in methanol (4 L), stirred for 1 hour, and collected by filtration. The methanol rinse was then repeated one more time and the solid dried in a vacuum oven to afford 215.1 g of poly(allylamine) hydrochloride as a granular white solid.
[0000] 4. Preparation of Poly(allylamine)hydrochloride Crosslinked with Epichlorohydrin
[0049] To a 5 gallon vessel was added poly(allylamine) hydrochloride prepared as described in Example 3 (1 kg) and water (4 L). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted by adding solid NaOH (284 g). The resulting solution was cooled to room temperature, after which epichlorohydrin crosslinking agent (50 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 35 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and placed in portions in a blender with a total of 10 L of water. Each portion was blended gently for about 3 minutes to form coarse particles which were then stirred for 1 hour and collected by filtration. The solid was rinsed three times by suspending it in water (10 L, 15 L, 20 L), stirring each suspension for 1 hour, and collecting the solid each time by filtration. The resulting solid was then rinsed once by suspending it in isopropanol (17 L), stirring the mixture for 1 hour, and then collecting the solid by filtration, after which the solid was dried in a vacuum oven at 50° C. for 18 hours to yield about 677 g of the cross linked polymer as a granular, brittle, white solid.
[0000] 5. Preparation of Poly(allylamine)hydrochloride Crosslinked with Butanedioldiglycidyl Ether
[0050] To a 5 gallon plastic bucket was added poly(allylamine) hydrochloride prepared as described in Example 3 (500 g) and water (2 L). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted to 10 by adding solid NaOH (134.6 g). The resulting solution was cooled to room temperature in the bucket, after which 1,4-butanedioldiglycidyl ether crosslinking agent (65 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 6 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and dried in a vacuum oven at 75° C. for 24 hours. The dry solid was then ground and sieved to −30 mesh, after which it was suspended in 6 gallons of water and stirred for 1 hour. The solid was then filtered off and the rinse process repeated two more times. The resulting solid was then air dried for 48 hours, followed by drying in a vacuum oven at 50° C. for 24 hours to yield about 415 g of the crosslinked polymer as a white solid.
[0000] 6. Preparation of Poly(allylamine)hydrochloride Crosslinked with Ethanedioldiglycidyl Ether
[0051] To a 100 mL beaker was added poly(allylamine) hydrochloride prepared as described in Example 3 (10 g) and water (40 mL). The mixture was stirred to dissolve the hydrochloride and the pH was adjusted to 10 by adding solid NaOH. The resulting solution was cooled to room temperature in the beaker, after which 1,2-ethanedioldiglycidyl ether crosslinking agent (2.0 mL) was added all at once with stirring. The resulting mixture was stirred gently until it gelled (about 4 minutes). The crosslinking reaction was allowed to proceed for an additional 18 hours at room temperature, after which the polymer gel was removed and blended in 500 mL of methanol. The solid was then filtered off and suspended in water (500 mL). After stirring for 1 hour, the solid was filtered off and the rinse process repeated. The resulting solid was rinsed twice in isopropanol (400 mL) and then dried in a vacuum oven at 50° C. for 24 hours to yield 8.7 g of the crosslinked polymer as a white solid.
[0000] 7. Preparation of Poly(allylamine)hydrochloride Crosslinked with Dimethylsuccinate
[0052] To a 500 mL round bottom flask was added poly(allylamine) hydrochloride prepared as described in Example 3 (10 g), methanol (100 mL), and triethylamine (10 mL). The mixture was stirred and dimethylsuccinate crosslinking agent (1 mL) was added. The solution was heated to reflux and the stirring discontinued after 30 minutes. After 18 hours, the solution was cooled to room temperature, and the solid filtered off and blended in 400 mL of isopropanol. The solid was then filtered off and suspended in water (1 L). After stirring for 1 hour, the solid was filtered off and the rinse process repeated two more times. The solid was then rinsed once in isopropanol (800 mL) and dried in a vacuum oven at 50° C. for 24 hours to yield 5.9 g of the crosslinked polymer as a white solid.
[0000] 8. Preparation of Poly(ethyleneimine) Crosslinked with Acryloyl Chloride
[0053] Into a 5 L three neck flask equipped with a mechanical stirred, a thermometer, and an addition funnel was added poly(ethyleneimine) (510 g of a 50% aqueous solution, equivalent to 255 g of dry polymer) and isopropanol (2.5 L). Acryloyl chloride crosslinking agent (50 g) was added dropwise through the addition funnel over a 35 minute period while maintaining the temperature below 29° C. The solution was then heated to 60° C. with stirring for 18 hours, after which the solution was cooled and the solid immediately filtered off. The solid was then washed three times by suspending it in water (2 gallons), stirring for 1 hour, and filtering to recover the solid. Next, the solid was rinsed once by suspending it in methanol (2 gallons), stirring for 30 minutes, and filtering to recover the solid. Finally, the solid was rinsed in isopropanol as in Example 7 and dried in a vacuum oven at 50° C. for 18 hours to yield 206 g of the crosslinked polymer as a light orange granular solid.
[0000] 9. Alkylation of Poly(allylamine) Crosslinked with Butanedioldiglydicyl Ether with 1-iodooctane Alkylating Agent
[0054] Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was suspended in methanol (100 mL) and sodium hydroxide (0.2 g) was added. After stirring for 15 minutes, 1-iodooctane (1.92 mL) was added and the mixture stirred at 60° C. for 20 hours. The mixture was then cooled and the solid filtered off. Next, the solid was washed by suspending it in isopropanol (500 mL), after which it was stirred for 1 hour and then collected by filtration. The wash procedure was then repeated twice using aqueous sodium chloride (500 mL of a 1 M solution), twice with water (500 mL), and once with isopropanol (500 mL) before drying in a vacuum oven at 50° C. for 24 hours to yield 4.65 g of alkylated product.
[0055] The procedure was repeated using 2.88 mL of 1-iodooctane to yield 4.68 g of alkylated product.
[0000] 10. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodooctane Alkylating Agent
[0056] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 9 except that 3.84 mL of 1-iodooctane was used. The procedure yielded 5.94 g of alkylated product.
[0000] 11. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodooctadecane Alkylating Agent
[0057] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (100 mL) and sodium hydroxide (0.2 g) was added. After stirring for 15 minutes, 1-iodooctadecane (8.1 g) was added and the mixture stirred at 60° C. for 20 hours. The mixture was then cooled and the solid filtered off. Next, the solid was washed by suspending it in isopropanol (500 mL), after which it was stirred for 1 hour and then collected by filtration. The wash procedure was then repeated twice using aqueous sodium chloride (500 mL of a 1 M solution), twice with water (500 mL), and once with isopropanol (500 mL) before drying in a vacuum oven at 50° C. for 24 hours to yield 9.6 g of alkylated product.
[0000] 12. Alkylation of Poly(allylamine) Crosslinked with Butanedioldiglycidyl Ether with 1-iodododecane Alkylating Agent
[0058] Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was alkylated according to the procedure described in Example 11 except that 2.47 mL of 1-iodododecane was used. The procedure yielded 4.7 g of alkylated product.
[0000] 13. Alkylation of Poly(allylamine) Crosslinked with Butanedioldiglycidyl Ether with Benzyl Bromide Alkylating Agent
[0059] Poly(allylamine) crosslinked with butanedioldiglycidyl ether prepared as described in Example 5 (5 g) was alkylated according to the procedure described in Example 11 except that 2.42 mL of benzyl bromide was used. The procedure yielded 6.4 g of alkylated product.
[0000] 14. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with Benzyl Bromide Alkylating Agent
[0060] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 11 except that 1.21 mL of benzyl bromide was used. The procedure yielded 6.6 g of alkylated product.
[0000] 15. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iododecane Alkylating Agent
[0061] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 7.15 g of 1-iododecane and 2.1 g of NaOH were used. The procedure yielded 20.67 g of alkylated product.
[0000] 16. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodobutane Alkylating Agent
[0062] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 22.03 g of 1-iodobutane and 8.0 g of NaOH were used. The procedure yielded 24.0 g of alkylated product.
[0063] The procedure was also followed using 29.44 g and 14.72 g of 1-iodobutane to yield 17.0 g and 21.0 g, respectively, of alkylated product.
[0000] 17. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodotetradecane Alkylating Agent
[0064] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was alkylated according to the procedure described in Example 11 except that 2.1 mL of 1-iodotetradecane was used. The procedure yielded 5.2 g of alkylated product.
[0065] The procedure was also followed using 6.4 mL of 1-iodotetradecane to yield 7.15 g of alkylated product.
[0000] 18. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodooctane Alkylating Agent
[0066] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 8 (5 g) was alkylated according to the procedure described in Example 11 except that 1.92 mL of 1-iodooctane was used. The procedure yielded 5.0 g of alkylated product.
[0000] 19. Alkylation of a Copolymer of Diethylene Triamine and Epichlorohydrin with 1-iodooctane Alkylating Agent
[0067] A copolymer of diethylene triamine and epichlorohydrin (10 g) was alkylated according to the procedure described in Example 11 except that 1.92 mL of 1-iodooctane was used. The procedure yielded 5.3 g of alkylated product.
[0000] 20. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 1-iodododecane and Glycidyl-Propyltrimethylammonium Chloride Alkylating Agents
[0068] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (20 g) was alkylated according to the procedure described in Example 11 except that 23.66 g of 1-iodododecane, 6.4 g of sodium hydroxide, and 500 mL of methanol were used. 24 grams of the alkylated product was then reacted with 50 g of 90% glycidylpropyltrimethylammonium chloride in methanol (1 L). The mixture was stirred at reflux for 24 hours, after which it was cooled to room temperature and washed successively with water (three times using 2.5 L each time). Vacuum drying afforded 22.4 g of dialkylated product.
[0069] Dialkylated products were prepared in an analogous manner by replacing 1-iodododecane with 1-iododecane and 1-iodooctadecane, respectively, followed by alkylation with glycidylpropyltrimethylammonium chloride.
[0000] 21. Alkylation of Poly(Allylamine) Crosslinked with Epichlorohydrin with Glycidylpropyltrimethylammonium Chloride Alkylating Agent
[0070] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5 g) was reacted with 11.63 g of 90% glycidylpropyltrimethylammonium chloride (1 mole equiv.) in methanol (100 mL). The mixture was stirred at 60° C. for 20 hours, after which it was cooled to room temperature and washed successively with water (three times using 400 mL each time) and isopropanol (one time using 400 mL). Vacuum drying afforded 6.93 g of alkylated product.
[0071] Alkylated products were prepared in an analogous manner using 50%, 200%, and 300% mole equiv of 90% glycidylpropyltrimethylammonium chloride.
[0000] 22. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with (10-bromodecyl)trimethylammonium Bromide Alkylating Agent
[0072] The first step is the preparation of (10-bromodecyl) trimethylammonium bromide as follows.
[0073] 1,10-dibromodecane (200 g) was dissolved in methanol (3 L) in a 5 liter three neck round bottom flask fitted with a cold condenser (−5° C.). To this mixture was added aqueous trimethylamine (176 mL of a 24% aqueous solution, w/w). The mixture was stirred at room temperature for 4 hours, after which is was heated to reflux for an additional 18 hours. At the conclusion of the heating period, the flask was cooled to 50° C. and the solvent removed under vacuum to leave a solid mass. Acetone (300 mL) was added and the mixture stirred at 40° C. for 1 hour. The solid was filtered off, resuspended in an additional portion of acetone (1 L), and stirred for 90 minutes.
[0074] At the conclusion of the stirring period, the solid was filtered and discarded, and the acetone fractions were combined and evaporated to dryness under vacuum. Hexanes (about 1.5 L) were added and the mixture then stirred for 1 hour, after which the solid was filtered off and then rinsed on the filtration funnel with fresh hexanes. The resulting solid was then dissolved in isopropanol (75 mL) at 40° C. Ethyl acetate (1500 mL) was added and the temperature raised to about 50° C. to fully dissolve all solid material. The flask was then wrapped in towels and placed in a freezer for 24 hours, resulting in the formation of solid crystals. The crystals were filtered off, rinsed in cold ethyl acetate, and dried in a vacuum oven at 75° C. to yield 100.9 g of (10-bromodecyl) trimethyl-ammonium bromide as white crystals.
[0075] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (300 mL). Sodium hydroxide (3.3 g) was added and the mixture stirred until it dissolved. (10-bromodecyl) trimethylammonium bromide (20.7 g) was added and the mixture was refluxed with stirring for 20 hours. The mixture was then cooled to room temperature and washed successively with methanol (two times using 1 L each time), sodium chloride) two times using 1 L of 1 M solution each time), water (three times using 1 L each time), and isopropanol (one time using 1 L). Vacuum drying yielded 14.3 g of alkylated product.
[0000] 23. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with (10-bromodecyl)trimethylammonium Bromide and 1,10-dibromodecane Alkylating Agents
[0076] 1,10-dibromodecane (200 g) was dissolved in methanol (3 L) in a 5 liter round bottom flask fitted with a cold condenser (−5° C.). To this mixture was added aqueous trimethylamine (220 mL of a 24% aqueous solution, w/w). The mixture was stirred at room temperature for 4 hours, after which it was heated to reflux for an additional 24 hours. The flask was then cooled to room temperature and found to contain 3350 mL of clear liquid.
[0077] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (30 g) was suspended in the clear liquid (2 L) and stirred for 10 minutes. Sodium hydroxide (20 g) was then added and the mixture stirred until it had dissolved. Next, the mixture was refluxed with stirring for 24 hours, cooled to room temperature, and the solid filtered off. The solid was then washed successively with methanol (one time using 10 L), sodium chloride (two times using 10 L of a 1 M solution each time), water (three times using 10 L each time), and isopropanol (one time using 5 L). Vacuum drying afforded 35.3 g of dialkylated product.
[0000] 24. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with (10-bromodecyl)trimethylammonium Bromide and 1-bromodecane Alkylating Agents
[0078] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g) was suspended in methanol (300 mL). Sodium hydroxide (4.99 g) was added and the mixture stirred until it dissolved. (10-bromodecyl) trimethylammonium bromide prepared as described in Example 22 (20.7 g) and 1-bromodecane were added and the mixture was refluxed with stirring for 20 hours. The mixture was then cooled to room temperature and washed successively with methanol (two times using 1 L each time), sodium chloride (two times using 1 L of a 1 M solution each time), water (three times using 1 L each time), and isopropanol (one time using 1 L). Vacuum drying yielded 10.8 g of dialkylated product.
[0079] Dialkylated products were also prepared in analogous fashion using different amounts of 1-bromodecane as follows: (a) 3.19 g 1-bromodecane and 4.14 g sodium hydroxide to yield 1.1.8 g of dialkylated product; (b) 38.4 g 1-bromodecane and 6.96 g sodium hydroxide to yield 19.1 g of dialkylated product.
[0080] Dialkylated products were also prepared in analogous fashion using the following combinations of alkylating agents: 1-bromodecane and (4-bromobutyl)trimethylammonium bromide; 1-bromodecane and (6-bromohexyl)trimethylammonium bromide; 1-bromodecane and (8-bromooctyl)trimethylammonium bromide; 1-bromodecane and (2-bromoethyl)trimethylammonium bromide; 1-bromodecane and (3-bromopropyl)trimethylammonium bromide; 1-bromohexane and (6-bromohexyl)trimethylammonium bromide; 1-bromododecane and (12-bromododecyl)trimethyl-ammonium bromide; and 1-bromooctane and (6-bromohexyl)trimethylammonium bromide.
[0000] 25. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with 11-bromo-1-undecanol Alkylating Agent
[0081] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (5.35 g) was suspended in methanol (100 mL). Sodium hydroxide (1.10 g) was added and the mixture stirred until it dissolved. 11-bromo-1-undecanol (5.0 g) was added and the mixture was refluxed with stirring for 20 hours, after which it was cooled to room temperature and washed successively with methanol (one time using 3 L), sodium chloride (two times using
[0000] 500 mL of a 1 M solution each time), and water (three times using 1 L each time). Vacuum drying yielded 6.47 g of alkylated product.
[0082] The reaction was also performed using 1.05 g sodium hydroxide and 10 g 11-bromo-1-undecanol to yield 8.86 g of alkylated product.
[0000] 26. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with N-(2,3-epoxypropane)butyramide Alkylating Agent
[0083] The first step is the preparation of N-allyl butyramide as follows.
[0084] Butyroyl chloride (194.7 g, 1.83 mol) in 1 L of tetrahydrofuran was added to a three neck round bottom flask equipped with a thermometer, stir bar, and dropping funnel. The contents of the flask were then cooled to 15° C. in an ice bath while stirring. Allylamine (208.7 g, 3.65 mol) in 50 mL of tetrahydrofuran was then added slowly through the dropping funnel while maintaining stirring. Throughout the addition, the temperature was maintained at 15° C. After addition was complete, stirring continued for an additional 15 minutes, after which the solid allylamine chloride precipitate was filtered off. The filtrate was concentrated under vacuum to yield 236.4 g of N-allyl butyramide as a colorless viscous liquid.
[0085] N-allyl butyramide (12.7 g, 0.1 mol) was taken into a 1 L round bottom flask equipped with a stir bar and air condenser. Methylene chloride (200 mL) was added to the flask, followed by 3-chloroperoxybenzoic acid (50-60% strength, 200 g) in five portions over the course of 30 minutes and the reaction allowed to proceed. After 16 hours, TLC analysis (using 5% methanol in dichloromethane) showed complete formation of product. The reaction mixture was then cooled and filtered to remove solid benzoic acid precipitate. The filtrate was washed with saturated sodium sulfite solution (two times using 100 mL each time) and then with saturated dosium bicarbonate solution (two times using 100 mL each time). The dichloromethane layer was then dried with anhydrous sodium sulfate and concentrated under vacuum to yield 10.0 g of N-(2,3-epoxypropane) butyramide as a light yellow viscous liquid.
[0086] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g, −80 sieved) and methanol (250 mL) were added to a 1 L round bottom flask, followed by N-(2,3-epoxypropane) butyramide (0.97 g, 0.0067 mol, 5 mol %) and then sodium hydroxide pellets (0.55 g, 0.01375 mol). The mixture was stirred overnight at room temperature. After 16 hours, the reaction mixture was filtered and the solid washed successively with methanol (three times using 300 mL each time), water (two times using 300 mL each time), and isopropanol (three times using 300 mL each time. Vacuum drying at 54° C. overnight yielded 9.0 g of the alkylated product as a light yellow powder.
[0087] Alkylated products based upon 10 mol %, 20 mol %, and 30 mol % N-(2,3-epoxypropane) butyramide were prepared in analogous fashion except that (a) in the mol % case, 1.93 g (0.013 mol) N-(2,3-epoxypropane) butyramide and 1.1 g (0.0275 mol) sodium hydroxide pellets were used to yield 8.3 g of alkylated product, (b) in the 20 mol % case, 3.86 g (0.026 mol) N-(2,3-epoxypropane) butyramide and 2.1 g (0.053 mol) sodium hydroxide pellets were used to yield 8.2 g of alkylated product, and (c) in the 30 mol % case, 5.72 g (0.04 mol) N-(2,3-epoxypropane) butyramide and 2.1 g (0.053 mol) sodium hydroxide pellets were used to yield 8.32 g of alkylated product.
[0000] 27. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with N-(2,3-epoxypropane)hexanamide Alkylating Agent
[0088] The first step is the preparation of N-allyl hexanamide as follows.
[0089] Hexanoyl chloride (33 g, 0.25 mol) in 250 mL of tetrahydrofuran was added to a three neck round bottom flask equipped with a thermometer, stir bar, and dropping funnel. The contents of the flask were then cooled to 15° C. in an ice bath while stirring. Allylamine (28.6 g, 0.5 mol) in 200 mL of tetrahydrofuran was then added slowly through the dropping funnel while maintaining stirring. Throughout the addition, the temperature was maintained at 15° C. After addition was complete, stirring continued for an additional 15 minutes, after which the solid allylamine chloride precipitate was filtered off. The filtration was concentrated under vacuum to yield 37 g of N-allyl hexanamide as a colorless viscous liquid.
[0090] N-allyl hexanamide (16 g, 0.1 mol) was taken into a 1 L round bottom flask equipped with a stir bar and air condenser. Methylene chloride (200 mL) was added to the flask, followed by 3-chloroperoxybenzoic acid (50-60% strength, 200 g) in five portions over the course of 30 minutes and the reaction allowed to proceed. After 16 hours, TLC analysis (using 5% methanol in dichloromethane) showed complete formation of product. The reaction mixture was then cooled and filtered to remove solid enzoic acid precipitate. The filtrate was washed with saturated sodium sulfite solution (two times using 100 mL each time) and then with saturated sodium bicarbonate solution (two times using 100 mL each time). The dichloromethane layer was then dried with anhydrous sodium sulfate and concentrated under vacuum to yield 14.2 g of N-(2,3-epoxypropane) hexanamide as a light yellow viscous liquid.
[0091] Poly(allylamine) crosslinked with epichlorohydrin prepared as described in Example 4 (10 g, −80 sieved) and methanol (250 mL) were added to a 1 L round bottom flask, followed by N-(2,3-epoxypropane) hexanamide (4.46 g, 0.026 mol, 20 mol %) and then sodium hydroxide pellets (2.1 g, 0.053 mol). The mixture was stirred overnight at room temperature. After 16 hours, the reaction mixture was filtered and the solid washed successively with methanol (three times using 300 mL each time), water (two times using 300 mL each time), and isopropanol (three times using 300 mL each time. Vacuum drying at 54° C. overnight yielded 9.59 g of the alkylated product as a light yellow powder.
[0092] An alkylated product based upon 30 mol % N-(2,3-epoxypropane) hexanamide was prepared in analogous fashion except that 6.84 g (0.04 mol) N-(2,3-epoxypropane) hexanamide was used to yield 9.83 g of alkylated product.
[0000] 28. Alkylation of Poly(allylamine) Crosslinked with Epichlorohydrin with (6-Bromohexyl)trimethylammonium Bromide and 1-bromodecane Alkylating Agent
[0093] To a 12-1 round bottom flask equipped with a mechanical stirrer, a thermometer, and a condenser is added methanol (5 L) and sodium hydroxide (133.7 g). The mixture is stirred until the solid has dissolved and crosslinked poly(allylamine) (297 g; ground to −80 mesh size) is added along with additional methanol (3 L). (6-Bromohexyl) trimethylammonium bromide (522.1 g) and 1-bromodecane (311.7 g) are added and the mixture heated to 65° C. with stirring. After 18 hours at 65° C. the mixture is allowed to cool to room temperature. The solid is filtered off and rinsed by suspending, stirring for 30 minutes, and filtering off the solid from: methanol, 12 L; methanol, 12 L; 2 M aqueous NaCl, 22 L; 2 M aqueous NaCl, 22 L; deionized water, 22 L; deionized water, 22 L; deionized water, 22 L and isopropanol, 22 L. The solid is dried in a vacuum oven at 50° C. to yield 505.1 g of off-white solid. the solid is then ground to pass through an 80 mesh sieve.
Testing of Polymers
Preparation of Artificial Intestinal Fluid
[0094] Sodium carbonate (1.27 g) and sodium chloride (1.87 g) were dissolved in 400 mL of distilled water. To this solution was added either glycocholic acid (1.95 g, 4.0 mmol) or glycochenodeoxycholic acid (1.89 g, 4.0 mmol) to make a 10 mM solution. The pH of the solution was adjusted to 6.8 with acetic acid. These solutions were used for the testing of the various polymers.
[0095] Polymers were tested as follows.
[0096] To a 14 mL centrifuge tube was added 10 mg of polymer and 10 mL of a bile salt solution in concentrations ranging from 0.1-10 mM prepared from 10 mM stock solution (prepared as previously described) and buffer without bile salt, in the appropriate amount. The mixture was stirred in a water bath maintained at 37° C. for three hours. The mixture was then filtered. The filtrate was analyzed for total 3-hydroxy steroid content by an enzymatic assay using 3a-hydroxy steroid dehydrogenase, as described below.
Enzymatic Assay for Total Bile Salt Content
[0000]
Four stock solutions were prepared.
Solution 1—Tris-HCl buffer, containing 0.133 M Tris, 0.666 mM EDTA at pH 9.5.
Solution 2—Hydrazine hydrate solution, containing 1 M hydrazine hydrate at pH 9.5.
Solution 3—NAD solution, containing 7 mM NAD+at pH 7.0.
Solution 4—HSD solution, containing 2 units/mL in Tris-HCl buffer (0.03 M Tris, 1 mM EDTA) at pH 7.2.
[0102] To a 3 mL cuvette was added 1.5 mL of Solution 1, 1.0 mL of Solution 2, 0.3 mL of solution 3, 0.1 mL of Solution 4 and 0.1 mL of supernatant/filtrate from a polymer test as described above. The solution was placed in a UV-VIS spectrophotometer and the absorbance (O.D.) of NADH at 350 nm was measured. The bile salt concentration was determined from a calibration curve prepared from dilutions of the artificial intestinal fluid prepared as described above.
[0103] All of the polymers previously described were tested in the above manner and all were efficacious in removing bile salts from the artificial intestinal fluid.
Use
[0104] The polymers according to the invention may be administered orally to a patient in a dosage of about 1 mg/kg/day to about 10 g/kg/day; the particular dosage will depend on the individual patient (e.g., the patient's weight and the extent of bile salt removal required). The polymer may be administrated either in hydrated or dehydrated form, and may be flavored or added to a food or drink, if desired to enhance patient acceptability. Additional ingredients such as other bile acid sequestrants, drugs for treating hypercholesterolemia, atherosclerosis or other related indications, or inert ingredients, such as artificial coloring agents may be added as well.
[0105] Examples of suitable forms for administration include pills, tablets, capsules, and powders (e.g., for sprinkling on food). The pill, tablet, capsule, or powder can be coated with a substance capable of protecting the composition from the gastric acid in the patient's stomach for a period of time sufficient to allow the composition to pass undisintegrated into the patient's small intestine. The polymer may be administered alone or in combination with a pharmaceutically acceptable carrier substance, e.g., magnesium carbonate, lactose, or a phospholipid with which the polymer can form a micelle.
[0106] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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The invention relates to a method for removing bile salts from a patient in need thereof and compositions useful in the method. The method comprises administering to the patient a therapeutically effective amount of a salt of an alkylated and crosslinked polymer. The alkylated and crosslinked polymer salt comprises the reaction product of crosslinked polymers, or salts and copolymers thereof having amine containing repeat units, with at least one aliphatic alkylating agent.
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This application is related to co-pending application Ser. No. 07/921,826 filed Jul. 29, 1992.
BACKGROUND OF THE INVENTION
In the information age, one of the most significant challenges facing business is the management of ever increasing amounts of information across increasingly complex and varied environments. As the competitive environment in which the business operates expands across the globe, the speed and ease of access to this information becomes critical. From a storage and processing standpoint, significant advances in computing hardware, including computer memory and computer processors, have kept pace with the increasing amounts of information required in day-to-day business operations. However, these advances in computing hardware are in part responsible for the increasingly complex and varied environments in which the information is found.
One reason that a variety of platforms are used to store and process data is that as business expands and competition increases, control is decentralized so that decisions can be made quickly by each business entity using local information. As a result of the decentralization of the business decision making process, the mainframe processors, previously the only platform on which to handle high volume information processing, are downsized to or integrated with local minicomputers and workstations. Along with the local minicomputers and workstations come a variety of software tools specific to that platform to assist in the processing of information.
Localized processing capability generally means even more information is generated but, the additional information and local changes to existing information may not be available throughout other areas of the business system.
One solution is to simply duplicate all information across all platforms. This solution, however means wasted resources in that if all of the duplicated information is not needed, the space could have been used to store other information. Also, duplication of information across multiple platforms also means that the information must be updated on each platform. Another solution is to provide access, i.e., though a network, to every other platform. The problem with this solution, however, is that each platform must then know how to operate under the systems of every other platform in order to take advantage of the availability of that platform's information. One platform, for example, may be a minicomputer using an Oracle database and another platform may be a mainframe using IBM's Database 2 (DB2).
What is needed is a method and system for managing access to a plurality of data objects located across a variety of platforms which provides quick, easy access to the information contained therein.
SUMMARY OF THE INVENTION
One embodiment of the system of the present invention includes an information access encyclopedia, or information repository, for selecting, updating, creating and deleting information describing and information included in a plurality of data objects across a variety of platforms which insulates users from the technical complexity of the platform on which the data resides. This embodiment of the information access encyclopedia of the present invention comprises first means for storing the information describing the plurality of data objects; second means for iteratively accepting and processing user queries based on previous queries of the information describing the plurality of data objects stored in the first means generating first results data; and third means responsive to the second means for generating second results data using the first results data. The second results data includes the information contained in the plurality of data objects.
One embodiment of the method of the present invention includes the steps of providing data which describes the plurality of data objects, attributes of the plurality of data objects, and relationships therebetween; providing at least one procedure operable to generate a query specific to at least one of the plurality of data object; iteratively accepting user queries based on the results of previous queries on the data; updating a first results file in response to the user queries; generating the query specific to at least one of the plurality of data objects with at least one procedure in response to the first results file; executing the query specific to at least one of the plurality of data objects; and generating a second results files in response to the executing step which includes information contained within at least one of the plurality of data objects.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference may be made to the accompanying drawings, in which:
FIG. 1 is a block diagram of one embodiment of the system of the present invention;
FIG. 2 shows an entity relationship diagram illustrating how data stored in one embodiment of the system and method of the present invention is modeled;
FIG. 3 is an entity relationship diagram illustrating how data in an exemplary system is modeled so that it can be stored in one embodiment of the system and method of the present invention;
FIG. 4 illustrates a data object table which includes information describing objects accessible through one embodiment of the system and method of the present invention;
FIG. 5 illustrates an attribute object table which includes information describing attributes of the objects included in the data object table of one embodiment of the system and method of the present invention;
FIG. 6 illustrates a relationship object table which includes information describing relationships between objects, attributes and relationships in one embodiment of the system and method of the present invention; and
FIG. 7 illustrates the fields included in each of four implemented relationship tables (one for one-to-one relationships, one for one-to-many relationships, one for many-to-one relationships and one for many-to-many relationships) which include data describing implemented relationships in one embodiment of the system and method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The system and method of the present invention provides an information access encyclopedia (IAE), or information repository, for managing access to a plurality of data objects located across a variety of platforms while insulating users from the technical complexities of the platforms on which the data objects reside, i.e., providing a seamless interface. The system and method of the present invention is implemented, for example, using an object oriented database management system (OODBMS) or a relational database management system (RDBMS) on a general purpose digital computer which is connected, for example, through a network to the various platforms on which the data resides and at which access to that data is needed. In particular, the system and method of the present invention implemented using an OODBMS takes advantage of inheritance, multiple inheritance, relationship definition (complex objects) and object identifier (OID) generation features provided by the OODBMS. Each of these features can also be implemented using the RDBMS approach but, with an increase in system size and complexity.
One embodiment of the present invention is illustrated generally in FIG. 1 . FIG. 1 shows an IAE 10 which includes an application programming interface (API) 15 , an IAE database 20 and a data object interface 80 . IAE 10 provides access to the data stored in exemplary data objects 150 , 160 and 170 . Exemplary data objects 150 , 160 and 170 can represent program files, text files, databases, etc. or any combination of program files, text files, databases, etc., depending upon the particular application.
Not only do exemplary data objects 150 , 160 and 170 represent different forms of data, but they also represent different forms of data on different platforms. For example, exemplary data object 150 can represent a database implemented using IBM's DB 2 on a mainframe while exemplary data object 160 represents a file directory structure on a microcomputer and exemplary data object 160 is an accounting system on a minicomputer.
Under the system and method of the present invention, components of each of the exemplary data objects are described in IAE database 20 . This descriptive information is browsed or navigated using API 15 . API 15 provides easy access to the data through a series of generalized query commands which are independent of the type of data and of the platform on which the data is stored. In processing these query commands, API 15 uses of its knowledge of the structure of IAE database 20 and of how data in IAE database 20 is modeled to browse or navigate IAE database 20 . Results of the browsing or navigating are then used by APIClass 85 to provide access to the data stored in or represented by exemplary data objects 150 , 160 and 170 by building queries specific to exemplary data objects 150 , 160 and 170 . APIClass 85 also generates specialized execution requests specific to the platform on which exemplary data objects 150 , 160 and 170 reside to process those specific queries. The access methods used by APIClass 85 are transparent to the user. The routines needed to perform both the specialized query generation and the specific platform execution command generation functions are provided by the user responsible for setting up IAE 10 whenever a data object is added to IAE 10 . Thus, to access the data in any of the exemplary data objects 150 , 160 and 170 , the user need only execute the generalized query commands provided by API 15 .
Through API 15 , applications using the IAE 10 can accomplish two tasks. First, the generic nature of API 15 and of the IAE database 20 allows immediate visibility of changes to exemplary data objects 150 , 160 and 170 and of additions of other data objects to those applications using IAE 10 . Furthermore, the generic query and update provided by API 15 and processed by APIClass 85 eliminate the need for duplicating methods for accessing each exemplary data object 150 , 160 and 170 for each application interfacing with exemplary data objects 150 , 160 and 170 . Without API 15 and APIClass 85 , these methods are provided by each of the applications requesting access to the information included in exemplary data objects 150 , 160 and 170 .
In order to include an exemplary data object 150 , 160 or 170 in the IAE 10 of the present invention, data representing and/or describing exemplary data object 150 , 160 or 170 must be entered in IAE database 20 . Data entered in IAE database 20 is modeled as shown in the entity relationship diagram (ERD) at 200 in FIG. 2 . The ERD 200 includes three object types: data object type 205 , relationship object type 210 and attribute object type 220 . Each of these object types are implemented as tables in one embodiment of the system of the present invention as shown in FIG. 1 .
Data object type 205 is implemented as data object table 22 shown in FIG. 1 . The data object table 22 includes the fields, shown in FIG. 4, Name 412 and OID 413 . Name 412 is a character field which identifies the object described in IAE 10 . OID 413 is a numerical field which identifies each instance of data object table 22 .
Attribute object type 220 is implemented as the attribute object table 24 in FIG. 1 . Attribute object table 24 includes the fields, as shown in FIG. 5, name 540 , OID 542 and sort sequence 544 . Each record in attribute object table 24 describes an attribute of an object described in data object table 22 .
Relationship object type 210 is implemented as the relationship object table 26 shown in FIG. 1 . Relationship object table 26 includes the fields, as shown in FIG. 6, relationship path name 630 , source OID 632 , destination OID 634 , OID 636 , primary OID 638 , secondary OID 640 , source cardinality 642 , destination cardinality 644 , source optionality 646 , destination optionality 648 , source implemented table 650 and destination implemented table 652 . Records in relationship object table 26 describe logical connections between the object records stored in data object table 22 , the attribute records stored in attribute object table 24 and the relationship records stored in relationship object table 26 . The logical connections are shown in FIG. 2 at 232 , 234 , 236 , 238 , 240 , 242 and 244 .
Each logical connection is represented by two records or instances in relationship object table 26 so that a connection may be traversed in either direction by API 15 . Each record or instance is referred to as a relationship path and represents one logical relationship between the two object types it connects. Each relationship path is referred to by its relationship path name 630 and connects the object represented by the field source OID 632 to the object represented by the field destination OID 634 in the relationship object table 26 . One of the relationship paths is designated as primary and the other relationship path is designated as secondary. If a record in relationship object table 26 represents a primary relationship path, then the field secondary OID 640 specifies which record in relationship object table 26 represents the corresponding secondary relationship path. If the relationship in relationship object table represents a secondary relationship path, then the field primary OID 638 specifies which record in relationship object table 26 represents the corresponding primary relationship path.
The ERD 200 further models the cardinality and the optionality of the relationships between data object type 205 , relationship object type 210 and attribute object type 220 .
The cardinality of a relationship between objects, relationships and attributes provides an indication of how many of each are members in the relationship. The cardinality of a relationship is either one-to-one (1-1), one-to-many (1-M), many-to-one (M-1) or many-to-many (M-M). Depending upon the application, data for any of the one-to-one, one-to-many, many-to-one or many-to-many relationships may be included in an external data source or in the corresponding IAE 10 implemented relationship table 28 a , 28 b , 28 c or 28 d . The field source implemented table 648 in FIG. 6 specifies where the source object data for the particular relationship is located. The field destination implemented table 650 specifies where the destination object data for the particular relationship is located.
If the actual data is stored in the IAE 10 , then, depending upon the cardinality of the relationship, the relationship data is stored in one version of the implemented relationship tables 28 a , 28 b , 28 c or 28 d . One-to-one relationship data is implemented in the 1-1 implemented relationship table 28 a shown in FIG. 1, one-to-many relationship data is implemented in the 1-M implemented relationship table 28 b shown in FIG. 1, many-to-one relationship data is implemented in the M-1 implemented relationship table 28 c shown in FIG. 1 and many-to-many relationship data is implemented in the M-M implemented relationship table 28 d.
The cardinality of a relationship is illustrated, for example, at 232 a and at 232 b in FIG. 2 . The single bar at 232 a indicates that one data object type 205 is related to many, as shown by the three bars at 232 c , relationship object types 210 . Thus, the relationship illustrated at 232 between data object type 205 and relationship object type 210 is a one-to-many (1-M) relationship. Relationships in an ERD, however, may be traversed in either direction. In other words, the relationship illustrated at 232 from data object type 205 to relationship object type 210 is distinct from the relationship illustrated at 232 from relationship object type 210 to data object type 205 . The second relationship, from relationship object type 210 to data object type 205 , has its own cardinality. The relationship illustrated at 232 between relationship object type 210 and data object type 205 is a many-to-one (M-1) relationship.
The optionality of a relationship between object types, relationship types and attribute types specifies whether or not that particular relationship must be defined at creation of the object. If a relationship is optional for an object then no data describing that relationship need be entered in IAE database 20 when an object instance is created. If a relationship is mandatory, then that relationship must be instantiated when the object is instantiated. As with cardinality, optionality of a relationship is directional. For example the relationship at 232 from data object type 205 to relationship object type 210 is mandatory. Therefore, each relationship instance must specify a source object type 205 and a destination object type 205 . However, the relationship at 232 from relationship object type 210 to data object type 205 is optional, as shown the circle at 232 b.
As an example, FIG. 3 illustrates, at 300 , an exemplary order entry database system which is modeled for access through the system and method of the present invention. The exemplary order entry database system 300 in FIG. 3 includes the data objects sales contact 301 , product 303 , order 305 and order line 307 . Sales Contact 301 is a table which includes information describing the customer base of an entity which uses exemplary order entry database system 300 . Sales Contact 301 includes the fields Sales_Contact_Name and Sales_Contact_ID. Product 303 is a table which includes information describing products available for ordering through exemplary order entry database system 300 . Product 303 includes the fields Product_Name and Product_Type. Order 305 is a table which includes information describing orders that have been made through the exemplary order entry database system 300 . Order 305 includes the field Order_ID. Order Line 307 is a table which includes information describing each entry line of an order described in Order 305 . Order Line 307 includes the fields Order_ID, Product_Name and Product —Type.
In order to provide access to the exemplary order entry database system 300 through the IAE 10 , the user initializes the system by first entering a record in object table 22 for each of the tables (sales contact 301 , product 303 , order 305 and order line 307 ) of the exemplary order entry database system 300 as shown at lines 408 through 411 in FIG. 4 . Next, each attribute or fields of each of the tables in exemplary order entry database system 300 is described in a record in attribute table 24 as shown at lines 523 through 531 in FIG. 5 .
FIG. 3 also illustrates the logical connections which relate the objects or tables which make up exemplary order entry database system 300 . Each connection is implemented as two relationship paths each represented by a relationship path name. As shown in FIG. 3, sales contact 301 is related to product 303 by the many-to-many relationship path shown at 310 with relationship path name “sells.” The relationship path at 310 also shows that product 303 is related to sales contact 301 by a many-to-many optional relationship with relationship name “sold by.” These relationship paths between data objects are descriptive of the functional connection between objects. As the relationship at 301 in FIG. 3 illustrates, a contact in sales contact 301 sells products in product 303 and the products in product 303 are sold by the contacts in sales contact 301 .
Thus, the next step in providing access to exemplary order entry database system 300 through IAE 10 is to describe each of the relationship paths between the objects which comprise exemplary order entry database system 300 as a record in the relationship object table 26 . The records describing the relationships shown in FIG. 3 are illustrated in FIG. 6 at lines 615 through 624 . The relationships shown in FIG. 3 could also be implemented outside the IAE 10 in an intersection table Sales Contact/Product, not shown, which includes the fields Sales_Contact_Name, Sales_Contact_ID, Product_Name and Product_Type. Thus, the user could navigate between the objects Sales_Contact 301 and Product 303 by looking up either the Sales_Contact_ID or the Product_Name in the intersection table.
Another method of describing relationships between objects is illustrated in FIG. 3 at 318 in the one-to-many relationship from order 305 to order line 307 and at 316 in the one-to-many relationship from product 303 to order line 307 . Since the relationships shown at 316 and at 318 are one-to-many relationships, the fields Order_ID and Product_Name can be included in each instance of order line 307 instead of in one of the implemented relationship table 28 a , 28 b , 28 c or 28 d and instead of in an intersection table.
Finally, data implementing the relationships described in relationship object table 26 is entered into IAE 10 . The data source is designated by the field source implemented table 650 and the destination data source is designated by the field destination implemented table 652 . If the implemented relationship data is stored externally, then implementing field names and field types are also required. If the implemented relationship data is stored internally in IAE 10 , then the data is entered either in the one-to-one implemented relationships table 28 a , the one-to-many implemented relationships table 28 b , the many-to-one implemented relationships table 28 c or the many-to-many implemented relationships table 28 d , based upon the cardinality of the relationship. Whether the implemented relationship data is stored external or internal and what that implemented relationship data is depends upon the application.
In one embodiment of the system and method of the present invention, meta data (data other than raw data, i.e., data describing the IAE 10 itself) is also stored in IAE 10 . API 15 uses this meta data to navigate IAE database 20 while processing the generalized queries from the user. A first results file, including data from IAE database 20 , is generated and is then used to build specialized query statements accessing the data stored in exemplary data objects 150 , 160 and 170 . The meta data stored in and describing IAE 10 includes instances of data object table 22 which describe data objects of IAE 10 (i.e., lines 401 through 407 in FIG. 4 ), instances of attribute object table 24 which further describe instances of data object table 22 (i.e., lines 501 through 522 in FIG. 5) and instances of relationship object table 26 which describe the logical connections or relationships which associate instances of data object table 22 , instances of attribute object table 24 and instances of relationship object table 26 (i.e., lines 601 through 614 in FIG. 6 ). This recursive nature of the IAE 10 further supports navigation by API 15 through other data objects stored in the IAE 10 .
While the relationships are classified as either optional or mandatory, to fully implement the IAE 10 as a self-describing database each relationship must be known to the IAE 10 schema access software. Furthermore, because these relationships define the structure of IAE 10 meta data, they should not be exposed to an application by any IAE 10 discovery or navigation function. Also, this embodiment of the system and method of the present invention relies on these relationships being implemented as named.
The embodiment of the system of the present invention, illustrated in FIG. 1, includes the IAE 10 meta-data stored in IAE Database 20 . IAE Database 20 includes object data table 22 , attribute data table 24 , relationship data table 26 , 1-1 implemented relationships data table 28 a , 1-M implemented relationships data table 28 b , M-1 implemented relationships data table 28 c and M-M implemented relationships data table 28 d.
For each implementation of the relationships described in relationship data table 26 , one record is included in either the 1-1 implemented relationships data table 28 a , the 1-M implemented relationships data table 28 b , the M-1 implemented relationships data table 28 c or the M-M implemented relationships data table 28 d , depending upon the cardinality of the relationship. The fields included in the 1-1 implemented relationships data table 28 a , the 1-M implemented relationships data table 28 b , the M-1 implemented relationships data table 28 c and the M-M implemented relationships data table 28 d are, as shown in FIG. 7, a source OID 701 , a relationship OID 703 and a destination OID 705 . Each of the relationships data tables 28 a , 28 b , 28 c and 28 d controls the cardinality of their members using indexes on the three fields included in each of the implemented relationships data tables 28 a , 28 b , 28 c and 28 d.
To enforce 1-1 cardinality on relationships, represented by the relationship OID 703 , between the source object and the destination object, represented by the source OID 703 and the destination OID 705 , respectively, 1-1 implemented relationships data table 28 a includes two indexes. One index is on the source OID 701 and the relationship OID 703 . The other index is on the destination OID 705 and the relationship OID 703 .
To enforce 1-M cardinality on relationships, represented by the relationship OID 703 , between the source object and the destination object, represented by the source OID 701 and the destination OID 705 , respectively, 1-M implemented relationships data table 28 b includes an index on the destination OID 705 and the relationship OID 703 .
To enforce M-1 cardinality on relationships, represented by the relationship OID 703 , between the source object and the destination object, represented by the source OID 701 and the destination OID 705 , respectively, M-1 implemented relationships data table 28 c includes an index on source OID 701 and relationship OID 703 .
To enforce M-M cardinality on relationships, represented by the relationship OID 703 , between the source object and the destination object, represented by the source OID 701 and the destination OID 705 , respectively, M-M implemented relationships data table 28 d includes an index on the source OID 701 , the relationship OID 703 and the destination OID 705 .
In implemented relationships data tables 28 a , 28 b , 28 c and 28 d , only the primary relationship path is implemented. To search the secondary relationship path, the record corresponding to the primary relationship path in the implemented relationships data tables 28 a , 28 b , 28 c and 28 d is read in reverse. For example, the destination OID 705 is read for the source OID 701 and the source OID 701 is read for the destination OID 705 . Whether a relationship path is primary or secondary is indicated by the fields primary OID 636 and secondary OID 638 .
Once the data to be accessed is modeled in IAE 10 , API 15 controls the access to the data by accepting and processing user requests for the data. Before any processing is done by IAE 10 , IAE DBInit 42 establishes a connection with the IAE database 20 . The specific database and server location is which contain IAE database 20 obtained from a userid profile.
Once a connection is established with IAE database 20 , IAE Tranlnit 52 establishes a transaction session under the specified database connection to IAE Database 20 . All database activity must be done under the scope of the specified transaction.
At this point, the user navigates through IAE database 20 to determine the objects, attributes of those objects, and relationships between those objects and attributes which are available for use in generating queries on the data in the IAE database 20 . The functions for navigating IAE database 20 include IAE Discover 32 , IAE DiscoverAttribute 34 and IAE Discover Relationship 36 .
Generally, navigation starts with IAE Discover 32 which returns information about the objects included in object data table 22 . The information returned includes a non-persistent object handle which used in subsequent discover and navigation queries. As noted earlier, meta data describing the IAE 10 is not accessible through navigation commands. Once the objects stored in IAE 10 are known, the user can then select a particular object(s) and then navigate either the attributes, stored in attributes data table 24 , associated with that object(s) or the relationships, stored in relationship data table 26 , associated with the selected object(s).
To navigate the attributes associated with the selected object(s), the function IAE DiscoverAttribute 34 returns all attributes and descriptive attribute data for the specified object handle.
To navigate the relationships associated with a selected object, the function IAE DiscoverRelationship 36 returns all relationships and descriptive relationship data for the specified object. A relationship through which to continue navigation may then be chosen from the returned relationships and the user is then given another object handle. By iteratively continuing in this manner, all data accessible through the IAE 10 may be navigated.
Various SQL commands or requests are also available to the user during the navigation of the data accessed through the IAE 10 . These requests include select, create, update and delete. In an OODBMS implementation of the present invention, as discussed below, the processing of each of these requests involves specialized class structures which take advantage of the inheritance, multiple inheritance, relationship definitions (complex objects) and OID generation features found in an OODBMS.
Within the transaction initiated using IAE Tranlnit 52 , a data object on which to process query commands is selected and Init 62 establishes an IAE session under which these processes are performed. Within this session, all information necessary to access the IAE Database 20 for the specified data object is collected. In this implementation of the present invention, Make APIClass 64 is called by IAE Init 62 and creates an instance of APIClass 85 and sets the object name and desired function (select, create, update or delete). Before the desired function requested by the query is actually executed, other functions within IAE APIClass 60 are executed to set up the environment. These pre-processing functions include IAE SetAttribute 66 , IAE SetWhere 70 , and IAE Set Update 74 .
IAE SetAttribute 66 is used to iteratively specify the attributes to be selected by a select request. Each call specifies an attribute (referenced by its handle), an optional sort sequence and a sort order. SetAttribute 68 is called by IAE SetAttribute 66 and maintains an array of the requested attributes and data value addresses in the user's address space.
IAE SetWhere 70 iteratively specifies the selection or “where” criteria to be used by all select, update and delete requests. This function specifies attributes (by handle), their comparative values and relational operators as well as conjunctive operators such as “AND” and “OR.” IAE SetWhere 70 is also used to select instances of a specified object by relationship. In this case, the parameter Operator has a value of “OP_ASSOCIATE,” the parameter WhereHandle is a relationship handle instead of an attribute handle, and the parameter Value is the OID (object identifier) to be used in the selection criteria. SetWhere 72 is called by IAE SetWhere 70 and collects attribute-operator-value triples used in IAE selection criteria. Valid operators used by IAE SetWhere 70 include “=”, “<=”, “>=”, “<>”, “<”, “>”, “ASSOCIATE” and “DISASSOCIATE.”
IAE SetUpdate 74 iteratively specifies the values to be used by an update or create request. IAE SetUpdate 74 specifies attributes (by handle) and their value. IAE SetUpdate 74 is also used to create or delete relationships between object instances. In this case, the parameter Operator has a value of “OP_ASSOCIATE” or “OP_DISASSOCIATE”, the parameter UpdateHandle is a relationship handle rather than an attribute handle and the parameter Value is the OID (object identifier) to be associated with (or disassociated from) the specified object instances. SetUpdate 76 is called by IAE SetUpdate 74 and collects relationship OID-OID pairs used when associating or disassociating one object instance with or from another object instance.
IAE Apply 78 then generates a database query using the information supplied by the functions IAE SetAttribute 66 , IAE SetWhere 70 and IAE SetUpdate 74 . The query is in the form of a standard query language (SQL) statement, represented by a statement handle which is used by other functions that need to access the generated statement. For create requests only, IAE Apply 78 returns the OID (object identifier) of the generated object instance. Apply 80 is called by IAE Apply 78 in generating the SQL request to access the needed data included in exemplary data objects 150 , 160 and 170 .
Just as IAE DBInit 42 establishes a connection to IAE database 20 , DBInit 102 establishes a connection between the IAE 10 and each of the underlying DBMS's represented by exemplary data objects 150 , 160 and 170 . DBInit 102 also returns necessary semantics for communicating with the selected underlying DBMS including a DBMS handle used by Tranlnit 112 of TransClass 110 .
Thus, for processing queries on exemplary data objects 150 , 160 and 170 generated by IAE Apply 78 , Tranlnit 112 establishes a transaction class instance which defines a transaction associated with the current database connection established by DBInit 102 .
In order to process the requests generated by API 15 , APIClass 85 uses the data supplied through the previous navigation or discovery of the objects, attributes and relationships in IAE database 20 . With these results, navigation or discovery of data in exemplary data objects 150 , 160 or 170 is performed. Any data stored in IAE database 20 which is needed to access the data stored in exemplary data objects 150 , 160 or 170 is retrieved through functions which include Discover 92 , GetAttributes 94 and GetRelationship 96 . The operation of these functions is similar to the operation of IAE Discover 32 , IAE DiscoverAttribute 34 and IAE DiscoverRelationship 36 .
The function SelectClass 132 processes a select request by the user. In an OODBMS implementation of the present invention, the processing done by SelectClass 132 includes creating a new instance of a class Select, not shown, allocating a new instance of a class called CommaThings which will include a list of attributes to be selected and corresponding sort criteria and allocating a new instance of a class called Table, not shown, which will include a list of “where” criteria to be used by the select request.
The function CreateClass 134 processes a create request by the user. The processing done by CreateClass 134 includes creating a new instance of a class called Create, and allocating a new instance of the class CommaThings which will include list of the attributes to be created.
The function UpdateClass 136 processes an update request by the user. The processing done by UpdateClass 136 includes creating a new instance of a class Update, allocating a new instance of the class CommaThings which will include a list of attributes and associated values to be changed, and allocating a new instance of a class Table which will include a list of “where” criteria used by the update request.
The function DeleteClass 138 processes a delete request by the user. The processing done by DeleteClass 138 includes creating a new instance of a class Delete, and allocating a new instance of the class Table which will include a list of “where” criteria used by the delete request.
APIClass 85 includes, as included in API 15 , the process of setting up the environment in which the second query is executed through a collection of functions. These functions include SetObject 140 , SetAttribute 142 , SetUpdate 144 , Set Create 146 and SetWhere 148 . SetObject 140 set the name of the data object instance to be acted upon. SetAttribute 142 specifies one attribute and associated sort criteria used by an instance of the class Select. SetUpdate 144 specifies one attribute-value-data type triple used by the class Create or Update. SetCreate 146 specifies the name of the IAE 10 data object to create. SetWhere 148 specifies one operator-attribute-value triple used by the class Select, Delete or Update.
Format 150 specifies how the information from the functions SetObject 140 , SetAttribute 142 , SetUpdate 144 , SetCreate 146 and SetWhere 148 is expanded into a database query statement specific to at least one of the data objects. Using this information, Format 150 formats the query statement and then stores the generated query statement in a query buffer. The format of the query statement generated by Format 150 varies from the simple case to the complex case depending upon the query command received from API 15 and upon the underlying DBMS which processes the query statement. The procedure or procedures executed to generate the specific query are provided by the user responsible for setting up IAE 10 . Generation and execution of the query specific to the exemplary data object 150 , 160 or 170 are transparent to the user.
The user continues processing queries within the specified transaction and makes no changes to the underlying DBMS until a Commit command is executed. Commit 114 processes the commit command by applying to the underlying DBMS all update requests made under the current transaction. The current transaction is then cleared and remains active for further activity. Rollback 116 , on the other hand, discards all update requests made but not yet applied through Commit 114 under the current transaction. The transaction remains active for further activity.
SavePoint 118 defines a marker or starting point inside the specified transaction class instance from which updates and changes are stored. The data is stored temporarily in memory under a currently active transaction until a Commit 114 command is executed. With the Commit 114 , the data is stored to the corresponding permanent file. Save points are used to maintain IAE data consistency during complex updates such as relationship instantiation or during instance deletes.
RollbackSavePoint 120 discards all updates made under the current SavePoint. Such updates may only be committed via the transaction scoped Commit 114 . After RollbackSavePoint 120 finishes processing, the transaction remains active for further activity.
Execute 122 passes the generated query statement (created by Format 150 of Schema Access 130 ) to the underlying DBMS and returns a handle to the results file generated by the executed query statement.
Bind 124 , for select queries, associates a requested attribute with a specified address in the user's address space.
Fetch 126 , for select queries, is used to fetch result data from the underlying DBMS query results. Fetch 126 places the retrieved data into the user's address space.
Free 128 releases all resources associated with the specified Statement generated by Format 150 .
DBEnd 104 terminates the connection to the underlying DBMS made by DBInit 102 .
IAE Fetch 82 iteratively polls data from the IAE result data table generated after a select request. For each returned instance, the parameter OID specifies the OID of the associated instance. Fetch 84 is called by IAE Fetch 82 and fetches the results of a select request.
IAE TranCommit 56 commits (updates the IAE Database 20 for) all IAE database 20 updates done within the scope of the specified transaction. After a commit, the current transaction is available for further work.
IAE TranRollback 58 rolls back (does not update the IAE Database 20 for) all IAE database 20 updates done under the scope of the specified transaction. After a rollback, the current transaction is available for further work.
IAE TranEnd 54 terminates the specified IAE transaction. If any updates are outstanding, they are NOT committed.
IAE Destroy 86 deletes all resources associated with building an IAE Database 20 request. Free 88 is called by IAE Destroy 86 and releases resources associated with the specific database.
IAE DBEnd 44 disconnects the user from the IAE Database 20 .
Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made thereto without departing from the spirit and scope of the present invention as defined by the appended claims.
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The system of the present invention having a first module ( 20 ) for storing information describing a plurality of data objects ( 150, 160 , and 170 ), attributes of each of the plurality of data objects, and relationships therebetween; a second module ( 15 ) for accepting and processing user queries generating first results data, the first results data including the information describing the plurality of data objects stored in the first module; and a third module ( 85 ) responsive to the second module ( 15 ) for generating second results data using the first results data, the second results data including the information contained in the plurality of data objects. The method of the present invention having the steps of providing data which describes the plurality of data objects, attributes of the plurality of data objects, and relationships therebetween; providing at least one procedure operable to build a query specific to at least one of the plurality of data object; accepting user requests querying the data; updating a first results file in response to the user requests; generating the query specific to at least one of the plurality of data objects with at least one procedure in response to the first results file; executing the query specific to at least one of the plurality of data objects; and generating a second results files in response to the executing step which includes information contained within at least one of the plurality of data objects.
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RELATED APPLICATION
The subject application is a continuation-in-part of U.S. patent application Ser. No. 207,546 filed June 16, 1988, now abandoned, in the name of the same inventors.
TECHNICAL FIELD
This invention relates to the field of filling containers such as bottles and cans with carbonated liquids, and more particularly to an improved filling valve for use in machinery for filling such containers.
BACKGROUND ART
Automatic machinery is used in modern bottling facilities for filling containers with gaseous liquids containing carbon dioxide and similar carbonations under counter-pressure Which enables predetermined quantities of liquid to be delivered into the containers. This machinery comprises mechanisms for handling the containers in which the empty containers are raised until the neck engages the filling device in order to receive a predetermined volume of liquid at which time the containers are lowered and directed toward the capping machine. The filling machinery includes a reservoir containing a liquid which flows under the effect of gravity. The gas above the liquid maintains the carbon dioxide in the liquid and is used to charge the container. A filling valve is located in the reservoir and extends through the tank. The valve connects the reservoir with the empty container and opens to allow the container to be filled with liquid.
When the container is engaged in the filling device, the gas valve fills the container with a counter pressure gas. The bottle is then filled with liquid by opening the filling valve. During filling, the gas contained in the container is evacuated through a vent tube towards a gas chamber in the tank. As soon as the level of liquid in the container reaches the aperture of the vent tube, the gas, which is located in the neck of the container, can no longer escape and the flow is stopped. The liquid and gas valves are then closed. A snifter is operated to release the remaining pressure in the container.
The valves are generally controlled by synchronized cams actuating so that the gas is first admitted to the container, filling the container against counter-pressurizing gas until the pressure of the gas and the liquid are equal. A second valve is then opened allowing the liquid to flow into the container under the influence of gravity and under a pressure head. When the container is filled, the cam actuator closes the valve and the container is lowered for capping. The pressure in the neck of the container may be controllably released by a snifter valve and the container quickly capped and crowned.
One prior art filling valve used with a carbonated liquid bottling machine is disclosed in U.S. Pat. No. 4,089,353 to Antonelli in which a filling valve is shown which connects a container to be filled with a tank containing supply of liquid with which the container is to be filled and pressurized gas. In the Meyer U.S. Pat. No. 3,500,879 a counter pressure type filler valve for introducing liquids into containers from a is provided with a swirl inducing member. Another typical control valve for filling containers with liquid under gaseous pressure from a reservoir is disclosed in U.S. Pat. No. 3,385,327 to Granier. The Fernades U.S. Pat. No. 4,086,943 shows a valve for filling containers with pressurized drinks. This patent is a typical back pressure filling valve for containers and provides an auxiliary passage for air and gas and a frusto-contical check valve for an elastimeric material to control the passage therethrough. The Dichiara U.S. Pat. No. 4,349,055 is for a filling valve for beverage container filling machines and is a cam operated valve having a screen filter mounted therein along with an auxiliary opening for the feeding of the liquid therethrough. The Kaiser U.S. Pat. No. 3,633,635 is for a filling element for counter pressure filling machines and includes a vessel or container for liquid and gas positioned beside the valve. The Yun U.S. Pat. No. 4,442,873 discloses a liquid filling valve for filling containers with carbonated liquid which has concentric valves for introduction of counter-pressure gas and liquid into the container.
The problem with these types of assemblies is that sharp angles and component obstructions create turbulence which separates and releases absorbed gas from the liquid and therefore foam in the bottle. The position of the screen in the high pressure area also produces additional foaming. Additionally, the screen position further restricts the flow.
SUMMARY OF THE INVENTION AND ADVANTAGES
The invention is a filling valve apparatus for use in filling container with a carbonated liquid comprising housing means having an orifice for allowing liquid to flow therethrough and including an inlet for allowing liquid to flow into the housing means and the orifice, an outlet to allow liquid to flow out of the housing means and said orifice, and having a valve seat between the inlet and the outlet. Also included is valve means moveable within the orifice between the inlet and the outlet and including sealing means moving against the valve seat for preventing the liquid from flowing through the orifice to the outlet and moving away from the valve seat for allowing liquid to flow through the orifice to the outlet. The assembly is characterized by including capillary screen means connected to the valve means at a position between the inlet and said sealing means.
The invention also includes the housing means comprising a cylindrical portion with an inner surface establishing a vertical cylinder having apertures establishing the inlet, a valve portion connected to the cylindrical portion with an inner surface bowing outwardly from the cylinder, a venturi portion connected to the valve portion having an inner surface funneling inwardly, and an expansion portion connected to the venturi portion with an inner surface flaring outwardly to a base portion establishing a horizontal shoulder for receiving a container wherein the liquid flowing along expansion portion is directed to the inside surface of the container. Valve means extends through the housing means wherein liquid flows along the inner surfaces between the housing means and the valve means. The valve means includes sealing means for moving between an open and closed position and having and external contour substantially complementing the inner surface of the valve portion such that the liquid flowing therethrough is compressed between the cylindrical portion and valve portion and the venturi portion.
The invention also provides the valve means comprising a valve stem having a passageway therethrough and extending through the orifice of the housing means and having a first end allowing gas to enter the passageway and a second end connected to the sealing means, and the assembly characterized by including cap means having a cylindrical sleeve for receiving the first end of the valve stem and having an annular shoulder for receiving and securing variable machining interfaces thereto.
A shortened distance in the orifice for the frame of fluid combine with the removal of any obstructions such as springs and screens combine to increase the flow speed with out undue foam. The screen being above the valve in the low-pressure area allows for little turbulence. Furthermore, the aerodynamic shape of the inside of the housing provides for a decrease in turbulence which prevent foaming. Additionally, the cap member may receive various types of actuating mechanisms, such as cam or lever actuators.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a cross-sectional view of a portion of the subject invention in the closed position;
FIG. 2 is a cross-sectional view of the subject invention in the open and filling position;
FIG. 3 is an exploded perspective view of a valve in accordance with FIGS. 1 and 2;
FIG. 4 is a cross-sectional view of a second embodiment of the cap member in the open position;
FIG. 5 is a cross sectional view taken along lines 5--5 of FIG. 1;
FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 1;
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 1; and
FIG. 8 is a cross-sectional view taken along lines 8--8 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A filling valve assembly for filling containers with a liquid is generally shown at 10 in FIGS. 1 and 2. Generally, filling machines utilizing such assembly 10 may be provided with a moveable filling table having a plurality of vertically moveable container supports which are spaced about the circumference of the table and adapted to receive containers such as bottles, cans or the like. The supports raise the containers into sealing engagement with the valve assembly 10 where the containers are filled with a carbonated liquid, and thereafter lowered and removed from the platforms.
The filling machines are provided with a filling reservoir 42. The reservoir 42 is supplied with a carbonated liquid which may be a pre-mixed liquid comprising syrup, fruit pulp, or the like. The carbonated liquid is supplied to the reservoir 42 through connections as are commonly known in the art. One filling valve assembly 10 is in vertical alignment with each container. A body of gas or air at a suitable pressure, such as 40 psi, is supplied to the upper portion of the filling valve assembly 10 and reservoir 42; the pressure of the gas or air is maintained at a desired pressure as commonly known in the art.
The filling valve 10 includes a generally cylindrical housing 11 having an orifice 40 therethrough. An upper valve stem guide 12 is slideably mounted within the orifice 40 of the housing 11 and has an aperture 14 therethrough. The upper valve stem guide 12 is generally cylindrical in shape. A fluid valve stem 13 having a gas passageway 29 therethrough is slidingly retained within the aperture 14 in the valve stem guide 12 providing liquid flow area between the housing 11 and valve stem 13. A lower valve stem guide 15 has an aperture 16 therein for receiving the valve stem 13 in sliding connection therewith. The lower valve stem guide 15 comprises a cylindrical sleeve portion 44 adjacent the valve stem 13 providing the aperture 16 and including radially extending spokes 46 connected to the housing 11. The lower valve stem guide 15 is formed as an integral part of the housing 11. The housing 11 includes longitudinally extending side openings 48 extending adjacent the spokes 46 and extending longitudinally downwardly therefrom to allow the liquid to flow into the orifice 40.
A lower coiled spring 17 is supported in the housing 11 between the upper and lower valve stem guides 12 and 15. The coiled spring 17 is a compression spring to bias the lower guide 15 away from the upper guide 12 and downwardly along the valve stem 13. The lower valve stem guide 15 provides a shoulder at the upper surface of the radial spokes 46 for receiving the first end of the coiled spring 17, while the upper valve stem guide 12 provides the upper radial groove 52 for receiving the second end of the coiled spring 17. A retainer 20 is provided to lock the valve stem 13 to the upper valve stem guide 12 so that the upper valve stem guide 12 slides with the valve stem 13 whenever it is driven by a cam C against a cam follower 21 as subsequently described. The valve stem 13 provides a groove 54 for receiving the retainer means 20, which is generally a washer, and the upper valve stem guide 12 provides a recess 56 for receiving the washer 20.
A cap member 22 is supported at the upper end of the valve stem 13 for supporting the cam follower 21. The cap member 22 includes an extending sleeve 26 extending adjacent the upper portion of the stem 13, and includes gas escape apertures 28 near the upper edge of the sleeve 26 and the valve stem 13. The apertures 28 are spaced circumferentially about the sleeve 26. A charging cap 24 is retained within the cap member 22 adjacent the upper edge of the valve stem 13 in its closed position. The charging cap 24 provides an upper shoulder 64 and the cap member 22 provides inwardly extending flanges 66 for engagement within the shoulders 64 of the charging cap 24 for retainment therebetween. The valve stem 13 is slideably retained within the sleeve 26 to a position adjacent the charging cap 24 to close the gas apertures and therefor prevent the supply of gas through the valve stem 13 and to a lower position to allow gas to flow into the apertures 28 above the upper edge of the valve stem 13. The cap member 22 is able to be snapped into engagement with the charging cap 24 and the valve stem 13 slid therein.
Also included is an upper coiled spring 23 extending between the housing 11 and the cap member 22. The upper coiled spring 23 is a compression spring which operates to bias the cap member 22 to follow the cam C movement and open and close the gas apertures 28.
The housing 11 includes an outwardly extending, circumferential flange 19 for receiving the lower end of the upper spring 23. The upper coiled spring 23 is bowed from a smaller diameter received by the cap member 22 adjacent the valve stem 13 to a larger diameter received on the flange 19 providing clearance between the diameter changes. Only one half of the upper spring 23 is illustrated in FIGS. 1 and 2. As an alternative embodiment as shown in FIGS. 1 and 2, an annular bracket 58 (only a portion of which is shown) may be included to be supported on the flange 19 and extending upwardly along the housing 11 and inwardly to a sleeve adjacent the valve stem 13 inside the spring 23'. The spring 23' in this embodiment is a coiled spring of uniform diameter. A second alternative embodiment is utilized particularly in the lever actuated system and is shown in FIG. 4, as subsequently described, and includes the upper coiled spring 23" bowed outwardly with uniform end diameters; the ends are received and retained by a radial notch 60 in the cap sleeve 26' and a radial notch 62 (best shown in FIG. 2) in the valve stem 13.
The upper valve stem guide 12 further includes a radially extending ridge 68 at its upper end to move against the upper edge 30 of the housing 11 preventing further downward movement of the upper valve stem guide 12 and valve stem 13 into the housing 11. When a cam C pushes against the cam follower 21, the valve stem 13 slides until the ridge 68 of the valve stem guide 12 abuts against the edge 30 of the housing 11 as shown in FIG. 1. The valve stem 13 is spring biased by the upper coiled spring 23 to return as the cam moves against the follower 21 allowing the valve stem guide 12 to slide out of the housing 11. The valve stem 13 provides a lower annular stop 31, and the lower stem guide 15 provides a stop 32 at its lower edge. As the cam follower 21 moves upwardly, the valve stem 13 and upper guide 12 slide out of the housing 11 until the valve stem annular stop 31 abuts against the lower stop 32.
The valve stem 13 includes a valve head 34 having an annular, outwardly curved and bowed portion forming a sloping, substantially symmetrical flange. The head 34 has an annular groove 35 formed therein at the outer diameter for supporting a resilient valve seal 36. The resilient valve seal 36 is radially extending outwardly from the groove 35 and may be made of rubber or other soft non-porous material. A second annular groove 37 is provided to receive a capillary screen 38 therein at a position above the valve element 36 along the sloping portion of the valve stem 13. The capillary screen 38 extends outwardly and radially from the stem 13 and has a downwardly curved radial edge. The screen 38 extends outwardly a distance to contact the inside surface of the housing 11 when in the open position, and provide slight distance between the edge and inside surface when moving to and in the closed position.
The housing 11 provides the side openings 48 of elongated shape for allowing the liquid to enter from the reservoir 42 therethrough below the coil spring 17 and spokes 46. The fluid is blocked by the valve seal 36 seated in a valve seat 43, as shown in FIG. 1. The valve seal 36 is open in FIG. 2 to allow the fluid to proceed to outlet 70.
The area through the housing 11 through which the liquid flows forms a shaped orifice including an enlarged chamber or valve portion 72 having annular arcuate walls 74 in which the screen 38 and valve seal 36 are situated forming the enlarged area and a second curved portion curving into a venturi portion 76 formed just below the valve seat 43, which has a continuous smooth flow into a continuous expansion orifice portion or outlet 70 and into a container 50.
The housing 11 includes inner surfaces forming the orifice 40 therethrough. The housing 11 includes the inlet or side opening 48 for allowing liquid to flow into the housing 11 and an outlet or the expansion orifice 70 to allow the liquid to flow out of the housing 11 and liquid orifice 40. The housing 11 includes a cylindrical portion 80 a first flow area wherein the inner surface 82 provides a vertical cylinder having a smooth surface with openings for the inlet 48. The cylindrical portion 80 is adjacent and below the spokes 46. The cylindrical portion 80 is connected to the valve portion or enlarged chamber 72 of a second flow area with the inner surface 74 bowing outwardly from the cylindrical portion and bowing inwardly providing the valve seat 43 to the Venturi portion 76. The valve portion 72 contains the enlarged head 34 and seal 36 and screen 38. The screen 38 contacts the upper area of the enlarged chamber 72 in the open position, and is near the center of the enlarged chamber 72 in the closed position.
The valve portion 72 is connected to the venturi portion 76 of a third flow area having the inner surface 78 funneling inwardly a conical portion comprising the expansion orifice 70. The conical portion 70 starts at the third flow area and expands therefrom. The conical portion is connected to the venturi portion 76, with the inner surface 84 flaring outwardly to a base portion 86. The base portion 86 establishes a horizontal shoulder for receiving the container 50 wherein the liquid flowing along the conical portion 70 is directed to the inside surface of the neck of the container, rather than flowing to the upper edge of the container 50 causing turbulence.
The valve stem 13 extends through the housing 11 wherein the liquid flows along the inner surface, between the housing 11 and the valve stem 13. The above described flow areas are taken between the housing 11 and the valve stem 13 including the structural protrusions therefrom. The valve stem 13 and spokes 46 are in contact and abutting in the open valve position providing a smooth surface therealong for the flow of liquid. The valve stem 13 includes the valve seal 36 for moving between an open and closed position. The valve head 33 and valve seal 36 provide an external contour substantially similar to and complementing the contour of the inner surface 74 of the valve portion 72 or enlarged portion to maintain a constant flow area through the valve portion 72. The effective area of the various portions through which the liquid flows decreases between the cylindrical portion 80 and the valve portion 72, and the venturi portion 76. The purpose of the curved aerodynamic surfaces and housing 11 prevents any agitation and turbulence of the liquid and therefore prevents foaming at the outlet. Furthermore, by decreasing the flow area until reaching the outlet, the pressure is increased which prevents foaming by not allowing the carbonated liquid and gas therein to expand causing foaming. The lower valve portion 72 and venturi portion 76 and outlet 70 are formed by the adjustable container seal 51, as subsequently described. By continually decreasing the flow area, the liquid is continually compressed so the gas may not expand therein prior to flowing into the container 50 which would cause additional foaming. Furthermore, the liquid may flow through the housing 11 without any obstructions, along the smooth, aerodynamic walls or surfaces to preserve the capillary action of the fluid.
The valve stem 13 includes at the head 34 a threaded bore 88 for receiving a vent tube 90 having threads 92 to be received within the valve head 33, and includes an annular resilient seal 94 therein for sealing the vent tube 90 to the stem 13. The vent tube 90 is effectively an extension of the valve stem 13. The vent tube 90 has an open bottom 96 and a pair of side apertures 98. The vent tube 90 also has an annular liquid spreading member 102 positioned below the venturi portion 76 and the spreading area 70 formed by the inner surface 84 of the expansion orifice to spread the liquid in the neck of the container 50. When the liquid filling the container 50 raises to cover the side apertures 58, the gas pressure is cut off which stops the flow of liquid into the container 50 preventing further filling thereof.
A container seal 110 may be a resilient rubber member and includes the curved area or expansion orifice 70 and fits into an annular grooved area 104 in a snifter 108, as subsequently discussed. A cone shaped end 106 guides the container top 50 into place.
The snifter 108 is mounted to one side of the valve 10 and has an insert 112 with a small bore 114. This insert is changeable to change the size of the aperture therethrough to match the valve and bottle seal 110 and varies the snift speeds in accordance with the opening therethrough. The snifter 108 includes a chamber 116 having a coil spring 118. A button 120 has an O-ring seal 122 in a grooved area 124 and an annular ledge 126 for supporting the coil spring 118. The seal 122 acts as a valve element against a valve seat area while the bore 114 connects into the venturi area 76 of the orifice of the valve 10. O-ring seals 130 and 132 seal the valve 10 in place so that the liquid and the container cannot leak therethrough. The snifter 108 provides a housing, which forms the inner surface 75 of the lower valve portion, and venturi portion 76. The bottle seal 51 forms the expansion orifice or conical portion 20.
The short distance between the feeding of the fluid through the opening 48 and into the container 50 along with the aerodynamic shape of the feeding orifice provide a faster fill for the bottles and this is further enhanced by a capillary action and columnar effect of the fluid.
The valve assembly 10 may be operated by a cam or lever. The charging cap 24 provides the shoulders 64 for receiving the first alternative cap member 22. As illustrated in FIG. 1, the cap member 22 is for receiving a cam follower 21 thereon to be operated by a cam C. Alternatively, as illustrated in FIG. 4, the cap member 22' for a lever actuator is generally spool shaped for receiving a lever L about the stem of the spool. In either cap member embodiment 22, 22', the charging cap 24 is common. Furthermore, both cap retainer embodiments 22, 22' include the sleeve 26, 26' as hereinbefore described. However, the lever actuated cap member 22' utilizes the symmetrical bowed spring 23", and the cam actuated retainer 21 may utilize either the cone-shaped spring 23 or the cylindrical spring 23'.
In operation, a cam C or lever L operates against the cam follower 21 or lever member 22' to drive the valve stem 13 downward against the coiled springs 23 and 17 until the upper valve stem guide 12 hits the stop 30 and the cam reaches the bottom of its drive. The valve element 3 is pressed against the valve seat 43. The upper spring 23 holds the cam follower 21 tightly against the cam at all times. The container 50 is then pushed into place in the bottle sealing rubber 51, with the stem 14 and the vent tube 90 pushed into the container 50.
The cam C or lever L is operated to move the cap member 22, 22' upwardly to positively open and place the inside of the container 50 in open communication with the superposed body of gas in the reservoir 42. Gas will quickly flow into the container 50, filling the same to a pressure substantially equal with the pressure of gas in the reservoir 42.
During this filling operation, the stem 13 and the vent tube 90 are retracted slightly to open the valve by pulling the valve element 36 off the valve seat 43 as shown in FIG. 2 to allow the carbonated liquid to pass through the opening 48 into the enlarged valve chamber 72 through the capillary screen 38 which is curved to fit against the upper curved area of the enlarged chamber 72. The enlarged area 72 of the orifice has a lower pressure, a lower velocity and feeds the carbonated liquid therethrough. The liquid passes through the venturi portion 76 where the velocity is substantially increased with a rise in pressure and as it passes the venturi area 76 it passes between the spreading member 60 and the expanding walls 84 and is fed into the container 50.
The short distance between the feeding of the fluid through the opening 48 and into the container 50 along with the aerodynamic shape of the feeding orifice without obstructions, such as springs and screens, provide a faster fill for the bottles. This is further enhanced by the capillary screen 38 being positioned above the valve seat in an enlarged area rather than below the valve element or below the venturi. The container seal 51 form part of the expansion of the venturi 76 and provides a smooth continuous laminar flow or capillary action of the liquid through the valve into the bottle to thereby reduce foam and allow more rapid filling of the bottles. The snifter 108 has also had the aperture enlarged and it interchangeable with different size apertures to also prevent foam for an adjusted filling speed. The valve seat 43 is also formed as part of the aerodynamic shape in an enlarged area 72 over the venturi 76. The pressure changes as the liquid passes through the venturi 76 and is rapidly dispensed into the container 50 by the liquid spreading member 102. The container 50 is filled, until the pressure is counter-balanced to indicate a full container 50.
The screen 38 automatically stops the flow of liquid into the container 50 when the pressure of the gas in the head of the container 50 is balanced with the pressure of the liquid above the screen 38. The natural surface tension of the liquid on the screen 38 will prevent further liquid from flowing into the container 50, thereby maintaining the fill height of each container 50 substantially equal. When the liquid flowing into the container 50 fills up past the aperture 98, there is no where for the gas in the head space of the container 50 to escape and consequently the pressure of the gas in the head space will build up as liquid flows into the container until it is substantially equal to the pressure of the liquid flowing through the screen 38 and liquid passage. At this instant, the liquid flow into the container 50 will stop. The mesh of the screen 38 depends upon the viscosity and surface tension of the liquid. The screen 38 includes an annular, downwardly curved edge about its periphery. The curved edge is advantageous when using pulp containing liquids to bring the pulp to the edge when the filling if stopped and the valve closed, so that the pulp is the first to flow out the valve assembly 10 during the next filling operation.
Once the container has been filled, the valve assembly 10 moves to a position gas closing the apertures 28 and valve 36. The snift valve 108 is then operated by a fixed cam (not shown) on the frame of the filling valve assembly I0 and places the head space of the container 50 in open communication with atmosphere. Any excess pressure in the head space of the container is released through the snifter 62 to atmosphere.
After the snift stage, the container 50 is lowered away from the filling table and conveyed to suitable container closing mechanism. The bottle 50 is then moved on a conveyor quickly to a capping station where it is capped.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.
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A filling valve assembly (10) is provided for use in filling containers ( with a carbonated liquid or other type of liquid. The assembly (10) includes a housing (11) having a filling orifice (40) for allowing liquid to flow therethrough. A valve element (13) is located within and movable through the housing (11) and includes a valve seal (36) movable against the housing (11) for selectively opening and closing the filling orifice (40). A capillary screen (38) is connected above the valve seal (36) and is moveable therewith. The orifice (40) is aerodynamically shaped and has an annular enlarged portion (72) smoothly feeding into a narrowed venturi area (76) to continually compress the liquid, and then into an expanded area (70) to the walls of the container (50). A container seal (110) forms part of the expanded area (70) to enhance the laminar flow.
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TECHNICAL FIELD
[0001] What is described is an electrical module with a microphone integrated therein.
BACKGROUND
[0002] A microphone module with an encapsulated MEMS microphone (MEMS=Micro Electromechanical System) is known from the publication J. J. Neumann, Jr., and K. J. Gabriel, “A fully-integrated CMOS-MEMS audio microphone,” 12th International Conference on Solid State Sensors, Actuators and Microsystems, 2003 IEEE, pp. 230-233. Described therein is a module having a volume for pressure equalization (back volume).
[0003] An electrical module with a built-in MEMS piezoresistive microphone is known from the publication D. P. Arnold et al., “A directional acoustic array using silicon micromachined piezoresisitive microphones,” J. Acoust. Soc. Am., vol. 113(1), 2003, pp. 289-298.
[0004] In the publication Mang-Nian Niu and Eun Sok Kim, “Piezoelectric Bimorph Microphone Built on Micromachined Parylene Diaphragm,” Journal of Microelectromechanical Systems, vol. 12, 2003 IEEE, pp. 892-898, a piezoelectric microphone having two piezoelectric layers of ZnO and a floating electrode arranged therebetween is described.
SUMMARY
[0005] Described herein is an electrical module with a built-in MEMS microphone that has a high signal-to-noise ratio.
[0006] An electrical module with a built-in microphone is described. The module comprises a base plate with an acoustic channel formed therein. One embodiment includes a first cavity connected via a sound inlet opening to the exterior, with a MEMS microphone chip arranged therein, and a second cavity, suitable as an acoustic back volume and connected to the acoustic channel. The microphone chip may be connected to the base plate, arranged above an opening formed in the base plate, and connected via this opening to the acoustic channel buried in the base plate.
[0007] The first cavity can coincide with the exterior. The diaphragm of the microphone chip separates the first cavity from the acoustic channel, which opens into a second cavity. The second cavity may be alongside the first cavity. The acoustic channel may run at least in part beneath the two cavities.
[0008] A pressure balance between the second cavity and the acoustic channel is possible by air interchange. A fast air interchange between the first and the second cavity—i.e., an air interchange in a period on the order of the oscillation period of the microphone diaphragm in the operating frequency range—may be prevented by the diaphragm of the microphone chip. A slow air interchange (in a period that is longer than the largest oscillation period of the microphone diaphragm in the operating frequency range) between the two cavities is nevertheless possible via a ventilation opening whose cross-sectional size is clearly smaller than the cross-sectional size of the diaphragm.
[0009] The acoustic channel may be at least sufficiently large in cross section that the pressure change in the proximity of the diaphragm of the microphone chip can be rapidly compensated. The cross-sectional size of the acoustic channel or the channel openings may be at least 5% of the diaphragm surface area.
[0010] Microphones that detect sound pressure via diaphragms are dependent on a large diaphragm excursion in reaction to the sound intensity in order to obtain the desired characteristics regarding sensitivity and noise behavior. For small components with built-in microphones, the attainable excursion is limited by the small diaphragm surface area. For this reason, only weak electrical signals can be obtained when the diaphragm excursion is transformed into an electrical variable. The compliance of a diaphragm manufactured in a separate procedure can be worsened by a high internal mechanical stress caused by a biasing of the diaphragm.
[0011] MEMS microphones described here have an air chamber (first cavity) connected to a sound input opening as well as a back volume formed by the acoustic channel and the second area. Back volume refers to enclosed air volumes, with which an acoustic short-circuit—an undesired pressure balance between front and back of the vibrating diaphragm—is prevented. For each diaphragm deflection, this air volume produces a restoring force in addition to the restoring force caused by the flexible diaphragm characteristics.
[0012] In the microphone specified here, the back volume may be formed by a horizontal acoustic channel formed in the carrier substrate below the two side-by-side cavities, and by the volume of the other cavity. With this particularly large back volume, the relative pressure changes in the back volume, caused by the diaphragm vibrations, and the associated restoring force affecting the diaphragm can be kept small.
[0013] In an embodiment, the module comprises a cover that has a separation ridge connecting two opposite side faces of the cover and sealing to the base plate. Between the base plate and the cover, for instance, the first cavity connected via a sound inlet opening to the exterior and the second cavity isolated from it by the separation ridge of the cover are formed. The sound inlet opening may be arranged in the cover.
[0014] The acoustic channel and the second cavity together form a back volume. An advantage of this embodiment is that the back volume is arranged partly in the base plate and partly thereabove. Thus a large portion of the module volume is used as the acoustic back volume.
[0015] A microphone chip comprises a carrier substrate, with a diaphragm capable of vibrating. The microphone chip may have a piezoelectric layer as well metal layers and/or electrode structures connected thereto, clamped therein above a recess or an opening.
[0016] There may be an adhesion-promoting and/or sealing mechanism, e.g., a glue layer or an epoxy resin layer, between the cover and the plate.
[0017] The microphone chip is arranged above a first opening provided in the base plate, which opens into the acoustic channel and the first cavity. The base plate has a second opening, through which the acoustic channel is connected to the second cavity. The cross-sectional size of the first opening may correspond to roughly the cross-sectional size of the microphone chip's diaphragm. The cross-sectional size of the second opening may be selected in such a way that a fast air interchange between the acoustic channel and the second cavity is possible.
[0018] With the microphone, the restoring force acting on the diaphragm can be reduced and the diaphragm excursion increased.
[0019] In an embodiment, the base plate comprises a first layer with a recess associated with the acoustic channel formed in it, and a second layer arranged above the first layer, which partly covers the recess for forming an acoustic channel up to the above-mentioned openings. The separation ridge of the cover may seal to the second layer.
[0020] The first layer of the base plate can optionally be a glass-fiber reinforced organic laminate, or contain ceramics. The first layer of the base plate can comprise several homogeneous or different dielectric sublayers arranged one above another, between which structured metal layers are arranged. The sublayers can be formed from a glass-fiber reinforced organic laminate or ceramics. The second layer of the base plate is formed with a first layer, which may include another material such as ceramic, formed like a solder stop mask (of acrylate or epoxy resin in one embodiment).
[0021] The second cavity can house at least one chip element, e.g., a resistor, a capacitor, an inductor, a filter, an impedance transformer and an amplifier. The chip element may be suitable for surface mounting.
[0022] The microphone chip can also be mounted with a flip-chip construction method and electrically connected by bumps to electrical contacts arranged on the upper side of the base plate. In another embodiment, the microphone chip can be electrically connected by bonding wires to electrical contacts arranged on the upper side of the base plate. The interfaces formed by the opposing mounting surfaces of the chip and the base plate may be sealed by adhesion, underfilling or soldering, for example. A solder frame or a frame made of potting compound may be arranged between the chip and base plate. In the case of a solder frame, it is expedient to form a solderable metallization, whose outline corresponds to the form of the frame in the lateral plane, on the upper side of the base plate and the lower surface of the microphone chip.
[0023] In one embodiment, the cover comprises a cap of plastic or ceramic coated with a conductive layer. The cover can also be formed from metal.
[0024] In case of a large acoustic pressure, such large peak-to-peak oscillation amplitudes of the diaphragm can occur that a nonlinearity in the electroacoustic transformation of the diaphragm oscillation into an electrical signal, and therefore signal distortion, results. This problem is remedied in one embodiment, in which a negative-feedback compensation circuit is connected to a diaphragm. Deflection of the diaphragm provoked by the compensation circuit opposes the deflection of the diaphragm caused by the acoustic pressure, and compensates it to a large extent, so that the diaphragm oscillates with a reduced amplitude or does not oscillate at all. The electrical parameter produced by the compensation circuit, for example, a potential, is proportional to the acoustic pressure or the signal to be detected. Any desired electrical circuit suitable for negative feedback is applicable as the compensation circuit.
[0025] According to another embodiment of the microphone, the diaphragm is clamped to the carrier substrate only at one side, while its end opposite the clamped end can oscillate freely above an opening formed in the carrier substrate when an acoustic signal is applied. Clamping on both sides is also possible, in which case only two opposite diaphragm ends are arranged above the carrier substrate. A diaphragm carrier capable of oscillation that is sealed to the carrier substrate on all sides, e.g., a flexible film, may be stretched over the opening in the carrier substrate. The diaphragm is located on the diaphragm carrier.
[0026] The following materials are suitable as a piezoelectric layer in all embodiments: ZnO, lead zirconate titanate (PZT) and aluminum nitride.
[0027] It is proposed that a diaphragm with at least one piezoelectric layer be to a large extent symmetrical regarding its layer succession and layer thickness. In particular, bending moments that develop due to different coefficients of expansion of sequential layers are compensated even for substantial temperature discontinuities. Warping of the diaphragm can therefore be avoided over a broad temperature range. This measure is particularly applicable to a bimorph diaphragm structure.
[0028] A microphone will be described in detail below on the basis of embodiments and the related figures. The figures show embodiments of different versions of the microphone on the basis of schematic representations, not drawn to scale. Identical or identically functioning parts are labeled with the same reference symbols.
DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 schematically shows an example of an electrical module with a built-in microphone;
[0030] FIG. 2A , an electrical module with a microphone chip, an acoustic channel and two cavities in cross section;
[0031] FIG. 2B , the view of the module of FIG. 2A from above;
[0032] FIGS. 3A , 3 B, another electrical module;
[0033] FIG. 4 , a microphone with a diaphragm comprising a piezoelectric layer;
[0034] FIG. 5 , a microphone with a diaphragm having a bimorph structure.
DETAILED DESCRIPTION
[0035] FIGS. 1 , 2 A, 2 B, 3 A, 3 B each show an electrical module with a built-in microphone chip MCH. The microphone chip can be formed, for example, in accordance with one of the configurations presented in FIGS. 4 and 5 .
[0036] Microphone chip MCH is arranged on a base plate BP above an opening formed therein—sound opening IN in FIG. 1 and/or opening W 1 in FIG. 2A . Microphone chip MCH may be tightly sealed on all sides to the upper side of base plate BP, on which a cover CAP is arranged.
[0037] A closed cavity, which is used as an acoustic back volume, is formed between microphone chip MCH, the upper side of the base plate and cover CAP. In addition, a chip component BE 1 electrically connected to microphone chip MCH is arranged in this cavity. Additional chip components BE 2 are located on the base plate BP outside of the closed cavity. The electrical connections between the module components just mentioned are buried in part in multilayered base plate BP.
[0038] FIGS. 2A , 2 B show another embodiment of an electrical module, in which the sound inlet opening IN is formed in the cover CAP. FIG. 2A shows the electrical module in a schematic cross section, and FIG. 2B shows a schematic view of this module from above through its cover.
[0039] Base plate BP comprises a lower layer S 2 and an upper layer S 1 arranged thereon. In layer S 2 , an acoustic channel AK is provided in the form of a blind hole or a trench extending in a longitudinal direction. As viewed from above, layer S 1 may cover this blind hole completely, up to a first opening W 1 and a second opening W 2 . Layer S 1 can be formed, for instance, as a solder stop mask.
[0040] A cover CAP, which has a separation ridge TS that interconnects two opposing sides of the cover, is arranged on layer S 1 . Cover CAP may be sealed tightly on all sides to the upper side of base plate BP or to its upper layer S 1 . A glue layer KS can be arranged between them for adhesion promotion or sealing.
[0041] A microphone chip MCH, which is sealed tightly on all sides to layer S 1 , is arranged above first opening W 1 of layer S 1 . A sealing frame KS 1 is arranged between microphone chip MCH and layer S 1 . Sealing frame KS 1 can be formed from potting compound in one embodiment. In another embodiment, sealing frame KS 1 can be formed as a solder frame.
[0042] Two cavities HR 1 , HR 2 , which are connected by acoustic channel AK and isolated from one another by microphone chip MCH arranged in first cavity HR 1 , are formed between the S 1 and cover CAP by separation ridge TS of the cover. First cavity HR 1 is connected via sound inlet opening IN to the outside.
[0043] Chip components BE 1 , BE 2 , which are electrically connected via contacts K 1 -K 3 arranged on the base plate to one another and to microphone chip MCH, are arranged in second cavity HR 2 .
[0044] On the upper side of microphone chip MCH, a contact surface AF is arranged, which is electrically connected, e.g., to the first electrode of the microphone, and to an electrical contact K 1 located on layer S 1 via a bonding wire. The contact K 2 shown in FIG. 2B may be electrically connected to the second electrode of the microphone.
[0045] The acoustic back volume is formed by an air volume enclosed in acoustic channel AK and second cavity HR 2 . The essential point is that acoustic channel AK connects the remote cavity HR 2 to the rear side of microphone chip MCH and thus makes available an expanded back volume.
[0046] FIGS. 3A and 3B represent another electrical module with a built-in MEMS microphone in cross section and in plan view through cover CAP, respectively. Layer S 1 here covers only one part of the recess provided in layer S 2 for the formation of acoustic channel AK. Opening W 1 , which issues into acoustic channel AK and is isolated by the lower surface of microphone chip MCH and a sealing frame KS 1 from first cavity HR 1 , is provided in layer S 1 .
[0047] Opening W 2 connecting acoustic channel AK to second cavity HR 2 is formed in that a part of layer S 2 , in the area of the recess formed therein, is not covered by layer S 1 .
[0048] In an embodiment, layer S 1 is completely covered by the cover CAP, wherein separation ridge TS rests upon on this layer and is fixedly connected thereto by glue layer KS. In this example, the height of separation ridge TS is less than the height of the external walls of the cover.
[0049] Microphone chip MCH is fixedly connected to layer S 1 by a frame-like glue layer KS 1 (or solder layer) arranged in the peripheral area of microphone chip MCH. Thus, opening W 1 of the acoustic channel is isolated from first cavity HR 1 . Layer KS 1 serves to seal off the interface between microphone chip MCH and layer S 1 .
[0050] FIG. 4 shows an example of a MEMS microphone chip with a piezoelectric microphone. The microphone chip comprises a carrier substrate SU in which an opening is formed, above which a diaphragm M 1 is arranged on a carrier TD capable of oscillating. The diaphragm has a piezoelectric layer PS 1 arranged between two metal layers ML 1 , ML 2 . Contact surfaces AF, which are electrically connected to the electrodes formed in metal layers ML 1 and/or ML 2 , are arranged on the upper side of carrier substrate SU.
[0051] FIG. 5 shows in schematic cross section a microphone chip with a carrier substrate SU and a diaphragm M 1 with a bimorph structure stretched out thereabove. Diaphragm M 1 has a first piezoelectric layer PS 1 arranged between an outer metal layer ML 3 and a central metal layer ML 2 , as well as a second piezoelectric layer PS 2 arranged between an outer metal layer ML 1 and a central metal layer ML 2 . The piezoelectric axes in the two layers PS 1 , PS 2 can be arranged in the same direction or in opposite directions.
[0052] A bimorph diaphragm structure has the advantage over a diaphragm with only one piezoelectric layer in that it is possible to obtain twice as large an electrical signal for the same diaphragm curvature, since the potentials of the two piezoelectric layers are additive.
[0053] The layer thicknesses of the layers forming diaphragm M 1 may be chosen to be symmetrical relative to metal layer ML 2 . The piezoelectric layers have the same thickness and the same orientation of their piezoelectric axes. The two outside metal layers ML 1 , ML 3 may be formed with equal thickness.
[0054] On the upper side of carrier substrate SU, electrical contacts AE 1 , AE 2 are arranged, which are electrically connected on the one hand via electrical leads to electrodes formed in metal layers ML 1 and ML 2 , and on the other hand, via plated-through holes DK to contact surfaces AF arranged on the lower surface of the carrier substrate SU.
[0055] In an embodiment, a ventilation opening, which is small in relation to the cross-sectional size of the diaphragm and serves for a slow pressure equalization in the range of ≧100 ms, can be provided to connect the enclosed air volume (back volume of the microphone) to the outside. The pressure is equalized slowly in relation to the period of an acoustic signal with the largest wavelength in the operating range of the microphone. This opening can be arranged in the diaphragm or in a wall of the container enclosing the acoustic back volume.
[0056] The module is not limited to the number or the special form of the elements, microphones and/or microphone chips shown in the figures, or to the audible acoustic range from 20 Hz to 20 kHz. Additional piezoelectric acoustic sensors, such as distance sensors operating with ultrasound, are also possible. A microphone chip can be used in any desired signal processing module. Different embodiments can be combined.
[0057] It is possible to form the carrier substrate as a multilayer structure with structured printed conductors integrated therein to realize, for instance, electrical leads, inductors, capacitors and resistors.
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An electrical module includes a base plate having an acoustic channel that opens into a first cavity at a first end and that is closed off by a microphone chip at a second end. The microphone chip borders a second cavity that opens to an exterior of the electrical module. The second cavity is separated from the acoustic channel by the microphone chip.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending U.S. application, Ser. No. 663,423 filed Mar. 3, 1976 (now abandoned) which is a continuation of U.S. Application Ser. No. 553,782 filed Feb. 27, 1975 (now abandoned), which is a continuation of U.S. Application Ser. No. 305,646 filed Nov. 10, 1972 (now abandoned).
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods for making carbon black.
2. Description of the Prior Art
The prior art discloses furnaces for making carbon black which consist of gas and air inlets, one or more oil injectors, a reactor chamber, and quench sections. Furnaces using these elements include those shown in U.S. Pat. Nos. 2,918,353; 3,009,784; 2,616,794; and 3,420,631. Oil feedstock is vaporized and injected into the reaction chamber where an air-gas mixture is combusted. Carbon black particles are formed and pass into a quench section.
The formation of carbon black can be visualized as taking place in three phases: (1) an induction phase in which the hydrocarbons are decomposed into elementary fractions; (2) a phase in which carbon black nuclei are formed; and (3) a particle growth phase in which the carbon black nuclei reacts with other nuclei and with the remaining hydrocarbon fractions. During this third phase, carbon black particles react with gases and other reactive species to produce such side effects as increased carbon monoxide content, oxygen group attachments and porosity. This third phase is ended when the available energy is reduced to a point which will not support further reactions.
The manufacturer has little control over the duration and nature of the processes of nucleation and reaction with the active species and carbon particles.
SUMMARY OF THE INVENTION
It is an object of this invention to provide new methods which overcome the deficiencies of the prior art as indicated above.
A further object of this invention is to produce a more uniform particle size black.
An additional object is to produce a better mixing of the feedstock with the hot combustion gases in the immediate area of conversion.
Other objects and a fuller understanding of the present invention may be had by referring to the following description and claims taken in conjunction with the accompanying drawings.
The present invention overcomes the deficiencies of the prior art and achieves its objectives by providing for the controlled diluting of the concentration of reactive species during the particle growth phase.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a sectional elevation view of one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention is shown in FIG. 1. Oil spray injector nozzle 11 is located in the front end section 14 of a cylindrically shaped carbon black furnace 15. The oil injector 11 emits oil vapor and compressed air into the cylindrically shaped primary reaction chamber 1. Chamber 1 is connected to a cylindrically shaped secondary reaction chamber 5 by an inter-chamber connector tube 10. The furnace is lined with refractory material represented by cross-hatching 16. Combustion air supply lines 17 pass air through valves 3 to venturi mixers 4. Combustion gas supply lines 18 feed combustion gas through valves 2 into mixers 4. Mixers 4 are connected to chamber 1. These mixers mix the air and gas and feed it to the tangential inlet slots 31 located in the outer circumference of chamber 1. There the combustion mixture is continuously injected and burned. This forms an envelope of flame around the air/oil spray which is being injected through oil injector 11.
The oil spray injected into chamber 1 is thermally cracked into elementary fractions by heat from the enveloping flame. The products of the thermal cracking, certain combustion products, and uncracked hydrocarbons are forced through tube 10 by the expansion of the combusting gases and by the pressure of the gas, air and oil vapor constantly entering the reactor.
Chamber 5 is similar to chamber 1. An external burner 13 is mounted radially to the outer circumference of chamber 5. A secondary venturi mixer 12 combines combustion gas from the secondary gas supply line 19, through valve 6, and combustion air from the secondary air supply line 20, through valve 7. Mixer 12 feeds this mixture to burner 13 where it is continuously combusted externally to chamber 5. The hot gas which results then passes into chamber 5 and contacts the turbulent mixture which has passed into chamber 5 from chamber 1.
The chamber 5, the flow velocity of the mixture decreases because the cross-sectional area of chamber 5 is larger than that of tube 10. The reactive carbon black nuclei and any remaining uncracked oil vapor are mixed with the combustion gas from burner 13. This gas dilutes the remaining reactive nuclei. It also maintains a high temperature causing thermal cracking of the remaining oil. The carbon black formed then passes with the gases and other products into the cylindrically shaped quench tube 9 where it is cooled by water quench spray 8 or 8'. Any number of quench positions and any length or diameter of quench tube can be used as long as the flow velocity is maintained high enough to prevent settling out of the solid products. The number of quench sprays, their locations, and the dimensions of the quench tube section depend upon the desired length of the particle growth phase.
One result of diluting the reactive species is increased surface area of the carbon black due to smaller particle size. The dilution reduces the opportunity for active nuclei to collide with reactive species or other nuclei to form larger particles.
This dilution also adds heat to the endothermic reaction. Particle size is dependent in part upon the temperature. By maintaining the temperature at a uniform level, the dilution encourages a thorough thermal cracking of all hydrocarbons and maintains a uniform particle size.
In conventional furnaces, the late-forming carbon black particles are substantially different from early-forming particles. This is due to the absorption of heat by the early-formed particles at widely varying temperatures. In the present invention all the carbon particles are formed under substantially the same conditions because the reactive species are insulated from each other and the temperature is kept constant.
An alternative to burner 13 is the recycling of part of the spent combustion gases of the carbon black formation process to an air inlet in chamber 1, tube 10, or chamber 5. This will reduce the concentration of reactive species. It is preferable to add such gases at a temperature near that of the reaction mass.
Another way to dilute the concentration of the reactive species is to add helium or other noble or inert gases and mixtures thereof at the appropriate position in the furnace as taught above.
Different primary and external burner configurations are possible. The number of burners may be increased or decreased. The primary burners may be placed radially on chamber 1 or may be placed parallel to the longitudinal axis of the furnace, in the front end of the furnace. The external burners may be in line, staggered around the circumference, or opposed.
While the invention has been described herein with reference to its preferred embodiments, it will be understood by those skilled in the art that various changes in equivalents may be made to adapt to a particular situation. Therefore, although specific preferred embodiments of the present invention have been described in detail above, the description is not intended to limit the invention to the embodiments disclosed herein, since they are to be recognized as illustrative rather than restrictive. It will be obvious to those skilled in the art, that the invention is not so limited. The invention is declared to cover all changes and modifications of the specific examples of the invention herein disclosed for purposes of illustration, which do not constitute departures from the spirit and scope of the invention.
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Methods are disclosed to produce carbon black by diluting the concentration of reactive species by the addition of substantially inert gases to the reactive gas stream prior to the termination of particle growth.
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BACKGROUND OF THE INVENTION
The present application relates generally to the field of multi-function tools. More specifically, the present application relates to a multi-function tool including locking pliers.
Multi-function tools typically include a pair of handles and an implement such as a pair of scissors or pliers, along with a number of pivotally attached ancillary tools used to perform any number of tasks. There have been several attempts to integrate a locking pliers into a multi-function tool with varying results. For example, some multi-function tools include locking pliers having non-retractable jaws that result in a device that is not as compact as a tool with retractable jaws. Other multi-function tools with locking pliers require several non-intuitive steps to unfold the jaws from the handles.
SUMMARY OF THE INVENTION
One embodiment of the invention relates to a locking pliers. The locking pliers include a pair of handles and a pair of interconnected jaws coupled to the handles. The pair of jaws are movable between a retracted position within the handles and an extended position extending from the handles. The jaws are slidably coupled to the handles and configured to slide between the retracted position and the extended position without opening the handles. When the jaws are in the extended position, the jaws have an unclamped configuration in which the jaws are adjustable by a user to permit the jaws to lock onto objects of various sizes and a clamped configuration in which the jaws are releasably locked onto an object.
Another embodiment of the invention relates to a multi-function tool. The multi-function tool includes a first handle, a second handle, and an ancillary tool pivotally coupled to a first end of the first handle. The multi-function tool further includes a first jaw having a tang coupled to the first handle and a second jaw pivotally coupled to the first jaw and having a tang coupled to the second handle. The jaws are slidably coupled to the handles and configured to slide between a retracted position within the handles and an extended position extending from the handles. When the jaws are in the extended position, the jaws have an unclamped configuration in which the jaws are adjustable by a user to permit the jaws to lock onto objects of various sizes and a clamped configuration in which the jaws are releasably locked onto an object.
Another embodiment of the invention relates to a multi-function tool having a pair of handles, each having a first end and a second end. A pair of jaws is coupled to the handles and the jaws have an unclamped configuration in which the jaws are adjustable by a user to permit the jaws to lock onto objects of various sizes and a clamped configuration in which the jaws are releasably locked onto an object. An adjustment mechanism is located between the handles and between the first end and the second end to permit adjustment of the clamped configuration distance between the jaws.
The invention is capable of other embodiments and of being practiced or being carried out in various ways. It is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a multi-function tool according to an exemplary embodiment with the jaws in a retracted configuration.
FIG. 2 is a side view of a multi-function tool of FIG. 1 with the jaws in an extended configuration.
FIG. 3 is a side view of a multi-function tool of FIG. 1 with the jaws in an extended and open configuration.
FIG. 4 is a side view of a multi-function tool of FIG. 1 with several tools or implements deployed from the handles of the multi-function tool.
FIG. 5 is an exploded view of the multi-function tool of FIG. 1 .
FIG. 6 is an exploded view of the jaw assembly of the multi-function tool of FIG. 1 .
FIG. 7 is an exploded view of one of the handles of the multi-function tool of FIG. 1 .
FIG. 8 is a side view of the jaw assembly in a clamped configuration with the jaws adjusted to a first position.
FIG. 9 is a side view of the jaw assembly in an clamped configuration with the jaws adjusted to a second position.
FIG. 10 is a side view of the jaw assembly in a unclamped configuration with the jaws adjusted to a first position.
FIG. 11 is a side view of the jaw assembly in an unclamped configuration with the jaws adjusted to a second position.
FIG. 12 is a top view of the multi-function tool of FIG. 1 .
FIG. 13 is a cross section of the multi-function tool of FIG. 12 taken along line 13 - 13 with the jaws in a retracted configuration.
FIG. 14 is a cross section of the multi-function tool of FIG. 12 taken along line 14 - 14 with the jaws in an extended configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4 , a multi-function tool 10 is shown according to an exemplary embodiment. The tool 10 includes a first handle or static handle 20 , a second handle or toggle handle 30 , a number of ancillary tools 28 pivotally attached to one or both handles 20 and 30 (see FIG. 4 ), and a retractable jaw assembly 40 (see FIGS. 2-3 ). In the exemplary embodiment shown in FIGS. 1-4 , the multi-function tool 10 includes a pair of locking pliers.
Referring to FIGS. 1 and 4 , multi-function tool 10 may have a compact or retracted configuration in which the jaw assembly 40 is stowed within the handles 20 , 30 . The compact configuration is useful for storing the multi-function tool 10 when not in use, permitting carrying in a pocket or attaching to a belt. The jaw assembly 40 may be moved to a deployed or extended configuration as shown in FIGS. 2-3 to allow a user to open and close handles 20 , 30 to manipulate jaw assembly 40 .
The first handle 20 and second handle 30 are coupled together at one end with a pivot mechanism, such as a pair of rivets 38 . The rivets 38 allow the handles 20 and 30 to pivot relative to each other and operate jaw assembly 40 . As shown best in FIG. 4 , according to one exemplary embodiment, a wide variety of ancillary tools 28 may be coupled to one or both of handles 20 , 30 . Exemplary types of tools 28 include blades, screwdrivers, bottle openers, can openers, scissors, files, box openers, and the like. One or both handles 20 , 30 may have a channel (or multiple channels) configured to house the ancillary tools 28 , the channel(s) open toward the exterior of the multi-function tool 10 permitting a user to pivotally open and close ancillary tools 28 when multi-function tool 10 is in the compact configuration, as shown in FIG. 4 .
Referring now to FIG. 5 , an exploded view shows the jaw assembly 40 according to an exemplary embodiment. The jaw assembly 40 is coupled to the first handle 20 and the second handle 30 such that the jaw assembly 40 can slide relative to the handles 20 , 30 between a compact or retracted position and a deployed or extended position. The jaw assembly 40 includes a pair of jaws 42 . A first end of the jaws 42 forms working portions 44 and a second end of the jaws 42 forms tangs 46 (see also FIGS. 8-11 ). The tangs 46 are coupled to the handles 20 , 30 via links, shown as a first or static saddle 50 and a second or toggle saddle 60 . The jaws 42 are coupled together at a pivot point 49 between the working portions 44 and the tangs 46 . A biasing member such as a spring 48 may be included. According to an exemplary embodiment, spring 48 is an extension spring coupled to the tangs 46 and is configured to bias the tangs 46 toward each other and, in turn, bias the working portions 44 away from each other. In another embodiment, one end of the extension spring may be attached to the static saddle 50 instead of the tang 46 while still biasing the working portions 44 away from each other.
The first saddle 50 and the second saddle 60 are each coupled to one of the tangs 46 and to an adjustment linkage or a mechanism, shown as a toggle assembly 80 , that allows a user to adjust positioning of the second saddle 60 relative to the first saddle 50 and positioning of the working portions 44 relative to each other. The first saddle 50 and the second saddle 60 are slidably coupled to the first handle 20 and the second handle 30 , respectively.
The jaw assembly 40 is slidably coupled to first handle 20 with a sliding mechanism in the form of a slide cap 52 that is coupled to the first saddle 50 with fasteners 54 . The slide cap 52 and the first saddle 50 are provided on opposite sides of a wall of the first handle 20 and the fasteners 54 are received by a first slot 22 (e.g., a narrow slot) that runs along the first handle 20 . A second wide slot or opening 24 is provided on one end of the first slot 22 (e.g., proximate to rivets 38 ) and is connected to the first slot 22 . The fasteners 54 are also coupled to a button retainer 55 ( FIG. 6 ). A slide button 56 is provided with a shoulder 57 that is trapped between the button retainer 55 and the slide cap 52 . A portion of the button 56 extends out through a button opening 53 in the slide cap 52 . A biasing member such as a spring 58 is provided to bias the button 56 outward, away from the button retainer 55 . The first slot 22 has a width that is large enough to receive a portion of the button 56 but too narrow to allow the shoulder 57 of the button 56 to pass through. The second slot 24 is wide enough to receive the shoulder 57 of the button 56 .
To deploy the jaw assembly 40 (e.g., to move the jaw assembly 40 from the compact or retracted configuration to the deployed or extended configuration) a user forces the jaw assembly 40 forward either by pushing forward on the button 56 or by “flicking” the tool 10 such that momentum of the jaw assembly 40 forces jaw assembly 40 forward (e.g., towards the end of the handles 20 , 30 coupled together with rivets 38 ). As the jaw assembly 40 moves forward, the button 56 slides along the first slot 22 , and jaw assembly 40 does not pivot forward. When the button 56 is aligned with the second slot 24 , the spring 58 forces the button 56 upward such that the shoulder 57 is received in the second slot 24 . Because the shoulder 57 is too wide to be received in the first slot 22 , the button 56 cannot slide until the shoulder 57 is disengaged and therefore functions as a lock for the jaw assembly 40 locking jaw assembly 40 in the deployed configuration.
To return the jaw assembly 40 to the retracted position, the user may push down on the button 56 to compress the spring 58 and force the shoulder 57 out of the second slot 24 , thus unlocking the jaw assembly 40 . The user may then pull back on the button 56 to slide it into the first slot 22 . The jaw assembly 40 is retracted by either continuing to pull back on the button 56 until the jaw assembly 40 is fully retracted or to turn the tool 10 upright (e.g., in a vertical position) and tapping it against a surface such that momentum of the jaw assembly 40 forces it into the retracted position.
The jaw assembly 40 maintains contact with the second handle 30 with a fore pawl 62 and an aft pawl 70 that are coupled to the second saddle 60 . The fore pawl 62 and the aft pawl 70 slide along and are retained by a slide rail 32 (see FIGS. 7 and 14 ) on the second handle 30 . According to one exemplary embodiment, the slide rail 32 is separately formed and coupled to the second handle 30 (e.g., with rivets). According to another exemplary embodiment, the slide rail 32 may be integrally formed with the second handle 30 as built-in walls, ridges, etc. The fore pawl 62 and the aft pawl 70 include arms (extensions, pegs, etc.) 64 and 72 , respectively, that are trapped between the slide rail 32 and the second handle 30 . The arms 64 , 72 partially prevent the fore pawl 62 and the aft pawl 70 from being pulled away from the second handle 30 while still allowing the fore pawl 62 and the aft pawl 70 (as well as the second saddle 60 and the rest of the jaw assembly 40 ) to slide along the length of the second handle 30 .
The fore pawl 62 and the aft pawl 70 each rotate about their own pivot points. The fore pawl 62 pivots about a first pivot pin 66 (see FIGS. 5 and 14 ) that couples the fore pawl 62 to the second saddle 60 . The aft pawl 70 pivots about a second pivot pin 74 (see FIGS. 5 and 14 ) that couples the aft pawl 70 to the second saddle 60 . By having different pivot points 66 , 74 , both the fore pawl 62 and the aft pawl 70 can always maintain contact with the lock slide rail 32 as the second saddle 60 pivots with respect to the second handle 30 as the jaws 42 are opened and closed.
Referring now to FIG. 6 , an exploded view of the jaw assembly 40 is shown according to an exemplary embodiment. The fore pawl 62 includes a protrusion or nose 65 that is in contact with a curved bearing surface 75 (see FIG. 13 ) on the aft pawl 70 so that a movement in one of the pawls 62 or 70 may impose a movement in the other. Springs 68 and 76 are coupled to the second saddle 60 and to the fore pawl 62 and the aft pawl 70 , respectively, to maintain rotational tension on the fore pawl 62 and the aft pawl 70 . The rotational tension helps to maintain a constant contact between the protrusion 65 and the bearing surface 75 .
A toggle 80 is coupled on a first end 82 to the first saddle 50 and on a second end 84 (opposite to end 82 ) to the second saddle 60 . The first end 82 is provided on a toggle yoke 86 while the second end 84 is provided on a threaded toggle eye 88 . The yoke 86 forms a longitudinal shaft or opening that is configured to receive the eye 88 .
The yoke 86 further includes an opening 92 that is configured to receive an adjustment wheel 90 . The adjustment wheel 90 is a cylindrical member with a threaded central opening that engages the threaded toggle eye 88 . The opening 92 in the yoke 86 is aligned with the longitudinal shaft in the yoke 86 and allows the adjustment wheel 90 to rotate while still remaining in the yoke 86 . In this way, with the toggle eye 88 engaging the adjustment wheel 90 , the adjustment wheel 90 may be turned to move the eye 88 relative to the yoke 86 . A retainer, such as a clip 94 , may be coupled to an end of the eye 88 to prevent the eye 88 from being moved out of the adjustment wheel 90 and disengage from the threaded opening in the adjustment wheel 90 . Moving the eye 88 relative to the yoke 86 in turn moves the second end 84 of the toggle 80 relative to the first end 82 of the toggle 80 , effectively lengthening or shortening the toggle 80 . By adjusting the toggle 80 with the adjustment wheel 90 , a user can change the length of the toggle 80 and the orientation of the first saddle 50 and the second saddle 60 to in turn adjust the orientation and range of motion of the jaws 42 .
In the embodiment shown in FIG. 7 (presenting vantage point different than the FIG. 5 view), the second handle 30 includes a locking mechanism with a lock 36 that is configured to selectively lock one of the ancillary tools 28 in a deployed position (e.g., a functional position, extended from the second handle 30 ). A tang of the ancillary tool 28 includes a flat or cutout 29 . According to an exemplary embodiment, lock 36 includes a spring arm 37 . The spring arm 37 is biased against a side of the ancillary tool 28 . When the ancillary tool 28 is moved into the deployed position, the cutout 29 allows the spring arm 37 to move into a space behind the ancillary tool 28 , locking the ancillary tool 28 in the deployed position. Some ancillary tools 28 (i.e., screwdrivers, saws, files, etc.) may experience forces when in use that are countered by the lock 36 allowing the ancillary tool 28 to remain in the deployed position. A user may unlock the ancillary tool 28 by pressing on the spring arm 37 to move it out from behind the ancillary tool 28 and rotate the ancillary tool 28 into a stored position within the handle 30 . While FIG. 7 shows the second handle 30 , it should be understood that a similar locking mechanism may be provided for ancillary tools 28 in the first handle 20 .
Referring now to FIGS. 8-11 , the jaw assembly 40 is shown both open ( FIGS. 10 and 11 ) and closed ( FIGS. 8 and 9 ) in both a maximum adjustment position ( FIGS. 9 and 11 ) and a minimum adjustment position ( FIGS. 8 and 10 ). In the minimum adjustment position, the toggle 80 is adjusted so that the first end 82 and the second end 84 of the toggle 80 are at a maximum distance from each other and the working portions 44 of the jaws 42 are at a minimum distance from each other (e.g., touching at the tip) when the jaws 42 are closed. In the maximum adjustment position, the toggle 80 is adjusted so that the first end 82 and the second end 84 of the toggle 80 are at a minimum distance (e.g., the toggle eye 88 is fully seated in the toggle yoke 86 ) from each other and the working portions 44 of the jaws 42 are spaced apart from each other when the jaws 42 are closed.
The pawls 62 , 70 are provided to compensate for a differing pivot axis for the second handle 30 (see FIGS. 1-4 ) and the second saddle 60 . The second handle 30 rotates around the rivet 38 and the second saddle 60 rotates around a first saddle pivot 78 .
The variation in the positions of the jaws 42 in the minimum and maximum positions is caused by a linkage formed between the saddles 50 , 60 , the jaws 42 , and the handles 20 , 30 (see FIGS. 1-4 ). The jaw assembly 40 is configured to grip and hold items using an over-the-center toggle clamp mechanism. In the open configuration, the jaw spring 48 pulls the jaw tangs 46 together, thereby opening the jaws 42 . As the second saddle 60 is pulled toward the first saddle 50 (when the handle 20 , 30 are squeezed together), the second saddle 60 rotates around a second saddle pivot 79 , and the jaw tangs 46 move away from each other, causing the working portions 44 to close.
In the closed or clamped position, the jaws 42 are held in place (e.g., releasably locked) by an over-the-center condition between the forces at the first saddle pivot 78 and the second saddle pivot 79 (see FIGS. 8 and 9 ). The over-the-center condition locks the jaws 42 in the closed or clamped position until the tool 10 is manually released or unclamped by a user. This locking feature allows a user to clamp down on an object with the tool 10 without having to maintain pressure on the handles 20 , 30 , leaving the user's hand available for another task.
The jaw assembly 40 opening angle can be adjusted by changing the distance between the first end 82 and the second end 84 of the toggle 80 (i.e., the distance between the toggle pivot pin 96 and the second saddle pivot 79 ). The shorter the distance, the larger the opening that will be formed by the jaws 42 in the closed or clamped position and the larger an object that can be clamped with the tool 10 . As described above, the distance may be adjusted by rotating the adjustment wheel 90 around the threaded portion of the toggle eye 88 . The adjustment wheel 90 pulls the toggle yoke 86 towards the second saddle pivot 79 .
In the embodiment shown FIG. 3 , the toggle 80 and the adjustment wheel 90 are between the first handle 20 and the second handle 30 proximate to the jaws 42 so that the adjustment wheel 90 may be manipulated by a user with the same hand that is holding the tool 10 . In this way, the user can adjust the size of the opening formed by the jaws 42 in the clamped position without having to reach to the back end of the tool with the other hand to make the adjustment as is the case with certain conventional locking pliers. The user may therefore use the other hand for another task such as holding the object to be clamped or other tools.
It is important to note that the construction and arrangement of the multi-function tool as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. While the detailed drawings, specific examples, and particular formulations given describe certain exemplary embodiments, they serve the purpose as illustration only. The invention is not limited to the specific forms shown. The configuration of multi-function tool may differ depending on chosen performance characteristics and physical characteristics of the components of the multi-function tool. For example, the implement may take a variety of configurations and perform different functions depending on the needs of the user. Furthermore, other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the invention as expressed in the appended claims. Elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention
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One embodiment of the invention relates to a locking pliers. The locking pliers include a pair of handles and a pair of interconnected jaws coupled to the handles. The jaws are movable between a retracted position within the handles and an extended position extending from the handles. The jaws are slidably coupled to the handles and configured to slide between the retracted position and the extended position without opening the handles. When the jaws are in the extended position, the jaws have an unclamped configuration in which the jaws are adjustable by a user to permit the jaws to lock onto objects of various sizes and clamped configuration in which the jaws are releasably locked onto an object.
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FIELD OF THE INVENTION
This invention relates to practice golf putting greens. More particularly, it refers to a portable lengthwise putting green wherein sectional panels are held together by mechanical locking features.
BACKGROUND OF THE INVENTION
The expanding interest in golf has created a demand for golf practice tools, particularly putting greens. The ability to putt accurately distinguishes the ordinary golfer from the skilled golfer. With an interest in improving golf putting skills, the portable golf putting green of U.S. Pat. No. 6,302,803 was developed. Although the portable golf putting green described in this patent has been commercially accepted and serves its intended purpose, a need exists for variations that suit particular markets.
SUMMARY OF THE INVENTION
The invention of this application is a series of one piece sectional polymeric panels attachable by locking features to adjacent panels in a lengthwise direction. The lengthwise fastened together panels are covered by a simulated grass layer to create a putting surface simulating a putting green. The one piece sectional polymeric panels are prepared by compression, blow, injection or other molding process to prepare a smooth, planar top surface integral with a bottom grid structure. Locking features are mounted at an end of each panel juxtaposed to an adjacent polymeric panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a cut-away perspective view of the polymeric panel of this invention showing front edge trim placement.
FIG. 2 is a cut-away perspective view of the polymeric panel of FIG. 1 with the edge trim in place covered with simulated grass.
FIG. 3 is a bottom view of the polymeric panel of FIG. 1 .
FIG. 4 is a sectional view along line 4 — 4 of FIG. 1 .
FIG. 5 is a perspective view of two cut-away polymeric panels showing a first locking mechanism.
FIG. 6A is a perspective view of a portion of the polymeric panels of FIG. 5 locked together.
FIG. 6B is a sectional view of a portion of the polymeric panels of FIG. 5 locked together showing the locating pin.
FIG. 7 is a perspective view of a portion of a rear polymeric panel showing a ball cup placement and placement of a backboard.
FIG. 8 is a perspective view of the portion of the rear polymeric panel of FIG. 7 with the cup and backboard in position.
FIG. 9 is a sectional view of the polymeric panel of FIG. 8 showing the backboard attachment.
FIG. 10 is a perspective view of the portable golf putting practice green with a first locking mechanism.
FIG. 11 is an exploded view of a polymeric panel with a filler block at each side edge.
FIG. 12 is a cut-away view of a polymeric panel with an installed filler block.
FIG. 13 is a cut-away view of two adjacent polymeric panels with a second locking mechanism in exploded view.
FIG. 14 is a cut-away view of two joined polymeric panels of FIG. 13 with the second locking mechanism.
FIG. 15 is a cut-away view of a rear polymeric panel showing an alternate attachment to the backboard.
FIG. 16 is a cut-away view of a rear polymeric panel of FIG. 14 showing the backboard attached with a second locking mechanism.
FIG. 17 is a cut-away view of a third locking mechanism for joining two polymeric panels.
FIG. 18 is a cut-away view of the third locking mechanism joining two polymeric panels.
FIG. 19 is a cut-away view of a fourth locking mechanism for joining two polymeric panels.
FIG. 20 is a cut-away view of the locking mechanism of FIG. 19 .
FIG. 21 is a sectional view of the fourth locking mechanism along line 21 — 21 of FIG. 20 .
FIG. 22 is a cut-away view of the portable golf putting practice green with a chipping station.
FIG. 23 is a perspective view of a molded polymeric or foam insert for inserting under simulated grass around a cup.
FIG. 24 is a bottom view of the molded polymeric or foam insert of FIG. 23 .
FIG. 25 is an exploded view of the molded polymeric or foam insert of FIG. 23 being mounted on a top surface of a front panel.
FIG. 26 is a perspective view of the carrying cases for a three panel unit and simulated turf.
FIG. 27 is a cut-away perspective view of a rear panel employing a ball return.
FIG. 28 is a view of the means of attaching the ball return receptacle to a side of the polymeric panel.
FIG. 29 is a sectional view along line 29 — 29 of FIG. 27 .
DETAILED DESCRIPTION OF THE INVENTION
Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Referring first to FIG. 10, the portable practice green 10 is a lengthwise unit having three panels mechanically locked together. Two panels or four or more panels could be used alternatively. Each panel is a polymeric unit having a flat top surface portion and an integral grid bottom portion. A front panel 22 usually has a cup 14 for receipt of putted golf balls and a ball remover stand 16 . A middle panel 18 is attached by a locking mechanism 20 to front panel 22 and back panel 12 . The attached panels are covered by a simulated grass 24 .
Referring to FIG. 1, the front edge portion 30 of panel 22 has a trim piece 26 attached to the edge portion 30 by a two sided sticky tape 28 . The panel has rolled raised edges 32 on each side. As seen in FIG. 2, the simulated grass 24 fits into trim piece 26 to give a clean front edge portion 30 to panel 22 . The grid structure 34 integral with the flat top 36 of panel 22 supports the panel as seen in FIGS. 3 and 4. A hole 38 in side edge 32 is adapted for receipt of locking hardware as seen in FIGS. 5, 6 A and 6 B. A block 40 molded in with the grid structure can receive a locating pin or threaded fastener.
A first locking mechanism 42 as seen in FIGS. 6, 6 A and 6 B has a bar 44 pivoting at a first end with a groove at a second end portion engaging the shaft 48 of threaded fastener 50 to lock polymeric panels 18 and 22 together. Pins 52 in polymeric panel 18 engage holes 54 in polymeric panel 22 prior to completing the locking step. The pin 52 can be aluminum, plastic or steel and the bar 44 is aluminum, plastic or steel.
A backboard 56 is attached by a pair of threaded fasteners 58 to a front end 60 of front panel 22 as shown in FIGS. 7 and 9. The golf ball receiving cup 14 is molded into front polymeric panel 22 . A hole 64 in cup 14 receives a terminal ring 66 at the end of a simulated flag stick 68 . A cup ring 70 provides a neat edge to cup 14 .
FIGS. 11-14 describe a second means of fastening the polymeric panels together by forming a groove 72 at an edge of each polymeric panel. As seen in FIG. 13, a metal bracket 74 fits into grooves 72 and is held in place by fasteners such as bolts 76 . When the groove 72 is not juxtaposed to an adjoining polymeric panel, a filler block 78 is placed in groove 72 . Groove 72 of panel 22 A can be used to receive an L-bracket 80 attached to a backboard 56 A. This provides an alternate manner of attaching the backboard 56 A to a front polymeric panel 22 A.
FIGS. 17 and 18 show a third means of locking two polymeric panels together. A slot 82 is formed in a rolled side 32 A. In addition, a portion of a bottom edge 84 of side 32 is cut-away and a side slot 81 formed to permit insertion on both an inner and outer bottom edge of side 32 A of a U-shaped plate 86 . Threaded fasteners 88 pass through holes 90 in plate 86 and through slot 82 to join two polymeric panels together.
FIGS. 19-21 show a fourth means of locking two panels together. A cammed S-hook 92 is mounted in a side slot 96 of a polymeric panel side 98 . By turning an alien wrench 94 , after sides 98 and 100 are brought together, the S-hook 92 engages a back edge 102 in opposite slot 104 . Rivets 106 hold the respective components in place. Each of side 98 and 100 has one S-hook and each side has a complimentary slot 104 with a back edge 104 to receive an S-hook 92 .
A chipping platform 108 as shown in FIG. 22 provides an area separated from practice green 10 so that a golf ball can be chipped onto the practice green 10 . The chipping platform 108 is made in the manner of the polymeric panels in the practice green 10 .
Each polymeric panel unit 12 , 18 and 22 is compression molded, blow molded or injection molded with a grid structure 34 on a bottom portion integral with a planar top surface 36 . Other types of molding of the polymeric panels that can be used include low pressure flow molding, rotational molding, structural foam injection molding and reaction injection molding. Synthetic turf or carpet made of wool fibers or polymer fibers can be used for the simulated grass surface 24 of the putting training green 10 and is laid point to point at the base of the rolled edges 32 and to the trim piece 26 . A thicker rug carpet is used on the chipping platform 108 shown in FIG. 22 to simulate a typical chipping surface. The chipping platform 108 is molded in the same manner as the polymeric panels 12 , 18 and 22 and has a planar top surface integral with a bottom grid structure.
The polymer employed in the molding and creation of the polymeric panels 12 , 18 and 22 or the chipping platform 108 can be any of the high strength polymers such as polyethylene, polypropylene and co-polymers thereof and structural foams such as made from polyurethane.
A raised pad 110 having a hole 112 conforming to cup hole 14 has contour lines 114 as seen in FIG. 23 . This pad 110 is placed under the simulated grass 24 in panel 22 B to provide an additional putting challenge to the golfer and more realistically simulate an actual putting surface. The pad 110 has a bottom shallow grid surface 116 and downwardly descending pins 118 to engage holes 120 on panel 22 B.
The portable practice green 10 can be easily disassembled and carried away in a first carrying case 121 . The three panels 12 , 18 and 22 and backboard 56 of FIG. 10 are placed vertically within carrying case 121 . The simulated turf 24 is rolled up and placed into a second carrying case 122 along with the flag stick 68 , all as seen in FIG. 26 .
As an auxiliary aid to the golfer, an optional ball return feature can be incorporated as seen in FIGS. 27-29. A ball trough 124 is molded into grid 34 . A switch 126 can lead to a battery to activate sound to show that a golf ball passed over switch 126 . The trough 124 leads to a ball return receptacle 128 mounted on a rolled side edge 32 A. A hole 130 in side edge 32 A allows the golf ball to exit the trough and land in receptacle 128 . The receptacle 128 can be mounted on side edge 32 A on nipples 132 by engagement with openings 134 .
The above description has described specific structural details employing the invention. However, it will be within one having skill in the art to make modifications without departing from the spirit and scope of the underlying inventive concept of this portable golf putting training green. The invention is not limited to the structure described but includes such modifications as are substantially equivalent to the elements of the golf putting training green.
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Multiple molded polymeric panels are mechanically fastened together in a lengthwise configuration with a backboard at one end opposite the starting position for a putting stroke. Each panel has a planar top surface and a bottom integral grid supporting structure. The side edges of the panels are raised and the panels are attached together end to end. A simulated grass overlies the joined panels and a receptacle for receiving a golf ball is provided in one panel. A first carrying case contains the panels and backboard and a second carrying case contains the simulated grass and simulated flag stick.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to storage devices and more particularly to a storage device for extension tubes typically used in conjunction with aerosol spray cans.
2. Background Information
In 1953, Norm Larson and his co-workers at Rocket Chemical in San Diego, Calif., developed a rust-preventive solvent that displaced water. Five years later, in 1958, WD-40 aerosol was packaged in the familiar blue-and-yellow spray can by the WD-40 Company for use outside the aerospace industry. The WD-40 brand® is a petroleum-based, multi-purpose product that is used as a lubricant, rust preventative, penetrant, and moisture displacer. Its five basic properties—cleaning, lubricating, penetrating, displacing moisture and preventing rust—generates thousands of uses at work, in the home, for the car, at the workbench, in the garden and on sports and recreation equipment. For example, U.S. Pat. No. 4,257,464 discloses a fabric cover treated with a mixture of TRI-FLON® and WD-40® where the cover is used to protect hand guns, rifles and firearms from rust and corrosion. Many other uses for WD-40 brand are set out in Tim Nyberg & Jim Berg, The WD-40 Book (Bad Dog Press, March 1997).
The WD-40 brand is the most important product offered by The WD-40 Company, serving as the cornerstone for all the Company does. Four out of five US households have a can of WD-40® which is sold through retail outlets and industrial distributors in over 150 countries. The success of WD-40® has spawned literally hundreds of imitators, some backed by billion-dollar corporations. However, strong brand loyalty has enabled WD-40® not only to withstand incursions by competitors, but to actually expand its market share in the multi-purpose category.
To enhance the application of the atomized liquids propelled by the WD-40® spray can, the WD-40 Company includes a single, plastic, hollow extension tube with each can. By focusing the conic shaped spray of the atomized liquids into a narrow stream and transporting that stream to at least a fixed point at the end of the tube, the tube creates a penetrating jet stream that not only reaches confined spaces but acts to enhance the five basic properties of WD-40®. The tube is central to many of the uses for WD-40® set out above.
The red, polypropylene WD-40® extension tube that is used in conjunction with the WD-40® spray can is manufactured by Summit Packaging Systems, Inc. of Manchester, N.H. This flexible, but resilient hollow tube may come in a variety of shapes and sizes. For example, Summit Packaging Systems part number 38009 has an outside diameter of 0.085 inches, an inside diameter (or “lumen”) of 0.040 inches and a length of 4 inches. Summit Packaging Systems part number 0115 has an outside diameter of 0.082 inches, a lumen of 0.035 inches and a length of 6 inches.
Like most manufacturers who supply an extension tube with their spray can, the WD-40 Company holds the tube to the WD-40® spray can through a single piece was of adhesive tape. This adhesive tape is comprised of adhesive film disposed upon a thin, clear, mylar layer, with the layer being approximately 1.25 inches in length and 0.75 inches in width. At the WD-40 Company factory, the tube is held in physical, vertical contact with the WD-40® can by adhering the tape to the can lengthwise along the can's circumferential exterior at approximately the vertical midpoint of the can's circumferential exterior so that the tube is interposed between the tape and the can's circumferential exterior. With the tube attached to the can by the adhesive tape, the can is then shipped to retailers and sold to consumers.
The adhesive tape holds the tube in direct contact with the WD-40® spray can through two mechanisms. The first mechanism is the adhesiveness of the tape itself, which adheres to the outer surface of the tube to hold the tube in place. The second mechanism relies on a wedging force initially formed in the gap between the mylar tape and the can.
In using the plastic tube, the light amber WD-40® solvent inevitably coats the outside surface of the tube. Upon replacing the plastic tube into its adhesive tape holster, the WD-40® solvent residing on the outside surface of the tube acts upon the tape's adhesive film, causing the film to loose its adhering properties where the tube meets the adhesive tape. In other words, the first mechanism of holding the tube to the can through the adhesiveness of the tape itself is quickly lost upon using the WD-40® product.
The wedging force is similarly lost through using the WD-40® product. In this case, the consumer's actions of repeatedly removing the tube from its tape holster and replacing the tube back into its tape holster inevitably widens the gap between the mylar tape and the can until the gap no longer offer no support for the tube. Among the problems with using mylar tape to secure an extension tube is that the tape is not rigid enough to withstand repeated insertions and removals of the tube.
With no mechanism left to store the tube in conjunction with can, the consumer is left to find an adequate storage location for not only the can, but the small, narrow tube itself. Since an adequate storage device for these tubes is not supplied with the WD-40® can, the tubes frequently become damaged or lost. The present solutions to this problem are to either use the WD-40® product without the tube or to replace the damage/lost tube with another tube. For example, the WD-40 Company will supply free tube replacements merely by phoning the corporate headquarters in San Diego, Calif. In either case, the consumer is left without the ability to use the tube for a period of time. It is the consumer's lack of ability to use the tube for a period of time that, in turn, upsets the enhancement of the five basic properties of WD-40® added through the use of the tube.
Other solutions have been put forth. For example, U.S. Pat. Nos. 5,544,783 and 5,558,247 relate to a spray can extension tube holder comprising a device that clips onto the spray can, the device having an exterior, C-shaped configuration, where the axial opening of this C-shaped configuration extends radially outward from the device. The axial opening of the C-shaped configuration permits the user to snap the extension tube through the exterior wall of the device. However, this axial opening does not secure the extension tube against an accidental force that is applied to the extension tube, particularly when that force is applied radially outward from the far end of the extension tube. Under such circumstances, the force leverages the extension tube against either the upper or lower portion of the opening of the C-shaped configuration and, using the wall of the device as a fulcrum, knocks the extension tube from the spray can extension tube holder.
As another example, U.S. Pat. No. 5,772,068 relates to a cylindrical aerosol extension spray tube holder permanently secured to a spray can. The holder has an axial bore extending longitudinally through at least a portion of the tube holder so that, as shown in the figures of U.S. Pat. No. 5,772,068, at least three quarters of the extension tube may be encased within the holder. By permanently securing the holder to a spray can, the holder may interfere with the user's grip on the can where the nozzle rotates into a position such as shown in FIG. 2 of U.S. Pat. No. 5,772,068. U.S. Pat. No. 5,772,084 also suffers from this same problem. Moreover, by encasing the majority of the extension tube within the holder, the user can not easily remove the extension tube nor quickly inspect the extension tube for wear.
Other art that might be relevant to this area includes U.S. Pat. Nos. 5,178,354, 5,143,263, 4,823,445, 4,819,838, and 4,305,528.
Thus, there is a need for a device that adequately stores the extension tube in conjunction with the can not only at the time of sale, but over time as the product contained in the can is consumed in use. The invention disclosed relates to a device that allows the consumer to store over time at least one extension tube in conjunction with its can. Although the problems with the storage device for the extension tube used with WD-40® can were the inspiration for the invention, the use of this invention is not limited to the WD-40® can, but extends to storing at least one tube to any packaging of fluid that makes use of an extension tube. The benefits of the tube storage device include providing a stable, secure platform attached to the can from which the tubes may be safely stored for display and selection.
SUMMARY OF THE INVENTION
The invention relates to a device for storing an extension tube with a spray can. With the can having an exterior surface and the exterior surface of the can having a cross-section, an embodiment of the invention comprises a sleeve having a cavity adapted to receive the tube. The sleeve is coupled to the can through two resilient wings on the sleeve where the interior surface formed by these wings has a cross-section that conforms to, and is smaller than the cross-section of the exterior surface of the spray can. Through a slot formed by the free ends of the wings, the can engages the interior surface of the wings by causing the slot to deform apart then return towards the original width of the slot as the can passes between the slot.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the first embodiment of the device according to the invention.
FIG. 2 is a section view of FIG. 1 taken on line 2 — 2 of FIG. 1 .
FIG. 3 is an elevation view of the first embodiment of tube storage device according to the invention.
FIG. 4 is a perspective view of the recessed portion of the second embodiment of the device according to the invention.
FIG. 5 is a perspective view of the peg of the third embodiment of the device 1 , according to the invention.
FIG. 5 a is detailed view of the peg of FIG. 5 taken within line a.
FIG. 5 b is detailed view of the peg of FIG. 5 taken within line b.
FIG. 6 is a perspective view of the annular ring of the fourth embodiment of the device according to the invention.
FIG. 7 is a perspective view of the annular ring showing a hinge and locking mechanism.
FIG. 8 is a perspective view of the base of the fifth embodiment of the device according to the invention.
FIG. 9 is a section view of the base of FIG. 8 taken on line 9 — 9 of FIG. 8 .
FIG. 10 is a perspective view of the body of the sixth embodiment of the device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Plastic, hollow extension tubes are typically used to enhance the application of atomized liquids by focusing the conic shaped spray of the atomized liquids into a narrow stream and transporting that stream to at least a fixed point at the end of the tube. Since there is no adequate storage device for these tubes when the tubes are not in use, the tubes frequently become damaged or lost. The invention disclosed relates to a device that allows the consumer to store at least one tube in conjunction with its can. The benefits of the tube storage device include providing a stable, secure platform attached to the can from which at least one extension tube may be safely stored, displayed, and selected.
For purposes of explanation, specific embodiments are set forth to provide a thorough understanding of the present invention. However, it will be understood by one skilled in the art, from reading this disclosure, that the invention may be practiced without these details. Moreover, well-known elements, devices, process steps and the like are not set forth in detail in order to avoid obscuring the present invention.
Reference is now made to FIGS. 1 to 8 to illustrate several embodiments of the tube storage device. In one embodiment, a sleeve adapted to receive at least one tube may be mounted onto the packaging of the fluid. As shown in FIG. 1, can 10 packages fluid for sale to consumers in a spray can and comprises actuator 12 residing on mounting cap 14 , where mounting cap 14 is crimped onto collar 16 . Cylindrical housing 18 is sealed at the top by collar 16 , forming chine or ridge 22 a , and sealed at the bottom by bottom part 20 , forming ridge 22 b.
Also shown in FIG. 1 is sleeve 30 . In a preferred embodiment, sleeve 30 comprises two side wings 32 and 34 , bent or curved in the form of a bow, as well as geometric protrusion 36 projecting outwards from the sleeve. The arcuate side wings 32 and 34 serve to define an axial slot between their mutually confronting axial edges as well as define an interior surface. Geometric protrusion 36 aids in applying and removing sleeve 30 from can 10 .
Opposite to geometric protrusion 36 , an axial slot directed along Y-Y′ of can 10 is formed in sleeve 30 right through sleeve 30 . In other words, geometric protrusion 36 and the axial slot of sleeve 30 are disposed in front of each other along the diameter of can 10 onto which sleeve 30 will be mounted. In this embodiment, the distance between the mutually confronting axial edges of side wings 32 and 34 is smaller than the diameter of the corresponding can 10 . Side wings 32 and 34 are elastically deformable until can 10 may extend through the axial slot.
Concurrently with defining an axial slot, side wings 32 and 34 of sleeve 30 define an interior surface, the cross-section of which nearly corresponds the exterior cross-section of can 10 . Although other cross-sections are possible for the fluid package, for the purposes of this embodiment, can 10 has a cylindrical cross-section. Thus, side wings 32 and 34 of sleeve 30 define interior cylindrical surface 37 in this embodiment, the cross-section of which nearly corresponds in diameter to the exterior diameter of can 10 . Other sleeve 30 interior surface shapes, such as a “U” shape, rectangular shape, “V” shape, etc., may be used and are a function of the exterior cross-section of the fluid package. Side wings 32 and 34 may also be shaped accordingly.
Sleeve 30 is shown in FIG. 1 with a surface into which at least one storage hole or cavity 38 is formed, either partially or completely through the vertical thickness of sleeve 30 ; As shown in FIG. 2, where cavity 38 is formed partially through the vertical thickness of sleeve 30 , the remainder of the thickness of sleeve 30 may be kept in tact or have drainage hole 39 formed through this thickness. Preferably, the storage cavities are shaped to retain tube 40 within cavity 38 , such as by tapering cavity 38 , although such securing may be accomplished by an insert included in cavity 38 or scoring the interior surface of cavity 38 .
Since side wings 32 and 34 are elastically deformable, sleeve 30 may be clipped onto can 10 radially through the axial slot until sleeve 30 reaches the desired storage position. This movement is shown by arrow M 1 in FIG. 1 . Moreover, since side wings 32 and 34 are elastically deformable, side wings 32 and 34 may spread apart sideways to elastically engage sleeve 30 onto can 10 axially by sliding sleeve 30 along the periphery of can 10 until sleeve 30 reaches the desired storage position. This movement is shown by arrow M 2 in FIG. 1 . By inserting tube 40 into cavity 38 , and inserting can 10 into sleeve 30 , sleeve 30 holds tube 40 to can 10 without directly contacting can 10 . The desired storage position may be that shown in FIG. 3 . As shown, the tubes are stored directly under the path of the spray stream from actuator 12 . This storage position permits the user to hold onto can 10 without contacting tube 40 or any embodiment of the tube storage device.
In another embodiment, rather than forming a cavity in the vertical thickness of sleeve 30 , at least one recessed portion 50 is formed axially along Y-Y′ (of FIG. 1) in the interior peripheral surface of the arcuate side wings 32 and 34 . As shown in FIG. 4, recessed portion 50 may exhibit in cross-section a concave shape of an arc of a circle in the manner of a rigid wedge. Where recessed portion 50 is formed axially along Y-Y′ in interior cylindrical surface 37 of the arcuate side wings 32 and 34 , recessed portion 50 holds tube 40 to can 10 in direct contact with can 10 , either by itself or in conjunction with can 10 , thereby restricting the tube from being knocked out of the tube's storage position by an accidentally applied, radial force. Recessed portion 50 need not extend through the vertical thickness of sleeve 30 . The surface of recessed portion 50 may have at least two distinct diameters or be scored to increase the retention of tube 40 .
In another embodiment, rather than forming cavity 38 as shown in FIG. 1 or recessed portion 50 as shown in FIG. 4, peg 60 is formed axially along Y-Y′ (of FIG. 1) in surface of sleeve 30 . As shown in FIG. 5, peg 60 may exhibit in cross-section a diameter, onto which the hollow portion or lumen of tube 40 may be inserted. Peg 60 may have two or more portions as shown in FIG. 5 a . Peg 60 need not exhibit in cross-section a diameter, but any shape that serves to retain tube 40 through interaction with the lumen of tube 40 . Such shapes include, but are not limited to, needle shaped, bent, diamond shaped, nipple-shaped, cigar-shaped, and square. Peg 60 may also be bifurcated as shown in FIG. 5 b for clamping to the side wall of tube 40 .
In another embodiment, rather than coupling tube 40 to can 10 through sleeve 30 , ring 100 having an annulus shape and adapted to receive at least one tube 40 may be mounted onto can 10 . As shown in FIG. 6, ring 100 forms a complete annulus that may be inserted onto can 10 axially by disposing ring 100 along the periphery of can 10 until ring 100 reaches the desired storage position. This movement is shown by arrow M 2 in FIG. 6 . To store the at least one tube 40 , ring 100 may have cavity 38 , as discussed in connection with FIGS. 1, 2 , and 3 , recessed portion 50 , as discussed in connection with FIG. 4, or peg 60 , as discussed in connection with FIGS. 5, 5 a , and 5 b . Although cavity 38 , recessed portion 50 , and peg 60 are illustrated in FIG. 6, only one of these is needed to retain the at least one tube 40 . In the preferred embodiment, ring 100 is a single piece construction. The single piece construction may be made of a resilient material, such as rubber, whose properties couples ring 100 to can 10 and are rigid enough to retain tube 40 in a fixed storage position. As shown in FIG. 7, ring 100 may also have hinge 102 that permits first end 104 to move in relation to second end 106 to form an opening in ring 100 as well as move in relation to second end 106 to engage second end 106 in a locked position.
In another embodiment, rather than coupling tube 40 to can 10 through sleeve 30 or ring 100 , base 200 is adapted to be coupled to the bottom of can 10 . As shown in FIG. 8, base 200 comprises a flat portion 202 and a side wall 204 extending upwardly therefrom and terminating at annular rim 206 . Flat portion 202 restricts base 200 to the bottom of can 10 and may also serve to insulate can 10 .
FIG. 9 is a section view of base 200 taken on line 9 — 9 of FIG. 8 . As shown in FIG. 9, the annular rim 206 extends radially inward to form lip 208 capable of coupling base 200 to can 10 at ridge 22 b through an overlapping rim-ridge technique. Annular rim 206 may be divided into two or more portions. Where can 10 lacks ridge 22 b , base 200 may be adapted to be coupled to bottom part 20 of can 10 by other techniques. For example, annular rim 206 may be made of a resilient material that forms a compressive seal between base 200 and can 10 upon inserting can 10 into annular rim 206 .
To store the at least one tube 40 , base 200 may have cavity 38 , as discussed in connection with FIGS. 1, 2 , and 3 , recessed portion 50 , as discussed in connection with FIG. 4, or peg 60 , as discussed in connection with FIGS. 5, 5 a , and 5 b formed into either sidewall 204 or annular rim 206 . Although cavity 38 , recessed portion 50 , and peg 60 are illustrated in FIG. 8, only one of these is necessary to retain the at least one tube 40 . By inserting tube 40 into base 200 and inserting can 10 into base 200 , base 200 holds tube 40 to can 10 in a position such as that shown in FIG. 8 .
In another embodiment, rather than coupling tube 40 to can 10 through sleeve 30 , ring 100 , or base 200 , body 300 is made of magnetic material and engages can 10 by magnetically adhering to can 10 . As shown in FIG. 10, body 300 may include cavity 38 , as discussed in connection with FIGS. 1, 2 , and 3 , recessed portion 50 , as discussed in connection with FIG. 4, or peg 60 , as discussed in connection with FIGS. 5, 5 a , and 5 b . Although cavity 38 , recessed portion 50 , and peg 60 are illustrated in FIG. 10, only one of these is necessary to retain the at least one tube 40 . By inserting tube 40 into body 300 and engaging can 10 to body 300 , body 300 holds tube 40 to can 10 .
The embodiments of the invention described in relations to FIGS. 1, 4 , 5 , and 7 above is made preferably from a single molding in which ABS plastic material was injected into the mold. Taking into account the structure and the function of the particular embodiment, materials such as glass, metal, wood, paper, cork, ceramic, cordage, fabric, stone or other material may be used for the embodiments of the invention to form a similar shape using appropriate methods.
While the present invention has been particularly described with reference to the various figures, it should be understood that the figures are for illustration only and should not be taken as limiting the scope of the invention. Many changes and modifications may be made to the invention, by one having ordinary skill in the art, without departing from the spirit and scope of the invention.
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The invention relates to a device for storing an extension tube with a spray can. With the can having an exterior surface and the exterior surface of the can having a cross-section, an embodiment of the invention comprises a sleeve having a cavity adapted to receive the tube. The sleeve is coupled to the can through two resilient wings on the sleeve where the interior surface formed by these wings has a cross-section that conforms to, and is smaller than the cross-section of the exterior surface of the spray can. Through a slot formed by the free ends of the wings, the can engages the interior surface of the wings by causing the slot to deform apart then return towards the original width of the slot as the can passes between the slot.
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The invention relates to automatically stabilizing towed vehicles to avoid their inherent tendency to sway or swerve when travelling at moderate or high speeds.
BACKGROUND OF THE INVENTION
It is well recognized that when a towed vehicle, such as a travel trailer, is towed behind a car or truck there is an inherent tendency to sway when travelling at moderate or high speeds, thus causing a hazardous or dangerous driving condition. This condition may be aggravated by travelling over uneven roadbeds, making sudden turns, encountering gusty winds and passing large vehicles, such as trucks, travelling at high speeds.
PRIOR ART
It is well known that applying the brakes of the towed vehicle will correct swaying of the towed vehicle and that the sooner corrective action takes place the greater the chance of avoiding a hazardous or dangerous condition. The time lag before applying the brakes is very critical because the first few moments of any swaying action of the trailer is extremely important in determining the total extent and magnitude of the sway condition.
In some arrangements the lateral acceleration of the trailer is detected and the brakes are applied when the lateral acceleration exceeds a predetermined magnitude. However, there is a serious delay in applying the trailer brakes and the swaying action of the trailer may assume dangerous proportions before corrective action is taken.
SUMMARY OF THE INVENTION
The present invention is directed to sensing hitch lateral force and providing signals corresponding thereto. When the signals attain a predetermined value one or both of the trailer wheels are braked automatically. Hitch lateral force reaches a substantial value before any other parameter, such as lateral acceleration. When the brakes respond to hitch lateral force the brakes are applied before the swerving condition assumes dangerous proportions.
The invention contemplates apparatus for automatically eliminating a sway condition in a trailer vehicle towed by a tow vehicle and having brakes for retarding its rate of movement, comprising a hitch connecting the trailer vehicle to the tow vehicle, sensing means on the hitch for providing signals corresponding to hitch lateral forces, and means connected to the sensing means and responsive to the signals therefrom for operating the trailer vehicle brakes for automatically eliminating a sway condition in the trailer vehicle.
DRAWINGS
FIG. 1 is an elevation of a hitch constructed according to the invention coupling a trailer to a towing vehicle,
FIG. 2 is a plan view of the hitch, and
FIGS. 3 and 4 are electrical diagrams showing circuits constructed according to the invention for operating the electrical brakes on the trailer in response to hitch lateral force.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, an automotive vehicle 1 is connected to a trailer 3 by a hitch 5. The hitch includes a ball 7 mounted in a socket 13 on a bracket 9 secured to the automotive vehicle by screws 11 in the usual manner. Ball 7 and socket 13 may be of conventional construction as long as they permit the trailer to rotate about the yaw axis. A crank 15 has one end secured to ball 7 and the other end is secured to a torque arm 16 which is welded or otherwise fixed to a member 17 attached by brackets 19 to trailer 3. The torque arm is eccentric to the ball hitch so that when the trailer sways the hitch lateral force is transmitted through crank 15 to apply a torque to torque arm 16 and rotation of the torque arm about member 17 is proportional to the force applied.
The end of torque arm 16 remote from crank 15 is pivotally attached to a lever 21 connected to a brake modulator 23 mounted on a plate 24 secured to brackets 19. The modulator may comprise a variable resistance, inductance, capacitance or any other suitable means. Since rotation of torque arm 16 is proportional to the torque applied, lever 21 operates the modulator in proportion to the hitch lateral force. The modulator provides a d.c. voltage or current proportional to the hitch lateral force which controls the electrical brakes on the trailer as described hereinafter. If the trailer is equipped with hydraulic brakes the modulator may include a valve operated by lever 21. A trailer hitch for operating hydraulic surge brakes in response to hitch lateral force is shown and described in U.S. application Ser. No. 552,084 filed Feb. 24, 1975 and assigned to the same assignee as the present application.
Referring to FIG. 3, brake modulator 23 may comprise a variable resistor including resistor elements 43 and 45 separated by an insulator 47 and a wiper 41 connected to the positive terminal of the d.c. source through resistor 48. As the wiper 41 is moved from insulator 47 into contact with resistor element 43 or resistor element 45, depending upon the direction of the hitch lateral force, the brake modulator provides an electrical signal which is proportional to the magnitude of the hitch lateral force. Brake modulator 23 is connected by resistors 25 and 27 to the base electrodes of transistors 29 and 31, respectively. The manual brake actuator provides a brake signal B which is applied through resistors 33 and 35 to the base electrodes of transistors 29 and 31, respectively, also. The collectors of transistors 29 and 31 are connected to the positive terminal of the d.c. voltage source. The emitter of transistor 29 is connected to the left brake 37 and the emitter of transistor 31 is connected to the right brake 39 and both brakes are connected to ground.
As explained above, the signal from brake modulator 23 is proportional to hitch lateral force and the signal is summed with and modulates the brake signal B if the trailer tends to sway or swerve while the brakes are being applied manually. If the forces acting on the trailer are of sufficient magnitude to cause the trailer to sway, the hitch lateral force will reach a substantial value before the sway starts. Hitch lateral force toward the left causes the trailer to sway to the right (looking forwardly of the trailer) and wiper 41 is moved into contact with resistor element 43 providing a hitch lateral force signal which is summed with the brake signal and applied to the base of transistor 31 to operate the right brake 39 and increase the braking force on the right wheel of the trailer to provide a compensating moment on the trailer to avoid a dangerous condition. Similarly, hitch lateral forces toward the right cause the trailer to sway to the left and wiper 41 is moved into contact with resistor element 45 providing a hitch lateral force signal which is summed with the brake signal and applied to the base of transistor 29 to operate the left brake 37 and increase the braking force on the left wheel of the trailer to provide a compensating moment on the trailer to avoid a dangerous condition. The braking force is increased on the wheel at the side of the trailer in the direction of the impending sway.
If the combination vehicle is travelling at constant speed and the brakes are not being applied, hitch lateral forces toward the left provide an electrical signal for operating the right brake 39 and hitch lateral forces toward the right provide a signal for operating the left brake 37. The dead space between resistor elements 43 and 45 is selected so that the brake modulator operates the brakes above a predetermined hitch lateral force to avoid excessive brake application.
FIG. 4 shows a modulator 23a for applying right and left brakes simultaneously. A variable resistor has elements 49 and 50 separated by an insulator 51. One end of each resistor element 49 and 50 is connected to the positive D.C. source and the other end is connected to ground. When the hitch lateral force is above a predetermined minimum a wiper 52 contacts resistor 49 or 51, depending on the direction of the hitch lateral force, and provides an electric signal through resistor 25 to transistor 29 and through resistor 27 to transistor 31 for operating both brakes simultaneously.
A hitch constructed according to the invention improves the stability of a combination vehicle, making it easy to control and safe at high speeds because the trailer will not jack knife even under adverse conditions.
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Apparatus for automatically eliminating a sway condition of a trailer towed by a tow vehicle. A hitch connects the trailer to the tow vehicle and has a sensor for providing signals corresponding to the hitch lateral force for operating the trailer brakes.
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to tie-down devices and more particularly to a novel tie-down or anchoring device having a car slidably carried on a track including latch means for releasably retaining the car at a critical location on the track.
2. BRIEF DESCRIPTION OF THE PRIOR ART
In the past, it has been the conventional practice to employ a variety of rings, bars extending across recesses, holes in fixed structures and the like for retaining the free end of a rope, strap, chain or other means. Such a device may take the form of a car sliding on a track and in some instances, a plunger is employed which when aligned with an aperture in the track, permits latching so that the car is retained at that particular place.
Problems and difficulties have been encountered when employing such a car and track arrangement that stem largely from the fact that the plunger is not self-locating and requires visual or physical of the plunger with the selected opening or hole in the track. Also, such a device necessitates that the plunger be held out of contact with the track as the car is moved along to a particular opening or hole into which the plunger is to be released for attachment therewith. This is a disadvantage since the device is under tension as the car is being moved so that the user or operator of the device must concentrate on alignment and must physically place a tension against the plunger so that it is held out of physical contact with the track.
Another problem residing with conventional tie down and anchoring devices resides in the fact that the element to which the strap or rope is to be tied that generally takes the form of a loop is unsupported on the car and has a tendency to flop or fall to the side of the car. Such a position requires the user or operator to physically raise the loop with his hands in order to thread the strap or rope through the opening in the loop for attachment. Such an unsupported loop is a distinct disadvantage in the use of conventional tie down and anchoring means.
Therefore, a long standing need has existed to provide a novel car and track arrangement wherein the car is self-locating to a selected position on the track so that its latching mechanism will automatically effect releasable securement. Also, a need has existed to provide a support for the attachment loop on the car which will provide a predetermined purchase for the attaching rope or strap and certainly a support construction which will permit the strap or rope to be secured to the loop without the user or operator having to hold and support the loop itself.
SUMMARY OF THE INVENTION
Accordingly, the above problems and difficulties are obviated by the present invention which provides a novel tie-down or anchoring means having a track that slidably supports a car thereon so that the car may be moved along the length of the track so that the car may be moved along the length of the track in a linear manner. In one form of the invention, the car is provided with a plunger spring-biased within a sleeve to bear against the upper surface of a track so that as the car is moved along the length of the track, one end of the plunger automatically seeks insertion into an opening. The car further includes an exposed flange with a hole for supporting in a universal manner, an attachment loop to which a rope, strap or other attachment means may be secured. The flange includes a shoulder portion adapted to support the attachment loop so that the longitudinal access of the loop is held in an upwardly and outwardly projecting manner with respect to the track whereby an exposed end of the loop is available in a cantilevered fashion for ready access by the user or operator.
Therefore, it is among the primary objects of the present invention to provide a novel tie-down or anchoring means which employs a spring-biased plunger normally biased to engage with the surface of a track and adapted to automatically insert into a selected opening for releasable engagement with the track.
Another object of the present invention is to provide a novel hold-down or tie-down means employing an attachment loop which is held in a ready position in which the loop is cantilevered outwardly at an angle to the track and the car, exposing an eyelet for ready attachment to a strap, or rope or the like.
Still a further object of the present invention is to provide an anchoring means slidably connecting a car and track in a tongue-in-groove arrangement, including releasable means for attaching the car at a selected position to the track and which includes an attachment loop adjustable to a given purchase position wherein the eyelet of the loop is ready for attachment to a strap, rope or the like.
Yet another object of the present invention is to provide a novel tie-down arrangement of the slidable car and track arrangement that is relatively inexpensive to manufacture and that may be readily installed without special tools or knowledge.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood with reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of a vehicle having a truck bed mounting the novel tie-down or anchoring means of the present invention;
FIG. 2 is an enlarged exploded view in perspective arrangement illustrating the novel tie-down device or anchoring means of the present invention;
FIG. 3 is a side elevational view of the invention;
FIG. 4 is a transverse cross-sectional view of the tie-down means shown in FIG. 3 as taken in the direction of arrows 4--4 thereof; and
FIG. 5 is a top plan view in reduced scope showing the track and car arrangement illustrated in the previous figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a truck 10 is illustrated having a bed 11 having continuous sidewalls terminating in a door 12 which is illustrated in a down position. The continuous sidewalls of the bed 11 define a storage compartment or cavity in which boxes, parcels or the like may be stored. In the present instance, numeral 13 indicates a box which is positioned within the compartment and that is intended to be transported by the truck. Normally, during transport, the box 13 will move about in the compartment, which is undesirable. Therefore, a means is required for releasably holding or tying the box to the truck bed so as to inhibit the undesired movement.
The novel tie-down means or device of the present invention is employed in combination with the truck bed 11 for such a purpose. However, it is to be understood that other applications and usages of the novel tie-down means are available without departing from the inventive concept. Such other applications may take the form of a tie-down for block and tackle purposes or for mounting on the side rail of sailboats for holding snatch blocks and other sailing rigging.
The inventive tie-down means of the present invention is illustrated in the general direction of arrow 14 which includes an elongated length of track 15 on which a car 16 is slidably carried. The track is retained against supporting structure such as the sidewall of the truck bed 11 by means of a plurality of bolt and nut fasteners such as represented by numeral 17. The track 15 further includes an elongated slot 18 having a plurality of spaced apart enlarged openings 20, more clearly seen in FIG. 2. The car 16 is intended to be slid along the track 15 until a plunger 21 aligns with a selected opening 20 and is insertably received therethrough to prevent movement of the car on the track.
Referring now in detail to FIG. 2, it can be seen that the track 15 includes a guide groove 22 which is in communication with the elongated slot 18. Therefore, the track 15 may be referred to as a "T-track" wherein the guide groove 22 slidably receives a guide member 23 carried on the bottom of the car 16. The guide member 23 further includes a central vertical portion 24 that travels through the elongated slot 18 as the car is moved rectilinearly along the track 15. The guide member 23, vertical portion 24, guide groove 22 and elongated slot 18 combine to form a "tongue-in-groove" arrangement for slidably mounting the car and track together.
FIG. 2 further illustrates that the car 16 includes a central portion 25 having a hole therein, identified by numeral 26, which receives a loop portion 28 of an eyelet 27. In one form of eyelet, a portion 30 is pivotally mounted so as to be depressed inside the loop so that another loop can be introduced for attachment thereto. Also, depression of the portion 30 permits an exposed end of the loop to be entered through the opening 26 so that the loop may be slid through the opening until the eyelet portion 27 is disposed in the opening. Such construction permits the loop 28 to be mounted in a universal manner on the central portion 25 so that lateral and longitudinal movement is permitted. The central portion 25 is of reduced dimension as compared to end flanges 31 and 32 which define shoulders at opposite ends of the central portion 25. Flange 31 cooperates with an end flange 33 to define a guide portion 34 therebetween which is an extension of the central portion 25. The guide portion 34 receives the sleeve 21 by means of sleeve sections 35 and 36 on opposite side of the guide portion 34. The guide portion 34 is provided with a central opening 37 which receives a spring 38. The opening 37 terminates in a slot 40 for receiving a bar 41 passing through aligned openings in the sleeve elements 35 and 36.
Referring now in detail to FIGS. 3 and 4, it can be seen that the spring 38 is compressed between the upper end of the opening 37 and the bar 41. Also, the extension of the spring 38 forces the bar 41 into the slot 40. Therefore, the normal bias of spring 38 will forcibly urge the sleeve 21 into an aligned opening 20 in the track 15, as is shown in FIG. 3. As shown in broken lines, sleeve 21 may be manually raised against the expansion of spring 38 until the terminating end of the sleeve clears the opening in the track at which time the car 16 is permitted to be moved on the track.
FIG. 3 also illustrates that the loop 28 may be rested, as shown in broken lines, against the shoulder of flange 32 in a position preparatory for attachment to a rope or other securement means. Normally, the user or operator would have to employ one hand to hold the loop in position for attachment to another securement member. However, in the present instance, the attachment loop 28 may be rested against the shoulder and be in a position for receiving the attachment means. Furthermore, the angle at which the attachment loop 28 rests against the shoulder of flange 32 may be said to be predetermined purchase angle and therefore be of assistance to the user or operator in aligning rigging or the like.
Referring now to FIG. 4, it can be seen that the sleeve elements 35 and 36 straddle the portion 34 of car 16 and that the spring 38 is captured within the cavity 37.
In FIG. 5, it is again noted that the track 15 may be readily secured to a supporting structure 11 by the screws 17. The screws are preferably installed in a countersunk fashion so that the head of the screw will not restrict movement of the guide member 23 as it moves through the slot 22.
Therefore, it can be seen that the tie-down device of the present invention provides a movable car on a track which may be located in a critical location by insertion of the sleeve elements 35 and 36 within an alinged opening. The sleeve 21 is normally biased so that its terminating end slides along the top of the track 15 until an opening is received at which time the expansion of spring 38 will urge the sleeve into the respective opening. Such a construction eliminates the need for visually aligning the sleeve with openings and eliminates the need to hold the sleeve under the load of a spring tension while attempting to locate the sleeve with a selected opening. Furthermore, the ability of the car 16 to carry an attachment loop 28 is provided and supporting the loop in a predetermined angular disposition with respect to the track is advantageous.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
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A tie-down device is disclosed herein having a movable car slidably carried on a stationary track which includes a spring biased vertically movable latch on the car operable to be insertably received into a selected one of a plurality of openings on said track for releasably retaining the car in a critical location on the track. The car further includes an attachment arrangement such as a tongue-in-groove construction for mounting on the track and a securement loop universally carried on a car flange for attachment to a tie-down line or cord.
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This is a continuation of copending application Ser. No. 07,374,599 filed on Jun. 30, 1989, now abandoned, which is a continuation of U.S. application Ser. No. 06/837,618 filed on Mar. 7, 1986, now abandoned.
BACKGROUND OF THE INVENTION
In present computer-controlled instrument systems, manual measurements are performed by manual adjustment of controls located on each instrument, and resulting data appears in indicators on each instrument. As those skilled in the art are aware, the number of controls, especially on an instrument such as an oscilloscope, is large enough to cause confusion (see FIG. 13).
BRIEF SUMMARY OF THE INVENTION
The method is a computer program employing interactive computer graphics which draws an image of the controls and indicators of a particular instrument on the computer display. The program allows the operator to move a cursor around the screen and select the instrument function which he wishes to adjust. When he adjusts the graphical image, the corresponding adjustments are made by the computer program to the actual instrument itself.
The electronic instruments are connected to the computer via an interface bus over which the program sends commands and reads back data. A variety of different electronic instruments can be supported including multiple instruments of a single type.
The invention provides a method of displaying multiple, independent instruments on the computer display which are all active at the same time. This allows an operator to be making adjustments to a system using one instrument while observing the effect of these changes in the system on another instrument.
In addition, the invention provides a method of displaying only those controls and indicators of an instrument which are relevant to its current mode of operation. Many electronic instruments have controls and indicators on their front panel which are used only in certain modes. This has the effect of cluttering up the panel, often referred to as "overdensity". Physical controls and indicators on the front panel of an instrument cannot be added or removed, of course. But because computer graphics forms controls and indicators that are only images on the display, they can be drawn only when needed and erased otherwise.
FIG. 4 is a block diagram of a type of instrumentation system with which this invention may be used. This particular system is comprised of a function generator 2, an oscilloscope 4 and a universal counter 6. The output of the function generator 2 is coupled to the inputs of the oscilloscope 4 and the universal counter 6. Communication between these instruments and a computer 8 is via a communication bus 10 and interface electronics 12. The computer 8 is controlled by a keyboard 14 and graphical displays are formed on a cathode ray tube 16. If desired, a mouse 18 is coupled to the computer 8 so as to control the position of a cursor on the screen of the cathode ray tube 16.
Before going into an explanation of the operation of the system, reference is made to FIG. 1 for a description of the general format of one presentation that may appear on the CRT 16. In a column at the left are a plurality of what are referred to herein as system view windows, SVWs, that respectively show the identification and certain data related to each of several different instruments. In this illustration, the top SVW 20 is for the function generator 2 that is filled with half-tone for reasons to be explained, an SVW 22 for the osciloscope 4, and an SVW 24 for the universal counter 6. What will be termed an interactive instrument window, referred to herein as an IIW, 26 occupies most of the rest of the screen. In addition to a label of instrument type and and identification, it contains a plurality of components for controlling the function generator 2. The SVW 20 for the instrument having components in the IIW is half-toned because there is no need to repeat information that is available in the IIW 26. When the control components for another instrument are presented in the IIW, its SVW is half-toned and the information for the instrument that was in the IIW is shown in its SVW.
The control components will, of course, be different for each instrument; but the control components for the function generator 2 are a ganged switch 28 for selecting whether the output of the generator is to be a sine wave, a triangular wave or a square wave; numeric entry components 32, 34, 36 and 38 for frequency, amplitude, offset and symmetry; a ganged switch 40 for selecting the mode of operation, i.e., whether it is to be continuous, gated or burst; and a toggle switch 42 for the output. Also on the screen will be a STATUS line and various softkeys that are not part of this invention. As an aid to the user, the active part of most components contains characters on a shaded background, and the inactive parts contain characters on a white background. In the particular situation illustrated in FIG. 1, the function generator 2 is outputting a continuous sine wave at 1.0 KHz having an amplitude of one volt, a zero volt offset and 50% symmetry, and its output is enabled.
An advantage of this invention is that the effects of the output of the instrument represented in the IIW on other instruments to which it is coupled appear in the appropriate system view windows. Thus, a continuous sine wave having the selected amplitude, offset and symmetry appears in the SVW 22 for the oscilloscope and the selected frequency of 1.00 KHz is Printed in the SVW 24 for the universal counter 6.
Another advantage of the invention is that only those control components of an instrument that are needed for performing a selected function appear in the IIW. In FIG. 1, the wave provided by the function generator 2 is continuous; but in FIG. 9, the function NBURST is activated and three other controls that only relate to burst mode, such as start, halt, and the number of pulses to be output appear. If they were present all the time, it would be confusing. A more dramatic situation is an oscilloscope. Those skilled in the art are aware of the fact that there are so many controls on the front panel of a conventional oscilloscope that it is sometimes difficult to select the proper controls and easy to make mistakes because there are so many of them. FIG. 12 shows an IIW of this invention when it contains the controls for an oscilloscope. For each of the control components of each major section of an oscilloscope, such as Vertical Amplifiers for each channel, the time base, and the triggering circuitry, a different set of related controls appears in the right-hand side of the IIW.
Although the algorithms for operating an instrument system containing this invention is fully explained infra, a brief summary is set forth below.
______________________________________ BEGIN 1 [ identify instruments on bus ] 2 [ set all instruments to power-on state ] 3 [ build the Instrument List ] 4 [ build the Window List ] 5 [ assign lst instrument found on bus to the IIW ] 6 [ draw the IIW ] 7 [ draw each SVW ] 8 [ enable user input devices (mouse and keyboard) ] 9 WHILE (the user has not selected the "Exit" softkey) DOBEGIN10 [ poll instruments for "data ready" ]IF ("data ready") THEN BEGIN11 [ execute service routine for the instrument ]12 IF (instrument is in IIW) THEN [ update the IIW ]12 IF (instrument is in a SVW) THEN [ update that SVW ] END13 [ check for user input ]14 IF (user made a selection) THEN BEGIN15 [ identify window selected ] CASE (window) OFIIW: BEGIN16 [ identify component selected ]17 IF (no component selected) THEN [ beep ] ELSE BEGIN18 [ execute instrument control command associated with user request ]19 [ update the IIW ] END ENDSVW: BEGIN20 [ erase the IIW ]21 [ update SVW for instrument just in IIW ]22 [ draw the IIW for instrument whose SVW was selected ]23 [ half-tone the SVW for instrument which was selected] END24 OTHERWISE [ beep ] ENDENDIF (softkey selected) THEN25 [ execute system function associated with softkey ]ENDEND______________________________________
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the appearance of the CRT of the system when a function generator is displayed in the interactive instrument window, IIW;
FIG. 2 is like FIG. 1 and identifies the various control components;
FIG. 3 is like FIG. 1 and identifies the coordinate locations of several windows;
FIG. 4 illustrates an instrument system that may incorporate this invention;
FIG. 5A is a legend for FIG. 5;
FIG. 5B illustrates an IIW component template for a function generator;
FIG. 6 illustrates the SVW component template for an oscilloscope;
FIG. 7 illustrates the SVW component template for a universal counter;
FIG. 8 is an instrument list and window list for the example system of FIG. 4;
FIG. 9 shows the additional control components made available on a function generator when it is in the NBURST mode of operation;
FIG. 10 illustrates the change in the SVW for the oscilloscope when the square wave control component of the function generator in the IIW is activated;
FIG. 11 illustrates the position of the cursor required to put the oscilloscope into the IIW;
FIG. 12 shows the function generator in its SVW and the oscilloscope in the IIW; and
FIG. 13 shows the front panel of an HP oscilloscope.
DETAILED DESCRIPTION OF THE INVENTION
Representation of Instruments on the Computer Display
There are two specific representations of any electronic instrument that can appear on the computer display. One is a full "front panel" representation of the instrument which appears in this particular implementation in the upper right area of the display and which occupies most of the available space. It is from this representation that the operator can interact with the various graphical components to control the instrument which is pictured. The area of the display in which this representation of the instrument appears is called the "Interactive Instrument Window", or IIW.
The second representation of the instrument is one which does not provide any controls, but instead shows a summary of the instrument's status. The status includes continually updated readings in the case of measurement instruments such as multimeters, universal counters, and oscilloscopes. Each instrument in the system shows this representation in an area referred to as its "System View Window", or SVW. A SVW for each instrument attached to the interface bus appears in a column along the left edge of the computer display in the program described herein. If more instruments exist in the system than will fit along the left edge of the display, the computer's softkeys may be used to scroll the SVWs up and down on the screen.
Although the operator cannot control an instrument from its SVW, he can point to and select a SVW. This has the effect of putting the instrument currently in the IIW back into its SVW, and bringing the newly selected instrument up into the IIW.
The IIW and SVWs are marked on the computer display shown in FIG. 1.
GRAPHICAL COMPONENTS
The graphical components which comprise each of these windows were designed to closely resemble their physical counterparts. Graphical components have been implemented to represent the types of physical controls and indicators shown below:
Ganged Switch: A control which is a "1 of N" selector, usually consisting of a number of pushbuttons connected together mechanically so that only one may be selected at any time; selecting a new member of the gang de-selects the previous one.
Rotary Switch: Similar to a Ganged Switch in that it is a component which is a "1 of N" selector, it consists of a knob with multiple stops or detents in its rotary action. It is usually used to select from a group of settings which are ordered numerically.
Toggle Switch: A control that is a "1 of 2" selector, usually with a lever that is placed in either an up or down position.
Momentary Contact Switch: A control switch used to provide a signal to trigger or initiate an action. It is usually a pushbutton which returns to its original position when released.
Numeric Entry Field: A combination control and indicator for relatively or absolutely specifying a numeric value. It may consist in hardware either as a keypad tied to an LED or LCD display (absolute) or as a series of momentary contact switches which are used to increment or decrement an existing value (relative).
Alphanumeric Entry Field: A combination control and indicator for entering text strings. It consists in hardware as a keyboard with buttons from which characters may be specified.
LCD Array: An indicator to display numbers. In hardware, it is either an array of 7-segment LEDs or LCDs.
Text Display Field: An indicator to display text strings. In hardware, it is often an array of 16-segment LEDs or LCDs, or 5×7 dot (or greater) LED or LCD cells.
CRT Screen: A two-dimensional display that graphically displays one parameter versus another (voltage vs. frequency, voltage vs. time, etc.). In hardware, it is usually a cathode ray tube display built into an instrument.
Labels: An indicator that displays a fixed alphanumeric string. Its hardware analogy is a silk-screened label on an instrument's front panel.
FIG. 2 shows the computer display marked up to indicate the various types of components which go into implementing the instruments in the example. Note that not all of them appear in this example.
Also present on the computer display in this method, but not part of the patent claim, are the computer's softkeys and a status area to display error information and prompts to the user.
INTERNAL DESIGN OF THE IMPLEMENTATION
To understand the operation of the algorithm of the method, it is necessary to first describe some of the major aspects of the internal design of the implementation described herein.
Drawing Graphics on the Computer Display
In order for the method to work, it needs the ability to draw the various components and windows on the screen. This means interacting with the particular hardware-dependent display mechanisms of the computer.
The implementation used here assumes the availability of a graphics display mode with at least 512 pixels horizontally and 200 pixels vertically. The display is then divided into 25 rows of 80 columns each, or 2000 "cells".
There are three major coordinate systems used in the method: absolute, window-relative, and component-relative. They are shown in FIG. 3. Note that the (0,0) origin for each system is at the lower left. A few routines called "graphical primitives" handle the very lowest level of graphics, that of writing basic graphical elements to the graphics plane. They all use standard algorithms documented in computer graphics literature. These routines are:
(a) drawing a line;
(b) drawing a dot;
(c) writing a character (via "bitblt"s);
(d) filling a rectangular box;
(e) specifying a pen color for drawing, writing, and filling;
(f) specifying a line type for line drawing;
(g) specifying a fill pattern for box filling; and
(h) specifying a writing mode: black-on-white or white-on-black.
For drawing graphical components, each component type has a draw routine which sequences calls to the graphical primitives to display the component in the desired appearance.
Erasing a component is a much simpler operation: the pen color is set to white, and a box corresponding to the location and size of the component is filled, which makes the component disappear.
A few routines called "graphical primitives" handle the very lowest level of graphics, that of writing basic graphical elements to the graphics plane. They all use standard algorithms
Major Software Data Structures
The major data structures used in the system are linked lists. There are three types which are important for understanding the implementation:
(a) Instrument List:
Each entry in the list represents one of the electronic instruments connected to the computer via the interface bus. The fields of each entry contain, or point to, information necessary to display or control the instrument.
(b) Window List:
Each entry in the list represents either the IIW (one per system) or one of the SVWs (one per instrument) used to display the instrument representations on the computer display. The fields of each entry contain, or point to, information necessary to display each window.
(c) Component Templates:
Two component templates exist for each type of instrument supported by the system. One defines the components in the instrument's IIW representation, and the other defines the components in its SVW representation. Each entry in a template contains the information necessary to display a component on the screen and indicate the I/O action associated with it.
Types (a) and (b) are dynamic data structures built when program execution begins.
The linked lists of type (c) are static data structures associated with each type of electronic instrument supported.
Instrument List
The instrument list contains information about each of the instruments which are connected to the computer via the interface bus.
Each instrument data structure has the following fields: ##STR1##
As can be seen from the diagram, some of the information in this structure pertains to the type of instrument (i.e., a certain model of function generator), and some of it pertains to the particular instance (occurrence in the system) of that type of instrument (i.e., a function generator connected to the interface bus at a certain address, and set to a certain state).
These fields are defined as follows:
Instrument Type: A code which represents the type of instrument; for example, a particular model of function generator.
Name String: A string of characters which is displayed in both the IIW and SVW to identify the instance of a particular instrument model (since more than one instrument of the same type can be connected to the computer's interface bus).
IIW Component: A pointer to the start of the IIW component template for this type of instrument.
Physical Address Info: A block of information (shown here as a single field, since it is specific to the hardware architecture of the computer and interface) which contains all the required addressing information for the interface bus driver to communicate with this particular instance of the instrument type.
SVW Window Pointer: A pointer to the SVW-type entry in the window list which is used to display the instrument's SVW representation.
State Info Block Pointer: A pointer to a block of memory which contains fields to completely specify the state of this particular instance of this type of instrument. Since the size and definition of a State Info Block is specific to the instrument type, the instrument list contains a pointer to the block, and not the block itself.
Next Instrument Pointer: A pointer to the entry for the next instrument in the list; it is the link.
Window List
The window list locates and is used to display a window on the computer display. Each window data structure contains the following fields: ##STR2##
These fields are defined as follows:
Window Origin: Absolute (x,y) coordinates which locate the origin (lower-left) of the window with respect to the lower left corner of the display.
Window Size: The type of window the structure represents, either the IIW or one of the SVWs.
Component Template Pointer: A pointer to the component template associated with this window; it is fixed for each SVW entry in the window list, but changes for the IIW entry based on the type of instrument which is currently represented in the IIW.
Instrument Info Pointer: Points to the entry in the instrument list which is represented by the window.
Next Window Pointer: A pointer to the entry for the next window in the list; it is the link.
Component Templates
A component template is a "form" for displaying information about the state of an instrument in a particular representation on the computer display. Each instrument type has two templates associated with it, one for its IIW representation and one for its SVW representation.
One copy of these templates serves every instrument of that type in the system. Each instrument, however, can be set to a different state, which gets reflected in the appearance of the component.
For example, the ganged switch component of the function generator in FIG. 1 has three buttons: Sine, Square, or Triangle. The button which will appear as a black background with white characters to indicate the current function of the instrument depends on the State Information Block for "Func.Gen.01". Similarly, the Numeric Entry Field that represents frequency displays an ASCII string, "1.00 kHz" corresponding to the current frequency setting of this function generator.
Each component included in the component template has at least one structure, and perhaps two, associated with it. The fields of these structures are as follows: ##STR3##
The fields in the Component Structure are defined as follows:
Component Origin: Window-relative (x,y) coordinates which locate the origin (lower-left) of the component with respect to the lower left corner of the window within which it resides.
Component Size: (dx,dy) coordinates which specify the size of the component in cells.
Component Type: The type of component the structure represents.
Component Label: A string of ASCII characters which is the label associated with the overall component.
Number of States: For those components which have discrete states associated with them (ganged switches, rotary switches and toggle switches), this is a positive number indicating how many states there are. For components that display varying values (Numeric Entry, Alphanumeric Entry, LCD Array, Text Display, and CRT), the number of states equals "1". For labels, this field equals "0".
State List Pointer: If the number of states is positive, this field will point to the start of the associated state list structure for the component. If the number of states equals "0", this field equals "NIL".
Next Component Pointer: A pointer to the component structure of the next component in the template, it is the major link in the template.
If a state list exists, it will consist of the base structure shown above replicated as many times as there are states. The fields in the state list structure are defined as follows:
State Origin: Component-relative (x,y) coordinates which locate the origin (lower-left) of the state button or entry/display field with respect to the lower left corner of the component within which it resides.
State Size: (dx,dy) coordinates which specify the size of the state button or entry/display field in cells.
State Label: A string of ASCII characters which is the label associated with a state button.
Dependent Template Pointer: A pointer to the first component structure of a dependent component template. The components in the dependent template will be drawn only when the controlling component is in the state associated with the dependent template pointer. Dependent templates are only associated with components that have discrete states (ganged, rotary, and toggle switches). It is these components, then, through which the invention solves the "overdensity" problem of front panel controls
High-Level Window Graphics
The low-level mechanics of drawing graphical images on the screen was covered previously. Now that an explanation of the major data structures has been presented, the high-level routines which analyze the templates, obtain state information, and orchestrate the low-level graphics can be explained.
The key software routine is known as the "Update Window" routine. It has four modes which operate on windows: it can CREATE, MODIFY, HALF-TONE, or ERASE them. A fifth mode, COMPONENT ERASE, is for its own internal use.
A window will be created when it is being drawn in its current location for the first time. If the window is already visible in its current position on the screen and it merely needs to be updated to reflect a state change in the instrument it represents, then it is modified. If an instrument is going from the IIW back to its SVW, the IIW will be erased. If an instrument is going from the SVW to the IIW, its SVW will be half-toned.
The "Update Window" routine is given a pointer to the window data structure in the window list for the window it will be operating on, and the mode parameter. The operation of each mode is explained below:
(A) mode=ERASE or HALF-TONE
This is the simplest mode of operation:
(1) Obtain "Window Origin" and "Window Size" from pointer to window list entry which is passed as a parameter.
(2) Set the n to white or half-tone.
(3) Box-fill primitive the entire area of the window with the selected fill pattern.
(B) mode=CREATE
This mode involves walking the component template, getting information about the state of each component, and drawing each component on the display:
(1) Obtain "Window Origin" from pointer to window list entry which is passed as a parameter.
(2) Use "Instrument Info Pointer" to obtain the "State Info Block Pointer" for the instrument represented within the window.
(3) Use "Component Template Pointer" to access the first component in the component template.
(4) Add "Component Origin" coordinates to "Window Origin" components to obtain absolute display location.
(5) Use calculated absolute coordinates and "Component Size" to fill a box the size of the component with a half-tone pattern.
(6) Write out the "Component Label" string starting at (absolute x, absolute y+dy) in "black-on-white" mode.
(7) Pass "Component Number" and "State Info Block Pointer" to the "State Inquiry" conversion routine for the particular type of instrument. This routine translates the relevant information in the State Info Block into the current state format for the type of component. These formats are:
a) State Number: Used by ganged, rotary, toggle, and momentary switches; it is a number which is used to index into the state list structure of the component.
b) State String: Used by Numeric Entry, Alphanumeric Entry, Text Display, and LCD components; it is a pointer to the string to be displayed as the component's state.
c) State Array: Used by the CRT component; it is a pointer to an array of data which gets scaled to fit the size of the CRT and displayed as dots on the computer display.
(8) Display the state information within the "frame" of the component already drawn using "State Origin" and "State Size" (component-specific algorithm).
(9) If the component currently being created has discrete states, index to the entry in the state list for the specified state. If "Dependent Template Pointer" is non-NIL, call the "Update Window" routine recursively at this time using "Dependent Template Pointer", and mode=CREATE. The recursive call begins with step (4) and returns here when complete.
(10) If "Next Component Pointer" is not "NIL", traverse the list to the next component and go to step (5).
(11) If "Next Component Pointer" equals "NIL", the routine is complete.
(C) mode=MODIFY
This mode is designed for speed of updating an instrument's representation. Only changes in state, not the entire window, are redrawn. It involves walking the component template as in the "create" mode, but with two major differences: if the state of a component has not changed since the last time it was updated, nothing is done. And if the state of a component with discrete states, the previous "Dependent Template" must be erased, and the new "Dependent Template" created:
(1) Obtain "Window Origin" from pointer to window list entry which is passed as a parameter.
(2) Use "Instrument Info Pointer" to obtain the State Info Block Pointer" for the instrument represented within the window.
(3) Use "Component Template Pointer" to access the first component in the component template.
(4) Add "Component Origin" coordinates to "Window Origin" components to obtain absolute display location.
(5) Pass "Component Number" and "State Info Block Pointer" to the "State Inquiry" conversion routine for the particular type of instrument. In addition to current state, a second parameter is returned for the various classes of components, as follows:
a) State Number: In addition to current state number, it also returns previous state number: the state number given back the last time "State Inquiry" was called for that component.
b) State String: In addition to the pointer to the state text string, it also returns a flag which indicates whether or not the string has been modified since the last time "State Inquiry" was called for that component.
c) State Array: In addition to the pointer to the state array, it also returns a flag which indicates whether or not the array has been modified since the last time "State Inquiry" was called for that component.
(6) Overwrite the old state information with the new state information ONLY if the state of the component has changed since the last "State Inquiry" operation (component-specific).
(7) If the component has discrete states, index to the entry in the state list for the previous state. If its "Dependent Template Pointer" is non-NIL, call the "Update Window" routine recursively at this time, with "Dependent Template Pointer" and mode=COMPONENT ERASE. When this process completes, index to the state list entry of the new state. If "Dependent Template Pointer" is non-NIL, call the "Update Window" routine recursively again, using "Dependent Template Pointer" and mode=CREATE.
(8) If "Next Component Pointer" is not "NIL", traverse the list to the next component and go to step (5).
(9) If "Next Component Pointer" equals "NIL", the routine is complete.
(D) mode=COMPONENT ERASE
This mode is only invoked from within the MODIFY mode:
(1) Use "Dependent Template Pointer" to access the first component in the dependent component template.
(2) Add "Component Origin" coordinates to "Window Origin" components to obtain absolute display location.
(3) Use calculated absolute coordinates and "Component Size" to fill a box the size of the component with a white pattern.
(4) If the component has discrete states, pass "Component Number" and "State Info Block Pointer" to the "State Inquiry" conversion routine for the particular type of instrument in order to obtain the current state. Index to the entry in the state list for the current state. If "Dependent Template Pointer" is non-NIL, call the "Update Window" routine recursively at this time, with "Dependent Template Pointer", and mode=COMPONENT ERASE.
(5) If "Next Component Pointer" is not "NIL", traverse the list to the next component and go to step (3).
(6) If "Next Component Pointer" equals "NIL", the routine is complete.
EXPLANATION OF THE ALGORITHM BY EXAMPLE
Now that the framework has been laid, consider a specific example which illustrates the algorithm of the computer program which implements the system explained above.
The system hardware configuration that will be used in describing the method is shown in FIG. 4. It consists of a computer with a graphics display keyboard and a mouse, three computer-programmable instruments (a function generator, an oscilloscope, and a universal counter), and an interface electronics card and bus cable which connect the instruments to the computer for control purposes. The output signal of the function generator is connected to the input channels of both the oscilloscope and universal counter to illustrate the stimulus/response nature of these instruments. The computer is executing a software program which implements the interactive graphics control invention described in this document.
The algorithm of the computer program which implements the interactive graphics to control these instruments has been set forth previously as part of the "Brief Summary of the Invention".
The notation used in the algorithm is that of a structured programming language. Each statement in brackets ([]) is a major operation performed by the program. Control logic keywords are shown in CAPS.
A graphical representation of the component templates used in this example are supplied, to facilitate understanding of how the "Update Window" routine operates. They are:
FIG. 5B: Function Generator IIW
FIG. 6: Scope SVW
FIG. 7: Universal Counter SVW
Each of the major operations of the algorithm as briefly outlined in the Brief Summary of the Invention will now be explained.
(1) [identify instruments on bus]
This process is hardware-dependent. For the computer and interface on which the invention has been implemented, there are a finite number of available bus addresses, and sending a READ SELF-ID command to each of these addresses results either in an instrument returning a message identifying its type, or the bus operation timing out, which indicates that no instrument exists at this address. Each legal address is tested, and a table is built listing address and corresponding instrument type.
For the hardware configuration of FIG. 4, the following table will be built:
______________________________________Address Instrument Type______________________________________0 Function Generator1 Oscilloscope2 Universal Counter______________________________________
(2) [set all instruments to power-on state]
Each instrument in the previous table is sent a "power-on" command over the interface bus, to put it into a known, initial state. This is in preparation for building the instrument data structures, whose State Info Blocks must reflect the current state of the instrument.
(3) [build the Instrument List]
For each instrument, space for the Instrument data structure and State Info Block is NEWed from the memory heap. All fields except the "SVW Window Pointer" are filled in (that one will be back-filled in the next step). Routines specific to the particular instrument type are called to fill in the State Info Block. This process continues until the table from step (1) is traversed.
The "Next Instrument Pointer" field of the last instrument in the list is set to point to the first instrument in the list, making the instrument list circular.
A pointer variable, "Next Polled Instrument", is initialized to point to the first instrument in the list.
(4) [build the window list]
The window list is built by walking down the instrument list, NEWing and filling in a window data structure (of "Window Type"=SVW) for each instrument. The "x" Window Origin and "dx" Window Size coordinates are fixed at 0 and 15, respectively in this implementation, so that the various SVWs will all appear in a column on the left of the display. The "Instrument Type" field of the instrument is used to obtain a pointer to the SVW template which is filled into the "Component Template Pointer" field. The "dy" Window Size coordinate also depends on instrument type, and it is obtained by traversing the SVW template and finding the component with the maximum "y"+"dy" coordinates. The "y" field is adjusted, based on "dy", so that the SVWs will start at the top of the display and build down, as shown in FIG. 8. The "Instrument Info Pointer" field is set to point back to the entry in the instrument list that the window represents.
When a SVW window has been built for every entry in the instrument list, the IIW window is then NEWed. The "(x,y) Window Origin" and "(dx,dy) Window Size" fields of the IIW are fixed at (16,7) and (64,18) in this implementation, based on its location in the upper right of the display. "Window Type" is set to IIW. This is the end of the list, so the "Next Window" pointer is "NIL". The other two pointer fields of the IIW window list entry are left blank for the moment.
(5) [assign first instrument in instrument list to the IIW]
The "Component Template Pointer" field of the IIW window is filled in with the "IIW Component Template Pointer" field of the first instrument in the instrument list. The "Instrument Info Pointer" is set to point to the first instrument structure in the instrument list.
A separate pointer variable, "Current IIW Instrument Pointer" is also set to point to the first instrument structure in the instrument list.
FIG. 8 shows the completed instrument list, window list, and other important variables as they would exist for the example system at this time.
(6) [draw the IIW]
At the present time, assume the display is blank. Since the IIW representation has to be redrawn completely, the "Create Window" routine is used.
In preparation for drawing the IIW, the window list is walked until the window where "Window Type"=IIW is found. The "Update Window" routine is supplied the pointer to that window and called with mode=CREATE.
Drawing of components begins with the top component in the component template shown in FIG. 5B. The power-up state of the function generator results in "State Inquiry" for the components yielding the following results:
______________________________________Component State______________________________________1 ("Label" components have no state)2 "Func.Gen.01"3 State 1 (enabled)4 "0 V"5 "50%"6 "1.000 V"7 "1.00 kHz"8 State 0 (sine)9 State 0 (continuous)______________________________________ Component State
FIG. 1 shows what the function generator's IIW will look like when the "Update Window" routine is completed.
(7) [draw each SVW]
The same process as performed in the previous step is done again, this time for each individual entry in the window list which has Window Type="SVW". As the window list is walked, the "Instrument Info Pointer" field of each window entry is compared against the "Current IIW Instrument Pointer" to see whether or not that window is the SVW for the instrument which is currently in the IIW. "Update Window" for the SVW for that instrument is called with mode=HALF-TONE. "Update Window" for all other SVWs is called with mode=CREATE.
Since the first SVW in the window list belongs to the function generator, it is the one which is half-toned.
The succeeding two SVWs, for the oscilloscope and the function generator, do get created.
At this point, the computer display should look just as in FIG. 1.
(8) [enable user input devices (mouse and keyboard)]
Now that initialization is complete, the proper commands to enable movement of the mouse and entries from the keyboard are sent to those devices. Until this point, the operator could not interact with the system.
Before operator inputs are enabled, the cursor is placed onto the display at a known, fixed position, so that its position can be tracked by the computer program.
(9) WHILE (the user has not selected the "Exit" softkey) DO
The loop which begins with this statement has two main functions:
(a) To check and see if any instrument are requesting service; that is, do any instruments have new state information to be displayed in the IIW or in an SVW;
(b) To respond to user inputs from the house or keyboard, and perform the instrumentation operations which the operator specifies, updating the IIW and/or SVW following the operation to reflect the change in instrument state.
The loop will continue until the operator selects the "Exit" softkey. When this softkey is pressed, the computer program implementing the invention will be terminated.
(10) [poll instruments for "service request"]
The poll routine walks the instrument list, using the "Physical Address Info" of each entry to send a command over the bus to each instrument, inquiring whether or not it is currently requesting service. It begins doing this for the instrument whose data structure is pointed to by the "Next Polled Instrument" variable. Polling continues until either a service request is detected, or the list is traversed back around to the first instrument polled.
If a service request occurs, the "Next Polled Instrument" pointer is set to the value of the "Next Instrument Pointer" field of the instrument requesting service, so that the instrument about to be serviced will be the last one to be checked on the next time the instruments get polled. This round-robin priority scheme assures that all instruments have an opportunity to be serviced.
(11) [execute service routine for the instrument]
If an instrument was found to be requesting service, its "Physical Address Info" and the "State Info Block" pointer are passed to the service routine for that instrument type. This routine analyzes the nature of the request, issues the appropriate commands over the bus to the instrument, and updates the State Info Block accordingly.
(12) IF (instrument is in IIW) THEN [update the IIW]
IF (instrument is in a SVW) THEN [update that SVW]
When the service routine is completed, the instrument which was serviced is checked to see if it is in the IIW; this is done by comparing the pointer to the instrument just serviced with the "Current IIW Instrument" pointer. If they match, the IIW display gets updated.
If it is not the IIW instrument, the "SVW Window Pointer" field is used to obtain "Window Origin" and "Window Size" information to determine if the SVW representation is currently on the screen. If it is, its SVW display gets updated.
The updating of the appropriate window is done by calling the "Update Window" routine with mode =MODIFY.
(13) [check for user input]
Operator inputs can take three forms:
(a) Moving the cursor around the display via rolling the mouse or use of the cursor control keys on the keyboard;
(b) selecting a graphical component to cause an operation via clicking the mouse button or pressing the keyboard RETURN key;
(c) pressing one of the keyboard softkeys.
Cursor movement is kept track of by the program, so that the current position of the cursor (in absolute coordinates) is always known when a selection is made. If the user input was of type (a), no further action is required.
(14) IF (user made a selection) THEN
If the mouse was clicked, or if the user pressed the RETURN key, then execute the operations within the BEGIN-END block.
(15) [identify window selected]
The first step in identifying the user request is to walk the window list using the absolute (x,y) coordinates of the cursor's current position to determine which window the cursor is located in. This is done by finding the window where cursor coordinates are greater than or equal to "Window Origin" and lesser than or equal to "Window Origin"+"Window Size". This check must match for both x and y coordinates.
(16) [identify component selected]
The program branches to here if the cursor was located within the IIW when the selection was made. This step executes the "identity selected component" routine. It is similar to the "update window" routine in that the component list for the IIW is traversed and state information is obtained.
The purpose of the routine is to determine if a valid component in the IIW was selected and, if so, to identify it. Not every type of component is eligible to be selected, but only those which qualify as "control" components. The control-type components are:
Ganged Switch
Rotary Switch
Toggle Switch
Momentary Contact Switch
Numeric Entry Field
Alphanumeric Entry Field
The "Identify Selected Component" routine is passed the "Component Template Pointer" of the IIW window, the "State Info Block Pointer" of the instrument pointed to by the window's "Instrument Info Pointer", and the coordinates (converted to window-relative) of the selected cursor position.
This step executes the "Identify Selected Component" routine. It is similar to the "Update Window" routine in that the component list for the IIW is traversed and state information For purposes of illustration, assume that the function generator is in the IIW, and the display appears as in FIG. 1. The operator has moved the cursor into the area of the "NBURST" button (assume absolute x=58 and absolute y=17) and clicked the mouse. The resulting window-relative coordinates, achieved by subtracting the IIW "Window Origin" from the selected coordinates, are (42,10).
Components 1 and 2 of the template are skipped over because they are not control components. The "Next Component" field of component 2 points to component 3.
Component 3 is of type "Toggle". The selected cursor coordinates are checked to see if they fall into the area of this component. They do not, so the "Next Component" field is obtained, which points to Component 4.
Components 4 through 8 do not match either. The next component to be compared against is component 9.
Component 9 is of type "Ganged". The selected coordinates do fall within the limits of the component structure; window-relative selected "x" is greater than or equal to 40 and lesser than or equal to 63; and window-relative selected "y" is greater than or equal to 5 and lesser than or equal to 15. Next, the selected coordinates are adjusted by the "Window Origin" of the component to make them component-relative. Now, the state list fields are compared in an analogous manner. The "CONTINUOUS" and "GATED" buttons did not match, but the "NBURST" button did.
So "Component 9, State 2" is identified as the selection.
(17) IF (no component selected) THEN [beep]
If the complete IIW component template is searched and the selected cursor coordinates do not match those of any component, then the operator made a selection either outside of the area of any component, or on a component which is not of type "control". The beep alerts the operator to the fact that no instrumentation operation will occur as a result of that selection.
(18) [execute instrument command associated with user request]
Software for each type of instrument includes an "Execute I/O Action" routine which translates selected component number (and state, if applicable) into the appropriate command(s) to be sent to the instrument to carry out the control request made by the operator.
This routine is passed, along with selected component number and state, the "Instrument Info Pointer" of the window. It uses the "Physical Address Info" of the instrument object to communicate with the proper instrument, and updates its "State Info Block" to reflect the new state of the instrument when the I/O operation is complete.
(19) [update the IIW]
To reflect the new state of the instrument, the IIW is updated via a call to the "Update Window" routine with mode=MODIFY.
Using the example of step (16), updating begins with Component 1 of the function generator list. Since no state changes for the function generator are indicated until Component 9's state is obtained, no changes to the computer display occur until this time.
Component 9 indicates that its new state equals "2" (BURST mode), while its old state equals "0" (CONTINUOUS mode). There is no need to redraw the mode ganged switch completely; but the state button corresponding to CONTINUOUS mode is box-filled with a white pattern, with its label "CONTINUOUS" drawn with a black pen in opaque mode. The state button corresponding to BURST mode is box-filed with a black pattern, with its label "NBURST" drawn with a white pen in opaque mode.
Since a ganged switch component can have dependent component lists, these must be checked also. The old state, CONTINUOUS, has no dependent list, so there is nothing else to be erased. The new state, BURST, does have a dependent list which must be drawn. A call to the "Create Window" routine is made at this point, with the start of the dependent list as the parameter. When this list is drawn, as in step (6), the "Create Window" routine exits, and the "Modify Window" routine continues with the next component of component 9. Since component 9 is the end of the list, "Modify Window" is complete, and the update process concludes.
At this point, the computer display will appear as in FIG. 9.
This step completes servicing of the operator selection in the IIW. The program returns to the beginning of the WHILE loop , step (9), to poll the instruments for service requests again.
(20) [erase the IIW]
The program branches to here if the cursor was located within an SVW when the selection was made.
Assume that just prior to the selection being made, the computer display appeared as in FIG. 11, with the cursor placed within the limits of the SVW for the oscilloscope. Then the operator clicked the mouse, causing the program to eventually get to this step.
The window list is walked to get the (x,y) and (dx,dy) coordinates of the window representing the IIW. The current IIW is erased by box-filling the entire area of the window with a white pattern.
(21) [update SVW for instrument that was just in IIW]
Up until now, the SVW associated with the function generator has been filled with a half-tone pattern. It now must be drawn showing the actual SVW representation for the function generator.
The window list is walked, comparing the "Corresponding Instrument" field of the IIW window with the "Corresponding Instrument" field of the SVW window until the matching SVW is found. Then, using the "Component Template Pointer" and the "Corresponding Instrument" fields, the "Create Window" routine is executed for the function generator SVW.
(22) [draw the IIW for the instrument whose SVW was selected]
The "Corresponding Instrument Pointer" field of the SVW which was selected is used to obtain the "IIW Component Template Pointer" of the instrument which is about to be represented in the IIW. This pointer is written into the "Component Template Pointer" field of the IIW window entry. The "Corresponding Instrument Pointer" field from the selected SVW window is also copied into the same entry of the IIW window.
Finally, the "Create Window" routine is called, using the "Component Template Pointer" and "Corresponding Instrument Pointer" of the new IIW as parameters.
(23) [half-tone the SVW for selected instrument]
The "Corresponding Instrument Pointer" field of the SVW which was selected is used to obtain the "SVW Window Pointer" of the instrument which was just drawn in the IIW. "Update Window" for this SVW is called with mode=HALF-TONE, in order to remove the instrument's representation from the SVW, since it is now in the IIW.
The result of steps (20) through (23) are shown in FIG. 12.
This step completes servicing of the operator's selection of a SVW. The program returns to the beginning of the WHILE loop, step (9), to poll the instruments for service requests again.
(24) OTHERWISE [beep]
If the coordinates of the selection made by the user did not fall within either a SVW or the IIW, the operator is alerted to the fact that no action will take place.
(25) [execute system function associated with softkey]
If the user input was the pressing of a system softkey, the action associated with the softkey is processed here. Softkeys provide system-wide functions in this particular implementation of the invention, and are used to assist with entering or modifying numeric values. They will not be discussed any further since they do not directly relate to the patent.
Note, however, that one of the softkeys is the "Exit" softkey, which will cause termination of the program.
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A system which uses interactive graphics displayed on a viewing means to control and indicate the operating parameters of an instrument. The interactive graphics which are displayed at any point in time depend on the present state of the instrument. Only those controls and indicators which are relevant to the present state will be displayed, which simplifies the display and reduces operator confusion. When the state of the instrument changes, controls and indicators will be redisplayed so as to be relevant to the new state. A control means allows the operator to interact with controls so as to change the state of the instrument. The controls and indicators can be displayed on the viewing means in a way that simulates their physical appearance. A plurality of instruments may be present in the system; if so, the operator can choose which to control, while a subset of parameters of the other instruments can be viewed simultaneously. The preferred method uses a computer program to display the graphics and control the instruments.
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This application is a continuation-in-part of U.S. provisional patent application Serial No. 60/072,574, filed Jan. 26, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to determining the prognosis of a patient with breast cancer by determining whether the HER-2/neu gene is amplified in tumor cells.
2. Description of Related Art
Breast cancer remains a major cause of illness and death among women in the United States, with over 180,000 new cases and 44,000 deaths per year (American Cancer Society, 1997). Possibly the most important predictor of clinical course in breast cancer is the presence or absence of lymph node metastases. Many prognostic indicators aid in evaluation of invasive cancers in addition to the presence or absence of lymph node metastasis, including tumor size, histologic type, tumor grade (differentiation reflected in extent of gland formation), nuclear grade (extent of nuclear alteration and frequency of mitosis), DNA content (ploidy), and hormone receptor status. A reasonable and desirable approach would be the use of prognostic factors to risk-stratify invasive breast cancer patients into low-risk and high-risk groups in terms of the probability of recurrence (McGuire, el al., 1990).
The HER-2/neu (ERBB2) gene is an oncogene which shares significant homology to the epidermal growth factor receptor (EGFR) gene (Yamamoto, et al, 1986) and the retroviral gene v-erbB. It was first detected as a mutated transforming gene in chemically induced rat neuronal tumors. It has been isolated from diverse sources, including: rat neuroblastoma (Schechter et al, 1985); human tumor lines from gastric cancer (Fukushige et al, 1986); salivary adenocarcinoma (Semba et al, 1985); and a human breast cancer cell line where HER-2/neu was identified in an amplified form (King et al, 1985). The gene has been localized to 17q11.2q12 (Human Gene Mapping 11, 1991), in a region where several genes relevant to breast cancer are located, including BRCA1 estradiol-17β dehydrogenase, NM23 and RARA.
Current evidence indicates that HER-2/neu protein over expression and gene amplification are indicative of poor patient prognosis at all stages of breast tumor development. Amplification appears early in tumor progression (Iglehart et al 1990 and Van de Vijver et al 1988), and when present is homogeneously distributed throughout the tumor (Press et al, 1994). Thus, it is a logical choice as a prognostic marker when used as an adjunct with other accepted prognostic indicators.
While such immunoassays for Her-2/neu protein have been commercially available, interpreting results is somewhat difficult. Protein denaturation or degradation during handling, staining embedding in paraffin and sectioning gives variable results, including both false negatives and false positives. Additionally, slightly different conditions during antibody-antigen binding results in false positives and false negatives. Unacceptable results have been reported for immunohistochemical detection of HER-2/neu amplification. See Thor et al 1989; Richner et al, 1990; O'Reilly et al, 1991; and Loveldn et al, 1991. By contrast counting the number of copies of the HER-2/neu gene in a cell represents a more objective determination and involves DNA markers which are less susceptible to degradation and provide less variable results.
HER-2/neu gene amplification status is useful as an adjunct in the evaluation of the prognosis of node negative breast cancer patients and is also an independent marker of high risk in node negative patients. Amplification of HER-2/neu is indicative of poor patient prognosis at all stages of breast cancer development and correlates with relatively shorter disease-free and overall survival.
Studies have shown positive correlation between HER-2/neu gene amplification and other common indicators of poor prognosis in breast cancer (Tsuda, et al, 1989 and Seshadri, et al., 1993 and Slamon et al, U.S. Pat. No. 4,968,603). However, even strong breast cancer prognostic factors, such as number of positive lymph nodes, tumor size and histograde do not predict patient outcome unfalteringly (Wright, et al., 1989 and Ro, et al., 1989). Current evidence indicates that HER-2/neu protein over expression and gene amplification are indicative of poor patient prognosis at all stages of breast cancer development (Seshadri, et al., 1993, Wright, et al., 1989 and Niehans et al., 1993). Because HER-2/neu amplification appears early in breast cancer progression (Iglehart, et al., 1990 and van de Vijver, et al., 1988) and, when present is homogeneously distributed throughout the cancer (Iglehart, et al., 1990 and Press, et al., 1994), it can serve as a prognostic marker for this disease (when used as an adjunct with other accepted prognostic indicators).
The use of Fluorescent In-Situ Hybridization (FISH) targeted to the HER-2/neu gene, has successfully demonstrated gene amplification in breast cancer cell lines and primary tumors, and has shown that FISH results are concordant with other measures of amplification (Kallioniemi, et al, 1992). [The gene has been localized to 17q11.2-q12 (Human Gene Mapping 11, 1991), in a region where several genes relevant to breast cancer are located, including BRCA1, estradiol-17 dehydrogenase, NM23, and RARA.] FISH technology combines the advantages of direct gene amplification assessment with direct localization in morphologically identified tumor cells. FISH is applicable to tumors of all sizes because studies can be performed on sections from the original specimen blocks used for diagnosis. In many samples, direct comparison can be made with FISH assays on normal cells from the same preparation. Further, if amplification were localized rather than diffusely distributed within a tumor, it would be detectable by FISH but could be diluted below detectable limits in extracted tumor DNA required for other procedures.
When performing an assay of such importance to the patient, it is critical to have appropriate controls. Sections of previously tested tissue are somewhat undesirable as controls due to cell variability, unclear boarders, necrotic tissue in the center of the tumor, variable responses to protease digestions and finite source material. Therefore, there is a need for quality control materials which can be run with every test which lack the above mentioned problems.
There is also a need for a set of statistical benchmarks to allow the medical practitioner to stratify the patient according to likelihood of cancer recurrence. This will aid the practitioner and patient in deciding whether aggressive treatments (e.g. chemotherapy, radiation and anti-HER-2/neu therapy) should be employed in lieu of a passive “watchful waiting” approach.
SUMMARY OF THE INVENTION
The present invention is directed to methods and reagents which determine the number of copies of the HER-2/neu gene in a breast cancer specimen. This method uses a FISH assay for HER-2/neu in surgically removed breast cancer tissue. Determination of an abnormally high copy number of the gene correlates with poor prognosis and such patients should be treated aggressively.
The present invention is also directed to a set of control slides, one of which has a normal copy number of the HER-2/neu gene, one has a high copy number of the HER-2/neu gene and one has a slightly elevated copy number of the HER-2/neu gene.
The present invention further includes the preparation of control slides using cell lines instead of primary tumor tissue. The preferred cell lines used for controls are one with high amplification of the HER-2/neu gene, one with non-amplification and one with low amplification.
The HER-2/neu gene detection system of the present invention is a kit consisting of DNA probe and detection reagents that yields a green fluorescent signal at the site of each HER-2/neu gene, on a blue fluorescent background of stained nuclear DNA The kit is intended to be used with sections (4 μm) of formal fixed, paraffin-embedded human breast cancer tissue. The kit is untended to include or recommend the use of another kit which includes the control lines.
The HER-2/neu gene detection system of the present invention is preferably a fluorescence in situ hybridization (FISH) DNA probe assay that determines the qualitative presence of HER-2/neu gene amplification on formalin-fixed, paraffin-embedded human breast tissue as an aid to stratify breast cancer patients according to risk for recurrence or disease-related death. It is indicated for use as an adjunct to existing clinical and pathologic information currently used as prognostic indicators in the risk stratification of breast cancer in patients who have had a primary, invasive, localized breast carcinoma and who are lymph node-negative.
A recent review and comparison is Ross et al, The Oncologist 3: 237-252 (1998).
BRIEF DESCRIPTION OF FIGURES
FIG. 1 is a survival curve of HER-2/neu amplification status with the cumulative probability of early recurrence.
FIG. 2 an interaction, without error bars, of Her-2/neu amplification and tumor size cumulative probability of overall survival Her-2/neu Amplification Status (amp+/amp−) and tumor size (>1 cm/ <1 cm)
DETAILED DESCRIPTION OF THE INVENTION
The HER-2/neu gene amplification detection system according to the present invention is a fluorescence in situ hybridization (FISH) DNA probe assay intended for formalin fixed, paraffin-embedded human breast tissue as an aid in predicting risk of breast cancer recurrence so that patient management decisions can be improved. Post surgery lymph node negative patients with no amplification may receive little or no further treatment whereas patients with tumors having the HER-2/neu gene amplified may receive more aggressive monitoring, chemotherapy and/or radiation. Clearly, the appropriate use of the drug HERCEPTIN® (Genentech, South San Frisco, Calif.), humanized monoclonal antibody to HER-2/neu, is determinable by measuring HER-2/neu gene amplification. In the few months since release of the commercial assay it has become accepted standard practice to include the HER-2/neu gene amplification detection system routinely on breast cancer patients and particularly before the particular therapy noted above.
The relationship between HER-2/neu gene amplification and probability of remaining disease free and surviving is demonstrated in the Figures. These clinical studies are based on breast cancer patients who had excision of a primary, invasive, localized breast tumor, who were node negative and who did not receive any adjuvant therapy except in cases of disease recurrence. While remaining disease-free is somewhat different from survival, both measures are important even when the data does not exactly parallel.
While this specification is described with respect to breast cancer, one skilled in the art will readily appreciate the application of the techniques herein described of use with other cancers where the HER-2/neu gene is amplified, such as ovarian, prostate, endometrial and certain colon cancers. In such situations, different control cell lines and different amplification cut off numbers may be required but the need for appropriate quality controls remains.
Briefly, the methodology is as follows. Sections of formalin-fixed, paraffin-embedded breast cancer tissue mounted on microscope slides are pretreated chemically (Pretreatment Step, reduction of peptide disulfide bonds) and enzymatically (Protein Digestion Step, digestion of proteins) to remove proteins that block DNA access. The DNA in the sections is converted from double- to single-strand by solution denaturation at 75° C. using a mixture of 20×SSC (saline sodium citrate) and formamide. A hybridization solution, containing labeled DNA probe which is complementary to the HER-2/neu gene sequence, is applied to the tissue section, which is then incubated under conditions favorable for annealing of probe DNA and genomic DNA sequences. Unannealed probe is washed off using a mixture of 20×SSC and formamide. The hybridized probe is detected using a fluorescently-tagged ligand (fluorescein-labeled avidin) which binds to the label on the DNA probe, thereby immobilizing the fluorescein at the site of the HER-2/neu gene. The remainder of the DNA is then stained with an intercalating fluorescent counterstin DAPI in Antifade). Excitement of fluorescein and DAPI by light from a mercury arc lamp with appropriate filters in an epifluorescence microscope results in the emission of green and blue light, respectively. The observer selects for these two colors by using a microscope filter set designed for simultaneous viewing of DAPI and fluorescein, and scores nuclei in the tissue section for the number of green signals on a blue background.
When performing such an assay of great importance to the patient, it is always necessary to use the best available controls. Tissue sections from an excised tumor are somewhat variable by being a mixed population of cells, sometimes having unclear boarders. Tissue sections can only be as good at the tumor itself which may have a necrotic center, have blood vessels through it, and contain a number of inflammatory response cells. The density of cells in a primary tissue section (tumor or normal) may be high with a 4 μm thick section having only a small part of a cell. In FISH assays, a protein digestion step is performed. The digestion conditions differ between different tumors and normal cell types. All of this requires skilled individuals to determine which cells are appropriate tumor cells to be considered on the slide. Additionally, tumor and normal sections represent a finite source of controls as each new tissue block will require rest and ardization before it can become a control standard.
By comparison, cell lines have the advantage of uniformity in cell type with no chance of misidentifying the cells. The cell concentration is regulatable so that the control slide will have cells evenly distributed and clearly separated. Since the cell line is uniform, the protein digestion conditions may be perfected, not merely optimized. Uniformity also reduces interpretation mistakes and permits use of less skilled, and less expensive, personnel. Because cell lines are used, the exact cell type may be used indefinitely as an permanent source of control cells without further need to restandardize the cell line. Should doubt remain as to the advantages of standardized controls over previously tested samples, several subclasses of U.S. patents are devoted to analytical clinical controls, their preparation and use.
In the present invention, the control slides include a slide with a normal copy number of the HER-2/neu gene, a slide with a highly amplified copy number of the HER-2/neu gene, and a slide with a lowly amplified copy number of the HER-2/neu gene. Representative examples are:
Level 1 Control
ATCC HTB 132 (MDA-MB-468)
non-amplification,
≦3 copies per cell
Level 2 Control
ATCC HTB 133 (T-47D)
low amplification,
3-10 copies per cell
Level 3 Control
ATCC HTB 30 (SK-BR-3)
high amplification,
≧10 copies per cell
The use of a control with a low level of amplification is preferred as clinical samples with low levels of gene amplification are the mostly likely to be miss detected. Such primary cancers may be difficult to find and standardize, thus the use of such a cell line has considerable benefits.
It will be appreciated that numerous other cell lines may be used as controls provided that the number of copies of HER-2/neu gene is adequately quantified and it is uniform in the cell line. Cell line controls should fall into one of the three level control ranges recited above. Once another cell line has been so standardized, it may be used in lieu of the specific cell lines recited above. It is preferred to use tumor cell lines originating from the same tissue as being tested from the patient. For example, the three cell lines above originated from breast cancers.
Briefly, control slides are prepared by culturing the cell lines, suspending a predetermined concentration of cells in plasma, clotting the plasma, formalin fixing, embedding in paraffin, sectioning and mounting on a slide. It should be noted that additional and alternative steps of preparing the slide for FISH may also be performed with a goal of preparing the control cell line to resemble breast tumor tissue for comparative parallel testing. Such sample preparation techniques are described for example, in Diaiostic Molecular Pathology , Vol. 1, IRL Press, N,Y.
While these steps are individually well known in the art, numerous variations on the above procedure may be used. For example, other solidifying materials may be used in the place of plasma provided that they do not alter the cellular DNA. Examples include agarose, gelatin, pectin, alginate, carrageenan, monomers, polymers etc. where the gel is formed by cooling, adding ions (calcium, potassium) adding a polymerizing or a cross linking agent, etc. Other fixatives are known and may be used if any is desired at all. Paraffin embedding may be standard but other similar materials may be used and may even be optional. Likewise, the thickness of the section cut from a block is variable and is optimized depending on the microscope and assay conditions.
The relative sensitivity and specificity of the HER-2/neu gene amplification detection system for measuring HER-2/neu gene copy numbers was accessed. Breast cancer specimens with a known HER-2/neu gene copy and expression levels were selected as archival tissue specimens. Amplification was previously determined by Southern Blot hybridization or dot blot using extracted DNA. Expression had been determined by Northern hybridization, Western immunoblotting and/or immunohistochemistry using total RNA, total protein or histologic sections from tumor tissue. Slamon et al, 1989 and Press et al, 1993. Gene amplification levels correlated with gene expression levels in approximately 90% of the breast cancers under research conditions. In a less standardized clinical setting, the divergence may be higher. The comparison with FISH was performed by the HER-2/neu gene amplification gene detection system on 140 breast cancer specimens. Forty-nine were considered true positive, 90 true negative, 0 false positive and 1 false negative. This is a the relative sensitivity value of 98% and the relatively specificity value of 100%.
The expected HER-2/neu gene detection system assay result in normal breast tissue (non-cancerous) was estimated in a population of 20 breast tissue samples from reduction mammoplasties. The overall observed mean was 2.2 signals per nucleus with a range of 1.8-2.6 signals per nucleus. The target population for analysis using the HER-2/neu gene detection system was patients with primary node-negative, invasive breast carcinoma. The expected prevalence of early recurrence within 2 years is 4 to 6%. The expected prevalence of recurrence within 3 years is 2 to 10%. The expected prevalence of disease related death (within 3 years) is 10 to 15% (Clinical Oncology, 1993, page 207).
A clinical study evaluated HER-2/neu gene amplification status in 220 women with node negative invasive breast cancer whose only course of treatment was surgery, unless diagnosed with disease recurrence. For this study population HER-2/neu amplification was shown to have predictive power independent of the other prognostic markers evaluated (patient age at diagnosis, tumor size, tumor grade, and estrogen receptor). HER-2/neu was shown to be the strongest predictor for early recurrence (within 24 months), recurrence and disease-related death.
The negative predictive value, probability of no disease being present in women with HER-2/neu non amplified tumors, was found to be high three years after diagnosis (93.3% based on a prevalence of 10.4%). The probability of being alive three years after diagnosis was 99.4%, based on a prevalence of 2.4%.
HER-2/neu was analyzed along with and controlling for the above listed prognostic factors. The combined effect (interaction) of tumor size and HER-2/neu amplification status is presented in FIG. 2 . One analysis used tumor size at 1 cm and additional analysis looked at tumor size at 2 cm. In both sets of analyses, tumor size is not significant (p>0.05) for predicting recurrence and disease-related death when the tumor is HER-2/neu amplified.
When the tumor is not amplified for the HER-2/neu gene, tumor size is also an insignificant predictor of recurrence and disease-related death within 3 years. With longer follow-up, disease-related death was significantly predicted in a comparison of tumors>1 cm. In this particular data set, there were no disease-related deaths for HER-2/neu non-amplified tumors.
These data show that for this study tumor size failed to be a good predictor of recurrence and disease-related death within 3 years. Tumor size is of little consequence in HER-2/neu positive tumors and orny becomes of value when evaluating disease-related death, in HER-2/neu negative tumors. HER-2/neu amplification was shown to have predictive power independent of all other prognostic markers evaluated and to be the strongest predictor for recurrence and disease-related death.
The following Examples utilized the commercially available Oncor INFORM HER-2/neu Gene Detection System (Ventana Medical Systems, Gaithersburg, Md., USA), Cat. No: S8000-KIT. The Procedure and Interpretation Guide enclosed with the kit is expressly incorporated by reference. This kit was the subject of a FDA PMA No. P9400004, the public contents of which are expressly incorporated by reference.
EXAMPLE I
PREPARATION OF HER-2/neu PROBES
Partial restriction enzyme digests of human Chromosome 17 DNA were prepared to create a library. Fragments were cloned into BAM HI restriction sites on a cosmid vector and grown in E. Coli HB 101. Positive clones were selected with Kanamycin containing medium. The cosmid probe set represent overlapping segments with a four member contig. A probe used to detect the cDNA is preparable using primers 5′-CGGCCAAGATCCGGGAGTTGGT-3′ SEQ ID NO: 1 and 5′-TCTTGATGCCAGCAGAAGTCAGGC-3′ SEQ ID NO: 2. Numerous publications exist regarding the HER-2/neu gene and other probes may be prepared and used.
Biotintylated HER-2/neu DNA probe was prepared containing a biotin-labeled single-stranded DNA fragment derived from human genomic DNA sequences, suspended in a solution of formamide, SSC and blocking DNA The probe DNA sequences are complementary to the sample HER-2/neu (erb-b2) gene sequence and specifically bind to them upon hybridization. The probe used below is the commercially available HER-2/neu probe (Ventana Medical Systems, Gaithersburg, Md.)
EXAMPLE II
SAMPLE PREPARATION FOR FISH ASSAY FOR HER-2/neu
Slides were prepared by cutting paraffin embedded tissue samples into 4 μm thin sections and applying them to silanized or positively charged slides. The slides were air dried and baked at 65° C.±5° C. overnight. The slides were deparaffinized in fresh xylene that has not been used for more than one week and repeated through three changes of xylene for five minutes each. The slides were then washed in fresh 100% ethanol that has not been used for more than one week for two minutes. The ethanol washing was repeated and the slides allowed to air dry.
The slides were pretreated by immersing slides in a coplin jar containing 40 ml of pre-warmed 30% w/v sodium bisulfite Pretreatment Solution in a 43° C.±2° C. water bath for 15 minutes. This solution is designed to reduce disulfide bonds, aid in protein digestion and improve probe penetration to target DNA sequences. The slides were then washed in 40 ml of 2×SSC at room temperature for 1 minute and then washed twice using fresh 2×SSC. The slides were then dehydrated through a room-temperature graded series of ethanol solutions for 2 minutes in each of 70%, 80%, 90%o and 100% ethanol and allowed to air dry inclined with label end down.
40 ml of Protein Digesting Enzyme Working Solution was freshly prepared by mixing 25 mg of proteinase K in 37° C.±2° C. of prewarmed 2×SSC. Slides were immersed in a coplin jar of prewarmed Protein Digesting Enzyme Working Solution and incubated at 37° C.±2° C. for 40 minutes. This solution is needed to digest protein and improve probe penetration. The slides were washed three times in 40 ml of fresh 2×SSC at room temperature for 1 minute. The slides were dehydrated through the room-temperature graded series of ethanol solutions for 2 minutes in each grade of ethanol: 70%, 80%, 900% and 100% and allowed to air dry inclined with label end down.
The slides were denatured by immersing them in a coplin jar containing 40 ml of pre-warmed Denaturation Solution (70% formamide/2×SSC, pH 7.0) in a 75° C. water bath for 8 minutes. The slides were immediately transferred to the pre-chilled (−20° C.±5° C.) 70% ethanol and rinsed for 2 minutes. The rinse was repeated in pre-chilled (−20° C.±5° C.) 80%, 90%, and 100% ethanol solutions, successively and allowed to air dry inclined with label end down.
The HER-2/neu DNA probe was prewarmed at 37° C.±2° C. for 5 minutes, vortexed for 1 minute and centrifuged for 2 to 3 seconds to collect contents in the bottom of the tube. 10 μl of probe solution was pipetted onto the denatured tissue section and covered gently with a 25 mm×25 mm glass coverslip. Larger tissue sections may require up to 20 μl of probe and larger glass coverslips. The slides were incubated at 37° C.±2° C. for 12 to 16 hours in a humidified chamber.
The coverslips were then removed by sliding it to the side and lifting the overhanging edge with forceps. The slides were washed in a coplin jar containing 40 ml of pre-warmed Post-Hybridization Wash Solution (50% Formamide/2×SSC, pH 7.0) in the 43° C.±° C. water bath for 15 minutes. The slides were then rinsed in a coplin jar containing 40 ml of pre-warmed 2×SSC in the 37° C. water bath with frequent agitation for 10 minutes and repeated with fresh 2×SSC and placed in a coplin jar containing 40 ml of 1×PBD (phosphate buffered detergent) at 18° C. to 25° C.
60 μl of Blocking Reagent One (0.05 g nonfat dry milk, Nonidet P-40, phosphate buffer and sodium azide) was added to each slide, a plastic coverslip placed over the solution and incubated 5 minutes in a humidified chamber at room temperature. The plastic coverslip was pealed off and blotted dry for re-use. The slide was tilted to allow fluid to drain briefly. This reagent contains salts, detergent, proteins and sodium azide (preservative) which aid in reducing non-specific binding of fluorescein-labeled avidin to the hybridized and washed tissue section.
60 μl of Detection Reagent (fluorescein labeled avidin in sodium azide preservative) was added to each slide and the plastic coverslip replaced over the solution. The slide was incubated 20 minutes in a humidified chamber at room temperature. After 10 minutes of the 20 minute incubation, one lifts and replaces the plastic coverslip to ensure even fluid distribution. This reagent detects hybridized probe DNA by binding to the biotin conjugated to the probe.
The plastic coverslip was then pealed off and discarded. The slides were washed in a coplin jar containing 40 ml of 1×PBD at room temperature for 2 minutes and the wash repeated 2 times using fresh 1×PBD.
The slides were removed from 1×PBD, tilted to allow fluid to drain briefly, then excess fluid was briefly blotted from the edge.
60 μl of Blocking Reagent Two (0.05 ml goat serum, Nonidet P-40, phosphate buffer and sodium azide) was added to each slide and a fresh plastic coverslip placed over the solution. The slides were incubated 5 minutes in a humidified chamber at room temperature, the plastic coverslip pealed off and blotted dry for reuse and the slide tilted to allow fluid to drain briefly. This reagent is a mixture of salts, detergent and proteins in a sodium azide preservative which reduce non-specific binding of the Anti-Avidin Antibody to the hybridized ans washed tissue section during the signal amplification phase of detection.
60 μl of Biotin-labeled Anti-Avidin Antibody was added to each slide and the plastic coverslip replaced over the solution. Incubation was for 20 minutes in a humidified chamber at room temperature. At 10 minutes of incubation, the plastic coverslip was lifted and replaced to ensure even fluid distribution. This reagent binds to fluorescein-labeled avidin what has previously bound to the hybridized probe and allows amplification of the fluorescent signal by providing multiple additional biotin moieties for binding by fluorescein-labeled avidin for each one originally bound with probe. The reagent contains sodium azide as a preservative.
The plastic coverslip was removed and discarded. Slides were washed in a coplin jar containing 40 ml of 1×PBD at room temperature for 2 minutes. This wash was repeated 2 times using fresh 1×PBD.
60 μl of Blocking Reagent One was applied to each slide and a fresh plastic coverslip placed over the solution. Incubation was for 5 minutes in a humidified chamber at room temperature. After that the plastic coverslip was pealed and blotted dry for reuse while the slide was tilted to allow fluid to drain briefly.
60 μl of Detection Reagent was applied to each slide and the plastic coverslip replaced over the solution. Incubation was for 20 minutes in a humidified chamber at room temperature. After 10 minutes of incubation, the plastic coverslip was lifted and replaced to ensure even fluid distribution.
The plastic coverslip was pealed and discarded and the slides washed in a coplin jar containing 40 ml of 1×PBD at room temperature for 2 minutes. The wash was repeated 2 times using fresh 1×PBD.
The cell nuclei were counterstained by adding 20 μl of DAPI/Antifade (DAPI, glycerol, P-phenylene diamine dihydrochloride, sodium bicarbonate, sodium hydroxide in phosphate buffered saline) to each slide and covered with a 24×50 mm glass coverslip. Stained slides may be stored in the dark at −15° C. to −25° C. for up to five days before analysis. This reagent is a mixture of a blue-fluorescing DNA-intercalating dye and a chemical which reduces photo bleaching. This is used to counterstain nuclear DNA blue to prolong probe signal fluorescence.
If the tissue section was insufficiently digested under the designated digestion conditions and is determined to interfere with interpretation of assay results, an extended protein digestion may be used as follows. The coverslip was removed by gently wiping off the immersion oil with tissue paper and soaking the slide in 40 ml 2×SSC, pH 7.0 in a coplin jar at room temperature until the coverslip falls off The slide was placed in a coplin jar containing fresh 2×SSC, pH 7.0 for several minutes to clean off any residual DAPI/Antifade.
The slides were placed in prewarmed Protein Digestion Enzyme Working Solution at 37° C.±2° C. The effect of this protein digestion and the initial digestion is cumulative. Twenty (20) additional minutes of digestion might be an appropriate starting time for tissue that seems very underdigested after the initial 40 minute digestion.
The slides were washed in 40 ml 2×SSC, pH 7.0 room temperature with agitation for 10 seconds, then dehydrated in 70%, 80%, 90%, and 100% ethanol at room temperature for 1 minute each and allowed to air dry. The process above is then repeated.
EXAMPLE III
PREPARATION OF CONTROL SLIDES
The control slides are prepared using the following cell lines:
Level 1 Control
ATCC HTB 132 (MDA-MB-468) cell line
Level 2 Control
ATCC HTB 133 (T-47D) cell line
Level 3 Control
ATCC HTB 30 (SK-BR-3) cell line
Each cell line is available from the American Type Culture Collection, Manassas, Va., USA and grown using standard media and techniques to produce approximately 1.5×10 8 cells. The cell growth is divided into approximately 30 5×10 6 cells. Pellets of the cultured cells were suspended in a plasma/thrombin matrix and clotted. Fibrin clotted blocks were then formalin fixed. Each block is paraflin embedded, cut into 4 μm sections and mounted on a silanized glass slide. The HER-2/neu Control Slides were stored at 18° C. to 25° C. prior to processing and at −15° C. to −25° C. after processing
EXAMPLE IV
SCORING OF CONTROL SLIDES
A non-amplified sample has a mean HER-2/neu signal per nucleus less than or equal to (≦) 4. Specimens with a mean signal per nucleus greater than (>) 4 are amplified for the HER-2/neu gene. Control Slides are divided into three (3) categories. These are listed below and should not be confused with the amplification cut-off value of 4.
LEVEL 1(0 to 3 signals/nucleus) CONTROL SLIDES
A Level 1 control has a mean signal per nucleus value of less than or equal to 3. This range of assay scores (0 to 3) is defined as non-amplified for the HER-2/neu gene. In most patient specimens, an internal non-amplified control is present in the form of cells that are identifiably non-cancerous by the criteria of histopathologic morphology.
Level 1 control slides are 4 μm sections of a formalin-fixed, paraffin-embedded human breast cancer tissue culture cell fine on silaized slides. The preferred cell line is MDA-MB468 (ATCC#HTB 132).
LEVEL 2 (>3 to <10 signals/nucleus) CONTROL SLIDES
A Level 2 control has a mean signal per nucleus value of greater than 3 to less than 10. This range of assay scores (>3 to <10) is defined as low amplified HER-2/neu gene amplification. Level 2 control slides are 4 μm sections of a fonnalin-fixed, paraffin-embedded human breast cancer tissue culture cell line on silanized slides. The preferred cell line is T471D (ATCC#HTB 133).
LEVEL 3 (SYMBOL≧210 signalsnmucleus) CONTROL SLIDES
Level 3 control specimens represent a highly amplified specimen. A Level 3 control has a mean signal per nucleus value equal to or greater than 10. This range of assay scores (≧10) is well above the cutoff of>4 signals per nucleus. Level 3 control slides are 4 μm sections of a formalin fixed, paraffin-embedded human breast cancer tissue culture cell line on silanized slides. The preferred cell line is SK-BR-3 (ATCC#HTB 30).
Level 1, Level 2 and Level 3 controls should be run and evaluated with each run of the HER-2/neu gene detection system assay. Paraffin-embedded human breast cancer cell lines are run simultaneously with each run of samples. The control slides are read by scoring 20 cells from each of two (2) randomly selected areas of the slide (total of 40 nuclei) and the results interpreted as described below. Scoring criteria for invasive cancer do not apply to the paraffin-embedded cell line controls.
Because breast cancer cell nuclei are often considerably thicker than the 4 μm sections of tissue required to perform the assay, the control tissue nuclei are frequently not intact. This effect of sectioning will result in the observation of fewer HER-2/neu signals than are actually contained in an intact nucleus.
The mean signal per nucleus of a Level 1 control must be less than the mean signal per nucleus of a Level 2 control for a processing run to be considered valid. For cell line controls acceptance ranges see the list below:
Based on 393 observations (40 nuclei scored per observation) of 4 μm sections of the Level 1 control cell line a mean of 2.4 (standard deviation=0.25) HER-2/neu signals per nucleus was determined.
Based on 102 observations (40 nuclei scored per observation) of 4 μm sections of the Level 2 control cell line, a mean of 3.5 (standard deviation=0.71) HER-2/neu signals per nucleus was determined.
Based on 338 observations (40 nuclei scored per observation) of 4 μm sections of the recommended Level 3 control cell line, an acceptance range of 15.8 to 20.0 HER-2/neu signals per nucleus was determined (determined by non-parametric analysis).
In addition to these HER-2/neu Control Slides, controls may also take the form of 4 μm tissue sections from invasive breast cancers that have been previously identified to have specific levels of HER-2/neu gene amplification by fluorescence in situ hybridization (FISH). Use of breast cancer tissue as control material requires qualification and validation by the user laboratory according to the laboratory's established procedures. While these controls may be useful to at or group tissues according to HER-2/neu amplification status such controls are time consuming to prepare and generally considered inferior to standardized controls. Additionally, controls from cell lines are homogeneous and reproducible, neither quality can be attributed to surgically removed tumors and their sections
For determination of HER-2/nem gene amplification level in tissue specimens, 40 nuclei were scored from specimens processed with two (2) lots of the control cell lines. Multiple observers were used (3 or 4) to achieve accurate estiates of the mean and standard deviation (SD). Acceptance ranges were calculated from the mean plus and minus three (3) standard deviations. The results of six (6) Level 1 tissue specimens are summarized below.
TABLE 1
Examples of Level 1 Tissue Specimen Means and Acceptance Ranges
Specimen
Mean ± SD, (no. of observations)
Acceptance Range
1.
1.96 ± 0.37, (N = 42)
0.85-3.07
2
2.14 ± 0.79, (N = 42)
0-4.51
3
2.01 ± 0.41, (N = 42)
0.78-3.24
4
2.08 ± 0.64, (N = 42)
0.16-4.00
5
1.70 ± 0.31, (N = 36)
0.77-2.63
6
2.01 ± 0.29, (N = 36)
1.14-2.88
In general, a 4 μm section of a Level 2 control tissue will exhibit a mean of greater than 3 to less than 10 (>3 to <10) HER-2/neu signals per nucleus (40 nuclei scored) when assayed with the HER-2/neu gene detection system of the present invention.
For determination of HER-2/neu gene amplification level in tissue specimens, 40 nuclei were scored from specimens processed with two (2) lots of the control slides, Multiple observers were used (3 or 4) to achieve accurate estimates of the mean and standard deviation (SD). Acceptance ranges were calculated from the mean plus and minus two (2) standard deviations. The results often (10) Level 2 tissue specimens are summarizd below.
TABLE 2
Examples of Level 2 Tissue Specimen Means and Acceptance Ranges
Specimen
Mean ± SD, (no. of observations)
Acceptance Range
1
3.93 ± 0.74, (N = 36)
2.46-5.41
2
5.69 ± 1.31, (N = 36)
3.07-8.31
3
3.97 ± 1.65, (N = 36)
0.67-7.27
4
3.56 ± 0.47, (N = 36)
2.62-4.50
5
3.05 ± 0.41, (N = 36)
2.23-3.87
6
6.35 ± 1.06, (N = 51)
4.23-8.47
7
8.07 ± 2.08, (N = 53)
3.91-12.23
8
6.17 ± 2.19, (N = 36)
1.79-10.55
9
5.52 ± 1.6, (N = 36)
2.32-5.52
10
8.21 ± 2.47, (N = 30)
3.27-13.51
In general, a 4 μm section of a Level 3 control tissue will exhibit a mean of greater than or equal to 10 HER-2/neu signals per nucleus (40 nuclei scored) when assayed with the HER-2/neu gene detection system.
In a study for determination of HER-2/neu gene amplification level in tissue specimens, 40 nuclei were scored from specimens processed with two (2) lots of the control slides. Multiple observers were used (3 or 4) to achieve accurate estimates of the mean. Acceptance ranges were calculated from the mean plus and minus two (2) standard deviations with the upper limit truncated at 20. The results of eight (8) Level 3 tissue specimens are summarized below.
TABLE 3
Examples of Level 3 Tissue Specimen Means and Acceptance Ranges
Specimen
Mean (no. of observations)
Acceptance Range
1
17.72 (N = 36)
12.34-17.72
2
17.46 (N = 36)
11.66-20.00*
3
15.95 (N = 36)
11.15-20.00
4
10.85 (N = 44)
6.25-15.45
5
14.54 (N = 42)
8.84-20.00
6
10.73 (N = 42)
6.16-15.31
7
15.09 (N = 36)
6.19-20.00
8
12.20 (N = 36)
4.46-19.94
*Acceptance ranges >20 have been set to 20 as discussed in the Interpretation Section of this Procedure and Interpretation Guide.
EXAMPLE V
FISH ASSAY FOR HER-2/neu AMPLIFICATION ON CLINICAL SAMPLES
Slides were viewed with an epifluorescence microscope equipped with a DAPI filter set and a DAPI/FITC/Texas Red triple band pass filter set (a filter set capable of simultaneously passing FITC and DAPI fluorescence). A FITC/Texas Red dual band pass filter set (a filter set that allows visualization of the FITC signal but not the DAPI counterstain) is helpful in resoling background from true signal. The microscope may be equipped with 10×, 40× (optional for viewing hematoxylin and eosin stained sections) and 100× objectives and a 100 watt mercury arc light source. Scoring should be performed in a darkened room with excessive light leaking from microscopes minimized.
Using the DAPI filter set and the same low power objective used to view hematoxylin and eosin stained sections, it was confirmed that the tissue section contains areas of invasion as previously identified in hematoxylin and eosin stained sections. Areas of invasion are scored; carcinoma in situ should not be scored.
Using the DAPI/FITC/Texas Red triple band pass filter set and a 100× oil objective, the FITC signal was present in approximately ¾ or more of the cancer cell nuclei in the area to be scored.
It should be noted that non-cancerous cell nuclei (e.g. from normal epithelium) may be more resistant to protein digestion and may show lower levels of hybridization than tumor cell nuclei; therefore, these non-cancerous cell nuclei are not a reliable gauge of hybridization efficiency for the cancerous cell nuclei. The hybridization signals to be scored within a cancer cell nucleus will be of similar size and intensity, whether separated or clustered.
With the DAPI filter set and a 100× oil objective, individual cancer nuclei were selected for scoring. Only cancer nuclei that are non-overlapping are selected. Severely truncated cancer nuclei were excluded. Cancer nuclei that are less than ⅓ the diameter of the average cancer cell nucleus are not selected. Overdigested and mechanically damaged cancer cell nuclei are not selected. Only cancer cell nuclei that have relatively well-defined borders are selected to be scored.
Using the DAPI/FITC/rexas Red triple band pass filter set and a 100× oil objective, probe signals were differentiated from background if present. FITC stain appearing over cytoplasm or in the extra-cellular matrix is considered background. Background confined to the cancer nucleus is more difficult to interpret and could interfere with counting, but the background is generally much smaller and more diffuse than true probe signal.
Using the DAPI/FITC/Texas Red triple band pass filter set and a 100× oil objective, the number of FITC signals present in each of 20 randomly-selected cancer nuclei that meet all the above mentioned criteria were counted. In FISH analysis, signals are often in different planes of focus within the tumor cell nucleus. Focusing up and down through the section to find all of the signals present in the cancer cell nucleus was used. If the signal count is greater than 20 per cancer cell nucleus, it was recorded as 20+ and not grouped with any other counts.
Scoring in a second area of invasive breast cancer was repeated following all steps above. The two areas examined were separate, distinct microscopic areas within a single section. The total number of cancer nuclei scored was 40 from 2 distinct areas of the same lesion in one section the mean number of HER-2/neu signals per nucleus was determined.
If more than 5% of the fluorescein signals (those of similar size and intensity to true signal within invasive tumor nuclei) are located over the cytoplasmic compartment or extra cellular matrix and all troubleshooting methods have been exhausted, the background is excessive and the assay repeated.
When the positive or negative control results fall outside the expected values, then the specimen results are unreliable and the assay repeated.
When 40 non-overlapping nuclei cannot be identified, then the sample is inadequate and the assay repeated on a new slide.
When signal intensity varies widely after all troubleshooting methods have been exhausted, then the specimen results is unreliable and the assay repeated.
Values at or near the cut-off (3.5 to 4.5 mean signals/nucleus) are expected to occur in approximately 3.6% of the patient population. Scoring of borderline specimens should be repeated by another qualified user or the test should be repeated using a new tissue section. If the value of 3.5 to 4.5 persists, then the borderline results should be interpreted with caution and increased emphasis should be given to the other clinical and prognostic information available to the practitioner.
A retrospective study of 220 node-negative breast cancer patient specimens were collected from multiple sources and analyzed at two clinical sites in the United States. This combined data set was used to determine the association of HER-2/neu gene amplification, using the HER-2/neu gene detection system of the present invention, to the clinical outcomes; early recurrence (within 24 month of diagnosis), recurrences, and death, due to breast cancer.
The clinical performance characteristics of the HER-2/neu gene detection system are described with amplification defined as>4 signals per nucleus and non-amplification defined as<4 signals per nucleus.
The HER-2/neu gene detection system was used to retrospectively identify the risk of recurrence and death for node-negative breast cancer patients meeting the following criteria:
1) Diagnosis of invasive breast cancer,
2) Available formalin-fixed, paraffin-embedded tissue for HER-2/neu analysis;
3) Primary treatment surgery only;
4) Clinical follow up for at least 2 years for early recurrence, 3 years for recurrence and death.
The safety and effectiveness of the HER-2/neu Gene Detection System was evaluated in a population of 220 node-negative, invasive breast cancer patients for early recurrence within two years. Two hundred twelve (212) of the 220 specimens were eligible for evaluation of recurrence at anytime and 210 of the 220 specimens were eligible for evaluation of disease-related death. (Eight (8) subjects did not recur and were lost to follow-up before 36 months; ten (10) subjects did not die of their disease and were lost to follow-up before 36 months.) The relationship of the HER-2/neu gene detection system assay result to the probability of remaining recurrence-free (disease-free survival) in lymph node negative breast cancer is presented in Table 4. The relationship of the assay results to the probability of surviving (overall survival) is shown in Table 5.
The survival curves presented in the figures are graphical representations of the probability of early recurrence-free survival, i.e., no recurrence within 24 months FIG. 1) survival for subjects with and without HER-2/neu amplification (FIG. 2 ). Error bars, where present, show the standard error around the values.
TABLE 4
Probability of disease-free survival of breast cancer patients with non-amplified
and amplified lesions.
Time from
Surgery
Probability of Remaining Disease-Free*
(in Years)
Non-Amplified
Amplified
(95% CI)†
N**
(95% CI)†
N**
0.5
100% (100.0% to 100.0%)
179
93.8% (85.7% to 100.0%)
31
1.0
98.3% (96.4% to 100.0%)
176
81.8% (68.7% to 95.0%)
27
1.5
96.7% (94.1% to 99.2%)
173
75.8% (61.1% to 90.5%)
25
2.0
94.4% (91.1% to 97.7%)
169
75.8% (61.1% to 90.5%)
25
2.5
93.9% (90.3% to 97.4%)
168
72.7% (57.4% to 88.0%)
24
3.0
93.3% (89.6% to 97.0%)
167
69.7% (54.0% to 85.4%)
23
5.0
85.9% (80.6% to 91.2%)
121
66.7% (50.6% to 82.7%)
19
10.0
70.5% (60.3% to 80.7%)
23
61.9% (44.5% to 79.3%)
4
Expansion of Table 4
Non-Amplified
Cumulative
Time from Surgery
Cumulative
No. Cases
Probability of Remaining
(in years)
N**
No. Events
Censored
Disease Free
0.5
179
0
0
100.0%
1.0
176
3
0
98.3%
1.5
173
6
0
96.7%
2.0
169
10
0
94.4%
2.5
168
11
0
93.9%
3.0
167
12
0
93.3%
5.0
121
24
34
85.9%
10.0
23
35
121
70.5%
Amplified
Cumulative
Time from Surgery
Cumulative
No. Cases
Probability of Remaining
(in years)
N**
No. Events
Censored
Disease Free
0.5
31
2
0
93.9%
1.0
27
6
0
81.8%
1.5
25
8
0
75.8%
2.0
25
8
0
75.8%
2.5
24
9
0
72.7%
3.0
23
10
0
69.7%
5.0
19
11
3
66.7%
10.0
4
12
17
61.9%
*Point estimate generated from the Kaplan Meier Statistic (Kaplan, E. L., and Meier, P., 1958)
†95% Confidence Interval (C.I.) generated from the Greenwood estimate of standard error (Greenwood, M., 1926)
**Number of Cases = number of cases at risk remaining in analyses at the time interval specified. The N values decrease with time due to patients experiencing an event (death or recurrence) or being censored (lost to follow-up).
TABLE 5
Probability of Overall Survival Tumor Size large (>1 cm)/small (<1 cm) and
HER-2/neu Amplification Status
Probability of overall survival of breast cancer patients with large/small and non-
amplified/amplified tumors.
Probability of Survival*
Time from Surgery
Small (≦1 cm);
Small (≦1 cm);
(in Years)
Non-Amplified (≦4)
Amplified (>4)
(95% CI)†
N**
(95% CI)†
N**
0.5
100% (100.0% to 100.0%)
39
100% (100.0% to 100.0%)
5
1.0
100% (100.0% to 100.0%)
39
100% (100.0% to 100.0%)
5
1.5
100% (100.0% to 100.0%)
39
100% (100.0% to 100.0%)
5
2.0
100% (100.0% to 100.0%)
39
80.0% (44.9% to 100.0%)
4
2.5
100% (100.0% to 100.0%)
39
80.0% (44.9% to 100.0%)
4
3.0
100% (100.0% to 100.0%)
39
80.0% (44.9% to 100.0%)
4
5.0
100% (100.0% to 100.0%)
29
60.0% (17.1% to 100.0%)
2
10.0
100% (100.0% to 100.0%)
6
60.0% (17.1% to 100.0%)
1
Probability of Survival*
Time from Surgery
Large (>1 cm),
Large (>1 cm);
(in Years)
Non-Amplified (≦4)
Amplified (>4)
(95% CI)†
N**
(95% CI)†
0.5
100% (100.0% to 100.0%)
117
100%(100.0% to 100.0%)
25
1.0
100% (100.0% to 100.0%)
117
100% (100.0% to 100.0%)
25
1.5
100% (100.0% to 100.0%)
117
96.0% (88.4% to 100.0%)
24
2.0
100% (100.0% to 100.0%)
117
96.0% (88.4% to 100.0%)
24
2.5
99.2% (97.4% to 100.0%)
116
96.0% (88.4% to 100.0%)
24
3.0
99.2% (97.4% to 100.0%)
116
88.0% (75.3% to 100.0%)
22
5.0
96.4% (92.9% to 99.9%)
89
68.0% (49.8% to 86.2%)
15
10.0
83.4% (74.2% to 92.6%)
21
51.0% (19.1% to 82.9%)
3
*Point estimate generated from the Kaplan Meier Statistic (Kaplan, E. L., and Meier, P., 1958).
†95% Confidence Interval (C.I.) generated from the Greenwood estimate of standard error (Greenwood, M., 1926)
**Number of Cases = number of cases at risk remaining in analyses at the time interval specified.
Tumor size was available for 186 specimens out of the 210 specimens in the “disease-related death” database.
The table above is calculated from these 186 specimens.
The N values decrease with time due to patients experiencing an event (death or recurrence) or being lost to follow-up.
EXAMPLE VI
MULTI-TIERED CUTOFFS FOR HER-2/NEU GENE COPY
The data from the above testing was analyzed to determine the effect for using a ≦3 cutoff and a≦10 cutoff on early recurrence (within 24 months), recurrence anytime and disease related death at any time. The relative hazard for each was calculated both unadjusted and adjusted for estrogen receptor, tumor size, patient age, study site and tumor grade. The results are in Tables 6.
TABLE 6
Relative Risk
Unadjusted
Adjusted
≦3
≦10
cutoff
cutoff
≧10
≦3 cutoff
≦10 cutoff
≧10
Early Recurrence
4.8
6.6
7.8
4.3
5.5
8.3
Recurrence
2.0
3.4
3.4
2.0
3.8
4.3
Death
4.7
5.8
6.9
4.5
7.3
11.0
As can be seen from this data, the higher the average HER-2/neu gene copy number per cell, the greater the risk to the patient.
Although preferred embodiments are specifically described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention. Other and further embodiments will be apparent to those in the art from the preceding description and examples. No unreasonable limitations or the like are to be drawn therefrom in interpreting the following claims.
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All references mentioned above are herein incorporated by reference.
2
1
22
DNA
Artificial Sequence
Description of Artificial SequencePRIMER
1
cggccaagat ccgggagttg gt 22
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24
DNA
Artificial Sequence
Description of Artificial SequencePRIMER
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tcttgatgcc agcagaagtc aggc 24
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This invention relates to a method, kit and controls for detecting HER-2/neu gene amplification as a predictor of breast cancer reoccurrence and patient survival The method is a fluorescent in-situ hybridization (FISH) assay using a labeled DNA probe. By determining the genetic nature of the cancer cells, appropriate treatment may be utilized. Control tumor cell lines with predefined amounts of HER-2/neu gene amplification are also disclosed.
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This application is a continuation of Ser. No. 08/534,072 filed Sep. 26, 1995 now abandoned, which is a continuation-in-part of Ser. No. 08/311,547 filed Sep. 23, 1994, now abandoned.
FIELD OF THE INVENTION
The invention relates to compositions for producing temporary washable colored markings on surfaces, especially outdoors in subfreezing temperatures and for marking snow or ice.
BACKGROUND OF THE INVENTION
A number of marking compositions are used for various purposes.
U.S. Pat. No. 3,288,618 (DeVries) relates to a colored reflective coating composition.
U.S. Pat. No. 2,371,353 (Fain) relates to a de-icing composition applied as coating to aircraft parts. The composition is formed of lithium chloride combined with potassium chromate, carboxymethyl cellulose and a wetting agent. The wetting agent can be Triton X-100 which is an alkylated aryl polyether alcohol such as iso-octylphenyl ether of polyethylene glycol.
U.S. Pat. No. 2,416,103 (Lampton et al.) discloses a de-icing paint or coating which is applied to aircraft parts or accessories such as propellers, rotors, wings, etc. The composition comprises a resin, a wetting agent, a freezing point depressing material. A wetting agent is selected from the group consisting of salts of sulfated alcohols and salts of sulphated acids, salts of sulphated fatty acid amides, salts of sulphated fatty acids esters. The freezing depressant may be barium thiocyanate or other salts such as sodium chloride and calcium chloride.
U.S. Pat. No. 2,783,209 (Pessel) relates to a marine marking composition comprising a glue and light colored finely divided solid material such as polyalkylene glycol, methyl cellulose, polyvinyl alcohol.
U.S. Pat. No. 3,297,585 (Hayden) discloses a visual indicator comprising aqueous solution of a fluorescent and an alcohol soluble basic dye dissolved in a mixture of glacial acetic acid, ethanol, glycerine and propionic acid.
Most known marker composition include flammable and/or toxic and/or environmentally suspect chemicals. Therefore, these compositions present certain dangers. Because the Environmental Protection Agency restricts the use of toxic chemicals in coating compositions a number of water based paints have been created to replace the flammable and/or toxic coating compositions.
For example, U.S. Pat. No. 4,792,357 (Bier) discloses a water-based paint comprising water-soluble salts in concentration of at or above 10% (weight/volume) and a pigment in the amount of at least 5% by weight. A filler is present in the paint composition in the amount of from about 20% to about 70% by weight. This paint is used only for interior painting of buildings, especially ceilings. The composition can not be used for marking the ground. The formulation includes a considerable amount of talc as a filler and a water soluble salt. The talc is used to create a thick, smooth mixture which spreads evenly, covers the substrate in one or two coats and dries to a permanent, washable covering.
U.S. Pat. No. 5,165,966 (Adams) relates to a process of painting snow with a biodegradable solution of a food coloring and a gelling agent such as household gelatin. However, the paint lies only on the top of the snow. Warm water is required to mix with dry ingredients. The paint contains no antifreeze. It is not clear how long it will disperse if left in the cold.
OBJECTS OF THE INVENTION
It is an object of the invention to provide compositions which are non-toxic and environmentally acceptable for coating of snow or ice and other surfaces such as for trail marking, sports field marking, hazard marking and for decorating outdoor surfaces, particularly snow and ice.
It is another object of the invention to create a water-based temporary coloring solution which can be utilized and kept outdoors indefinitely at low temperatures.
It is a further object of the invention to develop a product that provides a quality marking and excludes or limits the "bleeding" effect of a colorant on snow, ice and surfaces such as sand.
It is still another object of the invention to provide a covering composition which can be washed off surfaces by rain and will disappear with snow and ice as they melt.
It is also another object of the invention to create a composition which washes from most fabrics.
It is yet further object of the invention to lower the cost of a marking composition.
SUMMARY OF THE INVENTION
The invention relates to marking compositions. The compositions are mixtures of ingredients including at least water, an anti-freeze agent and water soluble colors. The compositions may include a stabilizer such as hydroxypropyl cellulose and/or an extender such as talc. The stabilizer produces an even coating of color. It may also be necessary to add a stabilizer when two colorants are combined together to improve color quality. The extender controls the melting effect of the anti-freeze and thereby the bleeding of the colorant on snow or ice.
The markings on the ground will be washed away with melting snow or falling rain. The ingredients can be dissolved in water. The composition may include specific agents such as additional antifreezes, antibacterial/fungus agents, such as sodium or benzoate additional stabilizers and additional extenders such as chalk or clay for controlling the quality of the marking and the melting effect of the anti-freeze. A chalk also enlightens the color.
A marking composition comprises:
(a) A salt selected from the group comprising sodium chloride, magnesium chloride and calcium chloride and taken in the amounts from about 1% to about 25%. Combinations of the above salts may also be used and their amounts can vary.
(b) Cellulose such as hydroxypropyl cellulose (HPC) in the amount up to about 0.5%. The cellulose acts as a stabilizer.
(c) Talc in the amount up to about 2%, acts as an extender.
(d) Colors in the amount from about 0.01% to about 2%.
(e) Water in the amount that adds to 100%.
The marking compositions may comprise the ingredients (a), (d) and (e) only.
DETAILED DESCRIPTION OF THE INVENTION
The marking compositions of the invention are prepared by dissolving water soluble salts such as sodium chloride, magnesium chloride and calcium chloride in water. A solution with 21% by weight of sodium chloride is necessary to lower the temperature to 0° Fahrenheit. A sealed 8 oz. container of this composition does not require toxicity labelling under ASTM-D4236 standards, is nonflammable and is soluble. If magnesium chloride is taken in the amount of about 21% by weight the composition can be used at minus 23° Fahrenheit. Calcium chloride in the amount of 25% by weight reduces the temperature of the solution to -20° Fahrenheit.
Each of the salts can be combined with each of the others or with other antifreezes such as alcohol. For example, 10% magnesium chloride and 15% sodium chloride or 10% calcium chloride and 23% sodium chloride will each reduce the temperature of the solution to -20° Fahrenheit.
A solution of a salt in water and color may be used when the quality of marking is not at issue. A stabilizer and/or an extender can be added to improve the quality of the marking. A preferred stabilizer is hydroxypropyl cellulose (HPC). The HPC acts as a thickening agent and assists in creating uniform color and in holding color combinations together. A preferred extender is talc. Talc minimizes the "spreading" or bleeding effect that occurs when combinations of a salt, such as sodium chloride, and colorant are used. When HPC is used in the amount of above about 0.5% an adverse effect on the solution is observed. The stabilizer can be removed in applications where the coloring quality is irrelevant and where no color combinations, e.g., red and blue to make purple, are necessary.
The extender selected from the group consisting of talc, chalk and clay acts to impede the effects of penetrating and spreading of the solution into snow or ice when a salt is used as antifreeze. For decorative and precise marking, especially on snow, it is necessary to prevent undue bleeding on snow surfaces or excessive penetration of color into the snow. For other applications talc or other extenders can be excluded from the compositions. The colors may be used alone or in combination with other colors.
Several colors have been developed using colorants chosen from the FD&C color list primarily for use with a solution comprising a salt (particularly NaCl) as the principal antifreeze. Red and yellow colors are used to make orange. A blue and a red color are used to create purple. A basic color is: red-FD&C Red #3, or Cochineal Red, or combinations thereof-50% of each of the two colors or 60% Red #3 and 40% Cochineal. The Red #3 is preferable since the cochineal is quite costly. FD&C Red #40 is not usable with more than about 10% sodium chloride to make red color. NaCl, MgCl 2 , and CaCl 2 cause FD&C Red #40 to become brown. It browns even more in freezing conditions. The other basic colors are blue-FD&C Blue #1; yellow-Yellow #5 and/or #6; green-a mixture of Yellow #5 and Green #3. Orange is made with a mixture of Yellow #5 and Red #3. Purple is a mixture of Red #3 and Blue #1. Other colors from the FD&C list can be used as well as mixtures of colors. Pastels can be created by reducing the concentration of color. Fluorescence can also be created. For example, FD&C Red #3 contains fluorescent components. The choices and concentrations of colors may be adjusted to meet ASTM-D4236 Standards for no toxicity warnings. Colorants other than FD8C colors may be used.
Antifreezes such as alcohol, glycerine or propylene glycol can be used with or in place of the salts. An alcohol such as ethanol used in the amount of from about 23% to about 40% by weight will lower the temperature of the solution to 0° Fahrenheit or -20° Fahrenheit respectively. A solution of 47% by weight of propylene glycol allows one to achieve -20° Fahrenheit. These other antifreezes may also be used in lesser amounts when combined with sodium chloride, calcium chloride or magnesium chloride. The antifreezes have an ability to lower the freezing point of the solution well below minus 6 Fahrenheit, the lower limit for sodium chloride. For example, a combination of 20% glycerol and 20% sodium chloride in the solution reduces the freezing point to -10 Fahrenheit.
The non-salt antifreeze solutions allow the FD&C Red #40 to retain its red color. Because these antifreezes do not have the same melting effect as the salts it is also possible to eliminate the extender.
EXAMPLE 1
Marking compositions were prepared from the following ingredients.
______________________________________ Product 1 Product 2 Product 3Ingredient % by weight % by weight % by weight______________________________________MgCl.sub.2 0% 0% 20%NaCl 20% 16% 0%CaCl.sub.2 0% 2.8% 0%Color .25%-3% .5% .5%HPC .5% .5% .5%Talc .5% .5% .5%Water Balance to 100% Balance to 100% Balance to 100%______________________________________
The dry ingredients were mixed with water at room temperature. The product may be produced as a liquid. It may also be produced as a dry blend or as a concentrate with subsequent addition of water or other liquid.
EXAMPLE 2
The cost of the composition of an orange-red colorant based on the formulation of Product 3 was calculated for the manufacture of 20,000 pounds of the color composition as follows:
______________________________________Ingredient $/lb lb. RM* Total RMC**______________________________________Water .0015 15,700 23,5520% MgCl.sub.2 .50 4,000 2.000.00.5% HPC 6.40 100 640.00.5% Talc .29 100 29.00.15% Red #3 31.40 50 1,570.00.15% Yellow #6 8.95 50 449.50 20,000 4,710.05______________________________________ *RM = raw material **RMC = raw material cost
From the foregoing, a cost per 8 fluid ounce container was calculated at $0.12.
EXAMPLE 3
A "kit" of four different colors was made using the following ingredients.
______________________________________Color Percentages Raw Material #LBS Raw Material______________________________________ Water 157,425 0.5% HPC 1,000 0.5% Talc 1,000 20.0% NaCl 40,000BLUE 0.3% FD&C Blue #1 150RED 0.3% FD&C Red #3 150GREEN 0.21% FD&C Yellow #5 105 0.09% FD&C Green #3 45YELLOW 0.235% FD&C Yellow #5 110 0.035% FD&C Yellow #6 15 200,000______________________________________
EXAMPLE 4
The following products were prepared by mixing the ingredients listed below at room temperature:
______________________________________Product No. 1Ingredient Amount in Grams Freezing Point______________________________________Color 3.0HPC 5.0Talc 5.0 (0° F.)NaCl 210.0Water 777.0Total 1,000.0______________________________________
______________________________________Product No. 2Ingredient Amount in Grams Freezing Point______________________________________Color 3.0HPC 5.0Talc 5.0 (+10.7° F.)NaCl 160.0Water 827.0Total 1,000.0______________________________________
______________________________________Product No. 3Ingredient Amount in Grams Freezing Point______________________________________Color 5.0HPC 5.0Talc 2.5 (-10° F.)NaCl 200Glycerol 200Water 587.5Total 1,000______________________________________
______________________________________Product No. 4Ingredient Amount in Grams Freezing Point______________________________________Color 5.0HPC 5.0Talc 2.5 (-4° F.)NaCl 160Glycerol 159Water 677.5Total 1,000______________________________________
The product can be prepacked in spray containers, cans, jars and other containers. It can be prepared as a concentrate or powder and prepacked accordingly in drums or other large containers. The concentrate or powder, to be mixed with water by the user, would be appropriate for large quantity applications. For small quantity applications, packets of concentrate or dry mixture may also be appropriate. The prepared product may be utilized for decorative purposes and entertainment and for marking sports fields, particularly ski, sledding and skating ones. It can also be utilized for construction sites, "SOS"-signs for skiers, hikers and climbers, for designating temporary crosswalks, for marking airport runways, for marking hazards on snow or ice, for police work in the snow and similar uses. In particular, the NaCl solution is usable for indoor art and crafts projects and outdoor on deserts, beaches, sand and for other purposes.
It is understood that various changes and modifications can be made in the invention without departing from the scope of the invention as defined by the appended claims.
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Temporary marking compositions for producing colors upon contact with a surface, especially one covered in snow or ice, are disclosed. The compositions contain water-soluble salts or a mixture of water-soluble salts, colorant and water. The compositions may include a stabilizer, an extender, additional antifreezes, anti-bacterial/anti-fungus agents and other ingredients. The compositions may contain only antifreezes such as alcohol, glycerol and propylene glycol or combinations of the salts and/or other antifreezes. The methods of marking are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved interstitial heat applicator whereby a local area of human or animal living tissue is heated by electromagnetic radiation.
2. Discussion of Background
Prior art microwave interstitial applicators utilize a conductor with a gap in the outer conductor. These type of structures invariably experience difficulty with respect to the energy which is radiated from the gap in the outer conductor of the applicator. Primarily, the difficulty is the travelling of the energy back along the surface of the outer conductor toward the input at the air-tissue interface. When this type of energy, which is radiated back along the outer conductor, is experienced, a heating pattern is developed so that heating occurs at the insertion point of the applicator. This is usually an undesirable result which in the very least detracts from the applicator's effectiveness and which creates not only a loss of heat at the point at which it is desired to be used but also provides an unintended heat "spot" where such heat spot is either uncomfortable or harmful. The harmful effects become more pronounced as higher power levels are used in order to heat localized growths by using a single applicator.
One type of prior art solution to this problem is disclosed in U.S. Pat. No. 4,448,198 wherein the applicators are provided with a "interconnecting means" in such a configuration so as to cause constructive interference within the emitted electromagnetic radiation when the applicators are inserted into the body tissue in a preselected spaced apart relationship. In a particular embodiment a plurality of parallel spaced applicators are placed in conjunction with an interconnecting means including a line stretcher to vary the phase of the electromagnetic energy provided to each applicator. Additionally, a catheter and a hypodermic needle are provided for inserting and positioning each applicator into the body tissue in a spaced apart relationship.
This and other prior art attempts to deal with these type of invasive hypothermia situations fail to provide accurate control of the applied power. That is, although the pattern of energy radiated from the gap and the outer conductor has been modified in the prior art with respect to its backward travel to the surface of the air-tissue interface, such modification is adapted to the particular situation and requires extensive modification for a different environment. Furthermore, the control of the spotting of the maximum heat is not at all precise and is not able to be duplicated from one application to another because of changing conditions and orientation.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a coaxial interstitial applicator which provides for enhancement of a desired radiation pattern at a specific location which at the same time provides for cancellation of undesired surface waves.
In accordance with a further object of the present invention, a gap, located a specific distance from the end of a probe and having a specific gap width, provides the particular enhancement of surface waves at the desired point of application and further the location and the size of the gap provides for the cancellation of surface waves to prevent unintended heating points or distorted heating patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete application of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a coaxial interstitial probe according to the present invention;
FIG. 2A is a graph of the heating patterns generated by the applicators of FIG. 2B and FIG. 2C respectively;
FIG. 2B illustrates an applicator with a gap according to the present invention which is utilized in the generating of the temperature graph of FIG. 2A;
FIG. 2C represents an applicator without a gap used in the comparison graph of FIG. 2A; and
FIG. 3 shows a test arrangement utilized to provide the temperature results of FIG. 2A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, there is shown the coaxial interstitial probe of the present invention, in cross-section, inserted into the tissue. The input is a microwave energy source which is, for purposes of the primary embodiment, a source producing 915 MHz. The applicator 10 having the central conductor 11, is positioned substantially beneath the air-tissue surface. The thin, coaxial-line center conductor antenna 11 is inserted into the tumor without the need for protruding past the tumor into normal tissue, as was required in prior art type of applicators. The microwave energy which travels back up the outer conductor 12 toward the air-tissue interface is minimized by the later-discussed relationship between the end of the tip 11 and the location and width of the gap 13. This improves over prior art types of devices wherein the tip needed to be inserted past the tumor and the backward heating of the normal tissue at the air-tissue interface was a significant problem or at least an uncontrolled problem.
The embodiment of FIG. 1 contains a gap 13 in the outer conductor 14. The distance between the gap and the end of the outer conductor 14 nearest to the tip 11 is equal to 1/4 wavelength (λ/4) wherein λ represents the wavelength of the frequency resulting from the 915 MHz input and the dielectric constant which is equivalently, formed by the combination of the Teflon (polytetrafluoroethylene) dielectric 15 between the inner conductor 11 and the outer conductor 14 as well as the dielectric constant of a covering 16 and the equivalent dielectric constant of the tissue into which the applicator 10 is inserted. It must be noted that whereas the dielectric constant is the same for all frequencies with respect to the inner and outer copper conductors 11 and 14 and the TEFLON dielectric 15 as well as the covering 16, the dielectric constant for different frequencies changes with respect to the tissue 18. In other words the tissue has a permittivity which effectively produces a variation in the dielectric constant of the muscle tissue depending upon the different frequencies being applied to the microwave input.
The gap 13 functions most effectively when it is equal to 1/3 of the diameter of the coaxial probe 10. This is an experimental finding which will be developed in conjunction with the showings of FIG. 2.
The utilization of a 1/4 wavelength for the distance between the gap 13 and the end of the outer conductor 14 provides for an enhancement near the end of the conductor 11 of any surface waves and further provides for a cancellation of surface waves at the gap 13. In order to see this more clearly, FIG. 1 shows an incoming wave A being divided into wave B which is passed down the probe and the waves C and D which are respectively passed through the gap 13 in both directions along the surface of the conductor 14 or the covering 16. At the end of the center conductor 11 the wave B is divided into return surface wave E and the wave F. Because the distance of travel of wave B is 1/4 wavelength and because the return distance is another 1/4 wavelength until the wave E reaches the gap 13 there has been a total of a 1/2 wavelength traversed by the wave E at the time it returns to the gap 13. This 1/2 wavelength provides for a 180° phase opposition to the wave C and therefore the wave E serves to cancel the contribution of wave C in order to eliminate any waves being passed to the air-tissue surface and thereby eliminating any uneven heating of the surface. Because of the aforementioned enhancement provided by wave D and wave F the portion near the tip 11 has increased heating.
The above discussed theoretical feature with respect to the 1/4 wavelength and the subsequent cancellation at the 1/2 wavelength as well as the enhancement near the tip 11 is exemplified by the FIG. 2A which shows detailed measurements both with the gap and without the gap. The graph of FIG. 2A was obtained by utilizing an interstitial applicator having 915 MHz signal applied at a power of 4 watts for a time of 6 minutes. Measurements taken with respect to the temperature of tissue were taken with 7 temperature probes 21-27 (BSD 200 thermometry) which were inserted around the applicator (probe) in muscle equivalent tissue at a distance of 10 mm from the outer conductor 14 in such a manner as to surround the applicator as shown in FIG. 3.
The FIG. 2A shows the results as having a peak in temperature change at approximately 20 mm which, as shown in FIG. 2A, corresponds approximately to the tip of the applicator taking into account that for the particular embodiment, the distance between the gap and the end of the outer conductor was 13 mm with an additional 6.5 mm being utilized between the end of the outer conductor and the end of the center conductor 11. This clearly shows that the heat is most effectively conducted toward the end of the center conductor 11 which provides an even application of maximum heat in the particular region of interest. That is, if a tumor is located a specific distance from the skin surface, the device may be positioned so that the tip of the center conductor 11 is located precisely within the tumor itself. This is a vast improvement over the hit and miss situation with respect to the prior art and it is quite easy to position the tip within the tissue to be heated in contrast with attempting to pass the probe through the tissue to be heated until it is in vicinity of the gap, which was necessary with prior art type of devices.
It is to be noted that the development of the embodiments of FIGS. 2-3 is such that the structure will function in a similar manner for different applications to different tissues in different locations in the body. Any change however in the frequency applied calls for an adjustment in the distance which is equal to 1/4 wavelength because, of course, the wavelength will vary not only because of the change in the applied frequency of the input power but also because of the aforementioned permittivity change in the muscle tissue. Therefore, a simple multiplication factor of 1/2 would not be effective if the frequency were doubled, for instance. This failure to provide a linear relationship is due to the aforementioned permittivity of the tissue and the fact that the equivalent dielectric constant is made up of each of the aforementioned items including the teflon dielectric between the inner 11 and outer 14 conductor and the covering 16, which is usually teflon.
Because of the complexity in calculating the effective wavelength due to the equivalent dielectric constant, which changes with the frequency on account of the permittivity of the muscle tissue, the maximum temperature change, for any other frequency may be determined experimentally by adjusting the distance between the gap and the end of the outer conductor 14 so that a maximum temperature change occurs at the approximate end of the center conductor 11 (tip). The 915 MHz frequency has been utilized because it is a normally accepted standard frequency application which has been approved by the FCC as one of the standard frequencies in medical applications.
The FIG. 2A further shows the positioning of the measuring points for each of the temperature probes shown in FIG. 3. The distances shown in FIGS. 28 and C are specific measurements which are utilized in the temperature measurements of FIG. 2A. The curve obtained for the gap as shown in FIG. 2A provided the maximum temperature change at the location of the tip. This maximum temperature curve was obtained when the gap 13 was limited to a value of 1/3 of the diameter of the cable. This 1/3 factor is an experimentally determined result and any change in applied frequency or change in diameter of cable used does not alter the effectiveness provided by keeping the ratio between the diameter of the cable and the length of the gap to a value of 3.
A change in the distance between the end of the tip of the inner conductor 11 and the end of the outer conductor 14 modified or shifted the curve of FIG. 2A and was thus undesirable because of either a lower temperature or a temperature peak which was not in the vicinity of the tip 11.
Although the maximum temperatures reached will be different, if different wattages and time frames and distances of the temperature probes from the coaxial cable are utilized, the basic curve structure of FIGURE 2A will remain the same and therefore any change in the applied wattage or the length of the time that it is applied or the distance from the particular probe will not effect the distances used for the length between the gap and the end of the outer conductor or the distance between the outer conductor and the tip of the inner conductor 11. As previously mentioned, a change in the application frequency of the input power will result in a requirement for the adjustment of the distance between the gap and the end of the outer conductor 14. This change in location of the gap, because of the change in frequency, is necessary in order to obtain an effective 1/4 wavelength distance and this change is complicated by the fact that the dielectric constant or the equivalent dielectric constant of the material is not strictly proportional to any change in frequency because of the permittivity of muscle tissue. Thus a new frequency being applied requires an adjustment of the length which is equivalent to the 1/4 wavelength and such adjustment can either be made through a series of calculations of the equivalent dielectric constant presented to the power input or by a experimental changing in the length in order to determine the most effective curve in order to obtain maximum temperature change at the tip of the conductor 11.
As previously mentioned the use of an effective 1/4 wavelength distance between the gap and the end of the outer conductor 14 in combination with the utilization of a gap having a width equal to 1/3 of the diameter of the coaxial cable provides a system whereby backward traveling surface waves are cancelled and forward traveling waves are enhanced due to the phase relationship between the location of the gap in the outer conductor and the radiating end of the applicator. With this type of system there is no requirement for an insertion beyond the tumor volume because the heating patterns are shifted toward the tip of the applicator.
Experiments have shown that when four applicators of the type shown in FIG. 1 are arranged in a rectangular and a co-planar phased array, the pattern which is produced is a spherical heating pattern which is ideally suited for localized heating of tumors.
Obviously, numerous modifications and variations of the present invention such as implementation at different wavelengths are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An interstitial applicator is provided in order to heat a localized region of living tissue by simultaneously enhancing energy passed at the end of a central conductor while cancelling signals traveling along the outside of the application by forming a gap in the outer conductor of a coaxial cable with the gap being located 1/4 wavelength from the end of the outer conductor. The width of the gap corresponds to 1/3 of the diameter of the coaxial cable which forms the applicator. This system provides for an enhancement of the heating at the particular area around the tip of the central conductor while at the same time forms a block to stop surface wave heat from travelling back to the skin/tissue surface.
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